Handling LEL Sensor Poisons

HANDLING LEL SENSOR POISONS

It is well known that certain chemicals inhibit or poison the catalytic bead in LEL (combustible) sensors, leading to partial or complete loss of sensitivity. Poisoning is defined as a permanent degradation, while inhibition is usually recoverable by exposure to clean air. For the best sensor performance, it is crucial for both instrument users and manufacturers to avoid operation of the devices in an environment containing poisons and inhibitors.

LEL Sensor Poisoning

The most serious poisons are silicon compounds, such as silanes, silicones and silicates. Just a few parts per million (ppm) of such materials are sufficient to degrade the sensing performance. These compounds are used in a wide range of products, including lubricants, mold-release agents, polishes, adhesives, cosmetic and medicinal creams, silicone rubbers (including caulking and sealant compounds), and others.

Lead compounds, such as tetraethyl lead in gasoline, is a wellknown poison which reduces LEL sensitivity, especially for combustibles with high ignition temperatures, like methane.

High concentrations of halogenated hydrocarbons are thermally decomposed to HCl on the catalytic bead, which can cause corrosion of the sensor and low signal readings. H2S and other reduced sulfur compounds, such as carbon disulfide, dimethyl disulfide, and trimethyl disulfide, as well as phosphate esters, nitro compounds (e.g., nitromethane, nitroethane, and nitropropane), are oxidized to mineral acids that may be corrosive to the sensor. Hot organic acids (such as acetic acid), and direct exposure to acid gases (e.g., HCl, sulfuric acid vapors) can also corrode sensors. Chlorinated hydrocarbons are frequently found in solvents including degreasing and cleaning agents. Harmful chlorinated substances are also given off by overheating some polymers and plastics such as PVC insulated wire during soldering.

The forementioned materials are known to have a detrimental effect on the catalytic bead. Silicones are usually considered as one major poison source, and H2S as an inhibitor. However, most compounds fall into both categories to various degrees. Some compounds may chemically react near the catalytic bead at elevated temperature. This makes the poison mechanism more complicated.

Operation Precautions

To keep the sensor operating for a longer time, special attention should be made to reduce exposure of the sensor or monitor to
poisonous environments. Here are some tips:
• Follow the precautions below for Assembly and Service.
• Always use a recommended filter in front of the sensor, and change the filter weekly, or immediately after the exposure to a poison.
• Clean the pump and replace the tubing, filter, and gasket after a serious exposure to poisons.
• Reduce the exposure time of the sensor in poison surroundings, and turn the monitor off when not in use.
• Decrease the flow rate of gases over the sensor during operation in poison environments, or use a diffusion-type monitor instead.

Assembly and Service Precautions

To avoid introducing poisons to the monitor:
• Do not use any molded plastic parts that have been manufactured using silicone mold release agents.
• Do not use silicone rubber, elastomer, or sealants for gaskets, potting or insulation. These materials are particularly hazardous during mixing and setting, when they give off substantial amounts of vapor. Avoid operating the monitor in areas where these compounds are mixed or are curing.
• Do not use polishes, cleaners or lubricants containing silicones in the area where the instruments are assembled, tested or stored. Most domestic furniture polishes contain silicones.
• Assemblers and service technicians should not use cosmetic or medicinal hand creams containing silicones.
• Silicone lubricants are common in valves and regulators used in gas-distribution systems. Never use these components with LEL sensors.
• Epoxy and adhesives must be poison-free. Avoid using self-stick labels on the monitor or any internal parts. Many adhesives used on labels contain silicone.