Carbon Dioxide Detection Requirement in Breweries – A Case Study

The Background

a1-cbiss were recommended by an air monitoring survey to tender for the supply and install of a gas detection system in two breweries in the UK. a1-cbiss were chosen because of their gas detection experience working with breweries and their ability to design and build a system suitable for the clients’ needs.

Due to the physical size and complexity of the two breweries, an external air monitoring survey was commissioned to provide the necessary experience and knowledge to ensure informed judgements and additional control measure requirements were recommended.

Certain areas have been identified as having (or potentially having) elevated levels of CO2 and require modification to remove the problem altogether for health and safety reasons.

The Challenge

An H&S pillar has been introduced across all sites which includes the detection of CO2 for which the Engineering Compliance Manager is responsible for implementing at UK sites.

During the fermentation process, yeast consumes oxygen and expels large amounts of Carbon Dioxide (CO2). CO2 has a density that is heavier than air and as a result it collects in small toxic pockets low on the floor and can build up in confined spaces in and around the process.

As CO2 is a mild asphyxiate, these pockets of CO2 can be hazardous to personnel, and therefore operating around the process machinery can be dangerous.

At exposure levels above 5% vol, personnel will begin to feel fatigue to the point of exhaustion merely from respiration and severe headache.

a1-cbiss were challenged with designing and integrating a gas detection system to meet the needs of the health and safety pillar.

The Solution

The a1-cbiss proposal consisted of a proven solution within the brewing industry.

To ensure a safe workplace, a fixed gas detection system was specified to provide visual warnings, communication to extraction or ventilation systems once alarm levels are reached and integration to data acquisition and reporting software.

Each detection zone provides two alarm levels (5,000ppm & 15,000ppm) with sufficient outputs from the gas detection system to interface with the alarm beacons/klaxons providing internal alarm notification as well as notification at each entrance to the zone thus providing a warning to workers. 

The beacons on site will be of the traffic light variety, illuminated green when healthy/no alarm, amber on low level alarm and red on upper level alarm.

Gas sensors are positioned around all the hazardous areas within the packaging cell, and cold yeast storage room which will be cabled back to a central MX43 control panel.

a1-cbiss own CDAS data acquisition & reporting software has been integrated on a local PC or into SCADA.

The PC screen used by health & safety will be configured to show a graphical view of each zone, including traffic light coded indication of current status and alarms.

Testimonial

Having gone through a thorough tender process involving two independent companies, we choose a1-cbiss to supply, and install a full CO2 monitoring system that will cover all site processes. The project installation has three phases, and is planned over a three year period.

Stage one installation has been successfully completed, and covers all the areas within the packaging cell, and cold yeast storage room.

My initial assessment of a1-cbiss is very positive. During the initial tendering process they were extremely knowledgeable, and were professional in presenting a monitoring system that was suitable for our requirements. Also a1-cbiss were flexible in supporting our three year project plan in-line with our capital budget requirements.

The a1-cbiss Installation team worked to good standard, and more importantly Health & Safety standards were adhered too at all times.