J Barnsley Cranes

Over the years we have worked very closely with J Barnsley Cranes, designing and manufacturing many hazardous area systems for cranes across the globe. With them we have had the opportunity to expand our expertise in the field of hazardous area crane controls and develop revolutionary solutions which we implement frequently into our designs.

Baytown Refinery Expansion Project – Houston, USA (NEC500)

Crane controls for Linde Baytown have been designed to meet the American standards for Class 1 Div 2 zones. Built to the NEC500 American standard these cranes have been built to be used at an ethane cracker at a plant in Baytown.

These cranes are an interesting example of how we have adapted the usual American way of designing control systems to incorporate a more European element. Traditionally American systems would rely on housing terminals in the Exd Chamber, with the other components which control the crane. We have introduced an Exe Chamber to this system which houses these terminals instead.

An important part of a control system is the radio which will control it. There is a large range of hazardous area radio transmitters with multiple features, such as toggle switching, joysticks or push-button commands. These transmitters need receivers which can be mounted in its own enclosure or in the master enclosure. The Baytown radios are an example of when panels have been specifically built to house the receiver.

The components used within the control systems on our cranes will vary from job to job, for example voltages can vary depending on the country in which it will be used. The Linde job for example requires the contactors within the panel to have a coil voltage of 120, whereas Fluor would use a coil voltage of 110. We can design and build not only to the standards for certification but also to suit the customers’ needs and the destination of the crane.

TCO Project – Kazakstahn (IECEx System)

This project has seen a large variety of control systems designed and built; including both hazardous and safe area systems. The explosion proof control systems designed were certified for an area which is IIB T5 to IECEx standards.

When designing any system, we must consider the allowable heat dissipation of a panel, this is dependent on both the size of the panel and the temperature classification which covers the location in which it is to be installed. Our inhouse software allows us to ensure the components within the panels did not exceed the maximum allowable heat dissipation guaranteeing that the systems were designed for safe use in the atmosphere they were being installed.

Due to the unique atmospheric location of these systems including a high ambient temperature of 60°C, special protection has been incorporated into the design of these panels to protect the intrinsically safe circuits of the radio. This design has seen the inclusion of more thermostats being used within the system to cover this larger range of ambient temperature, controlling the shut off of certain components when they reach certain temperatures, ensuring the heat within the panel never exceeds an allowed temperature.

FGP Project – Kazakstahn (ATEX – IIB)

Designed, built and certified to ATEX standards covering locations containing IIB gas group elements, these systems are also a prime example of when extra measures have been taken in the design of the system to ensure the constant control of interior components when temperatures hit either extreme; protecting the enclosure and components in the event of severe heat or severe cold spells.

The percentage of free space within a panel is an important factor we must consider when assessing the size on enclosure which will be required on a project to suit certification. With our inhouse software we can calculate the percentage of free space within a panel and ensure it complies with the standards for that certification. These IIB systems were designed using this software to take into account the required minimum free space allowance of 20% – ensuring the correct size enclosure was selected to house all of the components safely under the certification.

Equinor Mongstad Refinery – Onshore Norway

This is an excellent example of how we have used our inhouse software to ensure our design is safe and suitable for a certification in an IIC hazardous area. The previous systems have all been of the IIB variety, due to the location in which this system was being installed a higher standard of protection needed to be considered when designing for this more potentially hazardous area.

To save space on the crane J Barnsley Cranes opted to incorporate the radio receiver into the design of the main panel and avoid the need for a second panel to house it. Through doing this, they have not only saved the customer space on the crane but also saved them extra costs which would be involved designing and manufacturing a second panel.

As you can see from the pictures of the IIC system, it is uniquely different to the examples previously seen above. The IIC panel is fitted with a circular door which fits into the main structure of the enclosure; this is due to the enclosures having different flame paths which protect the components from the hazardous gases the system is being exposed to.