Hazardous gases are an unavoidable part of many industrial operations. Whether they’re used in refrigeration systems, generated during manufacturing processes or present in confined spaces, they can pose serious risks to both people and business operations.

The challenge is that many dangerous gases can’t be detected by human senses. Some are colourless, odourless and tasteless, while others can quickly overwhelm a person’s sense of smell. Without reliable gas detection, workers may have little warning before conditions become dangerous.

A well-maintained gas detection system provides continuous monitoring and early warning of gas leaks, helping protect your people, minimise downtime and support workplace health and safety requirements.

At Electrical & Automation Solutions (EAS), we help industrial businesses specify, supply, install, commission, inspect, test and maintain gas detection systems that perform when they’re needed most.

Why Gas Detection Matters

Gas detection isn’t just about sounding an alarm – it’s about giving people time to respond safely.

An effective gas detection system helps to:

• Protect workers from exposure to toxic gases.
• Detect combustible or flammable gas leaks before they become a major hazard.
• Identify oxygen-deficient environments that can lead to asphyxiation.
• Support safe entry into confined spaces.
• Reduce the risk of unplanned shutdowns and production losses.
• Assist with meeting workplace health and safety obligations.

For many industrial sites, gas monitoring is a critical layer of protection for both people and plant.

Common Hazardous Gases in Industry

Different industries face different gas hazards. Some of the most common include:

• Ammonia (NH₃)
  Widely used in industrial refrigeration systems throughout the dairy, food processing and cold storage industries.
  Exposure can cause eye irritation, respiratory damage and burns at higher concentrations, making early leak detection essential.
• Hydrogen Sulphide (H₂S)
  Commonly found in wastewater treatment plants, pump stations, sewer networks and effluent systems.
  Hydrogen sulphide is highly toxic and particularly dangerous because exposure can quickly reduce a person’s ability to smell the gas.
• Carbon Monoxide (CO)
  Produced by internal combustion engines, boilers and gas-fired equipment.
  Because carbon monoxide is colourless and odourless, reliable detection is essential wherever combustion equipment operates.
• Chlorine (Cl₂)
  Used in water treatment, chemical processing and some manufacturing applications.
  Even relatively small leaks can create serious health risks.
• Combustible Gases
  Hydrocarbon gases and vapours are used across many industrial processes. Monitoring helps detect leaks before gas concentrations reach explosive levels.
• Oxygen Deficiency
  Some industrial processes can displace oxygen, creating an invisible but potentially fatal hazard—particularly in confined spaces and enclosed plant rooms.

Fixed and Portable Gas Detection

Fixed Gas Detection Systems

Fixed systems continuously monitor critical areas and provide automatic warning when gas levels exceed safe limits.

Depending on the application, they can:

• Operate 24 hours a day.
• Activate audible and visual alarms.
• Interface with PLC or SCADA systems.
• Trigger ventilation or other safety systems.
• Alert operators to developing hazards.

They’re commonly installed in refrigeration plant rooms, chemical storage areas, wastewater facilities, boiler rooms and process plants.

Portable Gas Detectors

Portable detectors provide personal protection for workers carrying out activities such as confined space entry, shutdown work and maintenance.

While portable monitors are an important safety tool, they should complement – not replace – permanently installed systems where continuous monitoring is required.

Selecting the Right Equipment

No two sites are the same.

Choosing the right gas detection equipment depends on factors such as:

• The type of gas being monitored.
• Where the gas is likely to accumulate.
• Environmental conditions.
• The process or equipment involved.
• Manufacturer recommendations.
• Site-specific operational requirements.

Different gases require different sensing technologies, so selecting the correct equipment is essential for reliable performance.

EAS can help you specify the most suitable gas detection equipment for your application, then professionally install and commission the system to ensure it operates as intended.

Correct Installation Matters

Even the best gas detector won’t perform effectively if it’s installed in the wrong location.

Gas detectors must be positioned with consideration for factors such as:

• Whether the gas is lighter or heavier than air.
• Potential leak sources.
• Ventilation and airflow.
• Occupied work areas.
• Alarm visibility and accessibility.
• Integration with existing control systems.

Our experienced team works with customers, equipment suppliers and consulting engineers to ensure gas detection equipment is installed correctly and commissioned to manufacturer requirements.

Calibration Keeps Your System Reliable

Gas detectors naturally drift over time.

Without regular testing and calibration they may:

• Fail to detect dangerous gas levels.
• Produce nuisance alarms.
• Display inaccurate readings.
• Fall outside manufacturer specifications.

A detector that hasn’t been calibrated shouldn’t be relied on to protect people.

Routine inspection, functional testing and calibration confirm that sensors respond correctly and alarms activate when required.

Inspection, Testing and Preventative Maintenance

Gas detection systems are safety-critical assets and should be maintained accordingly.

EAS can tailor a preventative maintenance programme to suit your facility, including:

• Routine inspections.
• Functional testing.
• Sensor calibration.
• Alarm testing.
• System health checks.
• Asset register updates.
• Compliance documentation.

Maintenance may be scheduled monthly, six-monthly or annually, depending on your equipment, operating environment and manufacturer recommendations.

To make life easier, we can also schedule automatic service reminders so your gas detection system stays up to date.

Supporting Your Compliance

Every inspection and calibration is backed by clear documentation, including:

• Calibration certificates.
• Inspection reports.
• Test records.
• Asset registers.
• Maintenance history.

This provides confidence that your gas detection equipment has been maintained and gives you the records needed to support your internal maintenance and health and safety systems.

Why Choose EAS?

Gas detection systems only protect people if they’re working correctly.

That’s why our focus doesn’t stop at installation—we’re committed to helping customers keep their systems reliable for the long term.

Our services include:

• Assistance specifying suitable gas detection equipment.
• Supply, installation and commissioning.
• Inspection, testing and calibration.
• Preventative maintenance programmes.
• Asset registers and compliance documentation.
• Integration with PLC and SCADA systems.
• Ongoing technical advice and support.

With extensive experience across dairy, food processing, manufacturing, water and wastewater, utilities and industrial processing, we understand the environments where reliable gas detection matters most.

Keep Your Gas Detection System Ready

Whether you’re installing a new gas detection system or maintaining an existing one, regular inspection, testing and calibration are essential to protecting your people and your business.

If you’d like advice on gas detection, or it’s time to service your existing system, we’d be happy to help.

Contact the EAS team today on 07 834 0505 to discuss your gas detection requirements or arrange an inspection.

With the increasing number of severe weather events across NZ, power outages are becoming more frequent – and less predictable.

For many sites, a generator isn’t just a backup anymore. It’s critical infrastructure.

But here’s the issue:

A generator only protects your operation if it actually works when you need it.

We regularly see generators that haven’t been tested or maintained properly… and when the power goes out, that’s when the problems show up.

Why maintenance matters more than ever

A proper electrical preventative maintenance plan isn’t just a “nice to have” – it’s what ensures your generator will perform under pressure. Done properly, it gives you:

• Reliability and Availability

  Reduces the risk of unexpected failures when you need backup power most.

• Efficiency and Performance

  Ensures your generator runs as it should, without overloading or underperforming.

• Cost Savings

  Prevents major failures and extends the life of your equipment.

• Safety

  Faulty electrical components in generators are a real hazard if left unchecked.

With more outages and higher reliance on backup power, generators are being used harder and more often.

Common issues we come across:

• Batteries that fail under load
• Transfer switches that don’t operate correctly
• Loose or degraded electrical connections
• Protection systems that haven’t been tested
• Generators that haven’t been load tested in years

Most of these don’t show up until it’s too late.

Generator maintenance

A solid electrical preventative maintenance plan should include:

• Full visual inspections of cables, connections, and enclosures
• Voltage and frequency checks to confirm correct output
• Testing of circuit breakers, relays, and protection systems
• Grounding system inspections and testing
• Battery testing and load checks
• Control panel and wiring inspections
• Automatic Transfer Switch (ATS) testing
• Load bank testing to confirm real performance under demand
• Infrared thermography to identify hidden faults

This isn’t just ticking boxes – it’s about making sure the system performs in real conditions.

Is your generator ready?

Generators don’t fail when they’re sitting idle.

They fail when they’re suddenly called on to run at full load.

That’s why testing under real conditions and regular maintenance is critical

With weather events becoming more frequent, now’s the time to either:

• Get your existing generator properly checked and tested
• Or review whether your current setup is still fit for purpose

If you’re not 100% confident your system will perform when needed, it’s worth getting it looked at properly

Need a hand?

The EAS team can:

• Assess the condition of your current generator
• Carry out full electrical preventative maintenance
• Identify risks before they become failures
• Make sure your backup power system is ready when you need it

Get in touch with EAS – and make sure you’re not left in the dark.

If you’re running Variable Speed Drives (VSDs), brake resistors are one of those components that either quietly do their job… or cause you headaches when they’re wrong.

 So, what do they actually do?

When a motor slows down, it doesn’t just stop – it turns into a generator and pushes energy back into the drive. That energy has to go somewhere.

 Without a brake resistor, that energy builds up in the drive and can trip it out on overvoltage.

 A brake resistor takes that excess energy and safely burns it off as heat, letting your system slow down properly without nuisance trips.

Where we see them used

We’re dealing with these setups all the time across sites, especially where you’ve got:

• Pumps and conveyors that need controlled stopping
• High inertia loads
• Frequent start/stop processes
• Systems where downtime from trips isn’t an option

Where things usually go wrong

This is where experience actually matters.

On paper, brake resistors look simple. In reality, we regularly see:

• Resistors undersized for the actual duty
• Incorrect resistance values causing drive faults
• Poor placement – stuck somewhere with no ventilation
• No thermal protection wired in

All of these can lead to overheating, trips, or early failure.

What proper installation actually looks like

From recent jobs the EAS team have done, the key considerations to make sure you get it right are:

• Installing and positioning VSDs and associated gear properly on-site
• Running and dressing power, control, and thermistor cabling cleanly through MCCs and field cabinets
• Integrating filters, drives, and associated components so everything works as one system
• Testing motors, insulation, and cable integrity before energising
• Commissioning drives and confirming rotation, performance, and control with automation teams
• Labelling everything clearly so future maintenance isn’t a guessing game

EAS doesn’t just “fit a resistor” – we make sure the whole system behaves properly under real operating conditions.

The key thing to get right

Brake resistors need to be sized and selected based on how your system actually operates – not just motor size.

 That includes:

• How fast you need to stop
• How often it happens
• The load involved
• Heat dissipation and environment

Miss that, and you’re back dealing with trips, downtime, or burnt-out gear.

Need a hand with your VSD setup?

If you’re not 100% sure your system is set up right – or you’re planning upgrades – it’s worth getting it checked properly.

 We can:

• Assess whether you actually need a brake resistor
• Size and specify it correctly
• Install and integrate it with your VSD system
• Test and commission so it works first time

Get in touch with the team at EAS – we’ll make sure your drives run the way they should.