SO2 is a toxic gas which can cause respiratory issues and health complications with exposure to low concentrations. In a FGD (Flue Gas Desulphurisation) plant, it is possible that SO2 could be present in the local ambient air should a leak or plant fault occur.
To protect plant operatives and contractors, CEM Solutions (UK) Ltd were invited to work with the client to design a system to meet their specific requirements, providing a live SO2 measurement and alarm system.
During the initial site visit there was a number of “hot spots” identified as higher risk areas where pockets of SO2 were more likely to be found around the building. Suitable locations were agreed and a network of sensors was installed.
The STATUS Scientific electrochemical based gas detectors were connected to the CEM Solutions (UK) Ltd CEMWare data collection and reporting panel which in turn controlled six alarm beacons. Three alarm beacons were installed inside the building to alert onsite personnel and contractors to exit and three external beacons mounted above entry doorways to alert people who may intend to enter the building.
CEM Solutions (UK) Ltd worked with site health and safety team to identify safe levels and configured the CEMWare alarms accordingly.
The CEMWare data handling and reporting system was installed on the outside of the building under a stainless-steel weather hood to allow users to safely check the levels and location of the leak on the plant overview page where the sensors are clearly identified. In addition to this a remote connection is configured to allow users to remotely monitor the measurement data and alarm status. Digital outputs were connected to the site DCS and in turn the sites pager system to alert maintenance personnel to any issues.
Not everything goes to plan!
This was a bespoke system, designed from the ground up and there were some ‘teething issues. In the first weeks following commissioning the system had to go through a software change to eliminate some unexpected functionality.
An issue with the software caused the alarm relays to remain latched even when the SO2 levels had dropped below the configured levels. The CEM Solutions team studied the data and found a problem with a Modbus driver causing the error.
Since the software bug was found and resolved, the system has performed without fail, raising alarms when it should, keeping site operatives safe from possible SO2 fugitive emissions.
A second chance to get it right first time.
Following the success of the FGD building installation, CEM Solutions (UK) Ltd were invited to look at a second installation point, Lorry Wash.
This area is where site traffic is cleaned and there is low but theoretical risk of SO2 in the ambient air. A small panel was designed to house the power supply and alarm beacon with the monitor mounted at the side.
Installed and commissioned within the day, the system is now operational!
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