Rob Double states “Some diesel powered well service equipment sent offshore has limited protection, exposing the rig to an increased risk of explosion.”
Pyroban has developed kits for all types of engines from various engine manufacturers. Numerous explosion proof solutions for both electronic and mechanical engines spanning 15 bhp to 3500 bhp have already been developed and are available in a comprehensive kit format from Pyroban.

A typical Pyroban diesel engine solution includes an exhaust gas cooler, a shutdown valve to prevent engine overspeed and flame from the inlet, flame and spark arrestors, safety solutions for all electrics, a safe turbocharger and other safety critical components. An alternator, battery and radiator can also be added to the kit. A radiator manufactured by Broadland Radiators, a Pyroban Group Company, will be on display.

Equipment is delivered fully documented, warranted and with global service and parts support and the kits can be fitted by the equipment OEM.

Since 1999, as a direct result of ever tightening emission legislation, diesel engine technology has migrated towards electronic engine management systems making them more complex than the typical mechanical engines seen historically in the oilfield.

Pyroban has developed two main options for the control system of electronically controlled engines, one with gas detection and one without.

Pyroban’s new system, PCS 2™ will be launched at OTC 2012 and will be shown for the first time in a visual display that incorporates animation.

“This is the first time we are showing the PCS 2™ control system” says Rob Double. “It is ATEX 94/9/EC and IECEx certified for use all over the world.”
PCS 2™ can be used on any electronically controlled engine where gas detection is not required and it has five key shutdown features. In the event of engine overspeed, typically at about 2,300rpm, a switch triggers both the fuel shut-off and the Pyroban air intake shutdown valve to ensure that the engine shuts down. If the exhaust gas temperatures reach 195ºC, the water temperature reaches 105ºC or the oil pressure drops, the fuel is shut-off bringing the engine to a controlled stop. In emergency situations there is also an emergency stop that stops the fuel and triggers the air intake shutdown valve.

Visitors can also discuss Pyroban’s 3GP™, an alternate system for electronic engines that incorporates gas detection. 3GP™ is the control system that helps reduce downtime by eliminating the need for an exhaust flame arrestor, an essential component on the typical explosion proof diesel engine package.

Explosion proof diesel engine packages

One of the main features on the Pyroban stand at OTC will be the explosion proof diesel engine with tri-certification for use around the world. The engine has ATEX 94/9/EC, IECEx and NEC 505 certification, for use in Zone 2 (or equivalent) hazardous areas.

Pyroban has now broadened its offering to satisfy the demand for customers that require a complete explosion proof Powerpack. Custom radiator to flywheel or radiator to transmission Zone 2 Powerpacks are available from Pyroban that are fully certified in accordance with local requirements such as ATEX, IECEx or Class1 Div 2, and delivered fully documented and warranted.

At OTC, the Pyroban team will be providing information about the different engine packages available.

Explosion proof solutions
With significant explosion protection engineering experience, Pyroban can develop solutions for almost any type of equipment used in on and offshore applications.
Pyroban develops concepts and prototypes to create innovative solutions to ensure the safety of even the most complex equipment configuration used in hazardous environments offshore.

As engine and well service technology continually progresses, market needs are also changing and Pyroban expects some interesting discussions at OTC as businesses look to find a partner that can support increasingly complex hazardous area engineering challenges.

Explosion protection systems

Visitors to OTC can also discuss the new Flamepack system from Pyroban, a recent finalist in the UK HazardEx awards. Pyroban’s Flamepack is a new concept for the explosion protection of generator sets or pumps used in brown and green field oil and gas installations. Pyroban claims that the new Flamepack upgrade can be installed on to a new or used generator in one month after thorough engineering, and reduces major costs to achieve ATEX 94/9/EC compliance. The Flamepack is predominantly a self-contained, open frame module that sits on top of the generator set container and connects to the diesel engine with limited intervention.

Pyroban also offers a number of explosion protection systems to protect equipment such as forklift trucks, pallet trucks or mobile plant used offshore. Pyroban specialists will be available to discuss these ATEX compliant systems at OTC, which ensure the safe operation of equipment in Zone 1 or Zone 2 hazardous areas.

Pyroban systems are widely used in onshore applications, however when used in the harsh environment offshore, Pyroban offers an additional corrosion proof service. Special coatings are added to forklift trucks, access platforms and specialist cranes, components can be upgraded to high performance materials and areas that can become water traps are sealed. This ensures that the equipment has a prolonged life in the tough offshore environment.

Service and global support

In support, Pyroban has a team of experienced fast response engineers who can be in place offshore quickly with all the necessary medical certificates and survival training, anywhere in the world. The company supports the 24/7/365 nature of the oilfield and related services and is attuned to local requirements with a growing global footprint of manufacturing and service centres.

Specialist Pyroban engineers will also travel to onshore destinations to aid with commissioning, installation, fault finding and hand deliver parts if needed.

Hazardous area training

Pyroban’s training team provides a wide range of explosion prevention training services across the world, either at Pyroban facilities, or at customer locations. The training courses are designed to cut through the science and vast quantity of explosion proof legislation, including standards and guidance, with a flexible learning experience. The courses suit all levels of the oil and gas supply chain including detailed practitioners and engineers.