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If you are even asking yourself the question “should I be worried about explosive atmospheres (ATEX)” then the answer is most probably “yes”. The Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) require employers to control the risks to safety from fire, explosions and substances corrosive to metals. This entails compliance with BS EN 1127 (Explosive atmospheres - explosion prevention and protection), which in turn requires that any electrical equipment used is intrinsically safe and complies with BS EN IEC 60079.

It is generally understood that equipment for use in more obvious hazardous locations such as flour mills, coal mines, petrochemical plants and fuel transfer facilities, needs to be certified “intrinsically safe”. In other words, incapable of igniting an explosive atmosphere. However, hazardous locations also include water treatment plants, tunnels and underground passageways or any location where a build-up of naturally occurring flammable material (such as methane or dust) could occur.

Most people are familiar with the definitions of ATEX ‘Zones’ and if not, a quick web search will bring them up. Put simply, Zone 0 means an explosive atmosphere is very likely and Zone 2 means it is unlikely, with Zone 1 being the “grey area” in between. It is easy enough to identify from its markings whether a particular piece of equipment is suitable for a particular Zone, e.g. Ex ia for Zone 0, Ex ib for Zone 1 and Ex ic for Zone 2. However, the onus is very much on the plant operator to ensure which parts of their plant are in which Zones.

As if the issue of Zones wasn’t difficult enough, there is also the consideration of which gases are likely to be encountered. For example, equipment marked as Group IIB must not be used in Zones with hydrogen or acetylene likely to be present. Those gases would require at least Group IIC certification.

Then there is also consideration of the equipment’s temperature classification, which specifies the maximum surface temperature that could arise due to a fault when operating within the specified ambient temperature range. For example, equipment coded T2 (>300C) could potentially get hot enough to ignite gasoline! However, a coding of T4 (>135C) is generally considered acceptable, being safe for all gases apart from Carbon Disulfide, which requires T6 (>85C).

Test Products International (TPI) believes it has greatly simplified things however, with the triple certification of the TPI 9080Ex Smart Vibration Analyser. The TPI 9080Ex is IECEx/ATEX certified for Zone 1 and North American approved for Class 1, Zone 1 and is hence certified for use in hazardous locations, with ANY gas types, ANYWHERE in the world.

The TPI 9080Ex offers on-meter analysis for detection of machine faults such as unbalance, misalignment, looseness and bearing wear. With full colour OLED display and Bluetooth communications, the TPI 9080Ex features colour coded alarms and zoomable on-screen vibration frequency plots with cursor readout. It can store lists (routes) of up to 1000 machines, each with up to 10 measurement points, with full waveform and frequency spectrum (FFT) capture.

The included free-to-use VibTrend PC-based trending and reporting software features high-end benefits such as automatic email notification of alarms and report generation to implement a full CBM strategy.  Routes and readings can easily be transferred to/from the TPI 9080Ex via Bluetooth using a smart phone or tablet running the free TPI Cloud Bridge App. This allows service personnel to be sent routes and return readings, no matter where they are in the world. 

In-line with TPI’s philosophy of being the value leader, the TPI 9080Ex has a list price of only £3,500.

For more information please contact TPI Europe’s head office on +44 1293 530196 or take a look on the website at www.tpieurope.com or email This email address is being protected from spambots. You need JavaScript enabled to view it.

Peli Products (UK) launch three new personal utility cases as part of the Micro Case Series™. The redesigned models (M40, M50, and M60) are waterproof and dustproof and produced to protect small valuable items.

The new Peli Microcases boast an IP67 rating, giving protection against heavy rain, temporary water immersion, dust, sand or dirt. They offer excellent protection for all types of valuables and small devices when working in wet or hostile environments and for water sports and outdoor activities.

Manufactured using the legendary Peli guaranteed crushproof polymer, the new Micro Cases have been designed with several improvements. They feature a dedicated watertight O-ring gasket seal and redesigned dual latches.  The addition of a lock hasp allows a padlock to be fitted for greater security. The inner non-slip liner helps keep items in place and is removable for easy cleaning.

These new cases also offer more internal volume and like the previous range, they feature an automatic pressure equalization valve to balance interior air pressure.

The M40, M50, and M60 cases are available in clear with a yellow or black inner bottom liner and black.  They can be found here:  https://peliproducts.co.uk/collections/micro.

A leading oil and gas Company needed thermal insulation for a tank at one of its lubricant plants. The upper surface of the tank, which reaches a temperature of 110 °C (230 °F), serves as a walkway for operators. This creates a high risk of employees receiving contact burns from the hot substrate. Additionally, some pitting corrosion had occurred. Finding a solution that would lower the surface temperature to prevent burns and halt further corrosion was crucial. 

Unprotected tank’s upper surface, operating at high temperatures. 

What was the Issue? 

The high temperature of the tank causes a hazard for the employees walking upon it. According to the guidance set forth by the Occupational Safety and Health Administration (OSHA), the maximum temperature for exposed surfaces that an employee could come into contact with is 60 °C (140 °F), in line with ASTM C1055. Workers must be protected from exposed heated surfaces, so it was crucial to lower the surface temperature of this tank to eliminate this hazard. 

In addition to its high temperature, the metal tank surface had been experiencing pitting corrosion, necessitating pit filling and a protective coating that would prevent it from corroding further. 

Why was Belzona Chosen? 

Having previously used various Belzona products, this Customer had confidence in their Distributors’ recommendation that Belzona 5871 was the optimal solution.  

As well as offering thermal insulation to protect employees from contact-burn injuries, this product only needs two coats, enabling quick turnaround times. It also has excellent corrosion resistance which was essential as the tank top had been experiencing pitting corrosion. 

Protected from high temperatures with Belzona 5871. 

How was the Solution Applied? 

The surface was prepared by vapour blasting the substrate to meet SSPC-SP10 (Near-White Metal) standards and was then degreased. Additionally, some corrosion on the top of the tank required pit filling with Belzona 1121 (Super XL-Metal) ahead of the coating being applied. 

With the surface prepared, the first coat of Belzona 5871 was then applied using a short-bristled brush. This product expands, reducing the number of layers which are needed, the first coat was applied at the target thickness of 1000 µm (39 mil) wet film thickness, which results in 3000 µm (118 mil) dry film thickness. The second coat was then applied using the same method six hours later. The tank was back to full service just 12 hours after the final coat was applied.

Surface preparation before application 

   Tank top after one coat of Belzona 5871 

What was the Result of the Application? 

This application successfully offered thermal insulation protection for a Fortune 500 oil and gas Company. Following the application of two coats of Belzona 5871, the previously dangerous temperature of 110 °C (230 °F) has been successfully lowered to a safe level—below 60 °C (140 °F).

This case study shows how Belzona 5871 offers thermal insulation and creates long-lasting safety and durability. The solution not only mitigated the risk of contact burns but also introduced a valuable layer of protection against corrosion. 

Want to Learn More About Thermal Insulation with Belzona?

Please Click Here

. i.safe MOBILE, innovation and world market leader for explosion-proof mobile devices and solutions, will be presenting its latest tablet developments to the trade public at the SPS trade fair in Nuremberg from 14 to 16 November 2023: In addition to the Android-based IS940.1, the company has also developed a Windows tablet IS945.1 as a debut. The first 5G tablet for Zone 1/21, together with the 5G smartphone IS540.1, is the ideal addition to the equipment programme for knowledge workers in the field of predictive maintenance management in the process industry.

With two alternative operating systems (Android and Windows), the user has a tablet for data communication in the Zone 1/21 hazardous area that can be ideally integrated into the existing system landscape and infrastructure with 4G/5G campus networks or WIFI 6. The two energy-efficient tablet versions are equipped with the powerful QCM6490 chipset from Qualcomm® Technologies, Inc. optimised for IIoT, a clear 10.1-inch full HD display and a 16-pin ISM interface for secure connection of approved accessories. The world's first charging option for devices within the hazardous area offers the user a wide range of deployment options. Despite its robust design, the tablet is very light and easy to handle, supports Wi-Fi 6, Bluetooth 5.2, NFC and has customisable buttons. The feature package is rounded off by a powerful, replaceable battery, a main and front camera.

Innovation potential of 5G technology The 5G standard offers great potential in hazardous industrial sectors such as the chemical, pharmaceutical, petroleum processing and process industries: it enables the secure integration and consolidation of complex workflows and the networking of employees, machines and processes. Maintenance tasks, remote monitoring and the evaluation of process data in industrial environments i.safe MOBILE announces IS940.1 and IS945.1 p. 2/3 require fast data transmission and processing. In the 5G network, these can be transmitted many times faster than was previously possible in 4G networks. The i.safe MOBILE 5G product portfolio fits perfectly into the digital processes of the production structure within the 5G campus networks and has been developed for remote assistance, augmented reality, remote training and mobile machine data visualisation in explosion hazardous Zone 1/21. The high available bandwidth in the 5G network enables data transmission with the lowest latency, which is particularly helpful for remote maintenance tasks or audits.

A world first, which i.safe MOBILE is presenting for the first time at the SPS trade fair, is the charging option for tablets in hazardous areas. For example, a connection to the Ethernet network can be realised via a special interface. In the automation sector, the tablet is charged in the Ex-safe docking station directly within Zone 1/21 but can also be used as an operating station for process control systems or for MES (Manufacturing Execution Systems). This provides the user with almost unlimited application options for potentially explosive environments. The IS940.1/IS945.1 will be available from mid-2024.

www.isafe-mobile.com

The fact that Hart Door Systems has built a reputation for quality and longevity of its wide range of industrial doors, the importance of door maintenance should not be understated says Keith Fisher, Hart’s National Operations Manager.

Servicing industrial doors not only improves their reliability and operational functionality but servicing is also a requirement under Health, Safety and Welfare Regulations  which protect people who come into contact with the doors. Indeed failure to maintain industrial doors could put the user in breach of Government legislation incurring liability in the case of an incident involving an industrial door which is non-compliant.

As essential support for our clients Hart has comprehensive Service & Maintenance assistance as a specialist department which delivers a range of repair and scheduled maintenance options for its customers to further extend the life of their doors.

Given the very wide variety of industrial classifications we supply doors and shutters to, the emphasis has to be on designing servicing and maintenance packages which are tailored to match the specific needs of our clients’ businesses and the arising usage patterns of the various doors/shutters.

A preventative Servicing and Maintenance Agreement ensures Hart’s servicing is carried out correctly and at the precise frequency thus complying with Regulations. Typically during a Hart servicing visit all mechanical and electrical elements are checked for missing parts, general wear and tear and Compliance issues.

Mechanical checks include inspecting parts such as drive chain tension, alignment and lubrication, bearing wear and tear, motor oil levels and fabric tension and electrical checks include limit settings, cable connections and safety devices.

Hart also has a legal responsibility to ensure doors are left in safe working order after servicing. Again the issues are wide ranging such as measuring the closing forces of automatic doors where safe contact is the main strategy to prevent hazards.

The closing force of a door ensures correct force limitation under EN 12978 which prevents injury and crushing. Testing should always be carried out with an annually calibrated instrument according to DIN 18650, EN 12453 or EN 12445.

On completion of a Hart service visit, a paperless electronic copy of the engineer’s report will be issued which may include additional recommendations necessary to ensure the doors are safe and compliant to relevant legislation due to changing ‘shop floor’ circumstances.

The sophistication of door systems such as Hart’s Speedor range or its Typhoon shutter range has changed significantly over the years to cater for changing needs by its customers across the globe and indeed by changing climate. To ensure hard working doors in busy industrial environments continue to make a significant daily contribution to efficiency and safety, planned maintenance is essential.

www.hartdoors.com

ENDS 452 words

A clean work space is essential for health and safety, and the best tool for general cleaning up dust and loose product in the workplace is an Industrial Vacuum Cleaner. However, the vast majority of machines need to be plugged in to a power outlet, which necessitates appropriately positioned power outlets, and a trailing cable which itself presents a hazard.

Quirepace have introduced the IV62 eGX into the range of BVC Industrial Vacuum Cleaners to eliminate this risk. This is a powerful battery powered unit which, as standard, is provided with a 3-stage filtration dry product tank consisting of a paper sack collection, microfibre main filter and 3^rd stage HEPA filter. This configuration is suitable for most dry-product collection applications. The unit may be configured as both M-Class and H-Class rated units.

The unique Honda eGX electric engine is designed to replace petrol engines in the 2.5hp class and provides more than adequate power to run the BVC YP3 exhauster unit at full design speed. This new machine is designated BVC IV62 eGX.

The Honda eGX variable speed drive allows the operator to set the run-speed for the optimum performance for the job in hand. At full power the IV62 eGX has a runtime of 30 minutes, and at slower speed this can be extended to over 2 hours. The eGX fast charger provides 80% charge in 1 hour and 100% charge in 1.5 hours, making continuous running possible with spare batteries.

The BVC IV62 eGX makes it possible to clean up the industrial workplace without the hassle and hazard of trailing cables and availability of appropriate power outlets. Instantly available power combined with a large collection volume means that it has never been easier to maintain the cleanliness of the workplace

Quirepace Ltd

www.quirepace.co.uk
www.bvc.co.uk

Throughout the chemical sector, processes operating at high temperatures and with highly corrosive process media are common. Traditional signalling devices were not always compatible with such conditions and therefore are often over-looked as an additional accessory to monitor the status of the rupture disc.

Developments in technology mean even companies in this sector can now use rupture disc signalling systems, helping not only improve productivity and safety but also supporting with environmental concerns. German manufacturer, REMBE, is the European leader in the manufacturing of pressure relief devices and explosion safety systems and their product range encompasses some of the most robust rupture discs and signalling solutions available to add significant operational value within the chemical industry. Here REMBE discuss how its intelligent signalling solutions will keep you informed about the status of your entire plant while not being affected by the harsh operating conditions.

For processes operating with potentially harmful media the ability to shut down the process quickly and safely mean the risk of leakage is eradicated. Complying with explosive atmospheres and intrinsic safety industry standards, the signalling devices are designed to provide rapid notification of rupture disc activation, helping ensure safe management of the process while minimising downtime. REMBE’s signalling devices can easily be integrated with customers control systems to provide visual or acoustic notification of disc burst or to shut down the plant where required.

With non-invasive signalling devices, which make it impossible for the process medium to escape, processes with critical pressures and demanding media can also be reliably monitored. The following text explains the non-invasive monitoring unit NIMU in more detail.

Stop unnecessary downtime

For customers for whom compatibility with harsh operating conditions is of paramount concern the NIMU (Non-invasive monitoring unit) is a reusable rupture disc signalling system designed for rapid notification of rupture disc activation even in the harshest chemical environments. The REMBE NIMU sensor is not in contact with the process meaning it is not affected by challenging process conditions or corrosive media.

The intrinsically safe NIMU is installed into a tapping within the outlet of the rupture disc holder, completely isolated from the process so it does not create any leak paths and is not damaged following disc activation - critical for chemical customers where leak paths cannot be tolerated.

With the traditional membrane type signalling devices, false alarms were unfortunately common place, as the harsh operating conditions could cause the device to activate even if the disc itself had not opened. This false signalling would cause unnecessary and costly process downtime. Unlike these traditional devices, the NIMU is not negatively affected by the process.

 Fig. 1: Signalling device NIMU (Non-Invasive Monitoring Unit)

Additionally, membrane detection systems are single use, meaning additional replacement costs. With the NIMU this additional cost is eradicated – the NIMU enhances overall dependability of rupture disc installations while reducing long-term expenditure. Not only is the signalling device fully reusable following disc functioning it is also reusable after routine maintenance checks. Easy to inspect during such maintenance routines, its closed circuit design allows it to be refitted into the holder by the same operator inspecting the disc, simplifying and quickening the maintenance process, a must to meet the demanding productivity requirements within the chemical processing sector.

When used in combination with the REMBE IQ Safety Cockpit the operator can be instructed in the event of a system disruption and can implement the relevant emergency management protocols. The affected employees can be individually informed of a process shutdown and co-ordinated response to identify the cause and get the plant back up and running as quickly as possible.

Reliable Monitoring of Rupture Discs protecting FPSO processes

Rupture discs installed on a gas compressor module are designed to protect the tubes on a heat exchanger from rupturing due to overpressure. Rupture discs are selected due to their response time in milliseconds. As output is directly correlated to the production from the compressor module it is critical that a rupture disc with good life cycling capability is installed, otherwise as the operating pressures increase the rupture disc will be pushed to its operating limits and fatigue causing frequent failure and unnecessary loss of production through downtime. The vent lines of several heat exchangers and other equipment are typically connected the flare system with a common manifold to save space on deck. This leads to the fact that there is variable back pressure on the Rupture disc protecting a heat exchanger. This situation requires a double disc assembly. The first Rupture disc is designed is to protect the heat exchanger shell against excessive overpressure in case of tube rupture. The second disc is typically a forward acting disc designed to resist the back pressure and set at differential pressure the required relieving pressure of the first disc less the amount of maximum back pressure.

Conventional signallling devices which are invasive are not suitable for such a harsh environment since they would be wetted by the medium on the downstream of the second rupture disc. For customers for whom compatibility with harsh operating conditions is of paramount concern the NIMU (Non-invasive monitoring unit) is a reusable rupture disc signalling system designed for rapid notification of rupture disc activation even in the harshest chemical and corrosive environments. The REMBE NIMU sensor is not in contact with the process meaning it is not affected by challenging process conditions or corrosive media.

Engineers designed a version of NIMU for such double disc assemblies and a special design for forward acting rupture discs to provide a reliable and long life signalling device for such demanding applications of the Offshore industry. This way in addition to the first disc, the second disc’s condition could be continuously monitored improving the safety and reliability of the processes on FPSOs.

Fig. 2: Double Disc Assembly

Fig.3: Double Disc Assembly with signalling device NIMU

www.rembe.de

Tackling the complexity of online valve inspection with a smart and mobile inspection system

Almost all production processes require industrial valves, which control flow, prevent backflow, regulate pressure, and stop process flow when closed. As such, industrial valves play a crucial role in ensuring the safety and efficiency of production processes.

However, valves can fail in harsh operating environments with high temperatures, corrosive chemicals and abrasive particles. To maintain valves, it's important to inspect them during operation. But inspection procedures can be time-consuming and error-prone. As a result, leaks often remain undetected for a long time, leading to a decrease in process efficiency, a loss of product quality or ultimately to unplanned downtime.

Therefore, i.safe MOBILE, together with its strategic partner Senseven, has developed the first smart and mobile inspection system for valve leak detection in hazardous areas.

“As part of modern condition monitoring programs, companies are in need for easy-to-use and digital inspection tools to quickly and independently inspect their assets and share data within the team or management”, says Christoph Altman, CTO and Co-Founder of Senseven.

Valve Sense is a software guided inspection system based on i.safe MOBILE’s innovative 5G Smartphone IS540.1. The modern solution connects state of the art acoustic emission sensors to the phone and this way transforms it into a mobile inspection tool.

The Senseven software on the Smartphone guides the user through the inspection process, captures sensor data, processes it, and uses algorithms and artificial intelligence to determine if the valve is leaking or not.

In the past, interpretation of measurement results was a difficult and time-consuming task for inspectors. Now, with the Senseven software, data analysis can be automated, results can be reproduced, and decision-making can be significantly accelerated.

No training or expertise is required to detect leaking valves of water, gas, steam, air, and viscous liquids with this simple solution. Companies can therefore regularly inspect their assets without interfering with the process, identify faults themselves at an early stage, and respond immediately to them.

As a result, they are not dependent on expert knowledge, can increase the efficiency of their processes, avoid additional costs, and reduce employee safety risks.

When connected to Wi-Fi or a network via SIM card, all measurements are automatically synchronized with the Senseven Backoffice, a web platform, accessible from anywhere on mobile devices or a desktop, eliminating the need for data transfer via USB or card storage.

This solves the issue of having inspection data isolated, decentralized, and often stored on individual devices. The cloud approach makes it cumbersome for managers to extract valuable information of their assets in form of automated reports.

All inspection data can also be integrated to existing asset management systems to trigger internal processes.

“Valve Sense is built to handle harsh industrial environments in Ex-zones with the usual reliable safety standards of i.safe MOBILE . It offers a great opportunity for all companies with or without in-house valve inspection expertise. It is easy to use, inspections can be performed at any time, and companies can rely on the

performance of their valves without having to wait for the next maintenance cycle”, comments Martin Haaf, CEO of i.safe MOBILE.

Since valves are found in virtually every production process, Valve Sense can be used in any industry and for all valve types and sizes.

The benefits in a nutshell:
• Smart and mobile inspection tool for harsh operating environments in Ex-zones
• Software guided inspection process
• Automatic leak detection with the help of algorithms and AI
• Automatic data synchronization via 5G/4G or Wi-Fi
• Customizable reporting and software integration
• Lifecycle inspection data in one platform
• Fosters collaboration across management levels and locations

Valve Sense is available to buy globally from i.safe MOBILE, Senseven or authorized dealers.
Further information, the full scope of delivery and the data sheet can be found on: https://www.isafe-mobile.com/en/inspection/valve-sense/is-vs1a1.

By 2030, the EU aims to reduce greenhouse gas emissions by 55% and hydrogen is crucial in these efforts. Today, over 90% of hydrogen projects have yet to reach financial close and with so much untapped reserves to decarbonise heavy industries, how will Europe’s executives unlock hydrogen’s immense potential?

Reuters Events’ live webinar, ‘Securing hydrogen off-take and getting projects past financial close’, provides world-class insights and recommendations from Europe’s leading developers on November 23rd, 11am CET, to which you are warmly invited.

Register for the exclusive webinar 

Don’t miss as we unravel:

• Lifting your project off the ground by hearing from industry stakeholders at the forefront of getting hydrogen projects past financial close 
• De-risking your project proposal through securing long-lasting off-take commitment 
• How partnerships are formed across the value chain, working together to fund large-scale progress

Industry experts speaking:

• Ana Quelhas, Managing Director, EDP Renewables
• Rogaciano Rebelo, CEO, Madoqua Renewables
• Joe Seifert, CEO, EET Hydrogen

Join the exclusive webinar via this link

This webinar will equip listeners with the world-class insights to ensure the right steps are taken to successfully pass financial close.

Note: If you cannot attend, please sign up and we will send you the recorded discussion afterwards.

Best regards,
Reuters Events Renewables Team

Hart Door Systems has clinched a large order from a major UK producer of Syrup for a varied range of Hart’s industrial doors.

Doug Hart, Hart’s chairman, says the order covers a wide range of Hart’s doors from its Speedor Cleanroom and Speedor Mini doors to high-speed insulated roller shutters, pedestrian doors and fire shutters.

“This is a significant order across Hart’s product range. Being able to deliver doors from one manufacturer, as well as our acknowledged installation and service delivery as a single source of supply, were key to our success,” says Mr Hart.

“Our ability to advise the client throughout the time-sensitive project, which involved the client relocating to new premises, was also important in Hart’s success.”

Mr Hart adds: “This was the wide-ranging package from a single supplier, involving over 40 doors, finished in food-grade paint where appropriate. Brian Woodcock, our regional sales manager for the Midlands/South West, advised throughout.

“It is a clear message that Hart is a market leader which has the ability to take on complex projects and deliver a first-class service every time using doors from our comprehensive range such as Hart’s Speedor high speed doors to roller shutters such as our Typhoon and Terror Screen range and more.

“In particular it was important that our Speedor Cleanroom was part of this project as it is designed to work in strictly controlled environments where high hygiene standards are required including protection against dust and dirt for example.

“The fast opening and closing feature helps to control airflow, reducing contaminants as a result,” says Mr Hart.

www.hartdoors.com     sales: +44 (0)191 214 0404