Pyroban presents new extended explosion protection range at OTC
Written by Molokini
Written on Monday, 23 April 2012
At OTC 2012 in Houston, Pyroban will demonstrate its growing range of NEC, ATEX and IECEx certified explosion proof components, kits, packages and systems used to protect the global oil and gas industry.
"An explosion offshore has deep consequences for people, the environment, brand reputation and oil and gas production,” explains Rob Double, responsible for Pyroban's global oil and gas business. “We expect this subject to be high on the agenda for many visitors at this year’s OTC where Pyroban will show new components and products that help prevent an ignition offshore.”
For more than 40 years, Pyroban’s business has been safety and the prevention of explosions, and the company is well known for providing safety solutions for oil and gas customers all over the world.
“Pyroban provides a complete range of explosion prevention services from helping businesses understand their explosion risks through to the delivery of complex explosion protection engineering solutions,” says Rob Double. “At OTC, experienced members of the Pyroban team will be available to discuss specific explosion prevention topics alongside displays of explosion proof components and products, which have achieved tri-certification to ATEX, IECEx and NEC.”
At this year’s OTC, which takes place in Houston at the Reliant Centre on 30 April to 3 May, Pyroban will be exhibiting on stand 2541, Hall D, in the UK Pavilion. OTC is described as the world’s foremost event for the development of offshore resources in the fields of drilling, exploration, production, and environmental protection.
“We provide explosion prevention solutions for all levels of the global oil and gas supply chain,” says Rob Double explaining that Pyroban services are broadly filtered into eight categories consisting of consulting, components, engine kits, engine packages, bespoke solutions, systems, service and training, all of which will be featured on the Pyroban stand at OTC.
Hazardous area consulting services
In daily offshore operation, the potential release of flammable hydrocarbons presents a continued risk requiring proper planning and ongoing management to prevent a potential explosion. The consulting team from Pyroban can help oil and gas businesses effectively manage their explosion risks offshore and help put processes in place to ensure legal compliance and continued safety anywhere in the world.
At OTC the team will be discussing risk assessments offshore, hazardous area classification, gap analysis, ongoing explosion risk management, equipment verification services and equipment specification services. The team will also re-enforce the importance of focusing on the science behind an explosion and why legal compliance should never solely be the primary goal.
Explosion proof components
A number of new explosion proof components, many of which have tri-certification to ATEX, IECEx and NEC 505, will also be displayed on the Pyroban stand at OTC, manufactured by Pyroban Group companies. Pyroban has expanded its range of hazardous area components and this will be the first time that many of them have been shown to the public.
- Versions of the new Pyroban safety shutdown valves (SVH) will be shown, which are designed to shut down a diesel engine if it ingests a flammable gas, preventing engine “over-speed”. The slim “butterfly” SVH design suits a wide range of hazardous area applications and there is a choice of 3”, 5” and 8” valve sizes with electric, pneumatic or hydraulic actuation. The 3” and 5” versions can be supplied with an integral flame trap both of which will be on display for the first time at OTC and are certified to ATEX, IECEx and NEC 505.
- Pyroban will also be showing a range of explosion proof components from Pyropress, a Pyroban Group company, including the Perseus pressure switch that has tri-certification and the Hermes II pressure switch, which is Exd and Exia.
- An Exd and Exia Pyropress transmitter will also be shown alongside the Guardian Exia temperature and reed level switches designed for use in hazardous areas.
- Visitors will also see the Pyropress 4’’ and 6’’ explosion relief valves (ERV) which vent excess pressure. In the event of a crankcase explosion the M66 marine certified Pyropress ERV helps avoid a dangerous pressure rise and resultant engine damage. High temperature valves able to withstand 540°C are also available for relieving explosions in exhaust systems.
- The newest addition to the Pyroban flameproof alternator range is the 60 KVA version, with ATEX, IECEx and NEC 505 certification.
- An ATEX compliant centrifugal and auxillary spark arrestor for engines up to 1500bhp will also be shown, representing a full range offering
- Pyroban’s explosion proof 12V and 24V deep cycle batteries, which have tri-certification for use in hazardous areas anywhere in the world, will also be seen alongside a number of other explosion proof components.
Explosion proof diesel engine kits
Pyroban is well known for supplying complete explosion proof diesel engine kits for integration into well service equipment and a complete unit will be on display.
“It is important to show an explosion proof diesel engine with global certification at OTC this year because it brings best practice to Houston, the heart of the global oil and gas industry,” says Rob Double. “Well service equipment all over the world is powered by diesel engines and many of them are used in hazardous areas.”
Nitrogen vaporiser pumps, surface preparation equipment, cementing units, coiled tubing power-packs, high pressure fluid pumps and air compressors are all driven by diesel engines. However, unless they are suitably protected, diesel engines can be a potential source of ignition (such as hot surfaces, engine over-speed or sparks), leading to potential fire or explosion hazards.
Rob Double states “Some diesel powered well service equipment sent offshore has limited protection, exposing the rig to an increased risk of explosion.”
Pyroban has developed kits for all types of engines from various engine manufacturers. Numerous explosion proof solutions for both electronic and mechanical engines spanning 15 bhp to 3500 bhp have already been developed and are available in a comprehensive kit format from Pyroban.
A typical Pyroban diesel engine solution includes an exhaust gas cooler, a shutdown valve to prevent engine overspeed and flame from the inlet, flame and spark arrestors, safety solutions for all electrics, a safe turbocharger and other safety critical components. An alternator, battery and radiator can also be added to the kit. A radiator manufactured by Broadland Radiators, a Pyroban Group Company, will be on display.
Equipment is delivered fully documented, warranted and with global service and parts support and the kits can be fitted by the equipment OEM.
Since 1999, as a direct result of ever tightening emission legislation, diesel engine technology has migrated towards electronic engine management systems making them more complex than the typical mechanical engines seen historically in the oilfield.
Pyroban has developed two main options for the control system of electronically controlled engines, one with gas detection and one without.
Pyroban’s new system, PCS 2™ will be launched at OTC 2012 and will be shown for the first time in a visual display that incorporates animation.
“This is the first time we are showing the PCS 2™ control system” says Rob Double. “It is ATEX 94/9/EC and IECEx certified for use all over the world.”
PCS 2™ can be used on any electronically controlled engine where gas detection is not required and it has five key shutdown features. In the event of engine overspeed, typically at about 2,300rpm, a switch triggers both the fuel shut-off and the Pyroban air intake shutdown valve to ensure that the engine shuts down. If the exhaust gas temperatures reach 195ºC, the water temperature reaches 105ºC or the oil pressure drops, the fuel is shut-off bringing the engine to a controlled stop. In emergency situations there is also an emergency stop that stops the fuel and triggers the air intake shutdown valve.
Visitors can also discuss Pyroban’s 3GP™, an alternate system for electronic engines that incorporates gas detection. 3GP™ is the control system that helps reduce downtime by eliminating the need for an exhaust flame arrestor, an essential component on the typical explosion proof diesel engine package.
Explosion proof diesel engine packages
One of the main features on the Pyroban stand at OTC will be the explosion proof diesel engine with tri-certification for use around the world. The engine has ATEX 94/9/EC, IECEx and NEC 505 certification, for use in Zone 2 (or equivalent) hazardous areas.
Pyroban has now broadened its offering to satisfy the demand for customers that require a complete explosion proof Powerpack. Custom radiator to flywheel or radiator to transmission Zone 2 Powerpacks are available from Pyroban that are fully certified in accordance with local requirements such as ATEX, IECEx or Class1 Div 2, and delivered fully documented and warranted.
At OTC, the Pyroban team will be providing information about the different engine packages available.
Explosion proof solutions
With significant explosion protection engineering experience, Pyroban can develop solutions for almost any type of equipment used in on and offshore applications.
Pyroban develops concepts and prototypes to create innovative solutions to ensure the safety of even the most complex equipment configuration used in hazardous environments offshore.
As engine and well service technology continually progresses, market needs are also changing and Pyroban expects some interesting discussions at OTC as businesses look to find a partner that can support increasingly complex hazardous area engineering challenges.
Explosion protection systems
Visitors to OTC can also discuss the new Flamepack system from Pyroban, a recent finalist in the UK HazardEx awards. Pyroban’s Flamepack is a new concept for the explosion protection of generator sets or pumps used in brown and green field oil and gas installations. Pyroban claims that the new Flamepack upgrade can be installed on to a new or used generator in one month after thorough engineering, and reduces major costs to achieve ATEX 94/9/EC compliance. The Flamepack is predominantly a self-contained, open frame module that sits on top of the generator set container and connects to the diesel engine with limited intervention.
Pyroban also offers a number of explosion protection systems to protect equipment such as forklift trucks, pallet trucks or mobile plant used offshore. Pyroban specialists will be available to discuss these ATEX compliant systems at OTC, which ensure the safe operation of equipment in Zone 1 or Zone 2 hazardous areas.
Pyroban systems are widely used in onshore applications, however when used in the harsh environment offshore, Pyroban offers an additional corrosion proof service. Special coatings are added to forklift trucks, access platforms and specialist cranes, components can be upgraded to high performance materials and areas that can become water traps are sealed. This ensures that the equipment has a prolonged life in the tough offshore environment.
Service and global support
In support, Pyroban has a team of experienced fast response engineers who can be in place offshore quickly with all the necessary medical certificates and survival training, anywhere in the world. The company supports the 24/7/365 nature of the oilfield and related services and is attuned to local requirements with a growing global footprint of manufacturing and service centres.
Specialist Pyroban engineers will also travel to onshore destinations to aid with commissioning, installation, fault finding and hand deliver parts if needed.
Hazardous area training
Pyroban’s training team provides a wide range of explosion prevention training services across the world, either at Pyroban facilities, or at customer locations. The training courses are designed to cut through the science and vast quantity of explosion proof legislation, including standards and guidance, with a flexible learning experience. The courses suit all levels of the oil and gas supply chain including detailed practitioners and engineers.
ENDS – 1,945 WORDS
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