How They Make It Work: Emerson’s Rosemount 625IR Gas Detector

‘How They Made it Work’ is a column that features some of the latest technological advancements in the chemical process industry. Here, Chemical Processing asks experts from various technology providers to provide insight into their innovations and how they're helping chemical manufacturers operate their plants more efficiently and effectively.

Company:

Emerson

Technology:

The Rosemount 625IR is an advanced optical infrared (IR) gas detector certified for arduous industrial applications, including hazardous areas. The detector does not require field calibration and includes a five-year SIL 2-certified proof-test interval. It’s also been designed for fast function testing without the need for calibration gas. 

Significance in chemical operations:

The risk of explosion or fire is ever-present in many industries that use hydrocarbons. Personnel safety and asset protection through safe gas-leak detection is critical for modern chemical plants processing potentially explosive substances. Hydrocarbon point gas detectors, such as 625IR, are usually placed near potential hazardous gas-leak sources, with the number and location of sensors determined by the extent and geometry of the area requiring coverage, air movement and other factors. Given this complexity, a large chemical plant with reactors, heat exchangers, centrifuges, storage tanks and other equipment may require multiple gas detectors because there can be many potential gas-leak sources. Such environments also can have extensive air movement, which can move gas from leak points to other areas. These gas detectors must be very reliable because false alarms can stop production.

Unique features

625IR has many features that were designed to help reduce the installation complexity, the maintenance burden and simplify operation.

• Average response times of less than two seconds
• No field calibration needed
• 5-year SIL 2-certified proof-test interval
• Gas-free function testing
• A range of accessories designed to keep the detector working in all weather conditions
• Extended probe versions designed for fast, accurate gas detection in ducts
• Bright status indicator designed to help technicians easily see the device health during walkarounds 

Case study

A chemical plant in Decatur, Georgia, with several processing areas installed 17 of the 625IR gas detectors to replace older detection devices that needed frequent maintenance due to adverse weather conditions and other factors. Due to the increased maintenance needs, the plant operator was reluctant to put more detectors in the other areas. After realizing that 625IR had a considerably lower maintenance burden, the operator changed his mind and installed the gas detectors in the new applications as well as the existing ones.

Annually, the calibration cost of traditional older-style detectors would be $100 per point with calibration needed every three months. The 625IR detectors save an estimated $7,000 in maintenance costs. For example, 625IR reduced required maintenance intervals and time in hazardous locations and cut maintenance costs through the use of gas-free testing.