Optical Gas Imaging For The Chemical Industry: Safety

TECHNICAL NOTE
OPTICAL GAS IMAGING FOR THE CHEMICAL INDUSTRY

Optical gas imaging cameras are a proven method to detect dangerous and
costly gas leaks in time. Optical gas imaging technology has been successfully
applied in the oil refining, chemical, petrochemical and many other industries
to help improve worker safety and prevent costly production shutdowns.
The FLIR optical gas imaging camera lets you

see gas leaks quickly, easily, and from a safe
distance
Chemical compounds and gases are

invisible to the naked eye. Yet many
companies work intensively with
these substances before, during and
after their production processes. The
FLIR Gas Detection cameras are infrared cameras which are able to visualize
gas by utilizing the physics of fugitive
gas leaks. The camera produces a full
picture of the scanned area and leaks
appear as smoke on the cameras
viewfinder or LCD, allowing the user
to see fugitive gas emissions.
SAFETY
The key success factors of optical
gas imaging cameras for businesses
are safety, efficiency and profitability.
A gas detection camera is a quick,
non-contact measuring instrument
that can be used in hard-to-access
locations. It can detect small leaks
from several meters away and big
leaks from hundreds of meters away.
This way, operators do not need to
approach the leak from close by, which
improves the safety significantly.
emissions regulations & procedures

as set by the new IED (Industrial
Emissions Directive) within the EU
as part of the BREF (Best Available
Technique Reference) for Refining
or Mineral Oil & Gas. Chapter 5.1.4
is the draft BREF conclusion, for the
Refining or Mineral Oil and Gas industry sector, stating optical gas imaging
is one of three BAT (Best Available
Techniques) which must be used for
monitoring diffuse VOC emissions.
The petrochemical industry produces

hydrocarbon and other substances
using base feed stocks from the oil
refining companies either by conversion processes or further separation
that is not normally carried out at an
oil refinery. Most of the chemicals
used or made in these industries have
good visibility using the mid wave
gas detection camera. The chemical
industry produces non-hydrocarbon
or inorganic chemicals from base feed
stocks. These are often a mixture of
batch and continuous processes that
yield very high purity products. The
mid wave gas detection camera has a
good response to a lot of chemicals
found in this sector.
EFFICIENCY
Working with sniffers or probes can
be very time-consuming and a lot of
the time spent inspecting installations
that are safe and leak-free is wasted.
Using a Gas Detection camera you get
a complete picture and can immediately exclude areas that do not need
any action. This saves a lot of time
and personnel. With a gas detection
camera, measurements can be carried
out remotely and rapidly and most
important of all problems can be
identified at an early stage.
FLIR.COM
ENVIRONMENTAL REGULATIONS
Optical gas imaging allows the industry to comply with new industrial
OPTICAL GAS IMAGING

CAMERAS: BUY OR LOAN?
Although the cost of optical gas
imaging cameras has decreased
in recent years, purchasing a gas
detection camera is still a significant
investment for a lot of companies.
According to Frank Zahorszki, CEO of
Itema GmbH, a German service company specia
lized in thermographic
inspections, the purchase price of an
optical gas imaging camera should
not deter smaller chemical companies
from making use of this technology.
Today, more and more companies
are contracting outside service providers for leak detection and repair to
specialized service companies, says
Zahorszki. This begs the question
TECHNICAL NOTE
whether your company should buy or
loan an optical gas imaging camera.
The two main reasons for a plant
buying an OGI camera are the
amount of targets to inspect and the
just-in-time availability of the camera
in case of a leak. Companies that
only require one to five inspection
days per year, or companies that have
the convenience to wait for a service
company to come over, will opt for
an external contractor. Very often,
companies need to monitor different
types of gases with different types of
cameras, which justifies an external
service provider even more.
The gas detection camera technique
has a wide range of potential uses
in the chemical and petro-chemical
industries.
GF320: HYDROCARBONS
Optical gas imaging cameras like
the FLIR GF320 help to spot leaks in
piping, flanges and connections in petrochemical operations. The GF320 can
rapidly scan large areas and pinpoint
leaks and is ideal for monitoring plants
that are difficult to reach with contact
measurement tools. Literally thousands of components can be scanned
per shift without the need to interrupt
the process. It reduces repair downtime and provides verification of the
process. Above all it is exceptionally
safe, allowing potentially dangerous
leaks (e.g. methane) to be monitored
from several meters away.
GF346: IMPROVING WORKPLACE
SAFETY
Optical gas imaging cameras are an
efficient way to inspect the workplace for dangerous gas leaks. This
can especially be useful in foundries

or in other processes where significant amounts of carbon monoxide
(CO) are generated. CO is a colorless,
odorless gas usually formed during
the combustion process. Anywhere
there is a heated process leading
to the formation of smoke such as
moulds and cupola furnaces CO will
be present. Workers on charging
platforms or catwalks can unknowingly breathe high concentrations
of this gas. This can block oxygen
being transported, from the lungs,
causing the worker to suddenly lose
consciousness. High concentrations
may prove rapidly fatal without any
warning symptoms.
GF309: FURNACE INSPECTIONS
The FLIR GF309 is designed for
high temperature industrial furnace
applications. These cameras are ideal
for monitoring all types of furnaces,
heaters and boilers, particularly in the
chemical and petrochemical industries. Custom-built to see through
flames, the FLIR GF309 also features
a detachable heat shield designed to
reflect heat away from the camera
and camera operator, providing
increased protection.
GF343: LEAK TIGHTNESS TESTING
Carbon dioxide (CO2) is considered
to be a relatively inexpensive tracer
gas for tightness testing. The method
is also reliable, can be used to test
complex equipment, and CO2 is easy
to obtain. With optical gas imaging
cameras, like the FLIR GF343, you
can see CO2 leaks quickly, easily, and
from a safe distance. This is very helpful at turnarounds and shut-downs to
test the inertization and filling of the
equipment.
HSM is in part an image subtraction video

processing technique that effectively enhances
the thermal sensitivity of the camera.
GF306: CRACKERS , AMMONIA, SF6

Cracking is a conversion process
used in petroleum refineries which
converts the high-boiling, high-molecular weight hydrocarbon fractions
of petroleum crude oils to more
valuable gasoline olefinic gases and
other products. Gases escaping from
the cracking process can be highly
flammable and dangerous. Being a
non-contact measurement device,
OGI cameras like the FLIR GF306 are
ideal for monitoring chemical plant process areas/operations, such as steam
crackers and reformers, especially for
components that are difficult to reach
with contact measurement tools.
HIGH SENSITIVITY MODE
FLIR gas imaging cameras are surprisingly sensitive, so they can be
used to detect even smaller gas leaks
from about several meters away. This
is especially the case when operation
in the High Sensitivity Mode (HSM).
This is a special feature included in
all GF-Series optical gas imaging cameras. It is an image subtraction video
processing technique that effectively
enhances the thermal sensitivity of the
camera. The HSM feature subtracts a
percentage of individual pixel signals
from frames in the video stream from
the subsequent frames, thus enhancing the differences between frames,
which make leaks stand out more
clearly in the resulting images.
For more information about thermal imaging

cameras or about this application, please visit:
Captured gas leak from production site.
Gas leak is clearly visible on the thermal image.
www.flir.com/ogi
The images displayed may not be representative of
the actual resolution of the camera shown. Images for
illustrative purposes only. 2015 FLIR Systems Inc., All
rights reserved (created 11/15)

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TECHNICAL NOTE

OPTICAL GAS IMAGING FOR THE CHEMICAL INDUSTRY

The FLIR optical gas imaging camera lets you

Chemical compounds and gases are

emissions regulations & procedures

The petrochemical industry produces

OPTICAL GAS IMAGING

can especially be useful in foundries

HSM is in part an image subtraction video

GF306: CRACKERS , AMMONIA, SF6

For more information about thermal imaging

Gas leak is clearly visible on the thermal image.

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