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Hydrogen: Big Potential, Big Safety Challenges - Are You Ready?

Light, simple, abundant. That’s hydrogen (H2). Because hydrogen doesn’t create carbon dioxide (CO2) emissions when burned, it holds the promise of becoming essential for global energy transformation, pollution remediation, and decarbonising the planet. 

In fact, Hproduction, distribution, and usage is skyrocketing, having been fueled, in part, by environmental legislation and worldwide demand for clean energy.  

H2 is extremely attractive as a fuel source because of its ability to be both environmentally friendly and sustainable. However, before the adoption of hydrogen becomes even more widespread, there’s work to be done; namely, Hmust be produced, distributed, and used safely. 

Despite hydrogen’s potential to become a widespread clean-energy source, there are very real safety issues to contend with. Therein lies the challenge and the paradox. 

On one hand, hydrogen’s unique chemical properties make it an exciting fuel alternative. On the other hand, those same properties are what hold the potential for these dangers: 

  • Hydrogen has a propensity to leak. 
  • It is colorless, odorless, and tasteless, making it undetectable by human senses.  
  • Hydrogen has an invisible, high-temperature flame with low thermal radiation. 
  • It is fast detonating and more explosive than natural gas. 

 Leak Monitoring and Detection 

According to the U.S. Department of Energy, all fuels—including hydrogen—pose some degree of danger. While hydrogen’s non-toxic nature and ability to dissipate quickly when released are just a few of the reasons hydrogen may be safer to handle than other fuels, there’s still a need for safe use. 

Specifically, hydrogen has a wide range of flammable concentrations in the air and lower ignition energy than gasoline or natural gas, which means it can ignite more easily. Consequently, adequate ventilation and leak detection are important elements in the design of safe hydrogen systems. Because hydrogen burns with a nearly invisible flame, special flame detectors are required.1

Consistent monitoring, therefore, is imperative for hydrogen producers, distributors, and users. The question is, how?  

Although the need for monitoring and detecting hydrogen leaks is a relatively new challenge, here’s the good news …  

Here at MSA, we’ve been at the forefront of hydrogen gas and flame detection solutions. As one of the world’s largest and most experienced global suppliers of gas and flame detection equipment, MSA has pioneered the detection of combustible gases like hydrogen, methane, and propane.  

In fact, our in-house Research and Development team develops, tests, and manufactures its own fully certified portfolio of products and safety solutions—including the very latest hydrogen gas and flame detection technologies.  

Click here to learn about international standards, technologies and MSA’s solutions gas detection safety challenges.

What is COSHH and why is it important for engineering and manufacturing industries?

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The Control of Substances Hazardous to Health (COSHH) is a pivotal UK regulation overseeing the management, storage and disposal of dangerous substances. In sectors like engineering and manufacturing where chemicals and hazardous materials are frequently used, adhering to COSHH isn't just a legal requirement but crucial for safe and efficient operations.

This piece looks into COSHH, shedding light on its critical role in the engineering and manufacturing industries, and how abiding by these rules influences the safety and prosperity of businesses in these sectors.

Duties of employers

COSHH rules aim to protect both individuals and the environment from potential dangers posed by hazardous substances. These rules set clear standards for risk evaluation, the introduction of control strategies and the provision of adequate training and emergency preparedness. Following these regulations isn't just about legal compliance but also embodies responsible business conduct.

Employers are tasked with executing detailed risk evaluations to pinpoint potential dangers, introducing suitable control strategies to lessen risks, offering extensive training to their workforce and setting up solid emergency protocols.

Why adhering to COSHH matters

The possible risks and repercussions of neglecting COSHH are grave, spanning from health threats to workers due to exposure to harmful agents, to legal sanctions and even potential harm to machinery and the environment. Given the complex nature of engineering and manufacturing operations, which often involve substances that can be disastrous if mismanaged, COSHH compliance becomes an essential facet of operational soundness.

COSHH in the engineering and manufacturing sectors demands a pragmatic and systematic strategy. This encompasses correct storage - COSHH cabinets - accurate labelling, proper disposal techniques for dangerous substances, routine checks and updates of control methods, and continuous staff training.

By adhering to these regulations, businesses ensure the implementation of adequate safety protocols. For instance, in a factory utilising toxic chemicals, abiding by COSHH directives guarantees the installation of effective ventilation, safety gear and correct handling procedures. This not only reduces accident risks but also creates a safer workspace for the workforce.

COSHH adherence also holds weight in shaping a company's image. Firms recognised for their dedication to safety regulations, COSHH included, may draw and retain more clients and employees. In sectors like car manufacturing, meeting safety benchmarks often becomes a pivotal criterion in clinching deals with top brands, highlighting how COSHH compliance can boost a firm's market position.

Environmental conservation is another domain where COSHH plays a pivotal role. The disposal and containment methods outlined by COSHH prevent hazardous agents from polluting the environment. A case in point is a chemical engineering firm that adopted a COSHH-aligned waste management system, thereby curtailing environmental pollution risks.

While introducing COSHH in engineering and manufacturing can be challenging, given the intricacies of risk evaluations for diverse substances, the necessity for specialised training and the costs tied to compliance, these hurdles can be navigated with meticulous planning, expert collaboration and a dedication to ongoing enhancement and industry best practices.

Upholding COSHH compliance in operations

Grasping and abiding by COSHH is indispensable for the engineering and manufacturing sectors. It's a linchpin of ethical business operations, protecting workers, the environment and the enterprise itself. Whether you're an employer, a supervisor, or a worker in these fields, a profound understanding of COSHH is paramount. It guarantees not just legal adherence but also the thriving and sustainable functioning of the enterprise.

Hydrogen Safety: the importance of controlling static electricity

Countries around the world have set the strategic objective of reaching net-zero as soon as possible. One of the key enablers is the rapid development of the hydrogen economy. Vast amounts of public and private money are being invested in the production, storage and transportation of hydrogen as well as the fuelling station network for the increasing range of hydrogen vehicles.

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As the hydrogen economy rapidly develops, safety must be the top priority. Standardisation is a key step on this journey to net-zero. The ISO 19880-1:2020 Standard is very specific about the requirements for grounding and bonding, including for hydrogen delivery systems such as trucks or trailers. The Standard states that electrical resistance between metallic parts connected or in contact together should be less than 10 ohms.

Each day there are fires and explosions caused by the ignition of flammable and combustible chemicals. One of the most common causes of the ignition is a spark caused by a sudden discharge of accumulated static electricity.

When two differing materials move against each other, electrons can be exchanged, leaving an excess of positive charge on one material and an equal negative charge on the other. This is the generation of static electricity. During the transfer or processing of a material, significant amounts of static charge can accumulate very quickly, leading to the rapid increase of voltage on the object (e.g. road tanker).

Voltages can rapidly exceed the break-down voltage of the surrounding atmosphere and create the risk of a sudden discharge to a nearby conductor in the form of a spark.

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The amount of energy released by this sudden discharge can easily exceed the Minimum Ignition Energy (MIE) of the potentially flammable atmosphere and thereby lead to a fire or explosion.

The most effective way of avoiding a sudden static discharge is to ensure the object is grounded before and during the process by providing a low resistance path to true ground so that static electricity does not accumulate.

 

The reason that controlling static electricity is so important for hydrogen safety is that the MIE is only a fraction of that of other fuels. The very small amount of energy required to ignite hydrogen means that it is classified within Gas Group IIC (Gas Group B in the US).

Newson Gale’s Earth-Rite® II RTR is dedicated to grounding road tankers and large vehicles. It is certified to be installed and used in IIC environments, unlike many alternative systems.

International Standard

ISO 19880-1:2020 Gaseous Hydrogen – Fuelling Stations

10.2.3 Protection from ignition due to the accumulation of static charge

“The electrical resistance between metallic parts connected or in contact together should be less than 10 ohms.”

The Newson Gale Earth-Rite® II range of grounding systems continually monitor the connection resistance to a 10 ohms or less permissive threshold, and this has been verified by a third-party testing house.

Please visit our website to find out more:

www.newson-gale.co.uk

 

 

 

 

What’s all of the fuss about Hydrogen?

Having just spent a week at Offshore Europe in Aberdeen and a week at the Global IECEX Conference in Edinburgh there is no doubt ‘Hydrogen’ is firmly on everyone’s agenda…. Apparently, the future is ‘Hydrogen’!

People who have been working in or around potentially explosive atmospheres will be aware that Hydrogen is nothing new…its just another ‘IIC’ Gas and we have been classifying hydrogen zones and certifying equipment for hydrogen environments for 30+ years. The use of Hydrogen isn’t new, but the number of areas that will be classified as IIC is increasing dramatically.

So- what is special about Hydrogen? Below is a very simplified list (I have tried to be as non-technical as possible!) just to make people aware of some of the issues with Hydrogen that may affect risk assessment, area classification or product certication.

  • It’s very light, can pocket in ceilings and high areas. Gas detection positioning may be affected.
  • It can leak more easily than other gases if not properly sealed and may cause embrittlement and other issues
  • It is very easy to ignite with energy/sparks (very susceptible to static ignition for example)
  • It has a very wide flammable range so mor of the ‘leak’ will be ignitable.
  • It is very volatile (can detonate even in open air, produces very high pressures etc.)

Given this list, it’s fair to say that Hydrogen presents more of a ‘risk’ (in terms of both likelihood of ignition and consequence) than most other gasses, but that existing systems (ATEX, IECEX etc.) already take account of this for IIC Gasses.

There are also many new technical working groups working on Hydrogen specific standards, hydrogen fuel cells, hydrogen dispenser for example. In addition to new types of equipment there are many new retrofit issues (hydrogen generators forklift trucks etc.) which will have a knock on effect to the installed equipment.

Sites or processes that introduce Hydrogen as a new gas will need to reconsider the consequence analysis, classification and equipment EPLS as a minimum, even issues such as antistatic PPE may need to be considered.

 Given that the use of Hydrogen is increasing dramatically, Certification Bodies will no doubt get more requests for IIC Certification. Equipment Manufacturers will need to be aware that in some case (intrinsic safety, flameproof etc.) Hydrogen certication can be far more difficult (or even not possible) for some types of equipment, so start early if you think you will be involved in the Hydrogen boom!

This article was written by Sean Clarke @  Exveritas

Working with ageing and new industrial equipment

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A key focus for EEMUA is helping owners and operators of industrial assets to avoid damaging and costly incidents – by providing practical resources that support the industrial engineering community as it works with real-life’s range of ageing and new plant.

EEMUA’s many resources include ‘how to’ guidance publications, seminars, webinars, e-learning, classroom, live online, in-house and blended training throughout the year. For instance:

Mechanical Integrity Practitioner Certificate (MIPC®training keeps practitioner-level engineers on top of the latest industry developments and good practice in primary containment of hazardous substances, including for pressure systems.

The blended learning (live online classes, 1-1s, e-learning, with mentor support throughout the course) covers on-site application of EEMUA 177, 231 and 232 guidance, and the PSSR ACOP.

Certificated for 5 years via exam and portfolio assessment, the course adapts to the engineering needs of each learner and their site or sites through a 2-hour induction that can be fitted to diaries from September 2023.

The next MIPC course runs from 23 October 2023 for 27 weeks, 4 hours per week. Open to all practitioner-level engineers, the MIPC course is discounted for EEMUA Members and Associates.

 

EEMUA 194 Subsea Engineering Basics blended online learning is for practical design, specification, commissioning, operation, repair, maintenance, and refurbishment of ageing or new underwater energy production equipment.

Course Tutors’ incorporate decades of expert materials corrosion experience with the distilled know how of industry captured in the ‘how to’ guidance of EEMUA Publication 194 to capture reality in online learning.

The course’s live online classes, e-learning and 1-1 tutorials provide real-time interaction that ensures Learners immediately grasp the correct understanding and make the learning experience time-efficient.

Open to all and discounted for EEMUA Members, the next EEMUA 194 Subsea Engineering Basics course has a 2-hour Induction to fit diaries from October 2023, with learning starting 6 November 2023.

EEMUA TankAssessor course in Rotterdam, NL from 9 October. Given in Dutch, the four-day course provides understanding of: the design, material and fabrication aspects of tank construction with respect to repair or restrictions of use after degradation in service; principles, output and limitations of inspection methods and techniques; making sound assessments of storage tanks and their foundations’ integrity; offering guidance on repairs. With an exam to earn or renew a five-year certificate of competence, the course is open to all with the correct experience and discounted for EEMUA Members.

Next Seminar… The EEMUA Storage Tanks Seminar in Rotterdam, NL on 30 November is open to all for a whole day’s focus on: Current research projects relating to tank storage; Robotic tank cleaning; EEMUA Publications; Mothballing of storage tanks; Guidance for statistical analysis for tank floor inspection (New EEMUA Publication).

Free from shareholders and owners, EEMUA is the industrial engineering community’s not-for-profit association that invests all its revenue into sharing practical guidance resources, events, training, and more ~ all developed ‘for industry, by industry’ and proven by engineers in everyday use over more than 70 years. 

All EEMUA’s resources are free or discounted for EEMUA Members, and new corporate Members and Associates are always welcome, so please contact This email address is being protected from spambots. You need JavaScript enabled to view it. to make EEMUA’s many resources work best for you and your team.

What exactly does intrinsically safe mean?

It is widely accepted that any electrical equipment for use in Ex hazardous locations needs to be “intrinsically safe” and therefore incapable of igniting an explosive atmosphere. Obvious hazardous locations include flour mills, coal mines, petrochemical plants, fuel transfer facilities etc. However, some not so obvious hazardous locations include wastewater treatment plants or anywhere a build-up of naturally occurring flammable material (such as methane or dust) could occur.

In many of these locations there is a need for condition based monitoring (CBM) equipment, for example to measure the temperature or vibration of rotating machinery. This CBM equipment must therefore be certified as “intrinsically safe”. This is where things can become confusing however, as there are various certification routes. The main one is the International Electrotechnical Commission’s IECEx, which applies Worldwide. However, some regions also require “local” approval, such as the EU’s ATEX (Atmospheres Explosives) certification. Although this is basically an additional layer of bureaucracy on top of IECEx and the two are effectively identical. However, North American approval (USA & Canada) can appear slightly different, as explained below.

The whole concept of intrinsic safety is based on probabilities, including the likelihood of an explosive atmosphere existing in the first place. For IECEx & ATEX this is dealt with by the definition of the following zones, which put very simply, define the probability of an explosive atmosphere existing as: Zone 0: most of the time, Zone 1: occasionally and Zone 2: not very often. The North American system has previously used a classification system known as NEC500 that defines Class 1, Division 1 (equivalent to Zones 0 & 1) and Class 1, Division 2 (equivalent to Zone 2). However, this is gradually being replaced by NEC505 that uses identical zones to IECEx & ATEX.

The concept of intrinsic safety being based on probabilities is taken a stage further whereby equipment suitability for use in hazardous locations is based on the probability of a fault occurring:

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Test Products International (TPI) believes it has greatly simplified things with the triple certification of its very affordable 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 hence certified for use in hazardous locations anywhere in the world.

The TPI 9080Ex uses industry standard BNC connected intrinsically safe accelerometers and 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 9080 via Bluetooth using a smart phone or tablet running the free TPI Cloud Bridge App. This allows service personnel to receive and return VibTrend routes and readings, no matter where they are in the world.  

In-line with TPI’s philosophy of being the value leader, the TPI 9080Ex is available at the incredibly low 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.

Signalling systems for the chemical industry

Avoid unnecessary downtimes with intelligent signalling systems

Rupture discs and safety valves have become indispensable for manufacturing companies in the chemical industry. However, there is a need to catch up in terms of signalling.

The opportunities offered to operators here are both diverse and economically interesting. With non-invasive signalling that can be integrated into the rupture disc, even processes with critical pressures and demanding media can be reliably monitored.

Processes involving high temperatures and highly corrosive media are widespread throughout the chemical industry. In the past, conventional signalling was not always compatible with such extreme conditions, which is why it is now often overlooked as an additional process monitoring system.

The use of modern signalling equipment not only helps to improve productivity and safety but is also helpful in terms of addressing environmental concerns. The German manufacturer REMBE is a European leader in the production of pressure relief devices, explosion protection systems and the associated signalling devices. The company's product range includes some of the most robust rupture discs and signalling systems available on the market. These solutions create significant operational added value in the chemical industry by reliably monitoring safety systems and critical pressure relief devices.

In processes involving potentially harmful media, the risk of leakage can be reduced via a quick and safe shutdown. REMBE's well-designed signalling systems comply with both industry-relevant standards for explosive atmospheres and the intrinsic safety standards. By providing rapid notification of a burst rupture disc, they help to safely control the process while minimising downtime. High-quality signal transmitters can be easily integrated into the existing control systems in order to transmit a visual or acoustic signal when the rupture disc bursts and to shut down the system if necessary.

Avoiding unnecessary downtime through non-invasive signalling

The NIMU (non-invasive rupture disc monitoring) signal transmitter is suitable for systems exposed to harsh operating conditions. This reusable monitoring system is explicitly designed to provide rapid notification of a burst rupture disc. The REMBE NIMU sensor does not come into contact with the process itself, so it is not affected by harsh process conditions or corrosive media and ensures maximum tightness even for systems containing extremely corrosive chemicals.

The NIMU is mounted in a blind tap in the outlet on the rupture disc holder. Thus, the signal transmitter is completely isolated from the process. Potential leakage after the rupture disc has burst is also prevented – this is essential for customers in the chemical industry where leaks cannot be tolerated.

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Fig. 1: Signalling NIMU (non-invasive rupture disc monitoring)

The signal transmitter is fully reusable not only after the rupture disc has burst, but also after scheduled maintenance work. During such maintenance work, the closed circuit of the rupture signalling system makes it easy to perform a function test – the rupture disc can then be reinserted into its holder. Furthermore, the operator can do this without external assistance, which simplifies and speeds up the maintenance process. This is simply a must in the chemical industry due to the demanding productivity requirements.

 

Reduce environmental risks

Environmental concerns such as emissions control have become increasingly important for chemical manufacturers. The ability to quickly detect a leak within the process without external support brings significant benefits.

On the one hand, the SBK signal transmitter ensures fast and reliable fault signalling via the bursting of rupture discs and, on the other hand, has the unique ability to monitor leaks from upstream rupture discs. REMBE has specially developed this signal transmitter for processes with high temperatures where alternative signalling systems may no longer be suitable. The combination of leak detection and signalling in one product is a cost-effective solution. The materials used remain stable even at extreme temperatures and ensure high reliability in the long term without the risk of premature failure.

If the SBK signal transmitter is integrated into the process control system, it provides continuous monitoring of the rupture disc and reliable fault indication when the rupture disc bursts. Even marginal leaks within the process are detected. The application of the SBK monitoring system in the chemical industry, where the loss of process media is costly or harmful to health, significantly increases plant efficiency. At the same time, it ensures compliance with safety and environmental standards.

Integrated signalling – reduce installation points, ensure reliable monitoring

Whereas with other signalling systems the rupture disc and signalling devices must be installed and maintained separately, the SGK versions allow the signalling to be integrated directly into the rupture disc. Thanks to their unique design, it is not necessary to run a cable out of the rupture disc holder, thereby eliminating the need to drill a hole for the signal cable. Especially for processes with a low set pressure, where (for example) the non-invasive NIMU signalling may not be suitable, the SGK signalling systems allow continuous monitoring. The SGK versions are available with the KUB and IKB reverse acting rupture discs and the ODV triple-section rupture disc.

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Fig. 2: KUB clean reverse acting rupture disc with integrated signalling and replaceable seal.

www.rembe.com

 

Visit E2S at ADIPEC on Stand 8630 at the UK Pavilion to see the most modern and effective range of Warning Signals

E2S Warning Signals, the world’s leading manufacturer of safety critical warning signals will return to ADIPEC between October 2nd and 5th 2023 to showcase again its class-leading range of signalling products.

Featuring on the stand will be the industry’s most up-to date range of Alarm Sounders, Beacons, Loudspeakers and Manual Call Points, all designed to provide the most efficient and effective method of initiating and providing audible and visual warnings to ensure the safety of personnel and assets in onshore and offshore hazardous area installations, as well as for marine, industrial and commercial applications.

E2S Warning Signals modern and efficient products, allow systems designers to employ high performance signalling products whilst reducing the overall power requirement from their control systems; potentially enabling significant system cost savings. E2S Warning Signals also provide flexible, customer focused solutions to best meet end user specific requirements, all with a class-leading 10-year warranty and multiple global approvals with such as ECASEx, ATEX, IECEx, UL, PESO, CCCEx and DNV.

On the stand this year E2S will be showing the innovative D1x, STEx and GNEx range of explosion proof Beacons, Sounders, Loudspeakers Manual Call Points and Configured Assemblies.

The LM6 Alloy D1x, GRP GNEx and SS316L STEx ranges utilise common electronics to ensure the best possible performance whatever the material of choice, all configured for use in SIL 2 approved systems as standard.

The Ex d range of beacons/strobes features the highest light output available with LED and Xenon sources all with very low power consumption. Our Ex d Sounders offer highly configurable multi-stage alarms at outputs up to 128dB(A), the highest output of any Ex d electronic alarm sounder.

Our Status Lamp Assemblies and Alarm Bars showcase the flexibility and modularity of design inherent in E2S modern range of signalling and are perfect for use in wireless Fire and Gas systems and as part of rig packages in combination with our safe area products.

Visit E2S Warning Signals at Stand 8630 in the UK Pavilion

E2S Warning Systems – Signals For Your Safety

www.e2s.com

 

 

 

 

Explosion Proof ATEX/IECEx Zone 1 / 21 iPad Mini 6

Now CSA Certified for North America / Canada

Classes, Divisions and Zones


Atexxo Manufacturing has released the Apple iPad mini 6 which is global certified and suitable for use in Zone 1 and Zone 21 hazardous locations. The explosion proof iPads are originally manufactured by Apple then converted and certified according to the ATEX directives and IECEx standards by Atexxo Manufacturing. This makes the ATEX/IECEx Tablets suited for safe use in gas/vapour Zone 1 and dust Zone 21 hazardous areas. Sim-card can be installed by the end-user themselves. The devices are suited for Apple’s DEP (open) Business Manager Program.

All features of the original product are preserved, except for the fingerprint scanner.

The ATEX/IECEx iPad mini of the 6th generation comes with an aluminum case finish. The ATEX/IECEx iPads are suitable for use in extreme demanding environments. They are available in both 64gb and 256gb versions.

Beside safe use as a tablet computer, all versions are excellent for use as an explosion proof camera or RFID scanner. For Middle East countries, versions with blocked cameras are available.

Explosion safety level:

II 2G; II 2D; II 3D,  Ex db IIC T4 Gb, Ex tb IIIA T135°C Db, Ex tc IIIB T135°C Dc

Class I, Zone 1 AEx db IIC T4 Gb Class I Div 2, Group A, B, C, D T4

Features:

- 64Gb or 256 Gb + Cellular- Self Sim-Card Installation - Original Apple IOS software- Suited for Apple DEP (open) Business Manager Program- Global certified (ATEX, IECEx, UKCA, CSA, INMETRO)

 

Typical Applications:

- Connected fieldworker- Digital twins- - Industry 4.0- Oil and Gas extraction sites- Petro Chemical plants- Offshore platforms

For more information please contact our sales department

www.atexxo.com
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+31(0)186601299