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Fixed Gas Detectors, gas detection

Gas Detection in Cold Storage Facilities: Technologies and Best Practices | PK Safety

A worker walks through a cold storage room.

Eric Pedley |

Cold storage facilities are essential for preserving perishable goods, pharmaceuticals, and other temperature-sensitive products. However, these environments often use refrigerants like ammonia, carbon dioxide, and hydrocarbons, which pose significant health and safety risks should leaks occur. Here is what you need to know about gas detection systems in cold storage facilities to help you choose the optimal solutions for safeguarding employees, assets, and operational continuity. 

Why Gas Detection is Critical in Cold Storage Facilities

Cold storage facilities operate under unique conditions that heighten risks associated with gas leaks. Here are the primary factors contributing to this vulnerability: 

  • Temperature Fluctuations: Cold storage facilities frequently experience temperature fluctuations due to regular defrost cycles, which can stress refrigeration systems and increase the risk of leaks. With operating temperatures ranging from -50°F to +140°F, these shifts can compromise the integrity of refrigeration components over time, leading to potential failures if not properly managed.
  • Humidity and Condensation: High humidity levels and condensation can corrode metal components and seals, increasing the likelihood of leaks. Meanwhile, high-pressure spray-downs during maintenance can also introduce moisture and cause wear on seals and connections.
  • Confined Spaces: Cold storage areas are often confined spaces with limited ventilation, which can cause gases to accumulate and reach dangerous levels. Moreover, many refrigerants used in these facilities are odorless, making it difficult for personnel to detect leaks without the appropriate gas monitoring systems. 

Gas leaks can reduce the efficiency of refrigeration systems. In addition to higher energy consumption and operational costs, undetected gas leaks can disrupt operations, leading to product spoilage and financial losses. More importantly, exposure to high concentrations of refrigerant gases can lead to respiratory issues, eye irritation, and even asphyxiation. They can also cause chemical burns, fluid buildup in the lungs, organ damage, and, in severe cases, sudden death (Healthline, n.d.). 

Types of Gas Detection Solutions for Cold Storage Safety

Fixed gas detectors can monitor several gases simultaneously, making them ideal for facilities using different refrigerants or operating in varied conditions. These versatile solutions use a combination of electrochemical, infrared, catalytic sensors, and other advanced sensor technologies to detect diverse toxic refrigerants and monitor oxygen levels. Fixed gas detector installation enables continuous monitoring of critical areas, such as refrigerant lines, compressor rooms, and storage zones, where leaks are most likely to occur. When integrated with building management systems, they can trigger automated responses to protect employees and assets. 

At PK Safety, we offer fixed and portable multi-gas detectors to accommodate diverse applications, from cold-storage gas detection to LEL gas monitoring. Portable models are ideal for emergency response situations, spot-checking specific areas, or conducting routine inspections.

We also carry gas detection systems specifically engineered to perform reliably in low-temperature environments while delivering accurate readings. The RKI OX-600 Indoor Stand Alone Oxygen Monitor is a great option that uses a fast responding low-cost plug-in style galvanic cell sensor. This sensor is field replaceable with no tools required. The sensor can be remotely mounted with an optional remote sensor cable. 

Using a combination of fixed and portable gas monitoring solutions provides the most comprehensive safety coverage for cold storage facilities.

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How to Choose the Right Gas Detector for Refrigerated Storage

There are several factors to consider when selecting the optimal gas detection solution for your cold storage facilities. Here are the primary considerations to help guide your choice:

  • Understand the Facility Requirements: Conduct a risk assessment to determine the types and concentrations of gases in cold storage areas. This will help identify the appropriate sensors required and whether you need an oxygen sensor for cold storage. Remember, these facilities need sensors capable of functioning accurately in fluctuating temperature and humidity ranges. Ensure the selected sensors are rated for such conditions. Depending on the size and complexity of your refrigeration system, multiple sensors might be necessary. For instance, aside from monitoring O2 levels, your work environment might also require protection from potentially hazardous ammonia leaks. 
  • Evaluate Safety Standards: Familiarize yourself with the relevant safety standards and ensure that your gas detection system complies with all applicable requirements, such as ASHRAE 15, EN 378, and OSHA guidelines.
  • Ease of Integration: Modern facilities benefit from gas detectors that integrate with building management systems, allowing centralized monitoring of multiple zones. This feature is especially beneficial for large-scale facilities, where integrated detectors and emergency shutdown controls can trigger immediate responses to gas leaks.

Installation and Maintenance Best Practices for Cold Storage Gas Detectors

Follow these best practices to maintain safety and compliance:

  • Strategic Placement: Install fixed detectors near potential leak points and use portable devices during inspections to cover less accessible areas.
  • Maintenance Scheduling: Follow the manufacturer’s recommendations for calibration frequency and use certified calibration gases. Establish a routine maintenance schedule for conducting regular inspections and replacing aging sensors, filters, and other components that may compromise performance and safety (OSHA, 2013). 
  • Employee Training: Conduct ongoing employee training on using gas monitoring systems. This includes observing proper maintenance practices, understanding alarms, and executing emergency protocols. 

By following these practices, facilities can extend the lifespan of their gas detection systems and ensure consistent safety and operational efficiency in cold storage environments. Contact us today to discuss your cold storage gas detection requirements. We’re always happy to help. 

PK Safety’s Expertise in Cold Storage Gas Detection Solutions

After over 75 years in the industry, we’ve vetted hundreds of products from the top manufacturers, including gas detection solutions including those from RKI Instruments, BW Honeywell and RAE Systems. This experience allows us to offer our customers safety solutions with the latest and most reliable technology at the best prices. Moreover, we know all the relevant safety standards and regulations, enabling us to create tailored solutions to enhance the overall safety in your work environments.  

Here at PK Safety, our commitment to customer service includes expert guidance in selecting the optimal systems and ongoing support for maintenance and calibration. As a factory-authorized service center for RKI, BW, and RAE, we have in-house factory-trained technicians that can service your gas detectors. Contact us today at (800) 829-9580 for more information and to speak with our safety experts.

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