Custom Solutions for Classified Areas: Pressurized Control System for ISG

Key Features

  • Place: Egypt
  • Client: ISG SpA
  • Year: 2024
  • Total project hours: 900 hours
  • Physical and Serial I/O Points: 200 physical I/O points 600 serial signals (Modbus TCP) to/from ICSS

The Client

ISG S.p.A., a RAM Group company with over 70 years of experience in design and construction of gas and liquid treatment plants, has recently supplied a mechanical refrigeration system for cooling a hydrocarbon stream, as part of a strategic project at a major gas production site in Egypt.

The supply, marked by stringent technical requirements and challenging deadlines, will support the commissioning of a new well cluster, contributing to the expansion of the field’s production capacity.

The challenge

ISG sought a highly qualified system integrator to supply and install a pressurized control panel that would operate in hazardously classified areas (Zone 1, IIA, T3), and capable of ensuring full compliance with strict safety measures for preventing the risk of ignition.

Our solution

We designed a pressurized system (Ex p), a recognized and compliant solution to ensure protection against potentially explosive atmospheres. The system is based on maintaining a positive pressure of inert gas and clean air inside the enclosure to prevent flammable gases, dust, or fibers present in the plant from entering. A key element in guaranteeing the installation’s safety and compliance was the pressurization system’s integrity, which includes enclosure seals, pressure monitoring devices, and the purge and pressurization sequence.

We ensured proper installation in accordance with regulations and standards applicable to the specific classified zone, guaranteeing reliable and safe operation for electrical equipment in explosive environments.

Technical Data

The supply, carried out for hazardous areas Zone 1, IIA, T3, includes:

  • 1 pressurized unit control panel (UCP) Ex p composed of redundant Siemens S7-1500FH CPUs with ET200SP I/Os, Local AVEVA Plant SCADA HMI, Bently Nevada MMS and VFD in Profinet ring
  • 1 Engineering Workstation Laptop  (EWL)
  • 1 local distribution panel (LDP) in Ex db execution for field pumps, compressors and heaters
  • 7 local motor pushbuttons