1. Atlas Copco Serving the Oil & Gas industry
In this presentation I like to focus on the the oil & gas Industry what is a great potential for future business and where we today have the product portfolio and the competences available to penetrate deaper in this market.
In a first part I will present a market survey of how the market is organised and what the market channels are for the part what has a lot of opportunities.
As a specific opportunity we see the sales of Zone 2 equipment, I will briefly explain what Zone 2 comprehend. Then I want to walk through the todays available product portfolio concluding in a clear vision of the
Division what we want to be in the oil and gas industry.
As the oil & gas market often requests specialized or customized equipment, a dedicated, flexible and versatile design & manufacturing team is required and this will be offered by AC Hurricane.
PRODUCT PRESENTATION – ZoneAir XATS 1020
August 2010
Koen Verleyen

2. Introducing the ZoneAir compressor range
Dedicated compressors for hazardous area applications
ATEX certified for Zone 2 area
No mechanical sparks / No electrical sparks / Max surface temp < 200°C
Including Pyroban explosion protection system
Optional Pyroban 3GP gas detection system
Inside DNV offshore container

3. Agenda ATEX directive Rig safe <> Zone 2
ZoneAir XATS Features & benefits
ZoneAir XATS 1020 – Applications
Other ZoneAir equipment

4. ATEX directive Zone classification
ATEX (ATmosphere EXplosive) is a European directive concerning equipment and protective systems intended for use in potentially explosive atmospheres.
Since July 1, 2003, it is compulsory by law to certify explosion-proof equipment according to ATEX 94/9/EC.
The „zones“ represent work areas in which an explosive atmosphere can occur.
Note: in USA & Canada the NEC/CEC codes have different classifications. (Zone 2 = Class 1, Division 2)
No hazard
Safe area (rig safe)
Occasional hazard
Zone 2
ATEX Category 3G
Frequent hazard
Zone 1
ATEX Category 2G
Permanent hazard
Zone 0
ATEX Category 1G

5. ATEX directive Zone classification

6. ATEX directive Zone classification

7. ATEX directive Equipment Classification
Equipment Group
Group I = mining / Group II = non-mining
Category from Group II
Cat 3 / Cat 2 / Cat 1
Explosion material Group
G = gas / D = dust
Explosion sub-group
IIa / IIb / IIc
Temperature Class
T1 / T2 / T3 / T4 / T5 / T6
Identification for Zone 2 compressors:
II 3G IIa T3
CE label
Notifying body (eg Sira = 0518)
Explosion protection symbol

8. ATEX directive Classification
Explosion groups: gases & vapors in 3 groups IIa, IIb, IIc equipment for IIc can be used for IIb and IIa
Temperature class: max equipment surface temperature T6 equipment can be used for T5-T1

9. ATEX directive What changes needed on our equipment?
For Category 3G equipment
Technical file
Avoid / isolate mechanical sparks (anti static hoses, fans, flame arrestors…)
Avoid / isolate electrical sparks (eg increased safety components)
Limit surface temp to <200°C (extra cooling)

10. ATEX directive Protection concepts (EN60079)
This refers to principles which are suitable for preventing ignition sources in systems, devices and components.

11. ATEX directive Protection concepts (EN60079) - examples
Control panel

12. ATEX directive Protection concepts (EN60079) - examples
Emergency stop
Battery

13. ATEX directive Also the customer has a responsability !
Compliancy with ATEX 99/92/EC: minimum requirements for improving the safety & health of workers potentially at risk from explosive atmospheres.

14. Agenda ATEX directive Rig safe <> Zone 2
ZoneAir XATS Features & benefits
ZoneAir XATS 1020 – Applications
Other ZoneAir equipment

15. Rig safe / Zone 2 compressors differences
No certification / no clear definition
ATEX 94/9/EC certified
for safe area only
for Zone 2 area (occasional explosive hazard)
Standard components
Safe components (ATEX), No ignition sources
Maximum 200°C surface temperature
Standard engine
- Some require mechanical / no electric controls
- Others are OK with electronic Tier 3 / electric controls
ATEX engine
- Including explosion protection kit (flame arrestors, exhaust gas cooler, water cooled manifolds and turbo charger, safe electrics, …)
Optional 3GP gas detection system (replacing the exhaust flame arrestor)
Offshore features: spillage free frame, spark arrestor, over speed valve, pneumatic starter, battery switch, platform shutdown, manual fuel cut-off valve, offshore paint …
Normally inside DNV frame
ATEX certification for zone 2 requires that all electrical equipment iis ATEX certified and that surface temperature not exceeds 200degC or 392degC. To reach this very expensive equipment is required and prices go up from 5-10times a standard unit.
Due to this often less specified units that only partly comply with ATEX are developed and call rigsafe or safezone. The specification is defined by the suppliers. As we look into the market there are mainly Zone2 portable compressors from IR build in 1980’s and continuously refurbished.
Note: Coates Offshore has defined a “safezone” compressor – similar to rig safe but with a marine engine for lower surface T, compared to industrial engine / no certification / only for safe area.

16. Atlas Copco rig safe equipment
DrillAir range - TwinAir offshore - others models on request
B18-62/2175 booster offshore - other models on request
NOTE: please specify exactly the requried features, because customers have different view on rig safe specification

17. Agenda ATEX directive Rig safe <> Zone 2
ZoneAir XATS Features & benefits
ZoneAir XATS 1020 – Applications
Other ZoneAir equipment

18. Atlas Copco ZoneAir XATS 1020
Model : ZoneAir XATS 1020
ATEX 94/9/EC certified for Zone 2
Powered by Cummins QSM 11 engine (Tier 3)
15 ft DNV container
FAD
Pressure
1020 cfm / 29 m3/min
150 psi / bar

19. Specifications ATEX 94/9/EC certified for Group II Cat 3 IIa T3
Fully CE compliant compressor
DNV certified 15ft container + certified slings
3-layer offshore paint (epoxy, polyurethane)
Sound attenuated (OND compliant)
Cummins QSM 11 Tier 3 engine (500 hp)
Pyroban explosion protection system
Pneumatic starter with air reservoir
Pyroban 3GP gas detection system (option)
Stainless steel fueltank for 8 hours operation (option)
External fuel tank connections
SS braided fuel lines
Manual fuel cut-off valve

20. Specifications (2)
Atlas Copco C190 element with auto regulating system & separator tank
Aftercooler + waterseparator and auto drain system
Internal Lighting
Stackable for transport and operation
Separate air inlet duct for cooler air
Spillage free subframe (110% bonded) – can slide out for repair and maintenance jobs
Forklift slots
Stainless Steel hardware
Marine cable transfer point
Central drains

21. Specifications (3) Anti-static fans and belts
Teflon coated Aluminum coolers
Earthing point
ATEX control panel with SS lockable cover
2 horns and flasher lights
2 E-stops on opposite sides
Emergency Platform Shutdown ESD
Ambient conditions -10°C - +50°C
All technical documentation, certificates, manuals, drawings

22. Engine Cummins ATEX engine QSM11 Tier 3 compliant engine
Power: 500 hp, de-rated to 352 hp (262 kW) for ATEX application
6-cylinder with 10.8-litre displacement
Pneumatic starter with air reservoir for +3 start attempts
Shutdown on overspeed, low oil pressure, high water temp, gas detection
Pyroban kit included

23. Pyroban explosion protection
    
Inlet Shutdown valve | shuts engine down if engine overspeeds. Also contains integral inlet flame arrester.
Water cooled exhaust gas cooler | limits surface and exhaust temperatures to the specified temperature class.
Water cooled exhaust flexible | Maintains temperature Class whilst insulating engine vibration / movement
Spark arrester | Stops hot carbon particles exiting the system
Crankcase / Airbox breather |
Pyroban EExd flameproof alternator |
Pyroban EExe increased safety battery |
Exhaust Flame arrester | heavy, maintenance intensive component used to prevent flames reaching atmosphere from the exhaust system
Option 3GP | gas detection system (eliminates exhaust flame arresters)

24. Pyroban engine components
Exhaust temp switch
195°C set point
Easily re-calibrated
Simple functionality test
Volt free N/C contact
Opens on rising temperature
M20 gland entry
½ inch NPT thread fitting
Water temp switch
100°C set point
Easily re-calibrated
Simple functionality test
Volt free N/C contact
Opens on rising temperature
M20 gland entry
½ inch NPT thread fitting

25. Pyroban engine components
Oil pressure switch
0.8 bar falling set point
Easily re-calibrated
Simple functionality test
Volt free N/O contact
Closes on rising pressure
M20 gland entry
1/4 inch NPT thread fitting
Speed sensor
Magnetic flywheel pick up
Supplied with connector and lead
Covered under 3GP system cert
5/8-18UNF thread
Supplied with 5/8 to 3/4-16 UNF adapter

26. Solenoid control valve
Pyroban engine components
E-stop switch
ATEX certified EEx de
Volt free contacts
N/C
Open to shutdown
Panel mount
Supplied as standard
Solenoid control valve
ATEX certified EEx d
12V and 24V dc versions
M20 gland entry
¼ inch NPT pipe fittings
Controls air intake flap
Controls fuel ram
Universal port configuration
Suitable for gaseous and liquid media

27. Pyroban engine components
Pyroban ESB battery
ATEX/ EC Ex certified Ex de
12V 110AHr or 24V 55AHr
Deep discharge
AGM (absorbed glass matt) cell construction
Integral battery isolator
Stainless Steel 316
Supplied fully charged / Suitable for air freight
Alternator
ATEX/IECEx certified Exd
12V 45A DC or 24V 16A DC or 24V 25A DC
Supplied with 4m or 8m cable
Min 2000 RPM, Max 8000 RPM

28. Pneumatic starter Model: Jetstream from IPU
Pre-engaged air starter eliminates the possibility of sparks.
Air reservoir inside container, external filling point + internal re-fill when compressor is running

29. Engine Surface temp + exhaust gas temp < 200°C
Confirmed by thermal tests

30. Fuel system Stainless steel fueltank for +8 hrs operation at full load
External fuel supply (3-way valve) for bulk tank connection
Manual fuel cut-off valve
Mechanical fuel gauge in fueltank (level indication)

31. Fuel system Fuel pre-filter 30 micron + water separator
Cummins fuel filter
Stainless Steel braided fuel lines

32. Compressor New AC C190 element
Same components as the standard XATS 456 / XATS 950
Best in class performance and efficiency

33. Control system
Ex d (flame proof) box with digital controller Xc2002 ATEX + Intrinsic Safe barriers
Ex e (increased safety) box with remote push buttons + analogue gauges for vessel pressure & discharge temperature.
3GP display of gas detection system (option)
2 E-stops on opposite corners

34. Control system Intrinsic safe transmitters (ATEX approved)
Regulating p / vessel p / air discharge p
Element T / air discharge T
oil stop valve p sensor
Fuel level switch (low level warning)

35. Control system 2 ATEX horns and flash lights on opposite corners
active at safety shutdown

36. Customer connections Marine cable transfer point
Water proof entrance for external power supply (ESD and internal lights)
Filling point for air reservoir (6-12 bar air pressure)
2 “ air discharge (will become 2* 2” + 2* ¾”)
After cooler drain + water separator drain (auto + manual override)

37. Cooling system
Cold air in from long sides / hot air out from short sides
Engine cooling with direct fan drive (2-pump – 2-loop system)
Compressor cooling with hydraulic fan drive

38. Oil reservoir for hydraulic fan drive
Cooling system
Oil reservoir for hydraulic fan drive

39. Cooling system
Cummins 2-pump – 2-loop system: the extra low temp cooler loop is necessary to meet the Tier 3 emission levels while improving engine performance and efficiency.
ENGINE COOLERS
COMPRESSOR COOLERS
Driver therm.
90°C
Passenger therm.
60°C
Pump
Plenum / Collector
Exhaust heat exchanger IC
Cummins
Outer
Rad.
Inner
C190
After
cooler
Hydraulics
Oil E6 E5 E8
Engine
pump

40. Central drains
Drain liquids fast and efficient

41. Exhaust muffler
Including spark arrestor
Heat wrap will be installed

42. Pyroban exhaust gas cooler
Will be placed horizontally underneath engine on ASR Unit 2

43. Sub frame
Slide out the sub frame for major repair jobs

44. General overview Horn + flashlight Control Panel Emergency stop
Fuel pre-filters
Central drains
3GP system + calibration bottles
Battery + isolation switch
Hydraulic oil tank for fan drive
Fuel tank
Fuel fill neck + manual cut-off valve

45. General overview (2) Air reservoir for air starter
Compressor oil filters
Air filters

46. Pyroban 3GP gas detection (optional)
Pro-active gas detection system with forced gas calibration
Full ATEX 94/9/EC compliance
Provides redundant safety shutdown system (essential to 94/9/EC compliance)
Extra I/O’s for customized control and monitoring
Replace the exhaust flame traps
Reduce offshore maintenance and guarantee longer uptime (no 8-24 hr maintenance intervals)
Reduce engine back pressure and therefore increase life expectancy
No solvent disposal, better for environment

47. Pyroban 3GP gas detection (optional)

48. Calibration gas bottle
Pyroban 3GP gas detection (optional)
Main Enclosure
Gas Sensing Head
Houses main electronics
IP68 stainless steel 316
Din rail assembly
EEx n certified (non-sparking)
Integral gas test on start up
IP54 stainless steel 316
Gore Tex gas path
Pellistor based sensing technology
Calibration gas bottle
User Display
Integral low bottle pressure switch (15 bar)
1 bar output pressure
2 litre 200 bar bottle contents
Available worldwide
0.5% propane in air (25% of LEL Propane)
Non flammable, non toxic, non asphyxiant.
IP66 stainless steel
Override & set up functions under flap
Clear, wide temperature range display

49. ZoneAir 3D tool – features & benefits
Learn about the top 15 features & benefits
Available on

50. Agenda ATEX directive Rig safe <> Zone 2
ZoneAir XATS Features & benefits
ZoneAir XATS 1020 – Applications
Other ZoneAir equipment

51. Field de-commissioning
ZoneAir applications
Offshore life cycle
Field exploration
Field development
Field Production
Field de-commissioning
UBD drilling
Cuttings handling
Well testing
UBD drilling
Pipeline testing, de-watering, dyring
Fracturing
Gas lifting
sandblasting
Painting
Fracturing
Gas lifting
Inert gas blanketing
Cleaning
Dismantling
Disposal

52. Well testing (gas flairing)
Explore financial viability of the well:
By analysing oil content, gas content, water content, mud/sand content
By analysing pressure (stable or drop)
Equipment is able to:
Quickly control pressure & flow rate at the surface
Separate the resulting effluent into 3 separate fluids (Gas, oil & water).
Collect samples
Disposal of resulting waste fluids/gases in an environmentally sound manner.
Excess gases are burnt off using compressed air to accelerate the flow = GAS FLAIRING

53. Well testing: typical rental package
compressor 2,200 – 4, bar >> gas flairing + pneumatic controls
Saturated steam generator 4.5 MBTU 10 bar >> raise effluent temp, reduce viscosity for better separation
Sand Filters
Heat exchangers
2 operators (1 per shift)

54. Sandblasting & painting
Maintenance on offshore rigs or FPSO vessels require rig safe or Zone 2 equipment.
XATS 1020 delivers air for typically 3 nozzles.

55. Drilling waste management
Development wells will be drilled to tap into the underlying hydrocarbons
Large quantities of waste materials including drill cuttings and lubricating fluid (drilling mud) must be dealt with, depending on regional legislation
Methods of disposing vary from region to region, and range from discharging directly into the sea (frequently used offshore Asia Pacific) to storing waste in silos for shipping onshore and safe disposal
Air compression systems are used in order to facilitate the transportation of drill cuttings, through processing equipment and into silos for offloading
Rig safe compressors are typically used as they do not need to be positioned in the hazardous areas, although some North Sea customers prefer to use Zone II as a best practice measure due to the added safety benefits

56. Drilling waste management
Different types of MUDS can be used:
Oil based muds (OBM)
Water based muds (WBM)
Synthetic based Muds (SBM)

57. Underbalanced drilling (UBD)
Procedure used to drill oil and gas wells where the pressure in the wellbore is kept lower than the fluid pressure in the formation being drilled. As the well is being drilled, formation fluid flows into the wellbore and up to the surface

58. N2 / O/G
Gas lifting
N2 / O/G N2
Inert gas is injected into the drilling mud to reduce its its hydrostatic force throughout the well depth.
This gas is commonly nitrogen, but air, CO2, processed gas and natural gas are alternatives
Advantages:
Avoid formation damages
Increase rate of penetration
Avoid differential sticking (drill pipe stuck to the wall)
O/G
O/G
O/G
O/G

59. Pipeline Services Pipeline services Cleaning Dewatering Drying
Inspection
Coating
Corrosion
Mechanical
Wiping Pigs
Cracks
Leakages
Coating pig
De-watering
Pigs
Cleaning Pigs
Deformations
Temperatures
Abrasive
Flushing

60. ZoneAir applications: typical customers

61. Agenda ATEX directive Rig safe <> Zone 2
ZoneAir XATS Features & benefits
ZoneAir XATS 1020 – Applications
Other ZoneAir equipment

62. Other ZoneAir equipment
Other Zone 2 certified equipment available on demand
Examples:
ZoneAir PB32XRVO1550 compressor bar
5 units ordered driven by CAT C32 ATEX
ZoneAir XAHS 375 compressor bar inquiries only driven by Iveco 7675si ATEX
ZoneAir PB9-64/5000 booster bar 4 units ordered driven by CAT C9 ATEX

63. PB32XRVO1550 Zone 2 compressor 1550 cfm / 365 psi

64. ZoneAir XAHS375 ATEX certified Inside 10 ft DNV container
Driven by mechanical ATEX engine Iveco 7675si
All mechanical control system (Sentinel)
No electrics

65. PB9-64/5000 Zone 2 booster 750 cfm / 5000 psi

66. We are committed to your superior productivity through interaction and innovation.

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