your first choice for explosion prevention - Pyroban Group Ltd

YOUR FIRST CHOICEFOR EXPLOSION PREVENTION

PROTECTING INDUSTRYREPLACEMENT PARTSSERVICE ANDSUPPORTADDED SAFETYZONE 21/22

FROM EXPLOSIONCONSULTING ANDRISK ASSESSMENTTRAININGZONE 1(DIESEL ANDELECTRIC)ZONE 2(DIESEL ANDELECTRIC)

SCIENCE OF EXPLOSIONSThere is always the risk of a flammable material releasein businesses that produce, store or move flammable gas,liquid or powder.HOW TO MANAGE THE RISKSafety can only be achieved through a holistic approach toexplosion prevention.To effectively manage the risk, many factors need to beconsidered in conjunction with each other.It only takes one weak link to cause an explosion.If the released gas, vapour or powder comes into contactwith air and an ignition source, an explosion could happen.Stronggovernanceandhazardousarea policyRiskassessmentand consultingTrainingThe expertise of explosion prevention companies keepsthese elements apart.Deep safetycultureCentralcontrol roomshutdownAreaclassificationGas is not smart or selective and the consequences ofsuch an ignition have been well reported over the last fewyears, particularly in the Gulf of Mexico and America.This significantly affects people, environment, a brandreputation, share value and production levels.CorrectlyspecifiedhazardousareaequipmentEquipmentprotectioninc. rotatingequipmentProactiveservice andsupportHAZARDOUS AREAHAZARDOUS AREACONSULTINGTRAININGEx-Solutions Consulting can provide expert, independenthazardous area classification, consulting and trainingbenefitting from the 40 years of explosion protectionexperience from Pyroban. We assist customers across theworld helping to ensure that they operate safely in potentiallyexplosive atmospheres. Services include:• Gap analysis and Site Safety Audits• Hazardous area risk assessment• Hazardous area classification (HAC)• Ex equipment compliance inspections• Design and product manufacturing and certificationand documentation supportPyroban’s training team provides a wide range of explosionprevention training services across the world, either atPyroban facilities, or at customer locations.The training courses are designed to cut through the scienceand vast quantity of explosion proof legislation, includingstandards and guidance, with a flexible learning experience.The courses suit all levels of the supply chain includingdetailed practitioners and engineers.

KEYArcing and sparking componentsElectric sparks and arcs (i.e switches) and mechanicalsparks (i.e friction).Hot surfacesA forklift truck has many surfaces which couldbecome hot and are possible sources of ignition.Surface temperature limitation ensures the engine,motors, brakes, electrical and other componentsremain below the auto-ignition temperatures offlammable materials.Engine overspeed or flame from inlet or exhaustIf flammable gases/vapours are present in theatmosphere, the diesel engine could ingest themthrough the air intake. The result can be flash backsthrough the inlet or backfires in the exhaust.Overspeed can also occur when the engine ingestsflammable gas mixed with air and diesel fuel whichcan lead to the engine running out of control atelevated speed.This can result in catastrophic failureof the engine. Another risk can be misfiring of theengine which can lead to an explosion further downthe exhaust system which could then ignite thesurrounding atmosphere.Industrial vehicles with similar ignition sourcesEXPLOSION PROOF CONVERSIONS (DUST)ZONE 21 / 22 - ELECTRIC & DIESELMANAGING RISK WITHADDED SAFETYPyroban can convert almost all forklift trucks and vehicles forsafe operation in Zone 21 or 22 areas.Conversions may include Ingress Protected (IP) enclosuresfor arcing and sparking components, surface temperaturelimitation, cladded forks and more. Often, trucks arerequested with both gas and dust protection for use in Zone1 and Zone 21 or 22 areas, Zone 2 and Zone 22 areas. Theconversion will incorporate both levels of protection oftenin single components, such as Ex d enclosures certified forZone 21 use.Converted equipment is ATEX 94/9/EC compliant or compliantto relevant local regulations.For discretionary safety areas, extended hazardous areasadjacent to formally classified Zones or for use in somehazardous area maintenance situations, Pyroban providesthe added safety system Gascheka duo.Gascheka duo is a gas detection and shutdown controlsolution for all types of electric, diesel and LPG equipmentwhich is supplied as a kit for on-site installation.Gascheka duo provides visual and audible warning tooperators of the presence of gas/vapour and uses eitherinfrared or pellistor sensing technology.Visithttp://gaschekaduo.pyroban.com

LEGAL COMPLIANCERegional legislation governs Health and Safety issuesrelating to explosion protection of equipment across theworld. Regulations usually affect the hazardous area (site)and the equipment operating in the areas.Local and regional guidelines exist such as ATEX in Europe,NEC / NFPA in the US and the international IECEx.ZONE 1 OR ZONE 2?Businesses should define their hazardous areas correctlyaccording to the appropriate zones. Often, Zone 1 areas areover cautiously defined and the majority could be classifiedZone 2. Pyroban can help you check that classifiedhazardous areas are accurately defined before introducingnew equipment such as explosion proof forklift trucks.TRUCK MANUFACTURERS APPROVALBe aware that ISO standards stipulate that trucks shouldonly be modified with approval by the original manufacturer.When buying an explosion protected truck, we advisechecking with your truck supplier to ensure that there iswritten consent by the manufacturer to the explosionprotection provider. This will prevent any problems withproduct and public liability, warranty and technical support.CERTIFICATION AND TESTINGCertification and testing are crucial elements in the Pyrobanbusiness. All Pyroban products are certified, with manyhaving tri-certification to ATEX 94/9/EC, IECEx and NEC505. With in-house test facility procedures and approvalto national standards, Pyroban can ensure quality at everystep in the processQUALITYAdditional to the ISO9001:2008 quality standardcertification, each Pyroban Group company attains therequired level of 3rd party certification for the businessmarkets it serves including ATEX, IECEx, GB and NEC.ENGINEERING EXCELLENCEWith more than 40 years experience delivering complexengineering solutions, Pyroban has developed a globalfootprint of engineering excellence to deliver high qualityproducts across the world.Our engineering principle is to “understand the sciencebehind the technology” to ensure the products andsolutions are fully aligned to the markets served, focusedon compliance, functionality, quality, reliability and lifecycle cost.HAZARDOUS AREASERVICE & SUPPORTEXPLOSION PROOFREPLACEMENT PARTSPyroban provides all levels of service to suit the applicationand customer requirements, providing either direct supportor support through the equipment dealer (making our globalsupport infrastructure limitless).Our goal is to ensure maximum equipment availability andcontinued safety for operators in hazardous areas. We advisethree steps to ensure ongoing safety:1. Maintenance should be performed by trained technicians2. Follow maintenance schedules defined by the manufacturer3. Undertake an annual audit (now a legal requirement inthe EU) known as the EX-ASAPyroban supplies all replacement parts required to keep yourexplosion proof equipment functional and up to standard.Parts can be shipped quickly from Pyroban locations acrossthe world or directly from Pyroban’s global parts distributioncentre in the UK. These include:• Alternators• Batteries• Flame arrestors• Starter Motors• Shut-off Valves (SVH)• Spark Arrestors• Switches and sensors• Interface PCAs

ABOUT PYROBANIn 1969, the Pyroban brand was born from the developmentof a safety valve to prevent a repeat explosion after a majorincident at a chemical factory in the UK.Today, Pyroban has grown to become an internationalgroup of brands trusted to provide safety for some of theworld’s biggest consumer and business brands.Pyroban Group businesses help prevent explosions in a widerange of manufacturing and logistics operations, mines andoil and gas installations through hazardous area consulting,components, systems, solutions and training.Pyroban also provides a range of environmentaltechnologies to help businesses control their exhaustemissions to improve the air quality for workers and reducetheir carbon footprint.Global CoveragePyroban has proven experience reaching global markets,ensuring a support network in every continent.Pyroban offers a premium customer service experiencefrom an initial enquiry through to the supply and support ofa product or service.Pyroban manages the risk by being close to customers,ensuring the very best levels of support from staff andbusiness processes across the world.Pyroban BrandsPyroban Group Ltd is an international group of companiesdelivering through the following brands.EnvirosafeProtecting people, their investment and our environmentinfo@pyroban.comwww.pyroban.comOCTOBER 2012, ENGLAND