In the petrochemical industry, flammable gas detectors serve as a first line of defense for safety. At the heart of these detectors lies the sensor (probe)—a component that often fails unexpectedly. But contrary to popular belief, most failures aren’t due to poor quality, but rather due to environmental stress, incorrect usage, and poor maintenance practices.
This article outlines the four key categories of causes behind frequent sensor failures and offers actionable insights for prevention.
🔍 1. Environmental Factors: Temperature, Humidity, Corrosion
Sensors are often exposed to harsh conditions, making the environment the primary cause of failure.
🔸 High/Low Temperatures
High temperatures degrade internal electronic components, accelerate aging, and may cause thermal damage.
Low temperatures reduce sensor sensitivity and may cause brittleness or cracking.
🔧 Tip: Ensure detectors are rated for the working temperature range. Use shielding or ventilation in high-heat areas.
🔸 Humidity & Condensation
High humidity leads to internal moisture, corrosion, and short-circuiting.
Condensation can severely impact the sensor’s electrical performance.
🔧 Tip: In damp environments, choose sealed or waterproof-rated sensors and implement anti-condensation measures.
🔸 Chemical Corrosion
Corrosive gases or vapors can damage sensor components and housings.
Common in chemical plants where volatile solvents or acids are present.
🔧 Tip: Select corrosion-resistant sensor materials and install away from direct chemical sources.
🧪 2. Gas-Related Factors
🔸 High Concentration Gas Exposure
Sudden exposure to high concentrations of flammable gas can overwhelm and damage the sensing element.
This often happens during accidental leaks or explosions.
🔸 Gas Impurities
Dust, particles, or impurities in the sampled gas can block the intake or contaminate the sensor surface.
Over time, this leads to reduced sensitivity or false alarms.
🔧 Prevention: Use gas filters where needed, and conduct periodic cleaning to maintain accuracy.
⚙️ 3. Intrinsic Component Issues
🔸 Aging and Wear
Sensing elements and electronics degrade over time.
Typical sensor lifespan: 3–5 years depending on use conditions.
🔸 Manufacturing Defects
While less common, soldering issues, improper material selection, or poor assembly can cause premature failure.
🔧 Best Practice: Track service life and replace sensors proactively. Choose reputable suppliers with strict quality control.
🛠️ 4. Installation & Maintenance Issues
🔸 Improper Installation
Poor placement (e.g., near heat sources, ventilation outlets, or strong electromagnetic fields) affects sensor performance.
May cause false alarms, delayed detection, or total failure.
🔸 Lack of Routine Maintenance
Neglected cleaning and calibration can result in:
Dust buildup
Signal drift
Inaccurate readings
🔸 Overuse or Continuous Operation
Sensors under continuous high-frequency usage in industrial zones face accelerated wear.
🔧 Recommendations:
Install according to manufacturer guidelines.
Schedule monthly inspections, annual calibration, and environment checks.
🧩 Conclusion: Not a Quality Problem—It’s a System Problem
Frequent sensor failures are often wrongly blamed on quality. In reality, they reflect systemic issues in selection, installation, and maintenance.
✅ Start with the right sensor for the environment.
✅ Install smart, maintain regularly.
✅ Break the “good enough” mindset.
Have you experienced an unusual sensor failure? Share your story in the comments or contact us for expert support and recommendations.