Safety Alert: Hidden hazards in gas detection practices
Lessons from a US Coast Guard Safety Alert
United States Coast Guard Safety Alert 13-26 highlights the potentially serious consequences of weaknesses in gas detection practices when carrying cargoes capable of emitting flammable or toxic gases. The alert follows two explosions on bulk carriers carrying methane-emitting coal in 2023 and 2025. Investigations into both incidents remain ongoing and no cause has yet been determined. However, the incidents spotlight the importance of effective atmospheric monitoring and the need for gas detection systems to function as intended.
During bulk carrier inspections the USCG identified recurring deficiencies relating to operation, maintenance and use of gas detection equipment. This underlines that a gas detection system is only as reliable as the equipment, supporting hardware, procedures and competence that underpin it.
Safety implications
Gas detection equipment is frequently relied upon as a critical control measure when managing the risks associated with flammable or toxic atmospheres. If equipment is incorrectly calibrated, poorly maintained or improperly used, personnel may receive inaccurate readings and false reassurance regarding the conditions within cargo spaces or enclosed spaces.
This can lead to increased risk to personnel, vessels, cargoes and port infrastructure, as well as possible regulatory findings, operational restrictions or vessel detention where significant deficiencies are identified.
Common deficiencies identified
The US Coast Guard reports recurring findings including:
- Calibration gases not available, expired or unsuitable for the hazard being monitored.
- Gas detection instruments that are overdue for calibration, poorly maintained or non-functional.
- Officers unable to correctly carry out calibration or bump testing in accordance with manufacturer instructions.
- Use of incorrect regulators or calibration equipment that is incompatible with the manufacturer’s requirements.
These deficiencies demonstrate that reliable atmospheric monitoring depends not only on the detector itself but also on the complete management system supporting its use.
Reviewing your controls
Organisations should consider whether:
- Calibration and bump-test gases are available, within shelf life and appropriate for the hazards being monitored.
- Gas detectors are maintained, calibrated and functioning as intended.
- Correct regulators and associated hardware are available and compatible with the manufacturer’s requirements.
- Procedures for calibration, bump testing and operational checks are incorporated into documented management systems and take account of manufacturers’ instructions.
- Personnel are trained, familiar with the equipment carried and able to demonstrate correct operation and testing procedures.
- Verification of gas detection and supporting equipment is completed before loading cargoes capable of emitting flammable or toxic gases.
More than the detector
The US Coast Guard recommendations emphasise that effective gas detection relies upon a combination of suitable equipment, correct calibration materials, risk assessed procedures and competent personnel. Deficiencies in any of these areas can undermine an important layer of protection.
While the alert focuses on bulk carriers carrying methane-emitting coal, the underlying lessons are relevant wherever gas detection forms part of the control measures used to manage cargo hazards, atmospheric monitoring or enclosed-space risks. Organisations should review whether their arrangements provide sufficient assurance that atmospheric monitoring systems will perform effectively when needed.
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