WO2012150516A1 - Multi-sensor wireless gas monitoring system for petrochemcial storage facilities - Google Patents
Multi-sensor wireless gas monitoring system for petrochemcial storage facilities Download PDFInfo
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- WO2012150516A1 WO2012150516A1 PCT/IB2012/051897 IB2012051897W WO2012150516A1 WO 2012150516 A1 WO2012150516 A1 WO 2012150516A1 IB 2012051897 W IB2012051897 W IB 2012051897W WO 2012150516 A1 WO2012150516 A1 WO 2012150516A1
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04Q—SELECTING
- H04Q9/00—Arrangements in telecontrol or telemetry systems for selectively calling a substation from a main station, in which substation desired apparatus is selected for applying a control signal thereto or for obtaining measured values therefrom
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N33/00—Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
- G01N33/0004—Gaseous mixtures, e.g. polluted air
- G01N33/0009—General constructional details of gas analysers, e.g. portable test equipment
- G01N33/0027—General constructional details of gas analysers, e.g. portable test equipment concerning the detector
- G01N33/0031—General constructional details of gas analysers, e.g. portable test equipment concerning the detector comprising two or more sensors, e.g. a sensor array
- G01N33/0032—General constructional details of gas analysers, e.g. portable test equipment concerning the detector comprising two or more sensors, e.g. a sensor array using two or more different physical functioning modes
-
- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04Q—SELECTING
- H04Q2209/00—Arrangements in telecontrol or telemetry systems
- H04Q2209/80—Arrangements in the sub-station, i.e. sensing device
- H04Q2209/82—Arrangements in the sub-station, i.e. sensing device where the sensing device takes the initiative of sending data
- H04Q2209/823—Arrangements in the sub-station, i.e. sensing device where the sensing device takes the initiative of sending data where the data is sent when the measured values exceed a threshold, e.g. sending an alarm
-
- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04Q—SELECTING
- H04Q2209/00—Arrangements in telecontrol or telemetry systems
- H04Q2209/80—Arrangements in the sub-station, i.e. sensing device
- H04Q2209/88—Providing power supply at the sub-station
- H04Q2209/886—Providing power supply at the sub-station using energy harvesting, e.g. solar, wind or mechanical
Definitions
- This invention relates to the wireless remote detection of gas concentration using co-located gas sensors wherein at least two of the gas sensors employ different underlying measurement technologies.
- the information from the disparate gas sensors is jointly analyzed, more information about the gas can be determined than if the information from each sensor is analyzed individually.
- the invention is also suitable for deployment as a low-power system, e.g., using battery or solar power, because it allows a lower-power gas sensor to be used as a primary gas detector and because it provides for the gas sensors to be operated discontinuously.
- each large aboveground storage tank has a roof that floats on top of the stored liquid. This prevents having a potentially explosive vapor space between the liquid and the roof of the tank.
- the roof typically floats on pontoons and has a flexible seal around its perimeter to minimize the escape of liquid or vapor from inside of the tank. However, the escape of at least small quantities of liquid or vapor is inevitable.
- Covered storage tanks have a fixed roof above the floating roof that serves to protect the floating roof. It is therefore important to ensure that the internal atmosphere between the floating roof and the fixed roof does not contain a potentially explosive or toxic mixture.
- US 5,356,594 describes a portable gas-sensing system.
- This system described therein has a tag reader in addition to a single gas sensor so that it can, for example, read an optically-encoded tag mounted on a valve and atomically associate the gas concentration with said valve during a safety survey.
- it does not use multiple gas sensors.
- US Patent Application 2002/0118116A1 describes a dual-sensor system wherein all of the sensors are sensing disjoint parameters, for example, temperature and smoke concentration.
- the current invention differs in that there are multiple sensors that are sensing gas concentration.
- the GasAlertMicro5 series from BW Technologies is a portable multi-sensor. Unlike the current invention, the readings from multiple gas sensors are not jointly analyzed and it is a portable unit that is not designed to reduce power consumption through the use of a primary gas sensor or through discontinuous sensor operation.
- the current invention provides a new wireless apparatus for the monitoring of gas concentrations using co-located gas sensors wherein at least two of the gas sensors employ different underlying measurement technologies.
- the information from independent gas sensors is jointly analyzed, more information about the gas can be determined than if the information from each gas sensor is analyzed individually.
- the invention is also suitable for long-term deployment as an autonomous low-power system because it allows a lower-power gas sensor to be used as a primary gas detector. Subsequently, when the detected gas concentration reaches a threshold level, one or more secondary higher-power gas sensors can be activated to provide the aforementioned advantage of joint sensor data analysis. To provide a further reduction in power consumption, any of said gas sensors may be operated discontinuously.
- the primary gas sensor could be chosen on the basis of a longer operating lifetime rather than on the basis of lowest power. This selection criterion serves to maximize the autonomous operational lifetime of the invention, rather than minimizing power consumption.
- the invention comprises two types of units that communicate using wireless means.
- the Sensor Unit includes the gas sensors and at least one wireless communication link.
- the Communication Unit contains at least one wireless communication link and may also contain one or more wired communication links.
- the Communication Unit may therefore be used to relay information from the Sensor Unit to the system operator or to a remote monitoring system by wired of wireless means.
- the Communication Unit or the Sensor Unit may also be directly connected to an alarm system.
- This invention is presented in the context of use in the petrochemical industry where the accumulation of flammable, potentially explosive, or toxic gasses is of great concern but it is also suitable for deployment for other industrial applications.
- a further potential benefit of the invention is that the ease of installation and low installed cost may serve to hasten the upgrading of safety systems.
- major benefits of the current invention include: gas sensing at more frequent intervals (e.g., multiple times per day), thereby improving the probability of detecting a potentially catastrophic event: not having to expose personnel to potentially hazardous conditions and a reduction in power consumption.
- Figure 1 Function Block Diagram of the Proposed Apparatus
- the invention minimally comprises a Communication Unit 1 and a Second Unit 2 that communicate via wireless means using Antennas 3.
- the configuration of the Antennas 3 is not a facet of this invention.
- the Sensor Unit 2 comprises an Antenna 3; two or more co-located Gas Sensors 4; a Microcontroller or Microprocessor 5; a Power Source 6 such as batteries, solar panels, or a connection to an external power source; and a Wireless Communication Interface 7.
- Said Wireless Communication Interface 7 can be integrated with said Microcontroller 5, e.g., the Freescale MC13224. Regardless of the plurality of said Gas Sensors, a minimum of two different gas-sensing technologies must be employed to enable the joint analysis of data from said Gas Sensors.
- 'co-located' implies that the Gas Sensors have sufficient physical proximity to ensure that the joint analysis of their readings can be performed with an accuracy that is sufficient for a particular deployment scenario.
- the distance between the Gas Sensors is less than one meter.
- the Communication Unit 1 minimally comprises an Antenna 3; a Microcontroller or Microprocessor 5; a Power Source 6 such as batteries, solar panels, or a connection to an external power source; and a Wireless Communication Interface 7. It may include additional wireless or wired interfaces.
- the communication capability of the Sensor Unit 2 or the Communication Unit 1 may be configured to act as a communication relay or as part of a redundant network, such as a mesh network. These capabilities are well known in the current art.
- the Sensor Unit 2 and the Communication Unit 1 can have a minimal number of external physical connections, including the possibility of zero external connections, they can be readily protected by an environmentally-protective enclosure, thereby making them suitable for use in harsh environments.
- the current embodiment of the Sensor Unit 2 is intended for deployment on the floating roofs of petroleum storage tanks and is therefore immersible and meets the ATEX requirements for Intrinsic Safety, although these are not requirements of the current invention.
- the Microcontroller 5 and Wireless Communication Interface 7 is realized using a Freescale MC13224;
- the Power Source 6 is a lithium-thionyl-chloride battery pack;
- the Antenna 3 is a patch antenna.
- the Primary Gas Sensor is an Alphasense PID-AH Photo-Ionization Detector (PID) that measures the concentration of Volatile Organic Compounds (VOCs) in parts-per-million.
- the Secondary Gas Sensor is a Dynament TDS0034 Non-Dispersive Infrared (NDIR) Sensor that measures ambient hydrocarbon concentration as a percentage of the gas volume. With these two sensors, the current embodiment meets the minimum requirement of two disparate gas-sensing technologies.
- the Gas Sensors 4 can be operated discontinuously.
- a first advantage of discontinuous operation is that it reduces overall power consumption, which is important for battery- or solar-powered systems.
- a second advantage is that Gas Sensors may not need to be re-calibrated as often, thereby reducing maintenance requirements.
- a third advantage of discontinuous operation is that it can extend the operation lifetime of the Gas Sensors.
- one Gas Sensor can be operated as the Primary Gas Sensor.
- the Primary Gas Sensor is activated more frequently than any other Gas Sensor.
- the Primary Gas Sensor In the case where the Primary Gas Sensor has low power consumption, it can act as a gas detector, wherein the reading from said Primary Gas Sensor is compared to a threshold value. When said reading exceeds this threshold, a Secondary Gas Sensor is activated and readings are taken to exploit the aforementioned advantage of analyzing information from multiple disparate Gas Sensors. Because the Secondary Gas Sensor is only operated when said threshold is exceeded, a finite power source, such as a battery, can provide power for a comparatively longer period of time.
- a finite power source such as a battery
- Certain types of Gas Sensors such as catalytic bead sensors, have a comparatively shorter active operational lifetime and can remain useful for longer periods if they are not activated. Therefore, the Primary Gas Sensor can be selected based on the operational lifetime of the Gas Sensor, rather than on the basis of power consumption.
- said redundancy can be used to improve system robustness by supplying alternative identical Gas Sensors to operationally replace a railed Gas Sensor. Secondly, said redundancy can be used to extend system lifetime by providing a sequence of useable identical Gas Sensors.
- the aforementioned Primary Gas Sensor may be any Gas Sensor from a number of identical Gas Sensors.
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Abstract
The current invention provides a new wireless apparatus for the monitoring of gas concentrations using co-located gas sensors wherein at least two of the gas sensors employ different underlying measurement technologies. When the information from independent gas sensors is jointly analyzed, more information about the gas can be determined than if the information from each gas sensor is analyzed individually.
Description
This invention relates to the wireless remote
detection of gas concentration using co-located gas sensors wherein at least
two of the gas sensors employ different underlying measurement technologies.
When the information from the disparate gas sensors is jointly analyzed, more
information about the gas can be determined than if the information from each
sensor is analyzed individually. The invention is also suitable for deployment
as a low-power system, e.g., using battery or solar power, because it allows a
lower-power gas sensor to be used as a primary gas detector and because it
provides for the gas sensors to be operated discontinuously.
The processing and storage of chemical compounds,
such as petrochemicals, is quite widespread. Since many of these compounds can
be toxic, flammable, or potentially explosive, there are grave safety concerns
for personnel and for the environment. Additionally, the capital,
environmental, and human costs of a disaster at such a processing facility can
be staggering.
In the petroleum industry, each large aboveground
storage tank (AST) has a roof that floats on top of the stored liquid. This
prevents having a potentially explosive vapor space between the liquid and the
roof of the tank. The roof typically floats on pontoons and has a flexible seal
around its perimeter to minimize the escape of liquid or vapor from inside of
the tank. However, the escape of at least small quantities of liquid or vapor
is inevitable.
Covered storage tanks have a fixed roof above the
floating roof that serves to protect the floating roof. It is therefore
important to ensure that the internal atmosphere between the floating roof and
the fixed roof does not contain a potentially explosive or toxic mixture.
In the petroleum storage industry, a current
industry practice for monitoring covered storage tanks is to perform manual
inspections through roof hatches at monthly intervals. A minimal visual
inspection can check that the floating roof appears to be floating properly,
that there is no visible liquid on the roof, and that the seal is visibly
intact. Additional manual inspections include measuring the internal atmosphere
to check that the volatile has a gas concentration that is less than 50% of the
Lower Explosive Limit (LEL). Manual inspection is generally non-comprehensive
and, since it occurs only monthly, it could miss the timely detection of a
potentially catastrophic condition.
There are gas-monitoring systems in the current
art. For example, US 5,356,594 describes a portable gas-sensing system. This
system described therein has a tag reader in addition to a single gas sensor so
that it can, for example, read an optically-encoded tag mounted on a valve and
atomically associate the gas concentration with said valve during a safety
survey. Unlike the current invention, it does not use multiple gas sensors.
US Patent Application 2002/0118116A1 describes a
dual-sensor system wherein all of the sensors are sensing disjoint parameters,
for example, temperature and smoke concentration. The current invention differs
in that there are multiple sensors that are sensing gas concentration.
The GasAlertMicro5 series from BW Technologies is
a portable multi-sensor. Unlike the current invention, the readings from
multiple gas sensors are not jointly analyzed and it is a portable unit that is
not designed to reduce power consumption through the use of a primary gas
sensor or through discontinuous sensor operation.
The current invention provides a new wireless
apparatus for the monitoring of gas concentrations using co-located gas sensors
wherein at least two of the gas sensors employ different underlying measurement
technologies. When the information from independent gas sensors is jointly
analyzed, more information about the gas can be determined than if the
information from each gas sensor is analyzed individually.
The invention is also suitable for long-term
deployment as an autonomous low-power system because it allows a lower-power
gas sensor to be used as a primary gas detector. Subsequently, when the
detected gas concentration reaches a threshold level, one or more secondary
higher-power gas sensors can be activated to provide the aforementioned
advantage of joint sensor data analysis. To provide a further reduction in
power consumption, any of said gas sensors may be operated discontinuously.
Alternatively, the primary gas sensor could be
chosen on the basis of a longer operating lifetime rather than on the basis of
lowest power. This selection criterion serves to maximize the autonomous
operational lifetime of the invention, rather than minimizing power
consumption.
The invention comprises two types of units that
communicate using wireless means. The Sensor Unit includes the gas sensors and
at least one wireless communication link. The Communication Unit contains at
least one wireless communication link and may also contain one or more wired
communication links. The Communication Unit may therefore be used to relay
information from the Sensor Unit to the system operator or to a remote
monitoring system by wired of wireless means. The Communication Unit or the
Sensor Unit may also be directly connected to an alarm system.
This invention is presented in the context of use
in the petrochemical industry where the accumulation of flammable, potentially
explosive, or toxic gasses is of great concern but it is also suitable for
deployment for other industrial applications.
A further potential benefit of the invention is
that the ease of installation and low installed cost may serve to hasten the
upgrading of safety systems.
When compared to the current industry practice of
manual inspection, major benefits of the current invention include: gas sensing
at more frequent intervals (e.g., multiple times per day), thereby improving
the probability of detecting a potentially catastrophic event: not having to
expose personnel to potentially hazardous conditions and a reduction in power
consumption.
Figure 1: Function Block Diagram of the Proposed
Apparatus
Figure 2: Function Block Diagram of the Sensor
Unit
Figure 3: Function Block Diagram of the
Communication Unit
Figure 4: Cross-sensitivity of a Methane Gas
Sensor
Figure 5: Cross-sensitivity of a Propane Gas
Sensor
With reference to the block diagram in Figure 1,
the invention minimally comprises a Communication Unit 1 and a Second Unit 2
that communicate via wireless means using Antennas 3. The configuration of the
Antennas 3 is not a facet of this invention.
With reference to the block diagrams in Figures 1
and 2, the Sensor Unit 2 comprises an Antenna 3; two or more co-located Gas
Sensors 4; a Microcontroller or Microprocessor 5; a Power Source 6 such as
batteries, solar panels, or a connection to an external power source; and a
Wireless Communication Interface 7. Said Wireless Communication Interface 7 can
be integrated with said Microcontroller 5, e.g., the Freescale MC13224.
Regardless of the plurality of said Gas Sensors, a minimum of two different
gas-sensing technologies must be employed to enable the joint analysis of data
from said Gas Sensors.
Herein, 'co-located' implies that the Gas Sensors
have sufficient physical proximity to ensure that the joint analysis of their
readings can be performed with an accuracy that is sufficient for a particular
deployment scenario. In the current embodiment, the distance between the Gas
Sensors is less than one meter.
With reference to the block diagram in Figure 3,
the Communication Unit 1 minimally comprises an Antenna 3; a Microcontroller or
Microprocessor 5; a Power Source 6 such as batteries, solar panels, or a
connection to an external power source; and a Wireless Communication Interface
7. It may include additional wireless or wired interfaces.
If required, the communication capability of the
Sensor Unit 2 or the Communication Unit 1 may be configured to act as a
communication relay or as part of a redundant network, such as a mesh network.
These capabilities are well known in the current art.
Because the Sensor Unit 2 and the Communication
Unit 1 can have a minimal number of external physical connections, including
the possibility of zero external connections, they can be readily protected by
an environmentally-protective enclosure, thereby making them suitable for use
in harsh environments. The current embodiment of the Sensor Unit 2 is intended
for deployment on the floating roofs of petroleum storage tanks and is
therefore immersible and meets the ATEX requirements for Intrinsic Safety,
although these are not requirements of the current invention.
In the current embodiment of both the Communication
Unit 1 and the Sensor Unit 2, the Microcontroller 5 and Wireless Communication
Interface 7 is realized using a Freescale MC13224; the Power Source 6 is a
lithium-thionyl-chloride battery pack; and the Antenna 3 is a patch
antenna.
Herein we describe the current embodiment of the
Sensor Unit 2, which is a low-power implementation. The Primary Gas Sensor is
an Alphasense PID-AH Photo-Ionization Detector (PID) that measures the
concentration of Volatile Organic Compounds (VOCs) in parts-per-million. The
Secondary Gas Sensor is a Dynament TDS0034 Non-Dispersive Infrared (NDIR)
Sensor that measures ambient hydrocarbon concentration as a percentage of the
gas volume. With these two sensors, the current embodiment meets the minimum
requirement of two disparate gas-sensing technologies.
Under the control of the Microcontroller 5, the Gas
Sensors 4 can be operated discontinuously. A first advantage of discontinuous
operation is that it reduces overall power consumption, which is important for
battery- or solar-powered systems. A second advantage is that Gas Sensors may
not need to be re-calibrated as often, thereby reducing maintenance
requirements. A third advantage of discontinuous operation is that it can
extend the operation lifetime of the Gas Sensors.
To further reduce power consumption or to extend
the operational lifetime of the Sensor Unit, one Gas Sensor can be operated as
the Primary Gas Sensor. The Primary Gas Sensor is activated more frequently
than any other Gas Sensor.
In the case where the Primary Gas Sensor has low
power consumption, it can act as a gas detector, wherein the reading from said
Primary Gas Sensor is compared to a threshold value. When said reading exceeds
this threshold, a Secondary Gas Sensor is activated and readings are taken to
exploit the aforementioned advantage of analyzing information from multiple
disparate Gas Sensors. Because the Secondary Gas Sensor is only operated when
said threshold is exceeded, a finite power source, such as a battery, can
provide power for a comparatively longer period of time.
Certain types of Gas Sensors, such as catalytic
bead sensors, have a comparatively shorter active operational lifetime and can
remain useful for longer periods if they are not activated. Therefore, the
Primary Gas Sensor can be selected based on the operational lifetime of the Gas
Sensor, rather than on the basis of power consumption.
In the context of this invention, there must be at
least two disparate types of Gas Sensors, but this requirement for disparity
does not preclude the provision of redundant Gas Sensors within the Sensor
Unit. Firstly, said redundancy can be used to improve system robustness by
supplying alternative identical Gas Sensors to operationally replace a railed
Gas Sensor. Secondly, said redundancy can be used to extend system lifetime by
providing a sequence of useable identical Gas Sensors.
Therefore, for generality, the aforementioned
Primary Gas Sensor may be any Gas Sensor from a number of identical Gas
Sensors.
The aforementioned benefits of jointly analyzing
the information from disparate gas sensors can be seen by considering the
cross-sensitivity response of various gas sensors. With reference to Figure 4
and Figure 5, we can see that the shapes of the sensor response curves are
different for different types of gas. By jointly analyzing the response of
multiple disparate sensors to an unknown gas, we can therefore determine both
the concentration of the gas and the type of gas. This type of joint data
analysis is well known within the discipline of data analysis but has
heretofore not been used for analyzing gas emissions from petrochemical storage
tanks.
Claims (7)
- An apparatus for the monitoring of aboveground petroleum storage tanks comprising a Communication Unit and a Sensor Unit wherein the Communication Unit minimally comprises a Wireless Communication Interface; a Microcontroller or Microprocessor; and a Power Source, such as batteries, solar cells or line power and the Sensor Unit minimally comprises a Wireless Communication Interface; a plurality of Gas Sensors employing a minimum of two disparate gas-sensing technologies; a Microcontroller or Microprocessor; and a Power Source, such as batteries or solar cells; where said Communication Unit and said Sensor Unit communicate using wireless means; and where readings from said Gas Sensors are jointly analyzed.
- The apparatus of Claim 1 wherein the Gas Sensors are operated discontinuously.
- The apparatus of Claim 2 wherein a low-power Gas Sensor is used to detect gas levels exceeding a prescribed threshold whereupon an additional Gas Sensor is activated.
- The apparatus of Claim 2 wherein a Gas Sensor having a long operational lifetime is used to detect gas levels exceeding a prescribed threshold whereupon an additional Gas Sensor is activated.
- The apparatus of Claim 1 wherein the disparate gas-sensing technologies are non-dispersive infrared and photo-ionization.
- The apparatus of Claim 1 wherein the disparate gas-sensing technologies are catalytic bead and non-dispersive infrared.
- The apparatus of Claim 1 wherein the disparate gas-sensing technologies are catalytic bead and photo-ionization.
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US201161482957P | 2011-05-05 | 2011-05-05 | |
US61/482,957 | 2011-05-05 |
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Cited By (5)
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WO2017072159A1 (en) * | 2015-10-29 | 2017-05-04 | Inficon Gmbh | Infrared gas detector with secondary sensor |
EP3211416A1 (en) * | 2016-02-23 | 2017-08-30 | iQunet BVBA | A battery-powered, wireless gas sensing unit |
CN107991459A (en) * | 2018-01-25 | 2018-05-04 | 大同煤矿集团雁崖煤业有限公司 | Wireless digital gas detector |
US10393712B2 (en) | 2016-03-22 | 2019-08-27 | Cummins Inc. | Systems and methods using a gas quality sensor |
CN114245872A (en) * | 2019-06-11 | 2022-03-25 | Msa技术有限公司 | Gas sensor with individual contaminant detection elements |
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US20060114113A1 (en) * | 2004-11-26 | 2006-06-01 | Koichi Yokosawa | Gas detection system |
US20100219960A1 (en) * | 2007-07-17 | 2010-09-02 | Wgd As | Detector System and Method to Detect or Determine a Specific Gas Within a Gas Mixture |
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2017072159A1 (en) * | 2015-10-29 | 2017-05-04 | Inficon Gmbh | Infrared gas detector with secondary sensor |
US10309943B2 (en) | 2015-10-29 | 2019-06-04 | Inficon Gmbh | Infrared gas detector with secondary sensor |
EP3211416A1 (en) * | 2016-02-23 | 2017-08-30 | iQunet BVBA | A battery-powered, wireless gas sensing unit |
US10393712B2 (en) | 2016-03-22 | 2019-08-27 | Cummins Inc. | Systems and methods using a gas quality sensor |
CN107991459A (en) * | 2018-01-25 | 2018-05-04 | 大同煤矿集团雁崖煤业有限公司 | Wireless digital gas detector |
CN107991459B (en) * | 2018-01-25 | 2023-11-17 | 大同煤矿集团雁崖煤业有限公司 | Wireless digital gas detector |
CN114245872A (en) * | 2019-06-11 | 2022-03-25 | Msa技术有限公司 | Gas sensor with individual contaminant detection elements |
CN114245872B (en) * | 2019-06-11 | 2024-06-21 | Msa技术有限公司 | Gas sensor with individual contaminant detection element |
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