How to Choose a Gas Sensor for Industrial Facilities

Every industry works with different chemicals, each with unique risks. A food processing plant may handle CO₂, while a steel factory deals with CO or hydrogen. Before you even look at sensor models, identify:

• All gases used or emitted
• Their concentration ranges
• Whether they are toxic, flammable, or both

This will help you match the sensor’s detection range and sensitivity to real-world risks. Using a sensor not designed for the gases in your environment can delay detection — or fail entirely.

Choosing a gas detector also means considering the physical and environmental conditions where it will operate. A sensor that works well in a clean indoor lab may fail in a dusty, hot foundry. Key factors include:

• Ambient temperature range
• Humidity and moisture levels
• Dust, oil mist, or corrosive vapors
• Airflow and pressure changes
• Risk of explosion (hazardous zone rating)

For example, a gas leak detector installed near furnaces or exhaust ducts must be rated for heat and contaminants. Select a model with the right IP rating and sensor housing to prevent false alarms and early sensor degradation.

Technology matters. Different sensing principles suit different gases and environments. Here's how they compare:

• Catalytic bead sensors detect flammable gases through heat change durin combustion. They're cost-effective but sensitive to contaminants.
• Electrochemical gas sensors perform poorly at extreme temperatures and degrade quickly in adverse conditions (moisture, H₂S, CO).
• Infrared (IR) sensors are immune to poisoning and work well for hydrocarbons and CO₂ in dirty air.
• Photoionization detectors (PID) are ideal for volatile organic compounds (VOCs) but are not suitable for all gases.

Don’t pick based on price — pick based on performance in your actual environment.

Use this checklist to narrow down your choices:

1. Gas type and range compatibility
2. Sensitivity and response time
3. Output format (analog, digital, relay)
4. Power supply and consumption
5. Maintenance intervals and ease of calibration
6. Safety certifications (ATEX, IECEx, UL)
7. Integration with your SCADA or BMS system

Even one mismatch can lead to system failures or delays in response. Make sure your choice is both technically and operationally compatible.

Investing in the right sensor pays off over time — not only by reducing accidents but also by optimizing operations. A good detector:

• Lowers the risk of downtime from gas-related incidents
• Alerts staff faster to small leaks before they become emergencies
• Integrates with automation systems for faster response
• Meets insurance and regulatory requirements
• Improves worker confidence and safety culture

Sensor placement determines detection speed. Poor positioning leads to blind spots. For best results:
Place sensors:

• Directly above or below potential leak sources
• Near gas storage tanks, valves, compressors, and pipelines
• In enclosed areas with low airflow
• Along air movement paths or HVAC systems
• At breathing height if gases pose inhalation risks

Also consider redundancy — one sensor isn’t always enough. In large or high-risk zones, install multiple units with overlapping coverage.

Even experienced engineers sometimes overlook practical issues. Avoid these frequent errors:

• Installing the sensor too far from the gas source
• Using a sensor with too narrow a detection range
• Neglecting regular testing and recalibration
• Ignoring the effect of local airflow patterns
• Choosing consumer-grade devices for industrial tasks

Top 3 mistakes to avoid:

1. Choosing the wrong technology for your gas
2. Failing to train staff in detector use and alarm response
3. Skipping annual inspections and recalibration

A gas detection system should evolve with your facility. As operations expand, equipment is replaced, or new gases are introduced, revisit your setup. Look for:

• Modular sensors with swappable heads
• Remote calibration tools
• Real-time monitoring via wireless or Ethernet
• Cloud integration for maintenance alerts
• Event logging to help with audits or incident analysis

Plan for scale. A well-chosen industrial gas leak detector today should still serve you five years from now — with minimal changes.