Commissioning support for API pump skids powered by explosion proof Cat C32 engines and Pyroban Ex SCS

Three new Pyroban protected Cat® C32 engines featuring Ex SCS control systems have recently been commissioned by Pyroban onboard an FPSO (Floating production storage and offloading) destined for Brazil.

These dual certified ATEX / IECEx  prime movers  are rated for continuous duty in Zone 2 hazardous area operations. The engines have been converted using “explosion proof” Pyroban kits in combination with Pyroban’s Ex SCS engine control system as part of a total Ex solution powering the pumps.

Ex SCS combines EN1834-1:2000 safety shutdown with diesel engine control and monitoring and means the powerpacks do not need exhaust flame arrestors, eliminating daily cleaning requirements.

In this case, the Ex SCS application also includes driven equipment parameters such as mechanical seal system operating pressures, gearbox and pump vibration, gearbox oil temperature and pressure, diesel day tank level, suction and discharge pressure. In the picture Pyroban Engineer Martyn Ballinger is onboard the FPSO completing the successful commissioning of the PLC’s.

Commissioning support for API pump skids powered by explosion proof Cat C32 engines and Pyroban Ex-SCS

The programming on the Ex SCS units was bespoke for these pump skids and features a unique automatic starting sequence conducting pump safety checks before allowing engine start up.

The ATEX / IECEx engine control system features infrared gas detection and is a 100% stand-alone safety control system for ATEX 2014/34/EU compliance. A safety shutdown is triggered on detection of a flammable gas in the engine air inlet or in the atmosphere, diesel engine over speed, high exhaust gas and coolant temperatures, low oil pressure or if there is a manual emergency stop activation for example.

Commissioning support for API pump skids powered by explosion proof Cat C32 engines and Pyroban Ex-SCS

The EX SCS system was favoured over others due to its 3rd party IECEx certification which allows simple approval to INMETRO codes (for Brazil).

Pyroban invests heavily into IECEx certification with almost all electrical components dual 3rd party certified to ATEX and IECEx. The engines are built in accordance with ATEX and all necessary standards including EN1834-1:2000.

In this photo above, the operator can be seen operating the HMI screen of the EX SCS system. The colour 15” touchscreen HMI displays the current safety status and the diesel engine control and monitoring screens can also be integrated. For example, engine and driven equipment controls and sensor parameters can all be fed into Ex SCS. Viewable under direct sunlight the resistive touch screen is operable with a gloved hand.  Easy to use password protected inspection and test menu pages allow the end user to verify the machine will shutdown during annual audit cycles without removing field devices.

Commissioning support for API pump skids powered by explosion proof Cat C32 engines and Pyroban Ex-SCS

The FPSO is currently in dry docks which made the journey a bit easier for Martyn.

Pyroban engineers have all necessary offshore safety certificates and are ready to support customers in any of the global oil and gas fields offshore as needed.

About the explosion proof engine kits

The explosion proof engine kits or “Pyroban kit” from Pyroban includes an air intake shut-off valveATEX certified spark arrestor, water-cooled turbocharger, exhaust manifold as well as an exhaust gas heat exchanger and other components. With these kits, there is no plate type exhaust flame arrestor typically associated with daily cleaning to unclog the build up of soot from the exhaust system. This is an important feature for applications using Ex SCS as it reduces maintenance costs and gives operators the assurance of ongoing safety through the life of equipment.

Using Ex SCS means there is no reliance on an exhaust flame arrestor being fitted when in operation – which can sometimes be dangerously swapped out for a “dummy”. Manual handling issues also disappear.

Ex SCS is available for ATEX engine packages and Pyroban kits for engine brands such as Caterpillar, Cummins, JCB, Volvo, DDC, MTUPerkins and more. All Pyroban Kits and HazPak packages are designed and manufactured to be robust and reliable in harsh operating conditions and corrosive environments found in the oil and gas industry.

For more information contact our technical sales team on +44 (0) 1273 456800 or