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// EX / ATEX ZONES

Petrochemicals - integration, safety and installation monitoring in Ex zones

A petrochemical installation speaks many languages. Old controllers, new sensors, dozens of protocols, and the dispatcher needs one picture. We collect all signals from the installation and feed them to the control room as a single, coherent data stream. And where there are hydrocarbon vapours in the air, we make sure a spark never occurs.

A 3D animation in four parts. Earthing control: a tanker parks at a fuel storage tank; the earthing cable and the pump stay red until a monitoring unit in an explosion-proof enclosure confirms the earth connection, then the cable, pump and links turn green. Safety and communication: a petrochemical plant with a control room where an operator watches the screens, while ATUT communication stations across the site are networked to the control room and the cloud. A title card for CUKS-7, the central control and monitoring unit. PROFINET: an ATUT unit carries data between the plant installations and the control room.

// Characteristics

A petrochemical installation is kilometres of pipelines, tanks, pumps, compressors, and equipment from different eras that does not want to "talk" to each other. Modbus, Profibus, RS‑485, 4‑20 mA loops, pulse signals. Each device speaks its own language. A dispatcher cannot wait or analyse incomplete data... they have to make decisions quickly!

With knowledge, we combine this into one picture. With experience, we do it safely. The AT‑NODE collects signals from the entire installation, regardless of the protocol, and transmits them to the control room as PROFINET. One stream, one screen, the full status of the installation and devices in real time.

Where there is an explosive atmosphere, standard electronics will not enter. Our mine gas monitoring systems detect the hazard before a human can sense it. Intrinsically safe communication warns the crew. Ex lighting and personnel location tell you who is working in the zone and where.

And when a road tanker pulls up to refuel, the system will not allow the pump to start without reliable earthing. No earth connection, the pump will not start. An electrostatic spark has no way to form.

These are not stand‑alone products. This is a complete arrangement, from signal integration, through gas detection and communication, to earthing control and monitoring. All designed, manufactured, and commissioned by one team.

The threat passes. Life goes on.

// Applications

Our systems

An installation in an Ex zone needs not individual devices, but one coherent arrangement, from data collection to physical safety interlocks. Here are the areas where our systems operate where there is no room for a spark.

01

Signal integration: the entire installation in PROFINET

The AT‑NODE translates every protocol into the one language of the control room.

  • signal collection: RS‑422/485, Modbus, Profibus, 4‑20 mA, pulse signals,
  • conversion to PROFINET and transmission to the control room,
  • the dispatcher sees all data about the installation and devices in one place,
  • an end to dozens of independent systems "speaking their own language".
02

Road tanker earthing control

No reliable earthing - the pump will not start.

  • continuous control of the road tanker's earthing connection during refuelling,
  • pump operation interlock in the absence of correct earthing,
  • protection against electrostatic sparks when pumping fuels,
  • status signalling for the filling point operators.
03

Mine gas monitoring and hazard detection

  • measurement of gas concentrations and explosive atmospheres in installation zones,
  • sensors react before the hazard becomes apparent to a human,
  • automatic safety procedures when thresholds are exceeded,
  • integration of measurements with the visualisation system in the control room.
04

Intrinsically safe communication

  • intrinsically safe telephony and voice communication in hazardous areas,
  • emergency and loudspeaking communication for extensive facilities,
  • reliable communication where standard equipment is unacceptable.
05

Personnel location

  • identification and location of people working in installation zones,
  • real‑time information on who is where,
  • support for evacuation and access control to hazardous areas.
06

Ex lighting

  • intrinsically safe and flameproof LED lighting,
  • lighting for hazardous areas and critical points of the installation,
  • durable light sources for continuous operation in a harsh environment.
// Gallery

Deployments

// Video

Videos

A 3D animation captioned “Safety” and “Communication”: a petrochemical plant with a control room where an operator watches changing screens, while ATUT communication stations across the site are networked to the control room and the cloud. It ends with a title card for CUKS-7, the central control and monitoring unit.

Petrochemicals - Safety and Communication

A 3D animation captioned “PROFINET”: a blue ATUT unit at the centre of an industrial plant sends data along glowing lines between the halls, tanks and cooling tower and the control room and the cloud.

Petrochemicals - PROFINET Transmission