News

Operating in environments with hazardous dust and gas poses significant risks, and these dangers are compounded when dealing with very high pressures. Industries such as oil and gas extraction, chemical processing, and pharmaceuticals often work under these extreme conditions, where even minor lapses can lead to catastrophic events. The key challenges in such settings include the risk of explosions, equipment failure, and maintaining accurate measurements under pressure fluctuations. The high pressure HP1000 transmitter from ESI Technology is designed to address these challenges, ensuring safe and reliable pressure measurement in hazardous environments.

1. Explosion Risk: High-pressure systems in environments with flammable gases or combustible dusts are particularly prone to explosions. A small leak or a failure in the pressure containment system can introduce high-pressure streams of gas or dust into the surrounding area, which can ignite upon contact with a spark or heat source.
2. Equipment Failure: High-pressure systems exert immense stress on equipment. Valves, seals, and pipes must withstand these pressures without deforming or failing. In hazardous environments, any failure can lead to the release of dangerous substances, creating a significant safety hazard.
3. Measurement Accuracy: Maintaining accurate pressure measurements at such high levels is challenging. Inaccurate readings can lead to improper handling of pressure systems, which may result in over-pressurization or under-pressurization, both of which pose safety risks.

Ensuring Safety with the 5000 bar HP1000 Pressure Transmitter

The HP1000 from ESI Technology is specifically designed to operate safely and reliably in these high-pressure hazardous environments. Several features make this device an ideal choice for such demanding applications:

1. Robust Construction: The HP1000 is built with high-strength materials that can withstand pressures up to 5000 bar. This robust construction ensures that the transmitter maintains its integrity even under extreme conditions, minimizing the risk of equipment failure.
2. ATEX and IECEx Certification: These certifications are critical for equipment used in hazardous environments. The HP1000's compliance with ATEX and IECEx standards means it has undergone rigorous testing to ensure it does not ignite explosive atmospheres, either through sparks or heat. This certification provides confidence that the device can be safely used in environments with explosive dust and gas.
3. Accurate and Reliable Measurements: The HP1000 offers precise pressure measurements, essential for maintaining safe operating conditions. Its advanced sensing technology ensures that even at extremely high pressures, the readings are accurate and reliable. This accuracy is crucial for operators to make informed decisions and maintain safe pressure levels.
4. Durability and Long Life: Designed for longevity, the HP1000 can endure the harsh conditions typical of hazardous environments. Its durability reduces the frequency of maintenance and replacements, which is particularly important in environments where equipment downtime can be dangerous and costly.
5. Integrated Safety Features: The HP1000 incorporates features that enhance its safety profile. These include overpressure protection, which prevents the transmitter from being damaged by unexpected pressure spikes.

The high-pressure HP1000 pressure transmitter from ESI Technology is an essential tool for industries operating in hazardous dust and gas environments. By combining robust construction, advanced safety certifications, precise measurement capabilities, and durable design, the HP1000 addresses the unique challenges posed by high-pressure operations in such settings. Its ability to provide reliable and accurate pressure readings while ensuring safety helps prevent accidents and maintain efficient and secure industrial processes.

www.esi-tec.com

Kerstar is excited to announce the launch of its new cutting-edge Continuous Duty vacuum cleaner range which have been engineered to meet the most demanding cleaning needs. This new range includes two models: the DGF Twin Venturi Wet or Dry and the ESS 5.2KW High Suction 400v 50l Type H.

The DGF Twin Venturi Wet or Dry is an air powered vacuum cleaner designed for both wet and dry applications, offering unmatched versatility and reliability. Complementing this, the ESS 5.2KW High Suction 400v 50l Type H is a three-phase electric vacuum cleaner that provides exceptional suction power, making it an ideal choice for heavy duty tasks. Both models are ATEX rated vacuum cleaners for continuous usage, designed to operate for extended periods, even 24/7 if necessary. There are options available for use in ATEX Gas Zones 1 & 2 and Dust Zones 21 & 22, ensuring safety and compliance in hazardous environments.

These vacuums are fully mobile, allowing them to be easily moved or used as static fixed units. Their design makes them perfect for extracting debris alongside production lines and cleaning hard-to-reach areas - significantly enhancing operational efficiency. Kerstar’s Continuous Duty vacuum cleaners boast three stages of filtration, achieving a filtration efficiency of 99.995%, which is made possible through the incorporation of an H14 HEPA filter.

“We are delighted to introduce these robust and versatile vacuum cleaners”, said Kerstar’s Industrial Vacuum Specialist, Brian Folland. “Our new range is specifically designed to meet the rigorous demands of continuous operation in challenging environments, offering our customers unparalleled performance and reliability.”

Find out more about Kerstar’s new Continuous Duty vacuum cleaners as well as the entire ATEX certified and Type H (suitable for use with hazardous dusts) vacuum cleaners’ range by visiting www.kerstar.com

Reynolds Contamination Control (RCC) has announced the launch of a new sister company – along with a world first that’s set to underpin a new market focus.

The ATEX Particle Counting Company (APCC) was formed earlier this year to coincide with the unveiling of the first ever - commercially available - ISO11171:2022 particle counter certified for use in explosive atmospheres.

RCC, along with APCC, will now fall under the umbrella of newly-formed parent company Labtec Consultancy Ltd.

The new equipment is the culmination of many years’ in-house experience in particle counting and several months of exhaustive testing and certification procedures. As a result, ATEX now offers the only calibrated particle counter on the market – for both oil and fuels – that meets standards for hazardous locations (ATEX, IECEx,UKEX).

It will give ATEX access to previously untapped markets - including oil & gas, shipbuilding, green energy, chemical & pharmaceutical, food, mining and traditional energy.

Up to now, particle counting in these areas has required samples to be collected on-site and then physically taken away for analysis in a laboratory due to the risks presented by using electrical equipment in the area classified as Zone 1 explosive atmospheres – such as airport refuelling areas and offshore applications.

Technical Director Wayne Hubball said: “For many years now, customers have been asking us for kit that can be used in these situations. But the challenges of complying with exacting standards, sourcing the right components and producing something that’s portable and reliable have been difficult to overcome.”

However, ATEX’s recently forged links with Italian specialists MAM, combined with research and development by its own Engineering Director Peter Remmert, has helped to create an explosion-proof aluminium and AISI 316L, enclosure, that houses a state-of-the-art S50-P-Z1-** particle counter. Data can be retrieved ‘live’ or via the Cloud.

“The product is already creating a lot of interest,” said Wayne. “We’ve signed exclusive distribution agreements in Australia, Brazil, UK and Ireland for the S50-P-Z1-** and have had project discussions with OEM manufacturers in the offshore and hydrogen markets involving a specially developed stainless-steel variant (with offshore paint specification). We’ve also signed an agreement with a distributor for the African market.

“The Reynolds name has served us well over the last seven years or so, with its links to Osborne Reynolds, the 19^th century pioneer in the field of fluid dynamics. But the time has come to move on with a new identity that, while holding true to those early breakthroughs, reflects our own innovative – and more specialised - approach to fluid cleanliness.”

A major global provider of blast booths and blast rooms for important industrial sectors has chosen Hart Door Systems to supply its steel shutters as an important part of future installations.

Carl Crossman, project manager at Hart Door Systems, says the recent order demonstrates Hart’s ability to deliver a wide range of industrial doors and shutters globally.

“In this case,” explains Mr Crossman, “Hart’s industrial shutters are required for blast rooms where safety is paramount for abrasive blasting procedures.

“Complying with the Machinery Directive 2008, all Hart custom metal entry doors are designed and manufactured to the highest quality and safety standards,” says Mr Crossman.

“Our Custom stainless steel doors feature a standard specification but we can work with a client to design doors to meet specific needs.”

Mr Crossman says its Hart’s flexibility which delivers solutions for industrial door requirements. “We have to be hugely flexible as industry has such a range of activities which demand tailor-made solutions.

“We have a long track record of developing steel exterior and interior doors for major companies, airports, manufacturers, and as a specialist partner on Original Equipment Manufacturers’ projects.

“Hart’s custom commercial doors and shutters are available in sizes up to 10m, light or heavy-duty wind resistance, low use or high volume operation, standard or high speed, plastisol or powder coat in a variety of colours and automatic or manual electric operation.

“Complying with the Machinery Directive 2008, all Hart custom metal entry doors are designed and manufactured in Hart’s Tyneside factory to the highest quality and safety standards,” says Mr Crossman. “We can work with a client to design a door to meet specific needs.”

www.hartdoors.com

Introducing Dustlight – a mobile fine dust measuring device designed to safeguard workers from dust exposure in industrial and craft workplaces. The first-of-its-kind device, Dustlight, is equipped with Sensirion’s SEN5x sensor series, setting new standards in air quality monitoring.

In industries where hazardous environments are part of everyday operations, safety and reliability are paramount. One critical component ensuring both is the  EX connector. These specialised connectors play a crucial role in various applications where explosive atmospheres are present, such as oil and gas, chemical processing, mining and more. Here, Isaac Noble,  European product manager at connector specialist PEI-Genesis, delves into the applications and benefits of EX connectors and new developments with Hermetic EX connectors.

EX connectors are a subset of connectors specifically designed to meet the stringent requirements of hazardous locations classified as explosive atmospheres. When choosing connectors for hazardous missions, there are several key factors that should be considered. First, consider the different Zones connectors will be used in.

In the Dangerous Substances and Explosive Atmosphere Regulations 2002 (DSEAR), Zone 0 is defined as a constant explosive environment, Zone 1 indicates there is often an explosive atmosphere and Zone 2 is indicative of a rarely explosive atmosphere.

The UK Health and Safety Executive (HSE) explains, “the primary purpose of zoning is to facilitate the proper selection and installation of apparatus to be used safely in that environment, taking into account the properties of the flammable materials that will be present.”

In a worst-case scenario, it is possible that electricity running through connectors could become an ignition source if it comes into contact with flammable dust and gases in the environment or the surface or the connector reaches the ignition point of the gases and dust’s in the atmosphere. For this reason, all connectors used in explosive atmospheres must comply with the IECEx international standard which governs the installation and use of electrical equipment in these environments. 

Benefits of hermetic EX connectors

One notable feature of Hermetic EX connectors is their capability to uphold pressure via a hermetic glass-to-metal seal, all while meeting the necessary ATEX and IECEX requirements essential for deployment in hazardous environments. In dangerous environments where flammable gases, vapours, or combustible dust are present, even a small spark or uncontrolled temperature source can trigger an explosion or fire. All gases and dusts have an ignition point and by controlling and limiting the temperature the surface and internal connection can reach hermetic EX connectors significantly enhance safety for personnel and in addition allowing applications requiring pressure tolerance through the connector to maintain these standards.

At the same time, hermetic EX connectors feature a sealed enclosure that effectively protects the internal electrical components from exposure to the surrounding hazardous atmosphere. This sealing mechanism prevents moisture, dust and other contaminants from infiltrating the connector, ensuring consistent and reliable electrical performance over time.

Many hermetic EX connectors are also constructed from corrosion-resistant materials such as stainless steel or specialised alloys. This corrosion resistance helps maintain the integrity of the connector in harsh and corrosive environments commonly encountered in industries like oil and gas, chemical processing, and mining.

These types of connectors are designed and manufactured to comply with stringent industry standards and certifications for use in hazardous locations. These standards, such as ATEX (European Union), IECEx (International), NEC (National Electrical Code) and others, establish requirements for equipment intended for use in explosive atmospheres. Compliance with these standards ensures that hermetic EX connectors meet the necessary safety criteria and regulatory requirements.

The reliability and durability of hermetic EX connectors contribute to reduced downtime associated with equipment failure or maintenance. By providing a secure and consistent electrical connection up to the task of withstanding pressure up to 50bar; these connectors minimise disruptions to operations in hazardous environments, thus increasing productivity and efficiency.

Hermetic EX connectors are also used to protect sensitive electrical components from exposure to corrosive substances, moisture, and other environmental factors that could accelerate equipment degradation. As a result, equipment installed with Hermetic EX connectors may experience a longer lifespan, reducing the frequency of replacements and associated costs.

Applications for EX connectors and hermetic EX connectors

EX connectors are employed in drilling rigs, wellhead equipment, and production platforms to provide reliable electrical connections in areas where flammable gases may be present. These connectors ensure safe operation and prevent the risk of igniting potentially explosive atmospheres during drilling, extraction, and processing activities.

Refineries and petrochemical plants rely on EX connectors within crucial equipment like pumps, compressors, and instrumentation, strategically positioned in areas prone to flammable vapours. These connectors ensure uninterrupted communication and control, mitigating the risk of ignition in potentially explosive environments. Moreover, Hermetic variants find extensive application in turbo generators and expanders employing magnetic bearings, pressurised actuators, and LNG pumps, reinforcing safety protocols across various industrial processes.

In mining operations, where dust and methane gas pose significant hazards, EX connectors play a pivotal role in safeguarding equipment such as conveyors, crushers, and ventilation systems. By eliminating the risk of sparks, these connectors maintain operational safety amidst potentially explosive atmospheres, enhancing the reliability and longevity of mining operations.

Additionally, the versatility of EX connectors extends to railway and automotive sectors, where the presence of flammable fuels or gases demands meticulous electrical connectivity. These connectors facilitate secure electrical connections in fuelling systems, engine controls, and onboard electronics, ensuring uninterrupted performance while prioritising safety standards in transportation applications.

EX connectors play a vital role in ensuring safety and reliability in hazardous environments across various industries, including oil and gas, mining, and transportation. By providing sealed, spark-free electrical connections, these connectors mitigate the risk of ignition in explosive atmospheres, safeguarding personnel and equipment while enabling efficient operations in challenging conditions.

PEI-Genesis is an ATEX-approved assembler of the Amphenol Star-Line EX and Amphe-Ex, which are arguably the most popular EX connectors in the world due to their sturdy design and plethora of configuration options. With a broad range of reversible inserts; solder, crimp and pressure terminals; and flexible cable options, Star-Line EX connectors will meet application demands in petrochemical refineries, land and offshore drilling systems.

To find out more about PEI-Genesis’ connector solutions for hazardous environments visit www.peigenesis.com.

British Safety Council concerned at continued rise in work-related deaths in Britain

Commenting on the latest Health and Safety Executive data, showing a rise in work-related deaths in Great Britain for the second consecutive year, Dr Julie Riggs, Director of Education and Membership, British Safety Council, said: "The rise in work-related fatalities, as reported by the Health and Safety Executive, serves as a stark reminder that we cannot become complacent about the health and safety of workers. Put simply, the consequences of poor health and safety are too great a price to pay.

"For 50 years, the general direction of travel has seen safer workplaces with falling numbers of workplace deaths and non-fatal injuries; that for a second year this trend has reversed is cause for concern. It sends a message that we need to prioritise worker health and safety, understand the causes of rising fatalities, and take targeted action to return to falling figures and safer workplaces for all."

British Safety Council’s networks: 
Website:                         www.britsafe.org 
Twitter:                           www.twitter.com/britsafe 
Facebook:                     www.facebook.com/britishsafetycouncil 
YouTube:                       www.youtube.com/britishsafetycouncil 
LinkedIn group:            www.linkedin.com/company/british-safety-council 
Safety Management:  https://sm.britsafe.org 

Four Speedor high-speed doors have been installed by Hart Door Systems at a major frozen and cooked meat manufacturing in northern England. The doors, at just 1.5m wide and 1.95m high, are the second smallest Speedors ever manufactured by Hart.

“The contract demonstrates two things,” says Gordon Kipling, regional sales manager for Hart. “Not only is our Speedor range available in distinctly different types of doors but where applicable the doors can be available in reduced sizes for precise requirements.

“In this case there was a need to protect the production environment against drafts, humidity, dust and dirt by installing our Speedor Cleanroom with its fast opening and closing speed. Our pharmaceutical standard Cleanroom Speedors control airflow thus reducing contaminants.”

Designed specifically for manufacturing and research facilities, Speedor Cleanroom works in strictly controlled environments where hygiene standards are high, such as pharmaceuticals, food processing, electronics and micro-mechanics industries.

The main features of Speedor Cleanroom include maintaining strict air leakage requirements over specified pressure differentials. Complete with an intelligent control panel with digital display each Cleanroom has a reliable and clean in-line drive system complete with an integral safety brake and a non-touch safety light curtain ensures maximum protection to personnel.

Seals minimise pressure drops and protect the manufacturing environment against drafts, humidity, dust and dirt.

www.hartdoors.com

Automated Methane Monitoring Solution with OGI by FLIR delivers 24/7 Coverage of Methane Production, Transmission and Storage Infrastructure