How to Choose the Right Fire & Gas Detection System for Your Industrial Site

Osodi Hillary
How to Choose the Right Fire & Gas Detection System for Your Industrial Site

In every industrial environment, from oil & gas facilities to manufacturing plants and chemical processing sites, fire and gas risks are a constant reality. A single leak, flame event, or undetected toxic release can trigger catastrophic downtime, equipment damage, and major safety incidents. This is why selecting the right fire and gas (F&G) detection system is not just a compliance requirement; it is a strategic decision that protects your people, your assets, and your long-term operations.

1. Understand Your Site’s Risk Profile

Every facility has unique hazards, and your detection strategy begins with a thorough hazard and operability analysis (HAZOP). This assessment helps identify:

  • The types of gases present

  • Potential leak points

  • Open vs enclosed areas

  • Potential ignition sources

  • Areas with high personnel density

  • Consequences of worst-case fire or gas events

Different hazards call for different detector technologies. For example, hydrocarbon processing plants require fast flame detection and flammable gas monitoring, while pharmaceutical facilities may prioritize toxic gas detectors like chlorine or ammonia monitors.

A system is only effective if it's matched to the environment it protects.

2. Know the Detection Options Available

Modern F&G systems use multiple technologies. Understanding them helps you choose the right ones for your site.

a. Gas Detectors

These monitor airborne concentrations of flammable or toxic gases.

Common types include:

  • Infrared (IR) Gas Detectors — Accurate, fast response, resistant to poisoning

  • Catalytic Bead Detectors — Traditional flammable gas detection

  • Open Path Gas Detectors — Monitor large areas between transmitter and receiver

  • Photoionization Detectors (PIDs) — Detect VOCs and low-level toxic gases

Each type serves different purposes. For open, windy environments (e.g., tank farms), open-path IR detectors are ideal. For enclosed spaces, compact point sensors are better.

b. Flame Detectors

Flame detectors identify fires at the earliest spark.

Types include:

  • UV flame detectors — Speedy response

  • IR flame detectors — Excellent false alarm immunity

  • UV/IR hybrid detectors — Combines the strengths of both

  • Multi-spectrum IR detectors — Best for hydrocarbon fires

Flame detectors are essential in:

  • Offshore platforms

  • Fuel loading bays

  • Compressor stations

  • Gas turbine halls

c. Fire Detection & Alarm Devices

These devices detect smoke, heat, and early fire indicators.

Common devices include:

  • Multi-sensor smoke detectors

  • Thermal/heat detectors

  • Beam detectors for warehouses

  • Aspirating smoke detection systems

Aspirating smoke detection is especially useful for high-value or high-airflow environments like MCC rooms, control cabinets, and server rooms.

3. Consider Environmental Conditions

Environmental factors heavily influence detector performance.

Ask yourself:

  • Is the area dusty or humid?

  • Are there corrosive chemicals present?

  • Is the space enclosed or open air?

  • Are temperatures extreme?

  • Is there vibration from machinery?

Environmental realities determine whether you should choose ruggedized detectors, stainless steel housings, weather-proofing, heated sensor heads, or specific mounting techniques.

4. Detector Placement: The Blueprint of Efficiency

Even the most advanced detectors are useless if placed incorrectly.

Good design considers:

  • Airflow patterns

  • Leak behavior of specific gases (lighter gases rise, heavier gases sink)

  • Blind spots caused by equipment layouts

  • Ventilation and extraction systems

  • Human traffic patterns

This is where engineering companies like Gil Automations come in applying proven placement models and safety standards to ensure complete coverage.

5. Ensure Compliance With Standards & Regulations

To build a reliable F&G system, compliance is non-negotiable.

Your system should align with:

  • ISA / IEC fire & gas standards

  • NFPA Code requirements

  • IECEx and ATEX requirements for hazardous areas

  • OEM safety integrity level (SIL) certifications

Compliance isn’t just a formality; it determines whether your system performs under real emergency conditions.

6. Integration With Other Safety Systems

A modern F&G detection system doesn’t work alone; it must integrate with:

  • Emergency shutdown systems (ESD)

  • Fire suppression systems

  • SCADA or DCS

  • Alarm and notification systems

  • Ventilation and damper controls

The goal is seamless communication: detect → alert → respond automatically.

7. Ongoing Maintenance and Calibration

Even the best detectors degrade over time. Regular maintenance includes:

  • Scheduled calibration

  • Bump testing of sensors

  • Firmware updates

  • Visual inspections

  • Replacing end-of-life sensors

Neglecting maintenance is the fastest way to create blind spots.

8. Total Cost of Ownership (TCO)

Cheaper doesn’t always mean cost-effective. Consider:

  • Replacement sensor cost

  • Calibration frequency

  • Environmental wear

  • False alarm rates

  • Downtime risk

  • Integration costs

A well-designed system saves more money in the long run than the cheapest system.