Gas-Leak Detection | Customer Success

Common Challenges in Gas-Leak Detection and How to Overcome Them

by Astha Chavda on 06/10/25

Introduction

Gas leaks are among the most dangerous hidden hazards in industrial and commercial facilities. According to OSHA, undetected gas leaks contribute to hundreds of workplace incidents every year—many of them preventable. Even small leaks, if overlooked, can put employees at risk, damage equipment, disrupt operations, and result in costly regulatory penalties. 

Many facilities assume that simply installing detectors is enough. In reality, operational oversights, environmental conditions, and human error can leave dangerous gaps in safety. 

ESPM SENSE offers reliable fixed and portable gas detection solutions that help facilities identify hazards early, protect their workforce, and maintain smooth, compliant operations. With these solutions, companies can prevent accidents, minimize downtime, and ensure safety across all areas of their facility. 

Frequently Asked Questions

Challenge 1: Incorrect Detector Placement and Height

The Issue: Gas detectors are sometimes installed at the wrong height or location, which can prevent accurate detection. 

For example:

  • Lighter-than-air gases (like methane or hydrogen) rise, so detectors should be installed near the ceiling.
  • Heavier-than-air gases (like propane or butane) settle, so detectors need to be closer to the floor.

Impact: Poor placement can lead to delayed detection, missed leaks, and increased safety risk. 

How to Overcome It:

  • Understand the properties of the gases used in your facility.
  • Follow manufacturer and regulatory guidelines for detector height and placement.

✅ Correct placement ensures that detectors sense gas concentrations early, giving staff more time to respond. 

Challenge 2: Unreliable Sensor Performance

The Issue: Some facilities delay or skip regular calibration and maintenance of sensors, assuming detectors will work indefinitely. 
Impact: Sensors drift over time, leading to false alarms or missed leaks, putting employees and equipment at risk. 

How to Overcome It:

  • Follow manufacturer-recommended calibration and testing schedules.
  • Use certified calibration materials to ensure consistent readings.
  • Maintain detailed logs of calibration, testing, and maintenance for audits and quick troubleshooting.
  • Schedule periodic replacement of sensors nearing the end of their service life.

✅ By maintaining sensor reliability, facilities ensure early leak detection, reduce false alarms, and protect employees and assets. 

Challenge 3: Some Areas May Not Be Properly Monitored

The Issue: Even when high-risk spots are identified, some areas may not be effectively monitored if only fixed detectors are used. 
Impact: Leaks in these unmonitored areas can go unnoticed, putting employees and equipment at risk. 

How to Overcome It:

• Identify high-risk zones such as valves, pipelines, and confined spaces.

• Use a combination of fixed detectors for continuous monitoring and portable detectors for flexible, on-demand checks.

• Consider environmental conditions to ensure accurate detection.

• Implement centralized monitoring system to track installed all detectors across areas in real time.

• Train staff to Use MCP or DAMS software to track all detectors across the facility in real time 

✅ Placing detectors in the right spots and using smart monitoring tools ensures leaks are found quickly, keeping people and equipment safe. 

Challenge 4: Lack of Staff Training for Gas Safety

The Issue: Facilities often assume employees know how to respond to alarms without formal training. 
Impact: Slow or improper staff responses can worsen the consequences of a gas leak. 

How to Overcome It:

  • Provide regular training sessions on detector use, alarm interpretation, and emergency response.
  • Conduct mock-drills and scenario-based exercises to build confidence in handling gas hazards.
  • Create clear response protocols accessible to all employees.
  • Update training whenever new detectors or processes are introduced.
  • Provide general safety instructions related to gas hazards, including PPE use, evacuation routes, and hazard awareness.

✅ Well-trained staff respond quickly and correctly, reducing risks and ensuring safety. 

Challenge 5: Poor Record-Keeping and Compliance

The Issue: Facilities may neglect proper documentation of monitoring, maintenance, and incident responses. 
Impact: Poor records can result in regulatory penalties or in worst cases, operational stoppages. 

How to Overcome It:

  • Use detectors and monitoring software that log readings, maintenance activities, and alarms.
  • Maintain proper records for audits and compliance reporting.
  • Conduct regular internal reviews of reports to ensure accuracy and completeness.
  • Ensure staff understand compliance requirements and the importance of documentation.

✅ Accurate, automated documentation ensures compliance, reduces risk of penalties, and supports safer facility operations. 

Challenge 6: Using the Right Detector for the Job

The Issue: Facilities often use only one type of detector for all situations, without considering whether a fixed, portable, or staff-carried detector is most suitable. 
Impact: Using the wrong detector can create blind spots and missed leaks 

How to Overcome It:

  • Use fixed detectors for continuous monitoring in high-risk or confined areas.
  • Use portable detectors for temporary checks, maintenance work, or routine inspections.
  • Provide staff with detectors they can carry when entering hazardous zones.
  • Evaluate detection needs based on gas type and operational conditions.

✅ Choosing the right detector type ensures comprehensive coverage and reduces the chance of undetected leaks. 

Challenge 7: Lack of Centralized Monitoring Integration

The Issue: Alarms may not reach the correct staff if detectors aren’t linked to control systems or centralized monitoring. 
Impact: Delayed response to leaks, inefficient evacuation, or missed regulatory reporting. 

How to Overcome It:

  • Connect detectors to centralized monitoring system that triggers alerts in real time if leak detected in installed detectors.
  • Train staff through mock drills & trainings to respond to system alerts along with emergency plan.

✅ Proper integration ensures fast, coordinated responses to gas leaks and strengthens facility safety. 

Challenge 8: Risks from Aging Infrastructure

The Issue: Older pipelines, connectors, and valves can develop leaks over time. Their layouts may make detecting gas more difficult. 
Impact: Even with detectors in place, aging infrastructure can prevent early leak detection, increasing risk to employees and operations. 

How to Overcome It:

  • Conduct regular inspections and risk assessments focused on the condition and layout of pipelines and connectors.
  • Prioritize monitoring in areas with older or complex pipelines.
  • Replace or upgrade worn-out parts where feasible to reduce leak risks.
  • Use fixed or portable detectors in critical areas to ensure thorough monitoring.

✅ Keeping aging infrastructure in check helps detect leaks early, protecting people and maintaining safe operations. 

Conclusion

Gas leaks remain one of the most serious hazards in industrial and commercial facilities. Most failures don’t happen because detectors aren’t installed—they happen because of common mistakes: skipped or lack of maintenance, ignoring multiple gas types, improper placement, insufficient staff training, outdated infrastructure, or environmental interference. 

The good news is that every one of these challenges can be addressed with the right strategy, equipment, and training. With ESPM SENSE gas detection solutions, your facility can:

  • Detect leaks early, even in hazardous areas or high-risk areas
  • Protect employees, assets, and operations around the clock
  • Keep operations running smoothly
  • Stay fully compliant with industry regulations
💡Take action today: Make gas detection a strength, not a risk. Implement a comprehensive detection program with ESPM SENSE to safeguard your people, your facility, and your operations. 

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