Integrating flame detection into safety systems can create a safer and more reliable environment. (Image source: MSA Safety)

MSA Safety discusses the benefits of a layered defense incorporating both gas and flame detection for safety in industrial environments

In industrial settings, safety is paramount, especially in environments where flammable or toxic gases are present, such as the oil, gas and petrochemical industry.

A robust gas detection system is an important line of defense, but it is not the whole story. Integrating flame detection into your safety setup can create a safer and more reliable environment.

The role of gas and flame detection systems

Gas detection systems are designed to identify harmful gases in the air, whether combustible, toxic, or asphyxiating. They provide early warnings, helping to enable preventive action before conditions become dangerous. However, gas detection alone doesn’t account for what happens when a gas leak ignites.

Flame detection systems complement gas detectors by identifying the presence of fire, which may occur even where gas concentration hasn’t yet reached detectable levels. Together, these systems can contribute to a more comprehensive safety net that addresses both potential and actual hazards.

Why include flame detection in gas detection systems?

1. More comprehensive hazard mitigation

Gas detectors and flame detectors work hand-in-hand to prevent accidents and mitigate risks. While gas detectors alert you to the presence of a leak, flame detectors respond to fires that could result from undetected or ignited gases.

2. Faster response to fire emergencies

A gas leak can ignite in seconds, turning a potential hazard into an active emergency. Flame detectors react in real-time to the presence of a flame, helping to enable prompt action to contain the fire and prevent escalation.

3. Helps eliminate blind spots

Gas detection systems can only monitor specific zones. In scenarios where a leak occurs outside the detection range or a minor leak ignites directly, flame detectors can be an important second layer of protection.

4. Tailored for high-risk industries

In industries such as oil and gas, petrochemicals and manufacturing, the risk of fire due to flammable gases is ever present. Flame detection helps protect these high-stakes environments against both minor and catastrophic ignition events.

5. Meeting regulatory standards

Safety regulations often require both gas and flame detection systems for compliance. Adhering to these standards not only protects your team and assets but also ensures your operations meet legal and industry benchmarks.

6. Minimising damage and downtime

Early flame detection can activate suppression systems, limit the spread of fire, and enhance the safety of personnel. By containing incidents quickly, businesses can avoid costly equipment damage and extended downtime.

7. Enhanced operational safety and continuity

Combining gas and flame detection creates a more resilient safety framework that reduces the likelihood of accidents and enables a quicker recovery in the event of an incident. This reliability is key to maintaining trust and productivity.

A layered defense

Safety in industrial environments is not about choosing between gas or flame detection — it’s about understanding the benefits of both to build a layered defense.

While gas detectors prevent potential hazards by identifying leaks, flame detectors act as a safeguard when ignition occurs.

Safety managers may consider this combination a necessity in today’s high risk, high stakes industries. By integrating flame detection into your gas detection system, you help to ensure that your operations are protected from the full spectrum of potential hazards, safeguarding lives, assets, and your reputation.

MSA Safety is a North American manufacturer and supplier of safety equipment used in a range of hazardous environments, including construction, military, fire service, and chemical, oil, and gas production. The company has provided its products to sites all across the region, and also partnered with OSHA to highlight workplace safety in Houston. 

In drilling activities, bp uses advanced surveillance systems. (Image source: Canva)

The Gulf of America, historically known as the Gulf of Mexico, remains a crucial region for offshore energy production, with companies like bp leading the way in health, safety, and environmental (HSE) improvements.

In recent years, bp has taken significant steps to strengthen its safety culture, implement advanced technologies, and refine operational protocols to mitigate risks and enhance workplace safety.

bp’s approach to HSE in the Gulf of America is guided by its Operating Management System (OMS), which provides a consistent framework for managing health, safety, security, and environmental risks.

The OMS integrates bp’s safety leadership principles, the International Association of Oil & Gas Producers’ (IOGP) Life-Saving Rules, and process safety fundamentals. These elements collectively drive a strong safety culture, ensuring that best practices are embedded across BP’s operations.

To reinforce this culture, bp has prioritised psychological safety among its workforce. Employees in operations are encouraged to voice concerns and report potential hazards without fear of retaliation.

Training sessions have been expanded to help employees integrate safety principles into their daily routines, fostering a more open and proactive approach to risk management.

Life-saving rules and digital solutions

The IOGP Life-Saving Rules address high-risk activities that account for the majority of serious industry incidents.

Since their adoption, bp has measured their effectiveness, conducting site visits and safety audits to assess compliance.

In 2024, operational safety teams visited production sites in Azerbaijan, refining facilities in Spain, and terminals and pipelines in the US to ensure adherence to these critical safety measures.

Technology plays a pivotal role in bp’s HSE advancements. Digital solutions such as the IRIS system (for health, safety, security, and environment reporting) and the LENS platform (for learning and knowledge-sharing) have enhanced BP’s ability to standardise processes and collaborate across sites.

Additionally, the company has deployed Nova, an integrated management tool that helps monitor risk controls and enforce safety measures.

Despite bp’s efforts, the company faced challenges in 2024, reporting a fatality and several life-changing injuries across its global operations.

These incidents have reinforced the need for continuous improvement in safety protocols. To address these concerns, bp has focused on leveraging lessons learned to prevent future occurrences, including a renewed emphasis on safe manual handling procedures and emergency response preparedness.

Process safety remains a priority, with bp implementing stricter mechanical integrity frameworks in refining and production activities.

The company has also integrated IOGP’s Process Safety Fundamentals, ensuring that risk awareness and operational reliability are at the forefront of daily activities.

bp’s offshore operations in the Gulf of America benefit from enhanced monitoring and AI-driven solutions.

In drilling activities, bp uses advanced surveillance systems that allow experts in Houston and Sunbury to detect early warning signs of potential hazards, enabling timely intervention.

Additionally, bp’s US onshore subsidiary, bpx energy, has adopted AI-powered driving safety measures, significantly reducing driver distraction and tailgating incidents.

DOGE is planning to close the Louisiana OSHA office.

Several Louisiana federal agency offices are losing their leases as part of a statewide cost-cutting initiative spearheaded by the Department of Government Efficiency (DOGE), a federal watchdog established by the Trump Administration whose stated aim is to streamline government spending and minimise waste.

The DOGE website, which analyses government cost-cutting measures, claims that the initiative has saved over US$105bn across the country through asset sales, contract cancellations, fraud eliminations, and lease terminations. As of March 6, the expected savings per taxpayer were US$652.17.

The largest cost-cutting strategy among the terminated Louisiana agency leases involved the Social Security Administration in Houma, which had an annual leasing cost of more than US$550,000.

The agency's lease was terminated through a "agency-approved lease termination," which means that the agency consented to evacuate the premises, according to Louisiana First News. 

OSHA office to be closed

One of the eight federal agencies affected by these cuts in Louisiana is the Occupational Safety and Health Administration (OSHA). DOGE stated it was a “Mass Mod” termination, meaning leases that are cancelled through mass modifications.

OSHA's 8,041 sq ft Louisiana office, which is located in the state capital Baton Rouge, costs the US government US$187,451 every year. According to DOGE, closing this office space will save the government US$109,346. 

OSHA is a division of the United States Department of Labour that oversees occupational safety and health.

According to the Occupational Safety and Health Administration, OSHA strives to ensure safe and healthy working conditions by establishing and enforcing standards, as well as providing training, outreach, education, and assistance.

There has been no official statement from OSHA at the time of writing this report. 

Other health and safety organisations impacted

Other organisations that are closing their offices include the Office of the General Counsel (OGC), which is the legal team within the Department of Health and Human Services (HHS). A report by Fierce Healthcare hyas indicated that OGC is closing six of its ten regional offices. This however does not appear to be mandated by DOGE. 

The report stated that HSS regional offices in Boston, Chicago, Dallas, New York City, San Francisco and Seattle will close. In certain cases, these regional offices are located in government buildings that were temporarily added to the General Services Administration's (GSA) non-core property list last week. This list suggested that the government is willing to remove federal buildings from its national footprint. 

The Food and Drug Administration (FDA) could also be impacted by spending cuts, given that the US government is looking to divest from non-core properties. 

It remains unclear how the employees working for these all of these agencies will be affected. 

The ISF is committed to safeguarding workers in all industries. (Image source: Adobe Stock)

The American Society of Safety Professionals (ASSP), is playing a leading role in an occupational safety and health coalition committed to safeguarding workers in all industries to drive business success

The Intersociety Forum (ISF) of two dozen organisations, calls for employers to go beyond legal compliance and adopt risk-based safety and health strategies. The coalition has released a report that highlights several ways a business model of safety and health can create a strategic advantage that powers positive business outcomes.

By adopting proactive, risk-based safety strategies, businesses can unlock greater productivity, reduce costs and strengthen their global competitiveness, the report says. ISF urges today’s business leaders and policymakers to prioritise occupational EHS as a foundation of economic competitiveness. Embracing safety as a strategic priority will enable businesses to forge a safer, healthier and more prosperous future — one in which both businesses and workers thrive, and position the US as a global leader in safety, innovation and workforce wellbeing.

“We urge today’s business leaders and policymakers to prioritize environmental, health and safety practices as a foundation of economic growth,” said ASSP chief executive officer Jennifer McNelly, CAE. “When workers are protected from injuries and illnesses, they perform at their best, which fosters productivity, innovation and global competitiveness. Safety strengthens resilience and enables businesses to thrive.”

Despite advancements in technology, workplace injury and fatality rates have remained relatively flat for the past decade, the ASSP points out. In 2023, a worker died on the job every 99 minutes, according to the U.S. Bureau of Labor Statistics.

Three core principles

In its report, ISF identified three core principles that help ensure workers return home safe and healthy every day. These principles are:
1) Standards and worker well-being; safety is not just about compliance; it is about creating standards that foster business success while promoting holistic worker health.
2) Embracing risk and safety management systems, which help organisations proactively mitigate risk and embed safety into every aspect of decision-making; and
3) Revolutionising recordkeeping for predictive insights; traditional lagging indicators only tell part of the story. Leading indicators empower organisations to predict and prevent serious injuries, illnesses and fatalities.

“This guidance that goes beyond compliance can bring life to workplaces across the nation, empowering workers to perform at their peak,” McNelly said. “There are benefits to reducing operational disruptions and maximising efficiency through a sustainable workforce. Simply put, safety is good for business.”

“It’s vital that the coalition has achieved meaningful cross-organisation collaboration to speak as one voice from the safety industry,” she added.

Workers in the oil and gas industry are at risk of exposure to H2S. (Image source: Adobe Stock)

Hydrogen sulphide (H2S) causes challenges for many industries, with the oil, gas and petrochemicals industry being one of the most affected, says MSA Safety

Hydrogen sulfide is a highly flammable, toxic and corrosive gas found in several industries including oil and gas, wastewater and chemical processing, which cannot reliably be detected by smell.

Oil, gas and petrochemical facilities handle raw ‘sour’ gas and oil which are naturally high in H2S. Extraction and refining processes release H2S, which may accumulate in confined, poorly ventilated spaces like processing units, pipelines and storage tanks. Closed systems with high-pressure conditions amplify the risks for workers.

Exposure to high levels of H2S can be fatal, leading to loss of breathing, coma, seizures and death. It is the second most common cause of fatal gas inhalation exposure in the workplace, second only to carbon monoxide.

H2S can also be harmful at low concentration levels, causing headaches, dizziness, nausea, breathing difficulties and a sore throat. These health impacts can become more serious with prolonged exposure.

The health impacts of H2S depend on how much is inhaled and for how long. The recommended exposure limit set by NIOSH (the US National Institute for Occupational Safety and Health) for ten minutes is 10 ppm.

However, some U.S. states have developed ambient air standards for H2S well below OSHA and NIOSH standards due to concerns about health risks from chronic exposure.

For longer exposures to H2S, the recommended limits are much lower. For example, if you are exposed for up to 24 hours, the World Health Organisation (WHO) recommends a maximum exposure of 0.1 ppm.

In response to concerns about the risks of H2S to human health even at low concentration levels, some countries have introduced equally stringent guidelines requiring businesses to monitor H2S at such concentrations.

Balancing safety and operational efficiency is an ongoing challenge in the oil, gas and petrochemical industry. Some are tackling this challenge by integrating new technological solutions into their safety management practices and seeking out effective preventative measures, including regular training and effective ventilation. The use of Personal Protective Equipment is also important.

A particularly helpful method for avoiding excessive H2S exposure is constant monitoring by advanced gas detection systems such as MSA’s ALTAIR io 4 Connected Gas Detector, which can give an early warning of even subtle increases in H2S concentration, helping companies stay ahead of potential risks. The company has recently updated this to offer the option of a low-concentration hydrogen sulfide sensor that can detect H2S at very low levels.

Connected gas detection devices can help an organisation significantly improve worker safety by providing real-time monitoring of gas levels and worker location and behaviour, enabling safety managers to monitor the situation remotely and take immediate action if gas levels become or get close to becoming dangerous. This proactive approach to safety can help prevent accidents and foster a culture of safety within the organisation.

As with all toxic gases, early detection of H2S is an excellent way to alert safety managers to small increases in H2S emissions so they can help workers avoid harmful exposure, even at low concentrations.