December 2004

Process Industry Practices

Process Control

PIP PCCA001
Design of
Combustible and Toxic Gas Detection Systems

PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES

In an effort to minimize the cost of process industry facilities, this Practice has
been prepared from the technical requirements in the existing standards of major
industrial users, contractors, or standards organizations. By harmonizing these
technical requirements into a single set of Practices, administrative, application, and
engineering costs to both the purchaser and the manufacturer should be reduced. While
this Practice is expected to incorporate the majority of requirements of most users,
individual applications may involve requirements that will be appended to and take
precedence over this Practice. Determinations concerning fitness for purpose and
particular matters or application of the Practice to particular project or engineering
situations should not be made solely on information contained in these materials. The
use of trade names from time to time should not be viewed as an expression of
preference but rather recognized as normal usage in the trade. Other brands having the
same specifications are equally correct and may be substituted for those named. All
Practices or guidelines are intended to be consistent with applicable laws and
regulations including OSHA requirements. To the extent these Practices or guidelines
should conflict with OSHA or other applicable laws or regulations, such laws or
regulations must be followed. Consult an appropriate professional before applying or
acting on any material contained in or suggested by the Practice.

This Practice is subject to revision at any time by the responsible Function Team and
will be reviewed every 5 years. This Practice will be revised, reaffirmed, or withdrawn.
Information on whether this Practice has been revised may be found at www.pip.org.

Process Industry Practices (PIP), Construction Industry Institute, The

University of Texas at Austin, 3925 West Braker Lane (R4500), Austin,
Texas 78759. PIP member companies and subscribers may copy this Practice
for their internal use. Changes, overlays, addenda, or modifications of any
kind are not permitted within any PIP Practice without the express written
authorization of PIP.

PIP will not consider requests for interpretations (inquiries) for this Practice.

Not printed with State funds

December 2004

Process Industry Practices

Process Control

PIP PCCA001
Design of
Combustible and Toxic Gas Detection Systems
Table of Contents
1. Introduction .................................. 2
1.1 Purpose ............................................. 2
1.2 Scope................................................. 2

2. References ................................... 2
2.1 Process Industry Practices ................ 2
2.2 Industry Codes and Standards .......... 2
2.3 Government Regulations ................... 2

3. Definitions .................................... 3
4. Requirements ............................... 3
4.1
4.2
4.3
4.4
4.5

General Design.................................. 3
Equipment Location ........................... 4
Environment....................................... 4
Calibration and Testing...................... 4
Types of Combustible
Gas Detectors.................................... 5
4.6. Toxic Gas Detectors .......................... 6
4.7. Control Modules and Alarms ............. 7

Process Industry Practices

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PIP PCCA001
Combustible and Toxic Gas Detection Systems Criteria

1.

December 2004

Introduction
1.1

Purpose
This Practice provides the criteria for engineers for the design of detection and
monitoring systems that are installed in plant areas to alert personnel of the presence
of combustible or toxic gas.

1.2

Scope
The systems addressed in these criteria are for permanently installed, fixed
combustible and toxic gas monitors.

2.

References
Applicable parts of the following Practices, industry codes and standards, and references
shall be considered an integral part of this Practice. The edition in effect on the date of
contract award shall be used, except as otherwise noted. Short titles will be used herein
where appropriate.
2.1

Process Industry Practices (PIP)

PIP PCCA01D - Data Sheet for Combustible and Toxic Gas Monitors

2.2

Industry Codes and Standards

American Petroleum Institute (API)

API Publication 2031 - Combustible Gas Detector Systems and Environmental
and Operational Factors Influencing Their Performance.

The Instrumentation, Systems, and Automation Society (ISA)

ISA S12.13, Part I-1995 - Performance Requirements, Combustible Gas
Detectors
ISA S12.13, Part II-1987 - Installation, Operation and Maintenance of
Combustible Gas Detection Instruments
ISA 92.0.01 Part I-1998 - Performance Requirements for Toxic Gas-Detection
Instruments: Hydrogen Sulfide

National Fire Protection Association (NFPA)

NFPA 101 - Life Safety Code
NFPA 325M - Fire Hazard Properties of Flammable Liquids, Gases, and
Volatile Solids for LEL of Gases

2.3

Government Regulations

U.S. Department of Labor Occupational Safety and Health Administration

(OSHA)
Part 1910 - Occupational Safety and Health Standards

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Process Industry Practices

PIP PCCA001
Combustible and Toxic Gas Detection Systems Criteria

December 2004

3.

Definitions
LEL: Lower explosive limit, which is the minimum concentration of a gas in a gas/air
mixture at which the mixture will explode if exposed to an ignition source
owner: The party who owns the facility wherein combustible and toxic gas detection systems
will be used.
BPCS: basic process control system
approved testing laboratories:
FM: Factory Mutual
UL: Underwriters Laboratory
CSA International: formerly Canadian Standards Association
NRTL: Nationally Recognized Testing Laboratories

4.

Requirements
4.1

General Design
4.1.1

The detection system shall measure and provide indication and alarms for
specified concentrations of toxic gases or combustible gases in air.

4.1.2

The detection system shall be designed to

a. Allow for a timely operator response.
b. Prevent unauthorized system bypass or alarm reset.
c. Initiate appropriate action.

4.1.3

The owner shall specify on PIP PCCA01D the location, number of detectors,
and alarm limits for each detector.

4.1.4

The manufacturers requirements shall be followed as a minimum.

4.1.5

The system shall be composed of one or more detectors connected to a

control unit or logic device as specified on PIP PCCA01D.

4.1.6

The control unit or logic device shall provide audible and visual alarms in
the field and in attended control buildings.

4.1.7

The monitor and detector shall be approved for the electrical area
classification where it will be installed and shall be approved by UL, FM,
CSA International, or other recognized NRTL.

4.1.8

Refer to the following industry standards for additional information on

system requirements:
a. ISA S12.13, Part I-1995
b. ISA S12.13, Part II-1987
c. ISA 92.0.01 Part I-1998

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PIP PCCA001
Combustible and Toxic Gas Detection Systems Criteria

December 2004

d. API Publication 2031

e. OSHA Part 1910
f.

NFPA 325M

g. NFPA 101
4.2

4.3

4.4

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Equipment Location
4.2.1

Detector location shall be appropriate to detect the presence of specified

combustible or toxic gases (i.e., lighter or heavier than air) in the area in
which the detector is installed.

4.2.2

Point detectors shall normally be located adjacent to identifiable, single-spot,

potential release locations having a significant risk of toxic or combustible
gas leak (such as pump and gas compressor seals, valves, etc.).

4.2.3

Detectors shall not be located in areas having excessive vibrations.

4.2.4

Detectors shall be protected from direct sprays of oils and other liquids.

4.2.5

Prevailing wind direction shall be considered when detector location is

selected.

4.2.6

If gas detection is required at the inlet of air ducts, pressure and airflow
across the sensor shall be within manufacturer recommendations.

Environment
4.3.1

Each part of the detection system, alarms, and associated electronic circuits
shall be suitable for the environment in which the part will be installed.

4.3.2

Detectors shall have automatic temperature compensation for ambient

temperature and humidity changes.

4.3.3

As specified on the PIP PCCA01D data sheet, detectors shall be provided

with guards for protection from mechanical damage, rain, water wash, strong
wind, dust, and sand if required by site conditions. Sunshades shall also be
furnished if required by site conditions.

4.3.4

Radio frequencies shall not interfere with any device in the system.

4.3.5

Detector assemblies shall not be painted or otherwise covered, which would

prevent gas from diffusing into the sensor.

Calibration and Testing

4.4.1

Detectors shall be calibrated for the specified gas being monitored.

4.4.2

Detectors shall be designed to allow accurate, effective testing and

calibration at regular periods.

4.4.3

Detectors shall be readily accessible for calibration and ease of replacement.

If available, plug-in sensor heads shall be used.

4.4.4

Detectors shall be designed for testing without disabling the entire system or
causing shutdown of equipment.

Process Industry Practices

PIP PCCA001
Combustible and Toxic Gas Detection Systems Criteria

December 2004

4.4.5
4.5

An alarm shall activate in a continuously occupied area when a detector is

removed from service for any reason.

Types of Combustible Gas Detectors

4.5.1

General
4.5.1.1 The owner shall specify on PIP PCCA01D which type of
combustible gas detector shall be used.
4.5.1.2 If more than one combustible gas is present at a particular location,
the detector shall be calibrated for the hardest-to-detect (least
sensitive) component gas as specified by owner.
4.5.1.3 Transmitter ranges and meter scales for combustible gas indication
shall be 0-100% LEL (refer to NFPA 325M).
4.5.1.4 The use of point type or open-path detectors shall require the
approval of the owner.
4.5.1.5 Each sensor shall be calibrated using a gas that will actuate the highhigh alarm level of the analyzer to verify analyzer and alarm
operation.
4.5.1.6 Calibration frequency of the sensor shall be as specified by the
manufacturer or as stated by the owners applicable standard.

4.5.2

Catalytic Bead Detectors

4.5.2.1 Applications and Restrictions

1. Catalytic bead types shall not be used where silicones or other

compounds containing fluorine, chlorine, bromine, and iodine
and heavy metals such as tetraethyl lead may be present.
Comment: Sulfur compounds present in the area will shorten
the life of the detector.
2. Catalytic bead type detectors need oxygen to operate properly
and shall not be used in an atmosphere where no oxygen is
present.
3. If multiple gases may be present, the gas of primary interest
shall be specified, and the detector shall be calibrated for that
gas.
Comment: Easily oxidized fuels such as hydrogen may present
a special case; for these gases, see manufacturers
guidelines.
4. Continuous exposure to the target gas shall be avoided because
it will consume the cell and cause premature failure of the
sensor.
5. The detector manufacturer shall be required to furnish a
conversion table or chart that converts the LEL of other gases
to the LEL of the gas for which the detector is calibrated.

Process Industry Practices

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PIP PCCA001
Combustible and Toxic Gas Detection Systems Criteria

December 2004

Comment: Catalytic bead type detectors will detect all

combustible gases, not just the one for which the
detector is calibrated.
6. The detector manufacturer shall be required to furnish a
conversion table that converts from percentage of LEL to
percentage of concentration in air by volume.
4.5.3

Infrared (IR) Detectors

4.5.3.1 Point Type IR Detectors

Point type detectors shall be specified for the following applications:

a. Locations having inert gas backgrounds
Comment: IR detectors can be used in locations that have inert
gas backgrounds because such detectors do not
require oxygen to operate.
b. Locations having constant background of gases
Comment: IR detectors are not poisoned by a constant
background of gases and do not respond to
hydrogen.
c. If specific gases require detection
Comment: IR detectors can be tuned to detect somewhat
specific gases because they measure different
hydrocarbons at specific wavelengths.
4.5.4

Open Path IR Detectors

1. The installation of an open path type IR systems shall not be installed
without prior approval of the owner.
2. Open path IR detectors shall not be used in congested areas or in areas of
high traffic.
3. The IR source and reflector shall be installed on a rigid structure to
prevent movement caused by ambient atmospheric changes.

4.6.

Toxic Gas Detectors

4.6.1

The owner shall specify on PIP PCCA01D whether a toxic gas detector(s)
shall be installed by a project and which gas the detector shall check.

4.6.2

Transmitter range and meter scales for toxic gas analyzers shall comply with
owners specification.

4.6.3

The toxic gas detector shall be calibrated in accordance with the detector
manufacturers procedure and shall meet all specified requirements.
Comment:

4.6.4

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The life span of some toxic gas detectors will be shortened

considerably if exposed to a constant background of the
toxic gas being measured.

The detector zero shall be checked using a toxic-free gas.

Process Industry Practices

PIP PCCA001
Combustible and Toxic Gas Detection Systems Criteria

December 2004

4.7.

Control Modules and Alarms

4.7.1

General
4.7.1.1 The owner shall specify on PIP PCCA01D the control and logic
philosophy for toxic or combustible analyzers.
4.7.1.2 The logic shall be designed to be fail-safe.
4.7.1.3 Normally open (shelf state) contacts shall be closed during normal
operation and shall open on alarm.
4.7.1.4 If the system control is microprocessor based, it shall be field
programmable and be a fully addressable system.
4.7.1.5 Programmed information shall be stored in non-volatile memory.
4.7.1.6 Unless each device can supply individual alarms, toxic and
combustible gas control units shall not be installed together in the
same rack.
4.7.1.7 Silence, trouble, test, and acknowledge functions shall be included
in the design of the logic as specified by the owner.
4.7.1.8 A system alarm shall be activated upon the failure of any sensor.

4.7.2

Multi-Channel Control Units

4.7.2.1 Multi-channel control units shall have individual alarms for each
separate channel.
4.7.2.2 When control modules are used, each module shall have two
adjustable (0-100%) alarms for high and high-high levels.
4.7.2.3 The alarm functions shall be visibly displayed from the front of the
control module by indicating lamps.
4.7.2.4 Each control module shall incorporate self-checking circuitry so that
if a component fails, a common failure light on the control module
shall illuminate to indicate system malfunction.
4.7.2.5 Each channel shall have adjustments for span, zero, and alarm set
points and shall be capable of being individually adjusted without
affecting any other channel.

4.7.3

Field-Mounted Control Units

4.7.3.1 Each unit shall have independent alarm adjustments for high and
high-high levels.
4.7.3.2 If field-mounted control units are to be two-wire type transmitters,
alarms shall be initiated in the appropriate logic solver.
4.7.3.3 Field-mounted control units shall have self-diagnostic features and
shall generate a failure alarm upon detection of loss of a correctly
functioning system.

Process Industry Practices

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PIP PCCA001
Combustible and Toxic Gas Detection Systems Criteria

4.7.4

December 2004

Indication and Field-Mounted Units

4.7.4.1 Control units and field-mounted units shall incorporate an integral
digital readout device to indicate the level of gas concentration for
each channel.
4.7.4.2 The system shall be designed for field indication of visual and/or
audible alarms for any sensor that is in alarm condition as specified
by owner.

4.7.5

System Alarm Design Strategy

4.7.5.1 The design of the systems shall enable quick identification of any
specific location at the facility that is being monitored.
4.7.5.2 The failure of any component in the system shall generate a
malfunction alarm.
4.7.5.3 Each combustible gas or toxic gas detector shall have individual
alarms that indicate a high and high-high alarm when a leak is
detected.
4.7.5.4 Gas detector alarm types (i.e., audible, colored beacon) shall be as
specified by the owner on PIP PCCA01D.
Comment: Even within the same company different locations
may have different requirements and strategies for
types of alarms to be installed.
4.7.5.5 Combustible or toxic gas detection system alarms shall be selflatching and shall reset manually.
4.7.5.6 The operational function shall be documented (logic diagrams, true
table, P&ID), clearly identifying which detector activates which
beacon or horn.

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Process Industry Practices