Round the clock safety equipment without need for human interaction
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Flow Meter approved for Hazardous Environments
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Enabling Electrical Maintenance in Hazardous Areas
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Bespoke designed Atex Fans & Blowers
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Vertical-Mounting heaters for Hazardous are applications
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Cover Story – Magic Gel New Silicon Polymers Page
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Energy and waste management
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Training & Courses
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Latest News & Products
A RELIABLE, ROUND-THE-CLOCK SUPPLY OF SAFETY EQUIPMENT - WITHOUT THE NEED FOR HUMAN INTERACTION Designed to automate the issue and return of safety equipment, the Draeger Rental Robot makes masks, portable gas detectors and consumables available at any time – without the need for human interaction. By keeping a record of how often devices are used, it also supports the material planning process. In the petrochemical or chemical industry, for instance, employees generally receive their personal protective equipment (PPE) at central supply points which have restricted opening hours. With the Rental Robot, materials - whether rental or inventory devices - can be obtained at any time. The employees simply log on at the “service station” using a barcode or the radio frequency identification (RFID). Based on the respective user data, the Rental Robot identifies which products the employee may access and displays each of those devices on a screen. Optional information on the products’ performance range can also be displayed. Using the touch screen, the desired product can then be selected and removed from the device compartment. The return of the equipment is equally easy: once identified, the user puts the device back into the compartment. Consumables such as disposable masks can also be supplied, registered and recorded. As well as products from the Draeger product line, the Rental Robot can be filled with other devices or tools.
Flexible, simple registration
This allows contractors and other personnel who might be working on the premises during a shutdown period, for instance, to be registered for a defined period of time.
Efficiency in material planning and profitability The Rental Robot stores the issue and return of every product and automatically generates a trend analysis of device utilisation. Regular maintenance ensures that Draeger products are always operational. When the device is running short of supply, it can send a signal to the control station to ensure that the required items are replenished. As a result, material planning can be organised cost effectively and the Rental Robot can be replenished in accordance with demand. In the event of devices being damaged or lost, the stored data records can be used to provide information on the last application. When not in use, the devices are stored safely in a locked box. The financing of the Rental Robot can be arranged in a variety of ways depending upon customer requirements. Various solutions can be provided to calculate the costs for a year, project-related or according to the actual use.
For further information contact: Customer Service, Draeger Safety UK Limited, Ullswater Close, Blyth Riverside Business Park, Blyth, Northumberland, NE24 4RG. Tel: 01670 561200
The devices are issued to registered users only with existing identification systems, such as company ID cards etc., being used to confirm user identification. The list of authorised employees, as well as stored user data, can be extended or reduced as required. HAZARDOUS ENGINEERING SOLUTIONS
Above: Draeger Rental Robot
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fax: 01670 356266 Web: www.draeger.com.
Flowmeters
FLOW METER APPROVED FOR HAZARDOUS ENVIRONMENTS The advanced ST75 Flow Meter from Fluid Components is now Atex and IECEx approved for safety in hazardous and potentially explosive plant environments.
pharmaceuticals and semiconductors. The ST75 includes media temperature compensation to ensure performance in rugged environments and features accuracy to +/-2 per cent of reading with +/-0.5 per cent repeatability. Its precision flow element has a no-moving-parts design that employs platinum RTD sensors embedded in equal-mass thermowells, with microprocessor electronics calibrated to laboratory standards for a range of gases, including: natural gas, methane, nitrogen CO2, argon, all inert gases and compressed air. The ST75 Flow Meter is equally suited for low- and high-flow operations. It operates over a 0.01 to 559 SCFM (0.01 to 950 NCMH) flow range, depending on line size. For variable process conditions, the ST75 is factory preset to a turndown range at 10:1 to 100:1. The ST75 is remote mountable, suitable for equipment-crowded plants or hazardous factory areas where explosive, flammable or toxic gases may be present near the transmitter’s electronics. The remote-mount transmitter, which includes a full digital display, can be mounted up to 50ft (15m) away from its thermal mass-flow sensor in the process piping and connected via two 0.50in FNPT cables.
The IEC prepares and publishes international standards for
The ST75 provides an accurate, fast-response and lowmaintenance solution to small-line-size gas- and air-flow applications in hard-to-reach or hazardous locations.
electrical, electronic and related
It features fully scalable 4-20mA and 0-10V standard outputs that are user assignable to flow rate and/or temperature, and a 0-1kHz pulse output of total flow.
technologies, while the Atex
The instrument can be ordered for input power with 18 to 36V DC or 85 to 265V AC, with or without a built-in LCD digital display.
directive specifies design criteria for flow meters and other electrically powered instruments, to help prevent explosions and fires when combustible gases are present. Atex and IECEx approval for potentially explosive environments means that the ST75 Flow Meter is suitable for applications in hazardous plant areas in the European Community and elsewhere worldwide. Designed for line sizes from 0.25 to 2.0in (6 to 51mm), the ST75 Flow Meter provides three outputs: the mass flow rate, totalised flow and media temperature. It is suitable for applications in a range of industries, including chemical, electric power, food/beverage, advanced materials,
The ST75 features thermal dispersion technology, providing directflow measurement for higher performance at a lower cost by eliminating the need for temperature sensors, flow computers or other devices that are required with orifice plates, Venturis, Vortex shedding and other meters. Its no-moving-parts design ensures a long service life and, as there are no orifices or inlets to clog or foul, scheduled maintenance and unplanned shut-downs are reduced. The ST75 includes a rugged sensing element constructed with all-welded 316 stainless-steel and Hastelloy-C tips. It is enclosed in a rugged, all-metal, dust- and water-resistant NEMA Type 4X (IP66) rated package, designed for hazardous-area installations.
For more information, visit: www.fluidcomponents.com
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HAZARDOUS ENGINEERING SOLUTIONS
Electrical Maintenance
ENABLING ELECTRICAL MAINTENANCE IN HAZARDOUS AREAS Servicing and maintenance of electrical equipment in hazardous areas can be time consuming and costly if engineers are not provided with the correct tools to carry out the job quickly and safely. Custom-designed equipment is now available to assist, says Gordon Low of Cooper Crouse-Hinds. As industrial processing plants become more complex and safety requirements more stringent, these plants have to become more efficient in terms of their maintenance and servicing activities. The objective is to minimise costly production downtime and to guarantee the safe operation of plant, machinery and other electrical equipment at all times. However, when it comes to the repair, replacement, servicing and maintenance of electrical equipment in hazardous areas, the challenges facing servicing and maintenance personnel can be daunting, time consuming and costly, particularly if the engineer is not provided with the appropriate tools.
Furthermore, in hazardous gas or dust areas, before any electrical apparatus - such as electric motors, variable speed drives, valves, actuators and sensors - can be installed, repaired or maintained, the technician needs to ensure that the electrical connection or disconnection procedure is carried out safely, with all electrical apparatus isolated from the power supply. These measures are necessary because the explosion protection of the apparatus becomes ineffective once the enclosure is opened. Ensuring that all appropriate fire protection and safety fencing procedures are carried out is also important here. This type of preparation requires a Hot Work Permit, which can take 24hrs to be issued. Even if the permit arrives in a couple of hours, costly production downtime may already have been incurred. Therefore, when engineers look at selecting the most appropriate electrical equipment for their plant, the most important factors to consider are the life of the equipment, the likely maintenance effort required, how easy the equipment will be to use, and whether the equipment has any smart maintenance features and support options. Selecting electrical equipment on the basis of price alone can have far more damaging effects on the business in the medium to long term. A higher frequency of product failures and breakdowns may occur after installation due to inferior quality design and manufactured components. Companies should therefore consider the complete product lifecycle cost of the electrical equipment - including purchase price, initial installation costs, maintenance life costs, scrap costs and the cost of any unforeseen production downtime - before making any purchasing decisions. Often, this is referred to as the total cost of ownership of a product. In a typical hazardous area plant such as an offshore oil platform or onshore petrochemical plant, selecting the right portable lamp, cord reel, plug distributor or repair socket to work with, will have a
significant positive impact on the efficiency of the maintenance and servicing activities - and therefore on how productive the business is. Engineers should therefore start by ensuring that all their existing electrical equipment and new purchased products comply with the relevant European safety regulations and quality standards. Companies also need to conduct proper risk assessments on equipment located in hazardous gas or dust areas. This must comply with the latest Health and Safety and European Atex Directives (Atex 137 or Atex 118a, 1999/92/EC). The minimum requirements stipulated in Directive 1999/92/ EC (Atex 137) are that: ‘all necessary measures shall be taken to ensure that the workplace, the work equipment and the associated connection devices are maintained and operated in such a way as to minimise the risks of an explosion. While a range of standard, off-the-shelf explosion-protected electrical equipment is now available to help engineers minimise service and maintenance costs, some of this equipment can now be customised to suit the individual requirements of a plant or offshore oil platform. On the lighting side for example, portable Ex-lamps and torches, including LED versions, can be activated using one hand. Spotlights can be provided with displays showing the user how much operational time is remaining. Single- and double-lamp machine lights can be provided with rugged pipe made from polycarbonate and protected to IP68. For high-power lighting in Zone O hazardous areas, Ex tank inspection lights can be provided to check oil or gas-storage tanks quickly and safely. These lights can also be integrated with a custom-designed transport trolley if required. Other lighting products for hazardous areas include emergency lights, pendant light fittings, floodlights, and lamps for outbuildings and mast bases. Another important consideration for service and maintenance staff is the availability and flexibility of power supply. Technicians require cord reels and socket distributors that comply with the European Atex Directives, enabling repairs and servicing to be carried out in hazardous zones. For example, portable Ex socket distributors and cable drums are available for providing a flexible power supply to portable electrical equipment located in zones 1, 2, 21 and 22. The objective is to minimise the time and effort required by the engineer, while guaranteeing the safety of personnel at all times. One area in which Cooper Crouse-Hinds has seen continued growth in recent years is in mobile power distributors. Often custom engineered for specific projects, these typically comprise a trolley, Ex plugs and Exlink plug connectors. The ergonomically designed trolley is used to safely transport distribution boxes and other explosion-proof electrical equipment around a plant. The Ex plugs have a flexible mounting plate with wired Ex plugs for providing electrical power to various types of equipment. Cooper Crouse-Hinds’ own Exlink plug connections can then be used to enable electrical equipment - including actuators, motors, submerged pumps, liquid-level sensors, floating switches - to be connected and disconnected quickly and safely, without compromising the safety or integrity of the installation. Enabling users to maintain apparatus on a proactive or predictive basis, the Exlink range of Ex-approved plug-and-socket connectors from Cooper Crouse-Hinds enables the connection and disconnection of electrical apparatus in potentially explosive environments, without the use of tools and without the engineer having to isolate the apparatus from the mains or disconnect the terminals.
The Exlink range, which includes connectors, plugs, receptacles, inlets and elbows, can be used for any instrumentation device or electrical apparatus. www.crouse-hinds.com
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HAZARDOUS ENGINEERING SOLUTIONS
Latest News & Products
ACCESS ELECTRICAL LAUNCHES NEW WEBSITE Access Electrical (Services) Ltd is a specialist distributor in the Industrial Switch and Sensor market, with nearly forty years experience in the industry. In January their new website was launched enabling both existing and new customers to purchase on-line. Access stocks a wide range of explosion-proof certified products which meet the standards required for Hazardous area applications including snap-acting switches, safety switches, position switches, command devices, limit switches, Ex switchgear with radio technology, sensors, signal towers, enclosures and isolators. With back up from world class manufacturing partners SaiaBurgess, Steute, Rechner, Werma, Bernstein, Craig & Derricott, Schmersal, Pepperl & Fuchs, Datasensor, Euchner and Pilz, Access is able to provide a comprehensive service to the industry. High stock levels enable them to provide an ex-stock service on many of their items. Contact their friendly, professional sales team for further details or to arrange an appointment with one of the Sales Engineers for more in-depth technical and design advice. Or, if you know the item you require, why not try purchasing on-line at: www.access-electrical.co.uk?
Tel: 01582 697711 Email:sales@access-electrical.co.uk
Above: AES - New Website Home Page
LED HIGH BAY WITH IECEX/ATEX CERTIFICATION The Dialight SafeSite® Series LED High Bay now has IECEx/ATEX certification (Baseefa10ATEX148X, IECExBAS 10.0074X) for Zone 1 and 21 where it can replace conventional higher wattage fittings to deliver over 10,000 lumens at just 150W total power consumption. Offering exceptional light output performance for 10+ years, SafeSite LED High Bays significantly reduce maintenance, eliminating costly and sometimes dangerous lamp changes regularly required for traditional HID fittings. With its shock and vibration-resistant construction backed by Dialight’s five-year continuous performance warranty, the factorysealed LED High Bay also features instant on/off ability for outstanding reliability and safety. Conventional operating voltage makes change-out to LED fittings quick, safe and easy using existing wiring. About 50% weight and 75% lower-profile than conventional fittings, the LED High Bay also allows increased mounting versatility and ease of installation. With operating temperature range of -40C to +60C, mercury-free LEDs are also recyclable. Product release due end March 2011.
For further details, please contact: Tel 01638 665 161 Email highbay@dialight.co.uk HAZARDOUS ENGINEERING SOLUTIONS
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Bespoke designed ATEX Fans & Blowers
HALIFAX ATEX BLOWERS KILL ALL KNOWN GERMS. Now that MRSA and C. Difficile are seemingly endemic in our hospitals, sterilisation of everything used in a hospital is absolutely critical. While most of us visualise sterilisation as a high temperature process, not everything medical can withstand the high temperatures necessary to bring about absolute sterility. Items such a soft rubber goods, surgical implants, intravenous kits and the like would all be damaged by high temperatures. One option is gaseous sterilisation. Ethylene Oxide (EO) gas kills all known bacteria and their endospores, mould and fungi and is highly effective in sterilising materials that would be damaged by, for example, pasteurisation or Gamma radiation. Unfortunately, EO is carcinogenic, toxic, highly flammable, potentially explosive and gasifies at 10oC. It therefore requires great care in its utilisation and the design of EO sterilisation plant is a highly specialised one whereby all electrical and mechanical equipment must be fully compliant with hazardous area standards. Getinge UK of Sutton-in-Ashfield are a centre of excellence in the design and construction of EO sterilisation systems and install bespoke sterilisation plants worldwide for manufacturers of medical devices, sterilisation contractors and other healthcare product manufacturers. In a typical system, pallets of the products to be sterilised are placed in a conditioning area where the temperature is raised to around 55oC and the humidity to around 70% RH. This ‘activates’ any microbes and renders them more susceptible to the EO gas. The pallets are then loaded into the hermetically sealed sterilisation chamber and the integrity of the chamber is confirmed with a vacuum test. The chamber is then flooded with EO gas at below atmospheric pressure and the temperature maintained at the conditioning level by circulating heated water round a water jacket surrounding the chamber. During the typically 12 hour period the goods are exposed, it is critical that the EO gas is maintained as a homogenous environment throughout the chamber. To achieve this a specially designed explosion-proof Halifax Fan blower is used to continuously circulate the gas through manifolds on the sides and top of the chamber, changing the entire volume of the chamber typically 8 to 10 times per hour, eliminating gas stratification and ensuring that the gas penetrates every nook and cranny.
Once sterilisation is complete, the chamber must be progressively flushed with nitrogen while the EO gas mixture is bled off through a catalytic converter that converts the EO to CO2 and water. The Halifax blower continues to circulate the gas mixture in the chamber as the gases are of different densities and would stratify if not actively circulated. Once the concentration of EO is reduced to the point where it is safe to introduce air to the chamber, the pallets are moved to the post-condition area where the temperature is elevated to aid the degasification process. The potentially explosive nature of Ethylene Oxide means that the circulating blower has to be designed to meet the exact needs of every installation, and to full explosion-proof standards. Halifax’s design is based upon many years experience building fans and blowers to handle explosive gases and features spark-proof features such as brass rubbing strips and a coupling guard. The stainless steel 316 shaft is fitted with a dual cartridge mechanical shaft seal purged and cooled with water. The fan is rated to work down to very low sub atmospheric pressures but the high integrity, gas tight, stainless-steel casing is designed to +10Bar and tested to +11Bar. ATEX certified stainless-steel inlet and outlet flame arrestors protect against potential flame propagation beyond the fan in the event of internal combustion. ATEX certified accelerometers and vibration monitors are included for early detection of any imbalance in the fan impeller that might lead to contact with the casing, potentially causing a spark. According to Shaun Riley, EO Product Specialist at Getinge, ‘Although some of our competitors build their own blowers, we attach so much importance to this item that we wanted it designed, built and certified by specialists and supplied as a reliable fit-and-forget fully certified component. The hazardous nature of Ethylene Oxide meant that we wanted to deal with a manufacturer with a proven expertise in ATEX and hazardous gas applications. Halifax worked closely with us to develop a range of bespoke blower sizes that we can use for quotation purposes and then, once we have a contract settled, the blower design is fine tuned to the exact specification of that application. Although the blower comes to us fully certified to ATEX 94/9/EC for Category 2G, Zone 1, it is actually fully rated for duty at Category 1G, Zone 0, meeting the most demanding specifications of all our applications. We’re happy with Halifax Fan’s self certification for Zone 1 as this satisfies the environmental and gas groups with which we must comply but we also draw confidence from the increased safety margin of the Cat 1, Zone 0 rating to which Halifax builds the fans.
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HAZARDOUS ENGINEERING SOLUTIONS
ATEX EQUIPMENT
HAZARDOUS ENGINEERING SOLUTIONS
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Bespoke designed ATEX Fans & Blowers
HALIFAX FANS BLOW HOT OUT IN THE COLD.
The application demanded extra thickness 43D carbon steels for all the fan fabrications which were then subject to certified low temperature impact testing. A further major requirement was the surface preparation and protective coating of these fabrications. This work all had to comply with a stringent Statoil specification that required that all corners be ground to specific radii and all welds ground to a completely smooth surface finish prior to grit blasting. The prepared surfaces were then coated with a priority four-coat paint system to a nominal DFT of 370μm. All stages of preparation and protective coating were subject to thorough scrutiny by the client prior to the issuance of acceptance and guarantee certificates. The two main fans, 250kW Halifax size 64 Beaufort backward inclined units, were directly driven through spacer couplings and bespoke M12 bearing units by 6-pole EExe special project motors while the smaller 7.5kW purge fan, a Halifax size 19 Mistral backward curved unit, was directly driven by a 2-pole EExe special project motor. Overall the project included inlet boxes with weather hoods, bird screens, inlet attenuators, acoustic enclosures, outlet ductwork, fire/isolation dampers, motor snow shrouds and flexible connections all mounted on substantial and robust skids. The bearing units were also fitted with quick connect studs for vibration monitoring purposes.
Above: Flarestack fan & motor.
The design and supply of equipment for the oil, gas and petrochemical industries are demanding enough but it becomes all the more so when the equipment is to be installed in the sub-zero temperatures encountered north of the Arctic Circle. The centrifugal fans supplied to GBA Flare Systems for the the Air Assisted Process Flare as part of the Elevated Flare Package on Statoil’s Snorvit LNG Project on Melkoy Island, Hammerfest, Norway had not only to meet ATEX standards but temperatures down to -35o C. Two large centrifugal fans were required to supply air to the process flare to achieve smokeless combustion of waste gases, each fan being capable of supplying 50% of the total required air volume. In addition, a smaller purge fan was required to provide a steady supply of purge air into the riser when the combustion air fans are shut down in order to keep a minimum flow of air passing into the system and to prevent hydrocarbon gas falling back into the air riser. Due to the potentially hazardous environment, all electrical equipment and instrumentation had to be certified for at least Zone 1 IIB T3 or better, junction boxes had to be rated to IP65 and the fans themselves and associated equipment had to satisfy the requirements of ATEX Group II Category 2. The climatic conditions imposed their own demands. The whole package had to be suitably designed and constructed mechanically to cope with the harsh environmental conditions, notably an ambient temperature range between -20oC to +50oC and a maximum snowfall depth of 2.3 metres.
Control of the lead fan was achieved by an inlet vane control damper manufactured in stainless steel complete with a pneumatic actuator and position control, again certified to Zone 1 IIA T3. Stainless steel outlet fire dampers were fitted with pneumatic actuators for open/close operation and limit switches in EExe IP67 enclosures. All the linkages had to be enclosed for weather protection and interface connections were made through stainless steel EExe junction boxes. Following fine balancing of impellers and rotating assemblies, fan sets were subject to in-house witnessed run testing and all vibration levels recorded and accepted. During the course of the contract exacting and detailed files and records were produced and at every stage of design and manufacture certificates were obtained and issued to complete a full and comprehensive dossier of the project. According to Operations Director Ian Crum “this was one of the most demanding and comprehensive projects Halifax Fan has ever carried out. Out ability to carry out in-house testing and certify the fan sets to ATEX Category 2G and to issue a 48 month extended warranty set us apart from many of our competitors. We had to be extremely fastidious with our processes, testing and record keeping to meet the clients demanding standards but this is not surprising when you consider the operational environment of this equipment. I’m pleased to report that the installation is now operating to the complete satisfaction of the customer and the end user.”
For Further Details, Contact: Ian Crum - Halifax Fan Ltd Mistral Works, Brookfoot Business Park, Elland Road, Brighouse, W Yorks, HD6 2SD Tel 01484 475123 Fax 01484 475122 E-mail:- Ian@halifax-fan.com Web:- www.halifax-fan.com 15
HAZARDOUS ENGINEERING SOLUTIONS
Latest News & Products
NEW Exd FLAMEPROOF CONNECTION HEAD FROM STATUS Status Instruments has launched a new Exd flameproof connection head, developed for use in potentially explosive environments and certificated to either IECEx or Atex standards. Status’ SCH50 series is manufactured from aluminium and finished in a blue epoxy paint, or stainless steel.The connection head has been designed to house the company’s SEM200, 300 and TTR series of temperature transmitters as well as ceramic connection blocks. Sealed to IP68, the SCH50 can be specified with base or side entries as well as a display window option which allows the process value to be displayed when used with Status’ DM700HM/ XI loop powered indicator. All versions of the connection head come with a flameproof collar and temperature probes specifically designed to suit Exd applications can be supplied. Approval to either IECEx or Atex can be specified along with size entry size at the time of ordering. ‘Flameproof’ protection is the most widely used method of protection for electrical apparatus in hazardous areas. Standards
require that the apparatus enclosure is of sufficient strength and integrity to withstand an internal explosion of the hazard for which it was designed, without the explosion setting fire to the surrounding atmosphere. For more information contact : Status Instruments Tel: 01684 296818 email: sales@status.co.uk www.status.co.uk
PARKER RACOR LEADS THE WAY IN HEALTH AND SAFETY AND ENVIRONMENTAL INITIATIVES The Racor Filter Division Europe of Parker Hannifin, the global leader in motion and control technologies, is pioneering the way in environmental responsibility after embarking on a significant recycling scheme in partnership with the National Industrial Symbiosis Programme (NISP), which will see it reducing its waste to landfill by at least 75%. This important development comes at the same time as the company winning the prestigious RoSPA Occupational Health and Safety Award 2010. As part of the new environmental initiative, Parker Racor will be working to improve resource efficiency and sustainability, which will enable it to save 40 tonnes of virgin material, as well as cutting CO2 emissions by 103 tonnes. This achievement goes hand in hand with the company’s desire to be at the forefront of being environmentally friendly and, just as importantly, safe manufacturing processes. Indeed, as a RoSPA Gold Award winner, the company had to demonstrate the highest possible levels of health and safety standards, combined outstanding risk control to eliminate errors, harm or loss. This enlightened approach is very much at the heart of the entire Parker group, where Environmental, Health, Safety and Energy (EHSE) performance are measured assiduously through various methods, with two key metrics: energy use per unit of sales and HAZARDOUS ENGINEERING SOLUTIONS
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employee injury rate. These concerns go beyond mere compliance, extending to tangible improvements that are demonstrated by Parker Racor’s example. Ros O’Connor, Parker’s ESH Coordinator, explains, “We are totally committed to best practices in terms of health and safety and environmental responsibility. Just as we have a zero accidents goal, we also have a zero wastage one. While, these are tough objectives, demanding complete commitment from our workforce, they reflect our passion for excellence at all levels.” Please send all sales enquiries to: Parker Hannifin (UK) Ltd, Shaw Cross Business Park, Churwell Vale, Dewsbury, WF12 7RD Tel: 0044 1924 487000 Email: filtrationinfo@parker.com.
Industry Seminars
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HAZARDOUS ENGINEERING SOLUTIONS
Latest News & Products
LASER DISTANCE METER FOR HAZARDOUS AREAS … yet another world first for CorDEX Instruments The LaserMETER 3000XP is explosion-proof and is ATEX & IECEx certified for use within Zone 1 IIC T4 hazardous (explosive) areas. Designed and manufactured by CorDEX Instruments, a technology leader in explosion-proof equipment, this new addition to the company’s growing range promises easy and efficient distance measurement. Unlike traditional laser measuring devices that are either unsuitable for the environment or need a hot work permit, the handheld LaserMETER 3000XP is instantly useable and has a range of features making it eminently fit-for-purpose. This product has been developed from end-user feedback and CorDEX Instruments is therefore confident that its LaserMETER 3000XP incorporates every function needed for efficient operation. Weighing less than 1kg, the LaserMETER 3000XP is capable of measuring distances of 30m with a typical accuracy of 3mm. It also has Pythagoras, volume and area functions and is suitable for single or continuous measurement thanks to onboard mathematics. The robust IP65 flameproof design comprises a cast aluminium chassis with a shock resistant, anti-static over moulded body with an armoured lens and LCD which is backlit for day and night operation. The rechargeable battery is interchangeable with that of other CorDEX Instruments’ products and its reserve level is HAZARDOUS ENGINEERING SOLUTIONS
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continuously shown in the LCD. Another key benefit of the product is its ease of use. CorDEX Instruments has ensured the controls are optimally configured and even useable by an operator wearing padded industrial protective gloves. Prime applications for the LaserMETER 3000XP are of course at oil refineries, on rigs and pipelines and in chemical processing plants, gas distribution centres, coal mines. Its scope of use goes way beyond these traditional markets however. The printing, paper, textiles and surface coatings industries will also greatly benefit from its introduction as will those involved in sewerage treatment and aircraft refuelling. Indeed it is ideal for use in any environment where there is risk of explosion due to mixtures of gas and air or other flammable combinations. The LaserMETER 3000XP is supplied complete as standard with a rechargeable battery, charging station and wrist strap. Unit 6, Farfield, Main Road, Wykeham, SCARBOROUGH, North Yorkshire, YO13 9QD Tel: +44 (0) 1904 749020 Fax: +44 (0) 1904 352415 Email: info@cord-ex.com Web: www.cordexinstruments.com
Latest News & Products
VERTICAL-MOUNTING HEATERS FOR HAZARDOUS AREA APPLICATIONS * multiple approvals allow one explosion-proof heater design to be used worldwide February 14, 2011 --- Intertec has introduced a versatile new series of slimline vertically-mounted electric heaters for protecting sensitive outdoor equipment against low temperatures in hazardous areas such as chemical, oil and gas plants. Available in five variants with output powers from 200 to 600 W, the finned heaters are compact high-efficiency blocks with profiles of just 60 mm - making them ideal for mounting adjacent to panels inside enclosures. This versatile design typically makes it simple for engineers to use when configuring protective enclosures, cabinets and shelters for field-based equipment. The new CP Megatherm heaters are approved to IEC and other worldwide explosion proof standards like ATEX, CSA, UL and GOST. This makes it possible for one heater or enclosure configuration to be used anywhere in the world - greatly reducing design, system building and maintenance costs.
The flat rectangular shape of the CP Megatherm will be familiar to many instrumentation and plant engineers as it reprises Intertec’s original design concept for explosion proof heaters. In the late 1960s, Intertec launched a product called EEx 500 T4 onto the market. This pioneering heater is believed to have been the first practical alternative to heat tracing techniques for explosion proof applications, and remained in production until the 1990s - when changes in standards led to its discontinuation. Although Intertec has since produced a very wide variety of heater designs and shapes to suit different applications, the company still receives requests for the ‘old design’ and has now re-engineered it. The new heater exploits advances in insulation and sealing materials to deliver more power in a smaller form factor than the original product, as well as more application versatility across different temperature classes. The heaters use the Ex d (flameproof) protection principle and are available for the commonly-required T3 or T4 temperature classes - which restrict surface temperatures to a maximum of 200 or 135 degrees Celsius respectively. A temperature indicator strip is also attached to show potential problems such as incorrect installation or misapplication at an early stage. CP Megatherm heaters are supplied with a thermostat to limit the ambient temperature in an enclosure and protect against freezing and condensation. This thermostat is located in the electrical connection cable - a patented design that maintains the heater’s compactness and simplifies installation. If more precise temperature regulation is required, Intertec can supply heaters with an optional temperature controller. CP Megatherm heaters’ low-profile designs typically allow the heating element to be positioned in close proximity to any process equipment that requires protection. The heater body is fabricated from seawater-proof aluminium, with a black anodized finish. Additionally, the heaters are protected against ingress to IP68, so they are highly reliable even in corrosive atmospheres - such as hydrogen sulphide or ammonia for example. More information: http://www.intertec.info/
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HAZARDOUS ENGINEERING SOLUTIONS
Cover Story
NEW SILICON POLYMERS BEAT CHANGES IN NEW HAZARDOUS PRODUCT LEGISLATION Two part epoxy resins have long been the compound of choice for a number of applications including the potting of components and as a low cost solution for cable jointing and cable sheath repairs. But all that is set to change.
Conventional epoxy resins are generally of the polyurethane type. Polyurethane formulation contains a significant quantity of an ingredient called MDI which is an isocyanate, and the prime cause for concern that has led to the reclassification of MDI as a Carcinogen Category 2 , “suspected of causing cancer” by the EU. The consequence of the reclassification now means that Epoxy resins containing polyurethane must now be labelled with a new cancer warning and warnings concerning skin irritation (which has always been a known problem and highlights the need for good PPE) and possible allergy developments after prolonged exposure. Now, new Silicon Gel and Silicone Rubber technology provides a simple solution. Health and Safety at work, in manufacturing and on site in the construction industry is now a point of focus for every company. More pressure is being applied by Government legislation and by the duty of company directors to ensure the health and safety of their employees. Keeping up with legislation is a time consuming duty, particularly with potentially harmful products, but here at G.H.Lucas and Company Limited we are partnered with one of the leading European companies in the field of alternative compounds for encapsulation and cable jointing. Raytech Magic Gel and Rubber are two part compounds that crosslink to form solid gel or silicon rubber. These products are devoid of any harmful chemical ingredients and meet the EU directives of RoHS, COSHH, WEEE and REACH. They are approved by RINA, the Italian equivalent of Lloyds, and can be safely airlifted for delivery if required. Certificates are available to download, and very importantly, the packaging, any spill, any unused or unwanted product can be disposed of as “general waste”. Magic Gel and Rubber also have many advantageous properties when compared to their epoxy resin counter parts. They are non toxic and inert, have no shelf life and can be re-entered even after long periods of installation. This makes for easy routine inspection and maintenance in industrial, and in Hazardous areas. Test probes can be easily inserted and the gel will re-seal on withdrawal. Both products will crosslink at sub zero temperatures, unlike epoxy resins which will not commence curing at all in zero or sub zero conditions. Indeed the working temperature range of Magic Gel and Magic Rubber extends from -60C to +180C.
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Cover Story
Electrical properties far exceed those of epoxy resins, the dielectric strength of >23Kv/mm approximates to four times that of their equivalents. There is also a significant advantage in the process of cross linking silicon based products. Epoxy resins create a chemical reaction that is exothermic; the heat created by the reaction gives off noxious and potentially toxic vapours causing the need for more PPE in areas of poor ventilation. Both Magic Gel and Magic Rubber cross link without an exothermic reaction and in a substantially shorter time of under ten minutes. Hazardous Areas and Ingress Protection Both Magic Gel and Magic Rubber have superlative ingress protection greater than IP68. Cable joints filled with Magic Gel have been tested and have performed successfully at a depth of 100 metres, the extreme pressure has the effect of pressing the gel more tightly around the components. Because the products have very low viscosity they are able to completely fill voids and cavities ensuring total encapsulation. This quality enables enclosures with low IP ratings to become IP68 rated at a very low cost when compared to regular IP67 and IP68 enclosures. Magic Gel and Rubber have enabled the development of a complete range of products including the “Magic Box� range of seven different sizes of enclosures supplied complete with sufficient Magic Gel to completely fill the enclosures and cable glands and accessories for horizontal or vertical mounting and filling.
that could cause an explosion in an environment saturated with flammable gases, fluids, dust or powders like flour. TUV, the German approvals body has now approved Magic Gel to the ATEX directive for use with approved enclosures, recognising the many attributes I have already outlined, including the low viscosity that allows the complete filling of any void within the enclosure, and the very high degree of transparency from the optically clear version where visible displays from lamps, LED or liquid crystal screens are required. Raytech products comprise complete ranges of different gels and rubber compounds, as well as traditional style cable joints and innovative new pre filled gel joints. Products to create fire barriers, solutions for frost protection and process control using trace heating and applications for the fast growing photo voltaic industry.
Go to our website www.ghlucas.com for further details. Don Lucas Managing Director G.H.Lucas and Company Limited, P.O.Box 754, Altrincham WA15 5DX
Truly innovative cable joints pre filled with gel for high speed cable jointing of armoured and unarmoured cables are also available.
Tel 0845 437 4451
Equipment which must comply with the ATEX directive for installations in potentially explosive areas are normally produced using an explosion proof enclosure where the electrical contacts are often insulated and sealed with resins. This is to prevent sparking between contacts
Fax 0845 437 4452 Email sales@ghlucas.co.uk
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HAZARDOUS ENGINEERING SOLUTIONS
ENERGY & WASTE MANAGEMENT
shentongroup LAUNCHES DUAL FUEL WASTE TO ENERGY SYSTEM Pioneering, power solutions company, shentongroup, is launching a state-of-the-art dual fuel waste to energy system called Duplo™. As well as being a prime power source, Duplo™ can also provide hot water via an optional heat exchanger and be fitted with a control system that enables excess electricity to be exported to the National Grid.
Pioneering, power solutions company, shentongroup, is launching a state-of-the-art dual fuel waste to energy system called Duplo™. As well as being a prime power source, Duplo™ can also provide hot water via an optional heat exchanger and be fitted with a control system that enables excess electricity to be exported to the National Grid. Duplo runs on standard Diesel, Biodiesel, Natural Gas, Biogas or a combination of any of these using the very latest dual fuel technology. Having multiple fuel sources not only significantly improves the generator’s resilience for continuous operation but also appreciably reduces running costs compared to single-fuel solutions. Duplo reduces engine wear and produces far lower emissions than a normal diesel only system and has an enhanced ability to cope with variations in gas quality and pressure. An option to provide hot water via the Hexpac™ heat exchanger at the same time as generating electricity turns Duplo into a combined heat & power (CHP) system. This provides commercial or industrial premises with the option of an integrated approach to delivering both prime power and hot water. Duplo can also be fitted with control system that enables any excess electricity to be exported to the National Grid. This lets users take advantage of the Feed in Tariff Scheme (FITS), which pays businesses to generate their own electricity from renewable or low carbon sources. The scheme guarantees a minimum payment for all electricity generated by renewable sources as well as a separate payment for any electricity exported to the grid. Duplo is suitable for any commercial or industrial site with insufficient or no mains power. Systems are available in a wide range of sizes from 50kwe up to 2Mwe and more if require. Smaller Duplo systems are modular, fully integrated systems assembled into ISO containers for increased flexibility and ease of use. All Duplo systems are supported by shentongroup’s Infinium™ service and maintenance programme. This is a perpetual renewal, maintenance and warranty programme that provides for fixed cost on site service and maintenance for the working life of the system (excluding fuel).
shentongroup, Shenton House, Walworth Road, Walworth Business Park, Andover, SP10 5LH Tel: 0844 888 4445 Fax: 0844 888 4446 Email: info@shentongroup.co.uk shentongroup, is launching a state-of-the-art dual fuel waste to energy system called Duplo™.
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HAZARDOUS ENGINEERING SOLUTIONS
Training & Courses
CERTEX LAUNCHES NEW HEIGHT SAFETY COURSES Certex UK – one of the nation’s leading suppliers of lifting products and services – has introduced a new range of height safety and rescue courses to its already extensive portfolio of training packages. The set of six one-day courses are being run in conjunction with fall arrest training experts, HART who are the dedicated training division of Checkmate Safety, and cover all aspects of height safety from basic working at height; management of working at height; examination of height access equipment, rescue training; rooftop and ladder working. Adrian Kirkham, Training Manager at Certex UK, says that the courses have been introduced to meet a growing demand from within the industry. “Under current legislation, work is defined as being ‘at height’ if it is a place where a person could be injured falling from it; even if this is at or below ground level. As such,this affects a large number of UK workplaces who are now seeking to ensure that their employees are given the correct training to carry out their jobs safely.
“We have been looking for an appropriate partner to provide quality training inthis area and we are delighted to have teamed up with industry experts HART and Checkmate to offer this comprehensive range of courses,” he added. The courses are held either at one of Certex’s specialist training centres across the UK or – on request – at the clients’ own premises. As well as the standard six syllabuses, Certex will also put together special training packages to match the clients’ exact requirements, based on their specific needs. Most of the courses include both theory and practical training and there is an assessment at the end of each course. Participants will receive a certificate at the successful completion of the course. Andy Stock, from HART (Height and Rescue Training) the HAZARDOUS ENGINEERING SOLUTIONS
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specialist division of Checkmate Safety who will be delivering the training, is confident that the courses will encourage safer practice across a wide spectrum of industries. “Falling from height is one of the biggest causes of workplace deaths and major injury. We will be teaching people to use fall protection equipment safely; spot common risks and hazards; as well as making sure that they understand the current legal and best practice requirements and are therefore working within the law,” he said. The new range of height safety and rescue courses form part of a comprehensive and well established collection of training courses run by Certex that are directly relevant to today’s industry conditions and requirements.
Anyone wishing to find out more about the height safety and rescue courses or other Certex training opportunities, should contact: Adrian Kirkham on 0845 230 7475 or email akirkham@certex.co.uk Course details can also be found at: www.certex.co.uk/training
Latest News & Products
MARIGOLD INDUSTRIAL COMBINES EXTRA COMFORT AND CHEMICAL RESISTANCE WITH ITS LATEST GLOVES Hand protection expert Marigold® Industrial is combing high-level comfort with excellent chemical protection with its two latest products. The new Nitrile-supported Comfort G26G and Comfort Z51G synthetic protective gloves offer the wearer protection against many solvents and oil based chemicals in the work place as well as having a good resistance to abrasions and high levels of comfort. Suitable for many industrial applications as well as being food handling compliant, the CE Complex Design Comfort Z51G is a tough, flexible and chemical resistant glove with a long elbow length cuff, providing extra protection for the wearer. Available in 3 sizes, (8,9 and 10) Comfort Z51G is an ideal glove when handling aggressive oil based chemicals in industries such as chemical, automotive, printing and petroleum related industries. Its sister glove, Comfort G26G, available in 5 sizes from 6.5 to 10.5, offers the wearer extremely high levels of flexibility and comfort in addition to excellent dexterity, whilst boasting a superior raised grip pattern for enhanced safe handling. Also food contact compliant, the green Comfort G26G is an ideal glove for use in food preparation areas as well as the agrochemical industry, crop spraying, chemical and automotive industries.
Enhanced wearer comfort comes from the fact that both gloves support a high-comfort 100% cotton and seamless 13-gauge liner.
To contact the company call: +44 (0)845 075 3355 email: ukenquiries@marigold-industrial.com or for more information visit: marigold-industrial.com
AXAIR ‘ATEX’ FANS – AXIAL MODELS Axair Fans UK Limited distributes ATEX Category 2 Zone 1 plate mounted & cased axial fans for the ventilation of buildings and rooms in which explosive gasses diluted in air may be present. All products are manufactured by Sodeca and are accredited by Notified Body LOM as satisfying the standards contained in ATEX Directive 94/9/CE. Sodeca HCDF/ATEX and HDF/ATEX plate mounted fans are available in 11 basic impeller diameters, in two operating speeds according to model, and for both single and three phase electrical supplies. The maximum possible air flow rate is 48200m³/h. The motor has to be EEx-d (explosion-proof) type meaning that a flame caused by an explosion within the motor cannot escape to the surrounding atmosphere Sodeca HCT/ATEX is a cased axial range, the fans being contained within in a tube having flanges at each end. 10 basic sizes of impeller are available to provide air flow rates up to 72000m³/h. Non-sparking construction is achieved using cast aluminium impellers and an aluminium strip positioned within the steel casing. Sodeca HCT/ATEX range electric motors may be selected as EEx-e (increased safety), which is a reduced cost option of non-incendive construction, or EEx-d (explosion proof).
AXAIR FANS UK LIMITED Tel : 01782 349430 www.axair-fans.co.uk
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HAZARDOUS ENGINEERING SOLUTIONS
Latest News & Products
INTRINSICALLY SAFE AND EXPLOSION PROOF MANUAL CALL POINTS RELEASED TO HAZARDOUS AREA SOLUTIONS OCTOBER 2010 E2S, the leading European manufacturer of warning devices for use in hazardous areas, has extended its capabilities with the development of intrinsically safe and explosion proof manual call points, certified to both ATEX and IECEx standards. The IS-CP4 intrinsically safe units are approved for use in Zones 0, 1 and 2 environments and the BExCP3 Ex e d explosion proof versions for Zones 1 and 2. Both types are available with either break glass or push button operation. The devices are manufactured from corrosion proof, copper free, marine grade LM6 alloy and are sealed to IP66, enabling them to be used in both offshore and onshore installations. A comprehensive range of standard accessories and options can be specified; they can be fitted with a stainless steel lift flap and series and EOL resistors in a range of different values can be fitted as required. The units can be fitted with stainless tag and duty labels and, normally finished in red powder coat finish, special colours can be specified to enable rapid visual identification of special functions. The introduction of this new family complements the well-established BEx range of explosion proof sounders, beacons and loudspeakers and the IS-mini modular sounder and beacon family.
For further details, contact: Neal Porter - European Safety Systems Limited Impress House, Mansell Road, London, W3 7QH Tel: + 44 (0)20 8743 8880 Fax: + 44 (0)20 8740 4200 Email: sales@e2s.com Website: www.e2s.com
CLIFFORD & SNELL LAUNCHES ITS YODALEX RANGE OF MANUAL CALL POINTS Recently launched is the Yodalex range of high performance Manual Call Points from Clifford & Snell which further extends the company’s selection of Hazardous Area products. Designed in accordance with EN54-11 and offering ATEX, IECEx & GOST-R Approval for both gas and dust, this range has been designed for use within harsh environments such as the petrochemical industry as well as the oil & gas sectors where safety, quality and reliability are an essential part of the operational process. Developed using corrosion-resistant glass-reinforced polyester (GRP) materials, the Exd flameproof enclosure features high-tolerance machined flame paths constructed to withstand extreme pressures. These lightweight devices feature both Break Glass and Push Button options and are finished in red high-performance paint. Other features include IP66 Ingress Protection rating with a Certified operational temperature range of -55oC to +70oC and a dual M20 cable gland entry, fitted with a single certified stopping plug as standard. An LED model is also available and an optional Lift Flap on the BG version
CLIFFORD & SNELL LAUNCHES ITS LATEST YODALEX MANUAL CALL POINTS is offered which is standard on the PB version. The BG version also provides key-operated test facilities. All fixings are stainless steel.
For further details, contact: Clifford & Snell, Tom Cribb Road, Thamesmead, London SE28 OBH Tel: 020 8317 1717 Fax: 020 8317 2400 Email: sales@cliffordandsnell.com www.cliffordandsnell.com
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HAZARDOUS ENGINEERING SOLUTIONS
Buyers Guide
Cable Glands
Drum & Container Heating
Drum Handling
Encapsulants & Sealants
Test Certification
www.siracertification.com HAZARDOUS ENGINEERING SOLUTIONS
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G.H. Lucas and Company Ltd P.O. Box 754 Altrincham, Cheshire, WA15 5DX Tel: 0845 437 4451 Fax: 0845 437 4452 www.ghlucas.com