Continuous monitoring of CO2 in brewing rooms and carbonation bottling area.

Areas of concern for high levels of Carbon dioxide (CO2) in breweries include the fermentation room, inside the fermenters and in the bottling area. During fermentation a significant amount of CO2 is generated and depending on the setup, may be ventilated or captured for use. Any CO2 that escapes can collect in low lying areas, forming potentially hazardous pools of gas that can build up and displace Oxygen (O2). Levels of O2 and CO2 should be checked prior to cleaning the fermenters by lowering a portable O2 and CO2 detector into the vessel to determine if it is safe to enter. Being odourless and colourless, the presence of CO2 is not known until symptoms of exposure are experienced, unless gas detection equipment is used.

Using Critical Environment Technologies’ FCS 4-channel System Controller with a CGAS Detector CO2 Transmitter, along with a personal, portable O2 detector is the solution. CGAS Detectors mounted inside the fermentation room and in the bottling area provide continuous monitoring for potential leaks of CO2. The FCS Controller with a top mounted strobe mounted outside the room door provides a status of the air quality conditions inside the room prior to entry. If a CO2 leak is detected, the top mounted strobe will activate and an audible alarm will sound. The designated relays will activate a preset response, such as turning on a remote alarm device, actuating the mechanical ventilation system and/or triggering another set response as required.

 

Typical Brewery CO2 Monitoring System

Inside the fermentation room, there should be a CGAS Detector with an infrared CO2 sensor mounted on the wall at the breathing zone height (4 - 6 feet from the floor). It should be close to the fermentation tanks where the possibility of a Carbon dioxide leak is most likely to occur. The measurement range for Carbon dioxide is 0 - 5% volume. With the optional splash guard installed, the CGAS Detector enclosure is water tight (IP54 rated) and will withstand water spray or wash down applications.
During the bottling process, CO2 is used to pre-fill each bottle before it is filled with beer. Another CGAS Detector with a CO2 infrared sensor should be mounted in the bottling area to monitor and protect workers on the bottling line. The cGas Detector CO2 transmitter is available with analog output (p/n: CGAS-A-CO2-5%) or Modbus output (p/n:CGAS-D-CO2-5%).

The FCS-4-M-AI System Controller with a top mounted strobe should be mounted outside the fermentation room entry door. It will interface with the CGAS detector inside the room and will display the target gas levels for viewing prior to entering the room. The FCS is pre-programmed and field adjustable, offering 4 dry contact relays, priority settings, logic control, including time of day, data logging, audible alarm and a full colour, resistive touch screen. The FCS should be configured to set off alarms and activate the exhaust ventilation system, shut down the equipment or other alarm procedures as appropriate when a CO2 or O3 leak is detected or oxygen levels are deficient. The FCS-4 accepts Modbus® RS-485 digital communication or analog (4 - 20mA) signal (must add Option -AI). Up to a maximum of four transmitters can be connected to the FCS-4. If more than 4 channels are required, other models of the FCS are available that offer 8, 32 or up to 128 channels.

Remote visual and audible alarm devices such as the Remote Strobe / Horn (RSH-24V-R) should be set up inside each room and if there is another entrance to the room, an RDM Remote Display Module should be mounted outside the door of that entrance, to provide visual confirmation of gas level readings prior to entering the room.

The FCS and CGAS fixed system is fully set up, programmed, calibrated and tested prior to being shipped from the factory. It is ready to install upon arrival and operate following the warm up period.

The levels of O2 and CO2 should be checked prior to cleaning the fermenters by lowering a personal, portable O2 and CO2 detector into the vessel to determine if it is safe to enter. Follow local confined entry requirements and regulations.