Technologies and standards of the stationary

intrinsically safe weather measurement technology

V Our company is located in the Ruhr area, a region with a

long tradition in the german coal mining.
It was founded in 1975 as an engineer’s office for electronic
measurement technologies for the mining industry.
The transformation to the ‘WOELKE Industrieelektronik
GmbH’ with headquarter in Essen occurred in 1985.
Our technical employees are specialists in the fields of
physics, informatics, electronics and mechanics. They are
specialized to develop and manufacture weather-technical
measuring and monitoring devices for explosion hazardous
areas in national and international coal mines.
These patented measuring and monitoring devices are
worldwide applied very successful for many years.
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Table of contents
• Types of gases
Methane CH4
Carbon dioxide CO2
Oxygen O2
Carbon monoxide CO
Hydrogen H2, Hydrogen sulfide H2S (not part of this lecture)
Nitrous gases NOx (not part of this lecture)
• Surroundings temperature (not part of this lecture)

• Ventilation measuring units (not part of this lecture)

• Installation of stationary devices

Presentation of various steps of the displays and alarms
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

The ´mine gas´ Methane (CH4)

Risk of suffocation • Methane is a colourless, odourless and

by O2-deficiency tasteless gas, which is released during the
25 mining of the coal
%V/V Methane in air

• Methane is lighter then air and it is

sampled especially in higher located areas.
• Methane is not toxic.
Risk of suffocation at concentrations
> 25 vol.% CH4 by air extrusion.
15 Upper Explosion Limit (UEL)
• The explosive area of methane in air is
between 5 vol.% (LEL) and 15 vol.% (UEL).
The LEL moves further down by coal dust.
8-10 Most dangerous
• Therefore the switch off limit in the open
scross-section should be 1.0 vol.% CH4
5 Lower Explosion Limit (LEL) and for exception operation it should be
1.5 1.5 vol.% CH4.
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Four different measurement methods for the measuring of methane

• Thermal conductivity for the measuring range 0…100.0 vol.% CH4

(for the measuring in gas exhaustion pipes).

• Catalytic combustion for the measuring range 0…5.00 vol.% CH4.

• Catalytic combustion / thermal conductivity for the ranges 0…5…100 vol.% CH4.

• Infrared measurement technique for the complete range 0…5.00…100.0 vol.% CH4.
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Thermal conductivity

Better • CH4-measuring above the UEL (>15 vol.%)

Methane thermal conduction
Hot cover with
oxygen inside e.g. for the measuring in gas exhaustion pipes
• Measuring range 0…100 vol.% CH4
Platinum coil
with a resolution of 0.1 vol.% CH4
• Robust measurement method, not sensitive
colder
against sensor poisons
• Cross-sensitivities with other gases must be
considered
• Compensation of the temperature and
humidity influences with additional sensors
Hot resistance getting smaller

Principle of function
• Additional pressure compensation
for the measuring in gas exhaustion pipes
• The sensor consists of a platinum coil with highly
porous and pearl-shaped cover. • Not suitable for the measuring range <5 vol. %
• Methane has a better thermal conductivity than air, the CH4 cause of tolerances and resolution
pearl cools down and the hot resistance getting smaller.
• The change of the resistance is the measure of the
methane concentration.
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Catalytic combustion

Methane Water Carbon dioxide • CH4-measuring up to the LEL (<5 vol.%)

Hot catalyst
with oxygen
inside for the measuring in the open cross-section

Platinum coil • Measuring range 0…5.00 vol.% CH4

Heat
CH4 + 2 O2 -> CO2 + 2 H2O + heat of reaction
Principle of function
• The sensor consists of a platinum coil with highly
porous and pearl-shaped cover and catalyst (Pellistor).
• Methane is oxidised catalytically, the reaction heats up
the pearl and the hot resistance getting higher.
• The change of the resistance is the measure of the
methane concentration.
with a resolution of 0.01 vol.% CH4,
furthermore, safety switch-off of the sensor
• Approved measurement method, but sensitive
against sensor poisons like silicone, sulfur-
and silicon compounds as well as refrigerant
• Compensation of the temperature and
humidity influences with additional sensors
• Ageing and sensitivity depends on the
environmental pollution very much
• Cross-sensitivities with other gases must be
considered
• Not suitable for the measuring range above
5 vol. % CH4 cause of sensor switch-off
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Catalytic combustion / thermal conductivity

Catalytic combustion 0…5.00 vol.% CH4

Methane Water Carbon dioxide

• CH4-measuring from 0…5.00…100.0 vol.% CH4
Hot catalyst
with oxygen for the measuring in the open cross-section
inside

Platinum coil
• Measuring range 0…5.00 vol.% CH4 with a
Wärme
Heat
resolution of 0.01 vol.% CH4 by the catalytic
combustion sensor, furthermore safety switch-
off of the sensor and automatic switchover to the
thermal conductivity sensor with measuring
range up to 100.0 vol.% CH4
• The dangerous range between 5 and 15
Thermal conductivity >5.0 vol.% CH4
vol.% CH4 is displayed and monitored!

Hot cover with

Methane
Better
thermal conduction
• Approved measurement method, but sensitive
oxygen inside against sensor poisons like silicone, sulfur-
Platinum coil
and silicon compounds as well as refrigerant
• Compensation of the temperature and
humidity influences with additional sensors
colder
• Ageing and sensitivity depends on the
environmental pollution very much
• Cross-sensitivities with other gases must be
considered
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Infrared measurement technique

Methane molekule
• CH4-measuring from 0…5.00…100.0 vol.% CH4
for the measuring in the open cross-section
Infrared-
Optical
detector
filter • Measuring range 0…5.00 vol.% CH4 with a
IR-Source
resolution of 0.01 vol.% CH4, furthermore
measuring range up to 100.0 vol.% CH4 with a
resolution of 0.1 vol.% CH4

radiated damped • The dangerous range between 5 and 15

infrared-intensity infrared-intensity vol.% CH4 is displayed and monitored!
Methane molecule
stimulated to Measured • Advanced measurement method, not sensitive
vibrate value
against sensor poisons like silicone, sulfur-
CH4 + energy (IR) -> CH4 (radiated) and silicon compounds as well as refrigerant
Principle of function • Ageing and sensitivity do not depend on the
• The sensor consists of IR-source, measurement environmental pollution, long-term stable and
chamber and IR-detector with optical filter especially low maintenance
for the wavelength of methane.
• Methane in the measurement chamber is stimulated to
• Cross-sensitivities with other combustible hydro-
vibrate and damped the intensity of the specific wave- carbons (e.g. Ethane)
length for methane.
• Compensation of temperature and air pressure
• Damping of the intensity of the specific wavelength for influences with additional sensors
methane is the measure of the methane concentration.
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Advantages of the infrared measurement method

• The simple catalytic combustion measurement method can only measure up to 5
vol.% CH4 but the infrared measurement method can also measure and monitor the
dangerous range between 5 and 15 vol.% CH4.
• The catalytic combustion measurement method needs for a proper function a
minimum oxygen concentration of 12 vol.%. The infrared measurement method is
independent of the atmospheric oxygen concentration.
• The catalytic combustion measurement method is sensitive against sensor poisons,
which can kill the sensor very fast. The infrared measurement method is not sensitive
against sensor poisons.
• The catalytic combustion sensor can loose his sensitivity unnoticed, independent to
the working and environmental conditions. The two-channel infrared sensor can
compensate changes of the sensitivity over a wide range automatically. An error of
the sensor can be detected and displayed.
• Devices with the simple catalytic combustion measurement method are cheaper in the
acquisition than infrared devices. Because of the significantly longer lifespan and the
lower maintenance requirements the infrared devices are the cheaper choice over the
long term.
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Carbon dioxide (CO2)

Acute danger of life • Carbon dioxide is colourless and has only

from a concentration >10 Vol.% CO2 a
10 slightly sour taste and smell.
%V/V Carbon dioxide in air

Coma and apnoea • Carbon dioxide is formed by oxidation of

carbon and is not combustible.
8
• The danger of the carbon dioxide is the
oxygen suffocation in the blood.
Shortness of breath,
• Carbon dioxide is heavier than air and it
headache, dizziness accumulates at lower located places.
• The occupational exposure limit amounts
4 0.5 Vol.% CO2.
Premature tiredness
• The switch-off limit in the open cross-
2 section should be 1.0 Vol.% CO2.
1
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Infrared measurement technique for carbon dioxide (CO2)

Carbon dioxide molekule
• CO2-measuring from 0…10.00 vol.% CO2
for the measuring in the open cross-section
Infrared-
Optical
detector • Resolution of 0.01 vol.% CO2
filter
IR-Source
• Advanced measurement method, not sensitive
against sensor poisons
• Ageing and sensitivity do not depend on the
radiated damped
infrared-intensity infrared-intensity environmental pollution, long-term stable and
Carbon dioxide low maintenance
molecule stimulated Measured
to vibrate value • No cross-sensitivities, also not with environment
CO2 + energy (IR) -> CO2 (radiated) humidity

Principle of function • Compensation of temperature and air pressure

• The sensor consists of IR-source, measurement influences with additional sensors
chamber and IR-detector with optical filter especially
for the wavelength of carbon dioxide.
• Carbon dioxide in the measurement chamber is
stimulated to vibrate and damped the intensity of the
specific wavelength for carbon dioxide.
• Damping of the intensity of the specific wavelength for
carbon dioxide is the measure of the gas concentration.
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Oxygen (O2)

• Oxygen is a colourless, odourless and

tasteless gas.
22
No interference of the • It is absolutely necessary for sustaining
breathing process life.
18 • Oxygen combines by oxidation with almost
%V/V Oxygen in air

Pulse raising, problems every material

with muscle interaction
• A reduction of the oxygen concentration
14 can become dangerous for the personal.
Increased breathing,
vomiting, weakness, cyanosis • The switch-off limit in the open cross-
10 section should be 19 Vol.% O2.
Powerlessness, coma,
breathing cramp
5
Sudden death
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Electrochemical measurement method for oxygen (O2)

Membrane Electrolyte Lead-Anode • Oxygen measuring from 0…25.00 % O2
Isolator for the measuring in the open cross-section
• Resolution of 0.01 or 0.1 % O2
• Approved measurement method, long-term
stable and low maintenance
• Compensation of temperature and air pressure
influences with additional sensors
Gas Casing • Fields of operation both for personal protection
Working electrode Counter electrode and for early fire detection and fire monitoring
• Monitoring of oxygen poorness (<12 % O2)
Principle of function because of possible wrong measuring of CH4-
• Ambient air gets through the membrane into the devices with catalytic combustion sensors
electrolyte and the oxygen is reduced electrochemically
at the working electrode.
• At the same time the lead-anode is oxidized at the
counter electrode. Thereby current flows through the
sensor.
• The current is the measure of the O2-concentration.
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Carbon monoxide (CO)

Acute danger of life • Carbon monoxide is a colourless, odour-

less and tasteless gas.
250
• Carbon monoxide is formed during the
ppm Carbon monoxide in air

Disfunction of the central incomplete combustion of hydrocarbon

nervous system und the heart compounds and it is combustible in high
200 concentrations.
• It is highly toxic and a dangerous breathing
Heavy headache, dizziness poison.
Longterm unhealthy • The occupational exposure limit amounts
30 ppm CO.
100
• The switch-off limit in the open cross-
Headache section should be 50 ppm CO.
50
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Electrochemical measurement method for carbon monoxide (CO)

Membrane Electrolyte Counter electrode • CO-measuring from 0…500.0 ppm CO

for the measuring in the open cross-section
• Resolution 0.1 or 1 ppm CO
• Approved measurement method, long-term
stable and low maintenance
• Cross-sensitivities with certain gases
(e.g. H2 or H2S) can be minimized
• Compensation of temperature and air pressure
Gas Casing
influences with additional sensors
Working elektrode Reference electrode
• Fields of operation both for personal protection
Principle of function and espacially for early fire detection and fire
• Ambient air gets through the membrane into the monitoring
electrolyte and the CO is reduced electrochemically
at the working electrode.
• At the same time oxygen reacts at the counter
electrode. Thereby current flows through the sensor.
• The current is the measure of the CO-concentration.
• A fixed potential at the reference electrode minimized
the cross-sensitivity with certain gases.
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Hydrogen sulfide (H2S) Hydrogen (H2)

• Hydrogen sulfide is a colourless gas
with a strong smell of rotten eggs
• It is highly toxic and a dangerous
breathing poison
• The occupational exposure limit
amounts 10 ppm H2S
• The switch-off limit in the open cross-
section should be 20 ppm H2S
• Measuring range 0…100 ppm H2S with a
resolution of 0.1 or 1 ppm H2S
• Electrochemical measurement method
• Compensation of temperature and air
pressure influences with additional
sensors
• Cross-sensitivities with other gases
should be taken into account
• Hydrogen is a colourless, odourless
and tasteless gas
• Hydrogen has no toxic effect, but it is
combustible
• Measuring range 0…1000 ppm H2 with
a resolution of 0.5 or 1 ppm H2.
The measuring range is limited by
means of explosion protection
guidelines for group I
• Electrochemical measurement method
• Compensation of temperature and air
pressure influences with additional
sensors
• Cross-sensitivities with other gases
should be taken into account
 Technologies and standards of the stationary
intrinsically safe weather measurement technology
Nitrogen monoxide (NO)
• Nitrogen monoxide is a colourless,
odourless and tasteless gas
• It is toxic and a dangerous breathing
poison
• The occupational exposure limit amounts
25 ppm NO.
• Measuring range 0…100 ppm NO with a
resolution of 0.1 ppm NO.
• Electrochemical measurement method
• Compensation of temperature and air
pressure influences with additional
sensors
• Cross-sensitivities with other gases
should be taken into account
Nitrogen dioxide (NO2)
• Nitrogen dioxide is a red brown,
pungent smelling gas
• It is highly toxic and a dangerous
breathing poison
• The occupational exposure limit
amounts 5 ppm NO2
• The switch-off limit in the open cross-
section should be 10 ppm NO2
• Measuring range 0…20 ppm NO2 with a
resolution of 0.1 ppm NO2.
• Electrochemical measurement method
• Compensation of temperature and air
pressure influences with additional
sensors
• Cross-sensitivities with other gases
should be taken into account
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Ambient temperature

• Ranges of application are espacially the early fire detection and the air cooler
monitoring.

• Resistance measurement method with platinum sensor (PT100) or thermistor (NTC).

• Measuring range for ambient temperature -20.0…+60.0 °C with a resolution of 0.1 °C.

• Measuring range for temperature of machine parts -20.0…+200.0 °C with a resolution

of 0.1 or 1 °C.

• The construction of the sensor tip is essential for the T90-time, which means the
response time of the increase of the temperature.

• Robust metal sensors with thermal contact to the casing are too slow and thereby
unsuitable for the early fire detection.
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Measurement methods for the measuring of the ventilation

• Impeller anemometer

• Anemometer with differential pressure measurement technique

• Anemometer with Vortex measurement technique

• Hot-wire/hot-film anemometer
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Impeller anemometer

• Velocity measuring from 0.25…12.0 m/s

Pipe
for the measuring in the open cross-section
• Outdated but improved measurement method
nowadays mostly used in hand-held anemometers
Ventilation
• Lower measurement span start
• Largely independent towards density fluctuations
Impeller • High pressure drop and so unsuitable for the
measuring in pipes
Principle of function
• Vulnerable against pollution
• The sensor consists of a pipe und an impeller.
• The air flows through the pipe. The wind pressure hits • Vulnerable to trouble because of moving parts
the impeller and sets it into rotation.
• The rotation is converted into a frequency.
• The rotary frequency is proportional to the velocity.
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Anemometer with differential pressure measurement technique

Aperture
P1 P0
Pressure sensor
Principle of function
• The sensor consists of a section of measurement with
an aperture and a differential pressure sensor.
• The air flows through the section of measurement and
in front of the aperture an overpressure builts up.
• Behind the aperture is the static pressure.
• The differential pressure is the measure for the velocity.
• Velocity measuring from 0.4…15.0 m/s
for the measuring in the open cross-section
• Velocity measuring from 0.5…50.0 m/s
for the measuring in gas exhaustion pipes
• Improved measurement method
• Low maintenance, because of insensitivity
against pollution
• Lower pressure drop in pipes
• Compensation of temperature and air pressure
influences with additional sensors
• Higher measurement span start should be taken
into account
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Anemometer with Vortex measurement method

• Velocity measuring from 0.5…15.0 m/s
Transmitter for the measuring in the open cross-section

T • Velocity measuring from 0.5…50.0 m/s

Impediment
T Vortex
Receiver
Principle of function
• The sensor consists of a section of measurement with
impediment and transmitter/reveiver for ultrasonic
modulation or differential pressure measuring.
• The air flows through the section of measurement. At
the edges of the impediment occurs a periodic vortex
shedding.
• The vortices produce pressure differences, which can
be measured by ultrasonic or pressure sensors.
• The shedding frequency is proportional to the velocity.
for the measuring in gas exhaustion pipes
• Modern measurement method
• Largely independent towards density
fluctuations
• Low maintenance, because of insensitivity
against pollution
• Higher measurement span start should be taken
into account
• Higher pressure drop in pipes should be taken
into account
• Ultrasonic sensors can be react sensitive
against ambient noise
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Hot-wire/hot-film anemometer
• Velocity measuring from 0.15…15.0 m/s
Heated reference sensor
for the measuring in the open cross-section
• Modern measurement method
• Very low measurement span start, suitable for the
auxiliary ventilation
Section of
measuring • Low maintenance, because of insensitivity
Heated working sensor
against pollution by special filter
• Compensation of temperature and air pressure
Principle of function influences with additional sensors
• The sensor consists of a section of measurement with
a heated working element and a reference element.
• High pressure drop and so unsuitable for the
measuring in pipes
• The air flows through the section of measurement. The
heated working element is cooled down by the air flow.
• The reference sensor keeps constant. The measurement
bridge of both sensors gets unbalanced.
• This is the measure for the velocity.
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Installation of stationary devices

• Stationary monitoring device with alarming but without measured value output

• Stationary monitoring device with several alarmings but without measured value output

• Stationary monitoring device with alarming and measured value output

• Stationary monitoring device with alarming and data transmission

• Stationary monitoring devices with local switch-off, alarming and data transmission
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Stationary monitoring device with alarming but without measured value output

Power supply
(battery backup)

Mains
power
Monitoring device

Pros and cons

• Continuous monitoring of the gas concentration with display on-side.
• Audio-visual alarming only directly to the measuring point, if the limit value is exceeded.
• Suitable for the warning of the personal directly to the measuring point – no further warning displays at the escape routes!
• The personal on-side has to switch off the mains power manually – DANGEROUS, because it is not automatically!
• No measured value transmission into a ´safe area´, where the gas concentration can be controlled further on in case of
alarming. The personal must be sent ´blind´ into the potentially endangered area for the inspection!
• A continual monitoring is only possible with a battery buffered power supply, because a switch-off of the mains power
also switches off the monitoring device!
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Stationary monitoring device with several alarmings but without measured value output
Alarm device Alarm device Alarm device Monitoring device

Power supply
(battery backup)

Mains
power

Pros and cons

• Continuous monitoring of the gas concentration with display on-side.
• Audio-visual alarming directly to the measuring point and at the escape routes, if the limit value is exceeded.
• Suitable for the warning of the personal directly to the measuring point and at the escape routes!
• The personal on-side has to switch off the mains power manually – DANGEROUS, because it is not automatically!
• No measured value transmission into a ´safe area´, where the gas concentration can be controlled further on in case of
alarming. The personal must be sent ´blind´ into the potentially endangered area for the inspection!
• A continual monitoring is only possible with a battery buffered power supply, because a switch-off of the mains power
also switches off the monitoring device!
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Stationary monitoring device with alarming and measured value output

Evaluator
%
1.23 CH4
Alarm 1 2
Surface

1.23 to switch-off relay

Power supply
(battery backup)

Mains
power I-/F-output
Monitoring device

Pros and cons

• Continuous monitoring of the gas concentration with display on-side.
• Continuous monitoring of the gas concentration also above ground with automatically switch-off of the mains power!
• Audio-visual alarming directly to the measuring point, if the limit value is exceeded.
• Suitable for the warning of the personal directly to the measuring point – expandable with alarmings at the escape routes!
• Measured value transmission into a ´safe area´ - no personal must be sent ´blind´ into the potentially endangered area!
• Long cables at the measured value output – susceptible and high cost of cables for every device!
• A continual monitoring is only possible with a battery buffered power supply, because a switch-off of the mains power
also switches off the monitoring device!
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Stationary monitoring devices with alarming and data transmission

Monitoring Evaluator
devices
1.23 % CH4
23.1 ppm CO
Alarm 1 2
Surface

23.1 Power supply

1.23 to switch-off relay
(battery backup)

Mains
power
Data digital output
I-/F-outputs transmission

Pros and cons

• Continuous monitoring of the gas concentration with display on-side.
• Continuous monitoring of the gas concentration also above ground with automatically switch-off of the mains power!
• Audio-visual alarming directly to the measuring point, if the limit value is exceeded.
• Suitable for the warning of the personal directly to the measuring point – expandable with alarmings at the escape routes!
• Measured value transmission into a ´safe area´ - no personal must be sent ´blind´ into the potentially endangered area!
• Digital data transmission of several measured values to above ground – interference free and low cost of cable!
• A continual monitoring is only possible with a battery buffered power supply, because a switch-off of the mains power
also switches off the monitoring device!
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Stationary monitoring devices with local switch-off, alarming and data transmission
Monitoring Evaluator
devices
1.23 % CH4
23.1 ppm CO

Surface

23.1 Power supply

1.23
(battery backup) to switch-off relay

Mains
power
Data digital output
I-/F-outputs transmission

Pros and cons

• Continuous monitoring of the gas concentration with display and immediate automatically switch-off of the mains power
on-side – no time delay cause of evaluation of the data transmission system!
• Continuous monitoring of the gas concentration also above ground!
• Audio-visual alarming directly to the measuring point, if the limit value is exceeded.
• Suitable for the warning of the personal directly to the measuring point – expandable with alarmings at the escape routes!
• Measured value transmission into a ´safe area´ - no personal must be sent ´blind´ into the potentially endangered area!
• Digital data transmission of several measured values to above ground – interference free and low cost of cable!
• A continual monitoring is only possible with a battery buffered power supply, because a switch-off of the mains power
also switches off the monitoring device!
 Technologies and standards of the stationary
intrinsically safe weather measurement technology

Thank you very much for your interest.

If you have questions on this subject,

please contact us for additional informations.

WOELKE Industrieelektronik GmbH

Sieperstr. 1 - 3
D-42551 Velbert
Tel.: +49 (0)2051 – 80 29 64 40
Fax: +49 (0)2051 – 80 29 64 30
Internet: www.woelke-gmbh.com
E-Mail: info@woelke-gmbh.com