Detect oxygen leaks and monitor controlled atmospheres in welding, fire prevention, and inerting systems

Why Oxygen Monitoring Matters in Industrial Safety & Inerting 

Oxygen monitoring protects people, processes, and assets wherever controlled atmospheres are essential, such as welding purge, oxygen reduction, fire prevention, and inerting. Even minor oxygen ingress can undermine protective concepts, increase the risk of ignition, and compromise the effectiveness of inert environments. With the right oxygen sensor or analyzer, operators keep atmospheres stable, avoid costly downtime, and follow relevant standards and company rules. With the right industrial oxygen sensor or oxygen analyzer, operators can ensure controlled atmospheres remain stable, prevent costly downtime, and maintain compliance with strict safety standards.  

Industry Challenges: Risks of Oxygen Leaks and Poor Atmosphere Control  

Without reliable oxygen detection, operators face multiple risks:  

• Safety Hazards – leaks into inerted or oxygen-reduced environments can restore combustibility and raise ignition risk.  

• Welding Quality Issues – Oxygen exposure can cause weld oxidation, porosity, and weakened joints.  

• Ineffective Fire Protection – Oxygen contamination reduces the effectiveness of oxygen reduction systems that rely on nitrogen or other inert gases. Regulatory Non-Compliance – Failure to maintain controlled oxygen levels can lead to penalties and shutdowns.  

Solution Overview: Precision Oxygen Detection with Sensore Products  

Sensore provides zirconia oxygen sensors and transmitters engineered for industrial safety, fire prevention, and inerting. The portfolio covers applications from trace oxygen to percent levels, with measuring options from about 10 ppm up to 96 percent O₂, depending on the selected variant. It combines high accuracy, fast response, and long service life for reliable operation in continuous service.

Measurement scope  

• Trace and low oxygen for leak detection, purge control, and oxygen reduction fire prevention
• Percent oxygen for atmosphere monitoring and nitrogen blanketing
• Stable, temperature-compensated signals with variant-specific accuracy and MTTF up to ten years according to the datasheet

Housings and form factors 

• Cable mount modules for easy integration in equipment and field checkpoints

• Flanged process housings for secure fixed installation on pipes and vessels with fast response

• Panel or rack solutions for conditioned sample gas and control room environments

Compact micro modules for embedded OEM designs and space-constrained installations. Oxygen Transmitters and signal conditioning  

• OxyPro XT and OxyPro XT2 for setpoints, alarms, and seamless integration into control systems  

• Microx for compact signal conditioning and OEM integration, where size and simplicity matter. GSB Generic Sensor Board for OEM integration of our zirconia sensors, providing sensor control and signal conditioning for standard industrial integration  

Integration notes  

• Selection depends on oxygen range, gas matrix, temperature, pressure, flow, and installation method. Extractive sampling in a safe location or certified analyzer systems can be used for hazardous area classifications. Oxygen monitoring does not replace LEL gas detection.  
• Please refer to the respective datasheets for exact ranges, accuracy, and maintenance intervals.  

Applications & Industry Examples  

Sensore’s industrial oxygen sensors and analyzers are trusted in:

• Welding – Using the SO-B1-xxx to monitor trace oxygen levels during weld purging, ensuring strong, defect-free welds.  

• Fire Protection Systems – Applying the SO-A0-xxx for broader atmosphere monitoring in nitrogen or inert-gas suppression systems.  

• Inerting Processes – Deploying the SO-E2-xxx in silos, tanks, and controlled environments to detect oxygen leaks and maintain safe, inert atmospheres.  
• Chemical & Industrial Plants – Combining portable checks (SO-E2-xxx) with fixed installations (SO-A0-xxx or SO-B1-xxx) to safeguard processes where oxygen ingress threatens safety and product quality.  

Key Benefits of Sensore Solutions  

• Accurate detection from low ppm to percent oxygen ranges

• Long-lasting sensors with minimal calibration needs  

• Flexible mounting options: cable, flange, or fixed systems  

• Fast response time for immediate safety assurance  

• Proven zirconia oxygen sensing technology for industrial reliability  

Conclusion: Protecting Safety Through Oxygen Detection  

Reliable oxygen monitoring is essential to maintaining controlled atmospheres in welding, fire protection, and inerting systems. Sensore offers a wide portfolio of zirconia-based oxygen sensors and transmitters tailored to different installation needs. This includes micro sensors such as the SO-A0-xxx or the SO-E2-xxx, robust flanged housings such as the SO-B1, and advanced SMART transmitters like the OxyPro-XT and OxyPro-XT2.  

These examples represent only part of our range. Depending on the application—trace-level leak detection, continuous monitoring in safety systems, or integration into large-scale industrial processes—operators can select the sensor type, housing, and transmitter configuration best suited to their requirements.  

With this flexibility, combined with long service life, proven accuracy, and reliable performance, Sensore solutions help ensure safety, regulatory compliance, and operational integrity across industries.  

Important safety note  

Our zirconia oxygen sensors use an internally heated measuring cell at high temperature. We do not hold ATEX or IECEx certification. Do not install sensors directly in classified hazardous areas. Extractive sampling should be used in a safe location or certified analyzer systems for such environments. Oxygen monitoring does not replace LEL gas detection.  

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