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Hydrogen sulfide (H2S) gas can be fatal at high concentrations. But even low concentrations can cause health issues, particularly with prolonged exposure. So how can you best protect workers and minimise downtime? We answer your common questions about H2S.

What is H2S gas?

Hydrogen sulfide is a highly flammable, toxic and corrosive gas found in several industries including oil and gas, wastewater and chemical processing. It’s sometimes called ‘sour gas’, ‘sewer gas’ or ‘stink damp’ because of the way it smells like rotten eggs. However, H2S can’t reliably be detected by smell as it quickly deadens the sense of smell (a process known as ‘olfactory desensitisation or fatigue’).

How dangerous is H2S?

Exposure to high levels of H2S can be fatal, leading to loss of breathing, coma, seizures and death. It’s the second most common cause of fatal gas inhalation exposure in the workplace, second only to carbon monoxide[1].

But H2S can also be harmful at low concentration levels, causing headaches, dizziness, nausea, breathing difficulties and a sore throat. These health impacts can become more serious with prolonged exposure.

Low concentration vs. high concentration H2S – exposure limits

The health impacts of H2S depend on how much is inhaled and for how long. The recommended exposure limit set by NIOSH (the US National Institute for Occupational Safety and Health) for ten minutes is 10 ppm[2]. 

However, some U.S. states have developed ambient air standards for H2S well below OSHA and NIOSH standards due to concerns about health risks from chronic exposure[3].

For longer exposures to H2S, the recommended limits are a lot lower. For example, if you’re exposed for up to 24 hours, the World Health Organisation (WHO) recommends a maximum exposure of 0.1 ppm.

In response to concerns about the risks of H2S to human health even at low concentration levels, some countries have introduced equally stringent guidelines requiring businesses to monitor H₂S at such concentrations. That’s why we’ve recently updated our ALTAIR io™ 4 Connected Gas Detector, offering the option of a low-concentration hydrogen sulfide sensor that can detect H2S at very low levels*.

H2S in industry – the different sector impacts

H2S creates safety challenges for many industries. But some industries are more likely to be affected. These include:

Oil, Gas & Petrochemical (OGP)

OGP facilities handle raw ‘sour’ gas and oil which are naturally high in H2S. Extraction and refining processes release H2S, which may accumulate in confined, poorly ventilated spaces like processing units, pipelines and storage tanks. Closed systems with high-pressure conditions amplify the risks for workers.

Balancing safety and operational efficiency is an ongoing challenge in the OGP industry. Some are tackling this challenge by integrating new technological solutions into their safety management practices.

Waste water management

Wastewater facilities such as closed pipelines and sludge tanks have low oxygen levels and so provide the ideal conditions for H2S buildup. This is because sulfate-reducing bacteria which break down organic material and produce H₂S as a byproduct thrive in anaerobic (low-oxygen) conditions.

One of the key risks for waste water workers is when they’re entering confined spaces like tanks and sewer lines. For many waste water management businesses, real-time monitoring of gas levels is considered a must-have.

Steel production

The steel industry’s use of high-temperature processes and sulfur-rich materials can lead to the release of H2S, creating hazards for workers. Confined, poorly ventilated spaces and desulfurisation units pose particular risks. 

[1] Guidotti TL, 2010. Hydrogen sulfide: Advances in understanding human toxicity. Int. J. Toxicol 29, 569–581. [DOI] [PubMed] [Google Scholar][Ref list]

[2] https://www.cdc.gov/niosh/npg/npgd0337.html

[3] https://ohsonline.com/articles/2007/10/human-health-effects-from-exposure-to-lowlevel-concentrations-of-hydrogen-sulfide.aspx

Any industry that processes, uses, or manufactures materials that may give rise to a flammable atmosphere (gas, mist, liquid, dust or even small fibres) may have a potentially explosive atmosphere. Where fuel and oxygen (normally the oxygen in air) are present in the workplace, potential ignition sources must be rendered safe to an acceptable level for the risk. Industries that generate potentially explosive atmospheres classify the dangerous areas based on the likelihood and duration of the explosive atmospheres’ presence. This is referred to as a ‘Zone’ (Europe and NEC505) or ‘Division’ (NEC500).

When a Zone or Division has been established, the manufacturer must take special precautions to reduce the likelihood of an ignition being present to an acceptable level (and possibly to use mitigation measures to lower the consequence of an explosion). These special methods are normally achieved by applying defined ‘levels of protection’ (Referred to as ‘Category’ in ATEX and ‘Equipment Protection Levels’ in IEC). To technically achieve the defined level, we then apply protection concepts (pre-defined design and test methodologies) from published standards. In most cases, there is more than one way to achieve the level of protection; the designer must choose the most suitable to their equipment and manufacturing capability.

Definition of Categories /EPLs

Category 1 Equipment (Zone 0)  Ga, Da          
Must not have ignition sources that can become effective even in a rare malfunction. Equipment in this category is intended for use in areas in which explosive atmospheres caused by mixtures of air and gases, vapours or mists or by air/dust mixtures are present continuously for long periods or frequently.

Category 2 Equipment (Zone 1) Gb, Db          
May have effective ignition sources (with a malfunction applied) protected by a recognised concept. Equipment in this category is intended for use in areas in which explosive atmospheres caused by gases, vapours, mists or air/dust mixtures are likely to occur.

Category 3 Equipment (Zone 2) Gc, Dc           
Must also be protected by a concept when ignition capable (relative to the gas or dust) in normal operation. Equipment in this category is intended for use in areas in which explosive atmospheres caused by gases, vapours, mists or air/dust mixtures are not likely to occur.

The categories in normal practice are equated to the suitability for Zones. Apparatus will be marked with the grouping and category in addition to the marking required by the individual protection.

Given the onerous nature of an explosion, special certification schemes have been set up to control the design and certification of equipment for potentially explosive atmospheres.  Although the schemes differ globally (some are mandatory under law, some are simply procurement specifications), the basis for design and certification is similar, and the schemes normally rely on testing, constructional assessment and production (quality) control by a recognised Certification Body.

The Explosive Atmospheres market is both lucrative and expanding, but the level of certification requirements and checking (both by the buyer and the regulatory authorities) are undoubtedly increasing. To access this market, it is imperative that equipment manufacturers understand the design, manufacture and certification requirements of both discrete apparatus and assemblies to ensure that the products are designed and certified on time and correctly.

ExVeritas provides Product Certification, Management System Certification, Training and Site Safety Services. ExVeritas are an ATEX Notified Body and an IECEx Certification Bod with IECEX Test Laboratories in the UK and USA

www.exveritas.com

Resilience and innovation remain the cornerstones of the hazardous area industry. As the global landscape evolves, economic pressures, supply chain complexities, and the ever-growing demands for sustainability and compliance continue to shape the sector. Yet, these challenges also present opportunities for progress and leadership.
The hazardous area industry is advancing rapidly, fuelled by technological breakthroughs, stricter regulations, and a renewed commitment to safety. Across the globe, businesses are seeking smarter, more efficient ways to protect people, assets, and the environment. At Peppers Cable Glands, these shifts are seen not as hurdles but as catalysts for driving innovation and setting new benchmarks for a safer, more sustainable future.
In the face of mounting pressures, collaboration has emerged as the key to success. Peppers takes pride not only in delivering industry-leading products but also in being a trusted partner to their customers. Their innovative Quick Response Cell (QRC), strategic investments in advanced technology, and unwavering dedication to quality underscore their mission to make a tangible difference in the industry.
Looking ahead, Peppers is ready to help businesses navigate emerging challenges and capitalise on new opportunities. Whether addressing the demands of complex projects, upgrading aging systems, or meeting the latest regulatory standards, Peppers is committed to supporting their customers at every stage. With a comprehensive product portfolio — now including DNV marine approvals — and a dedicated team of experts, they provide solutions designed to exceed expectations.
The hazardous area industry thrives on adaptability, trust, and continuous innovation. These qualities are deeply embedded in Peppers’ approach to every project and partnership. As the industry moves forward, Peppers remains steadfast in their pledge to work collaboratively toward a safer, stronger, and more sustainable future.
Here’s to embracing the opportunities ahead and shaping a brighter tomorrow for the hazardous area industry.

www.cableglands.co.uk

Sometimes you need to clean up, and there is no convenient electrical outlet nearby. Accidental spillages need prompt rectification but using a conventional vacuum cleaner means trailing a lead across the floor which can hinder operations and potentially cause a trip hazard. Until now it has been difficult to find cordless vacuum cleaners with enough industrial power to handle bulk clean up in the manufacturing environment.

Quirepace have introduced the cordless IV60 eGX into the range of BVC Industrial Vacuum Cleaners to eliminate this risk. This is a powerful battery powered unit which, as standard, is provided with a 3-stage filtration dry product tank consisting of a paper sack collection, microfibre main filter and 3^rd stage HEPA filter. This configuration is suitable for most dry-product collection applications. The unit may be configured as both M-Class and H-Class rated units.

The unique Honda eGX electric engine is designed to replace petrol engines in the 2.5hp class and combined with the well-proven BVC YP3 turbine delivers powerful suction suitable for the toughest industrial cleaning jobs.

With a run-time of 1/2hr to 2 hrs depending on power setting, the new BVC IV60 eGX in either M-Class or H-Class specification, is ideal for spillages of potentially hazardous products, and the absence of any requirement to plug-in means BVC IV60 is immediately ready for use anywhere in the building.

In addition to the standard dry-product tank, BVC IV60 eGX is also available with wet tank, longopac®, and drop-tank options. It is also ideal for high-reach cleaning using lightweight carbon fibre cleaning poles. Like all BVC Industrial Vacuum Cleaners, a wide range of different hoses, tools and accessories are available from Quirepace’s Fareham factory and warehouse.

Contact Quirepace today and ask for a demonstration.

Quirepace Ltd

This email address is being protected from spambots. You need JavaScript enabled to view it.
www.quirepace.co.uk
www.bvc.co.uk

ADLER, Austria’s leading manufacturer of varnishes, paints, and wood preservatives, has introduced digital data acquisition for raw materials in its pre-commissioning area, marking a significant step in its digitalisation efforts. Employees in Ex-zone 1/21 now use mobile multifunctional sets from i.safe MOBILE, including the intrinsically safe IS530.1 smartphone and the IS-TH1xx.1 hand-held barcode scanner. These devices enable automatic raw material control during scanning, minimizing errors and reducing faulty batches. The collected data is stored in a database for full traceability, ensuring production transparency and process optimisation. Additionally, hazard warnings and work instructions are integrated into the mobile devices, improving both efficiency and safety.

Seamless Implementation and Increased Efficiency

The barcode scanning system was integrated into ADLER’s existing IT infrastructure with the help of i.safe MOBILE’s partner, ematric, who developed the necessary software. This integration allows for real-time order tracking and ensures accurate recording of each production step, minimizing the risk of overlooked tasks. Initially, there were concerns about workflow disruptions, but the system was implemented smoothly, leading to fewer incorrect batches and improved overall efficiency.

Enhanced Production Control and Quality Assurance

Material traceability is vital in ADLER's production process. The barcode scanning system helps employees quickly identify processed and remaining raw materials. In the pre-commissioning area, up to 1,200 raw materials and semi-finished products are compiled and weighed for each order. Digitalisation enhances quality assurance by preventing material mix-ups and costly mistakes. The IS530.1 smartphone also displays hazard warnings and work instructions, contributing to safety by providing clear visual information to employees for task completion.

Positive Employee Feedback and Future Plans

Employees have responded positively to the digitalisation initiative, resulting in increased job satisfaction. Following training, each worker was equipped with a multifunctional device. QR codes on raw material storage locations and production recipes facilitate quick material identification and help reduce errors. The system alerts employees in case of incorrect scans and shows expiry dates or special processing instructions. The implementation process took about six months from product selection to deployment.

Looking ahead, ADLER plans to extend digitalisation across the entire production process, enabling real-time monitoring. This expansion is part of a broader strategy to increase transparency and responsiveness to customer needs, while integrating insights from the project into future logistics planning. ADLER’s commitment to employee safety and satisfaction ensures that these digitalisation measures will contribute to long-term productivity and innovation.

“The scanners from i.safe MOBILE have truly made a difference,” says foreman Christoph Wolf from ADLER. “With their support, we’ve successfully sped up and simplified our work processes, reducing the error rate. We’ve made significant progress towards digitalisation.”

The Mobile Multifunction Set

With a large reading range of up to 18 metres, the devices are equipped with Zebra OEM imager scan engines for safe mobile data management. At ADLER, the i.safe MOBILE mobile multifunctional set ensures reliable data capture in hazardous areas. This represents a further step towards optimising processes, raising quality standards and ensuring the safety of employees.

www.isafe-mobile.com

It is generally well known that condition-based maintenance (CBM) of rotating equipment (pumps, fans, motors etc.) is the key to avoiding costly downtime. This is particularly the case in hazardous locations where routine or planned periodic maintenance is impractical or undesirable. However, any CBM equipment used in hazardous locations needs to be certified as intrinsically safe. But how do you decide if you have a hazardous location and at what level of hazard? The regulations put the responsibility for deciding on the plant operator and in many cases such as flour mills, petrochemical plants or fuel transfer facilities it can be fairly obvious. However, some less obvious hazardous locations include water treatment plants, tunnels and underground passageways or any location where a build-up of naturally occurring flammable material (such as methane or dust) could occur.

Wastewater pumping and treatment facilities, for example, emit flammable gases and vapours. These emissions come from substances that the wastewater could be carrying (e.g. oils, solvents or fuels from accidental spills) and from anaerobic digestion of organic matter (producing methane and hydrogen sulphide). According to the regulations, most pumping stations, spaces and buildings that make up a wastewater treatment plant must be considered hazardous locations.

But what level of intrinsic safety is required? Deciding the “likelihood” of an explosive atmosphere existing can be tricky to say the least! The simplest solution is to cover all eventualities by going for instruments certified for Zone 0 (hazard exists continuously). Normally, that would be much more expensive. Fortunately, Test Products International (TPI) has achieved a significant cost breakthrough with the very affordable TPI 9085Ex vibration analyser. With on-meter diagnostics and the all-important ability to TREND readings over time, the “go anywhere” TPI 9085Ex has WORLDWIDE certification for Zone 0, meaning it can be used in any atmosphere and anywhere.

The 9085Ex detects unbalance, misalignment and looseness in rotating equipment. It also measures “bearing noise” and displays it in bearing damage units (BDU) roughly equivalent to “percentage bearing wear”. In addition, the 9085Ex uniquely incorporates a directly contacting temperature sensor within its vibration probe. This gives a highly accurate, virtually instantaneous, surface temperature reading for the bearing, simultaneously as the vibration reading is taken. With a high BDU reading and high temperature, you know that what you are seeing really is a worn bearing and not some other source of vibration such as pump cavitation.

 The compact handheld TPI 9085Ex is extremely affordable and simple to use and should be included as standard in every maintenance tool kit. Using the FREE TPI Bridge App, “routes” and readings can be transferred to and from the 9085Ex anywhere in the world using mobile devices (e.g. smart phone or tablet PC) and then via Bluetooth to and from the 9085Ex. “Routes” are simply lists of machines showing exactly what readings need to be taken and where to take them. The readings are then automatically time and date stamped by the 9085Ex and saved back in the route for automatic transfer to computer-based trending software.

“Trending” is the very essence of condition-based maintenance. By looking at the trend of bearing noise and temperature readings, it is possible to determine well in advance when a bearing will likely need replacing. The TPI 9085Ex comes with powerful, yet simple to use, subscription free trending software, which includes automatic email notification of alarms and report generation, giving you everything you need for a full CBM strategy.

For more information please contact TPI Europe’s head office on +44 1293 530196 or take a look on the website at www.tpieurope.com or email This email address is being protected from spambots. You need JavaScript enabled to view it.

Parker Hannifin, the global leader in motion and control technologies, continues demonstrating its commitment to safety and performance in hazardous environments by announcing new certifications and product improvements for its EY and EX servo motor series.

As part of Parker’s ongoing dedication to meeting stringent government regulations and customer needs, the EY servo motor series has successfully obtained CCC certification, making it compliant for use in the Chinese market. This certification underscores Parker’s commitment to providing high-quality solutions for explosive environments, particularly in ATEX Zone 2 applications.

Additionally, following a rigorous re-certification process, Parker is proud to introduce a new polyurethane paint for the EX servo motor series. This innovative paint offers enhanced durability and resistance, ensuring the motor continues to meet the latest and highest standards of safety and performance. The EX series is already compliant with CE, IECEx, KOSHA, and CCC certifications for China, making it a versatile choice for ATEX Zone 1 applications.

Parker’s ATEX-certified servo motors are characterized by exceptional motion quality. The motors provide excellent acceleration and deceleration capabilities and impressive torque output across a wide speed range. They are suitable for use in a variety of industries facing stringent safety regulations in explosive atmospheres, including oil and gas, pharmaceuticals, automotive (painting lines), biogas production, gas turbine manufacturing, printing, and distilleries.

With these advancements, Parker reaffirms its position as a global partner for positioning and operating in hazardous areas, offering comprehensive drive packages tailored to meet the unique challenges of ATEX environments.

For more information about Parker’s EY and EX servo motor series and how they can enhance safety and performance in your applications, please visit:

www.parker.com

The SYMEGA.PRO was developed for grounding when filling or emptying mobile containers such as tankers, IBCs, FIBCs, drums and the like. 

The term grounding can be found in many subject areas. In this case, however, it refers to the avoidance of ignition sources in explosive atmospheres (gas and dust). Mobile containers that are not connected to ground can become electrostatically charged during transport, filling and emptying. If these objects come into contact with a conductive object, an electrostatic discharge may occur which, depending on the strength of the charge, can reach an energy that equals the minimum ignition energy of the explosive atmosphere present.  

To avoid charging, objects that contain flammable media must always be grounded during filling or emptying processes.  

But how can a temporary and secure connection be established at short notice? 

This is where the SYMEGA.PRO comes in. The SYMEGA.PRO has an grounding clamp that can be connected to an affected object. As soon as it is connected, the device checks the connection quality so that a potential-free contact can then be switched and grounded. This allows processes to be automated and pumps or valves to be enabled, for example. If the connection is interrupted, the SYMEGA.PRO immediately cancels the release. The decisive factor here is the resistance of the test lead that was established to the object using grounding clamps. These parameters can be freely set on the system. 

How can it be ensured that the grounding clamp is securely connected to the correct object? 

Depending on the object, different check modes can be activated. In addition to the familiar capacitance check for large objects that are not grounded, the system offers a timeout function that limits the process to a specific time. This is intended to prevent the grounding clamp from being clamped to another object for manipulation over a long period of time. To avoid loading faults, temporary loose contacts can be faded out in the check so that the process can continue undisturbed but safely. 

The ground connection on the SYMEGA.PRO can also be traced back to the main ground. These freely selectable functions in one device make the SYMEGA.PRO an ‘All.Grounder’ to which any type of container or device can be connected.

The advantages at a glance:

 ✓ An intelligent system for all applications 

✓ Capacity check of connected objects enables tamper protection 

✓ 24 VDC and 230 VAC power supply 

✓ Monitors the connection to the main ground 

✓ No loading fault due to loose contact 

✓ Safe grounding due to time limitation

www.rembe.de

When it comes to protecting people and plant from highly flammable compounds, attention is usually focussed on inflammable liquids such as solvents and other petrochemicals. However, dust and ultra fine powders can pose a very real threat in terms of fire hazard and have been the cause of many deaths around the world in industrial environments.

Back in 2008, 14 people were killed and 38 others were injured when dust exploded at a sugar factory in Port Wentworth, Georgia. The Occupational Safety and Health Administration, OSHA, reported back in 2012 that 130 employees had lost their lives in a period of just over 30 years. During the same period, it reported that 800 more people had been injured due to dust and fine powder fires and explosions.

As a particle progressively becomes smaller, its specific surface area increases, which accelerates its combustion, and hence, the quantity of energy liberated. Second, it is much easier to form a cloud of fine particles with air, and this also facilitates their combustion and flame propagation. When considering all the particles in a standard size bag of flour, for example, it is estimated that the total surface area is an incredible 340 square metres.

Anyone who has studied basic grade chemistry will know that the three essentials for a fire to start are fuel, oxygen and of course a source of ignition. Many fine powders can act as the fuel for the reasons outlined above, and of course there is a plentiful supply of oxygen given the fact it’s a main constituent of air, essential for life. So that leaves the third essential, a source of ignition. It is for this reason that two European directives have been introduced to control potentially explosive atmospheres. There are different directives for various environments.

ATEX Zones 21 and 22 are specific to hazardous dust environments, such as those in the coating sector and the food industry as outlined above.

In a hazardous dust environment, an ATEX Zone 21 is classified as ‘a place in which an explosive atmosphere in the form of a cloud of combustible dust in the air is likely to occur occasionally during normal operation’. On the other hand, an ATEX Zone 22 is classified as 'a place in which an explosive atmosphere in the form of a cloud of combustible dust in the air is not likely to occur in normal operation but if it does occur, it will be present for a short period of time only’.

Whether the danger is for a prolonged period, or for a limited short period, the directives call for electrical equipment to meet stringent standards. Clearly, it only takes one spark form a piece of electrical equipment to cause a major industrial catastrophe, hence the inclusion of the ATEX 22 directive that address the shorter periods of time.

FLIR are pleased to announce that their new FLIR Si2x series of acoustic cameras are certified for ATEX zone 22, ensuring safe and effective condition monitoring in hazardous environments. There are significant benefits of using the FLIR Si2x in explosive vapour environments.

Why Use an Acoustic Camera?

The FLIR Si2x acoustic imaging camera accurately detects extremely small leaks in compressed air systems and other gaseous environments. At a distance of 10 metres the cameras is capable of detecting leaks as small as be 0.0032 litres per minute from 2.5 m (8.2 ft). With real-time leak size and cost estimates, you can make quick, informed repair decisions to maintain efficiency.

Faster and More Accurate Detection

Traditional leak detection methods can't match the speed and accuracy of the FLIR Si2x. In addition to detecting compressed air leaks it efficiently quantifies leaks in industrial gases such as, ammonia, hydrogen, CO₂, methane, helium, and argon. The camera's mechanical fault detection mode also identifies and measures potentially faulty bearings, keeping your equipment in top condition.

Speeds Up Audits and Requires Minimal Training

Designed for ease of use, the FLIR Si2x allows you to quickly scan large areas without disrupting operations. Its intuitive interface requires minimal training, making it accessible to all team members and ensuring comprehensive safety audits with minimal downtime, and without the need for hot working permits. This facility means that any inexperienced or new member of staff can conduct an inspection with ease, allowing more experienced and senior members of the team to continue with other pressing issues.

To find out more about the Si2x-LD  and the Si2x-PRO acoustic camera and other instruments in the FLIR range please contact your local agent or your FLIR distributor.

https://www.flir.co.uk/instruments/acoustic-imaging/acoustic-leak-detection/explosive-vapor-Si2x/