Gas-Leak Detection | Customer Success

Best Practices for Installing Gas-Leak Detection Systems: A Complete Guide

by Jeet Sodagar on 28/08/25

Why Gas Detection Installation Matters

In industrial plants, laboratories, and confined spaces, gas-leak detection systems serve as the first line of defense against toxic, flammable, or oxygen-depleting gases.

A perfectly selected and mounted gas detector can fail its purpose if installed incorrectly — and We’ve seen this countless times in many years in the field.

A proper installation ensures accurate detection, timely alarms, and operator safety. In this guide, We’ll share time-tested best practices for installing fixed and portable gas detectors — the same methods we follow when deploying ESPM Sense FGD-X and PGD-X systems in real-world applications.

Immediate First Aid and Medical Response Steps

1. Choose the Right Detector for the Gas Type

Before installation, match your sensor type to the gas properties:


Gas Type	Example Gases	Recommended Sensor Type
Toxic Gases	CO, H₂S, NH₃, Cl₂, SO₂, NO₂	Electrochemical
Flammable Gases	Methane (CH₄), LPG, Hydrogen	Catalytic pellistor or NDIR
Oxygen Deficiency	N₂ or CO₂ environments	Electrochemical
VOCs / Hydrocarbons	Benzene, Toluene, Ethanol	PID

2. Determine Optimal Sensor Placement

Incorrect sensor placement is the #1 cause of missed gas leaks.
Each gas behaves differently depending on its density compared to air:

Expert Tip: Always place detectors near potential leak sources, not just open spaces — like gas cylinders, pipelines, or valves.


Gas	Example Gases	Recommended Sensor Type
Hydrogen (H2)	Lighter	Near ceiling
Methane (CH4)	Lighter	30–60 cm below ceiling
Ammonia (NH3)	Lighter	High, near potential leak source
Chlorine (Cl2)	Heavier	30–60 cm above floor
CO, H2S, NO2	Similar Density	Breathing zone (~1.5 m)

3. Avoid Common Installation Errors

Even a high-end detector like ESPM Sense FGD-X can underperform if installed poorly.

Here’s what to avoid:

❌ Installing in dead air zones or near ventilation outlets.
❌ Placing sensors too close to doors or fans, where air currents may dilute gases.
❌ Ignoring temperature and humidity — place sensors away from heat sources and condensation-prone spots.
❌ Running unshielded signal cables near power lines — it can introduce electrical noise and affect readings.
❌ To not provide proper earthing to detectors and not closing glands/blinds and instrument properly can damage internal parts permanently.

Pro Tip: Use shielded twisted pair cables and proper grounding for all analog and RS-485 connections.

4. Calibration and Commissioning

After physical installation, every detector must be bump-tested and calibrated using certified gases.

Steps:
1. Power on and warm-up the detector (usually 30–60 minutes).
2. Perform a zero calibration using clean, ambient air.
3. Apply calibration gas at a known concentration with the correct flow rate (usually 0.5-1.0 L/min).
4. Verify readings within the sensor’s tolerance range.

⚠️ Avoid using improvised or non-certified gas cylinders or liquids like IPA.
Over-concentrated gases can damage sensors permanently — especially electrochemical ones.

5. Mounting and Protection

Each sensor must be mounted on a stable surface, away from vibration or mechanical shock.

Use corrosion-resistant mounting brackets.
In outdoor or wet environments, use weatherproof enclosures (IP65 or higher).
Provide drip shields above sensors if there’s risk of condensation or wash-down water.

In confined or underground spaces, pair fixed detectors with PGD-X Portable Gas Detectors for personal safety during maintenance or inspection.

6. Ensure Proper Wiring and Integration

For networked systems:

Use 4–20 mA, RS-485 (Modbus RTU), or relay outputs based on your control system.
Label all connections clearly.
Verify wiring polarity and shielding continuity.
Check signal integrity at the controller end after installation.

For critical safety systems, connect detectors to:

Audible/visual alarms
Exhaust fans or ventilation systems
Automatic shut-off valves

7. Test, Document, and Train

Once installation is complete:

Conduct a leak simulation test at each sensor point.
Document calibration certificates, wiring diagrams, and test results.
Train operators to recognize alarm signals, reset devices, and respond safely.

Regular quarterly calibration and annual preventive maintenance ensure your system performs at peak reliability.

8. Combine Fixed and Portable Detection for Full Coverage

No system is truly complete without both fixed and portable gas detection:

Fixed Gas Detector: Constant monitoring in high-risk areas.
Portable Gas Detector: Personal protection during fieldwork or maintenance.

Together, they provide layered safety, ensuring early warning and rapid response to gas leaks anywhere in your facility.

Conclusion

After years of installing and troubleshooting gas detection systems, one lesson stands out:
“A gas detector is only as good as its installation.”

Taking time to install correctly — with proper height, calibration, and wiring — can mean the difference between a safe plant and a costly accident.

Choose robust and certified devices like ESPM Sense’s FGD-X, PGD-X, IoTified Area Monitoring panels for the best results. follow these best practices, and your system will serve you reliably for years to come

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