Content from the zip file C:\Users\danie\OneDrive - Elynox\justrite-project\example-documentation\Q-21699 - Saipem COMP2\Rev 1 Quote Sent\Zero Power Cooler Info.zip:
File: TUV_third-party-test_report.pdf
Report On
Environmental Testing of a Passively Cooled Emergency Tank Shower for Hughes Safety Showers Ltd
COMMERCIAL-IN-CONFIDENCE
Document 75942408 Report 01 Issue 1
July 2018
TÜV SÜD Product Service, Octagon House, Concorde Way, Segensworth North, Fareham, Hampshire, United Kingdom, PO15 5RL Tel: +44 (0) 1489 558100. Website: www.tuv-sud.co.uk
COMMERCIAL-IN-CONFIDENCE
Environmental Testing of a Passively Cooled Emergency Tank Shower for Hughes Safety Showers Ltd
Document 75942408 Report 01 Issue 1
July 2018
Hughes Safety Showers Ltd Whitefield Road Bredbury Stockport Cheshire SK6 2SS
Ian Veal Project Manager
Steve Boddison Authorised Signatory
REPORT ON
PREPARED FOR
PREPARED BY
APPROVED BY
DATED
02 July 2018
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CONTENTS
Section
Page No
1
1.1 1.2 1.3 1.4 1.5
2
2.1
3
3.1
4
4.1
5
5.1
REPORT SUMMARY … 3
Introduction … 4 Brief Summary of Results … 5 Product Information … 6 Deviations from the Standard … 6 Modification Record … 6
TEST DETAILS … 7
Temperature Cycling Test … 8
TEST EQUIPMENT USED … 15
Test Equipment Used … 16
INCIDENT REPORTS … 17
Incident Reports Issued … 18
ACCREDITATION, DISCLAIMERS AND COPYRIGHT … 19
Accreditation, Disclaimers and Copyright … 20
ANNEX A Hughes Safety Showers Ltd - Packing List … A.2
ANNEX B Results Data from Previous Test Completed for Hughes Safety Showers
in July 2017 (Not TÜV SÜD Product Service) … B.2
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SECTION 1
REPORT SUMMARY
Environmental Testing of a Passively Cooled Emergency Tank Shower for Hughes Safety Showers Ltd
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1.1
INTRODUCTION
The information contained in this report is intended to show verification of the Environmental Testing of the Hughes Safety Showers Ltd Passively Cooled Emergency Tank Shower to the requirements of the customer test plan as listed below.
Objective
Manufacturer
Description
To perform climatic testing to check the water contained in the tank shower be maintained between +16°C to +38°C during test (+40°C starting point).
Hughes Safety Showers Ltd
Passively Cooled Emergency Tank Shower
Model Number(s)
EXP-J-14KS/1500 with ZPC Cooler Option
Serial Number(s)
ZPC0001
Number of Samples Tested
One
Test Specification/Issue/Date
Generally, in accordance with EN 60068-2-14:2009 Test Nb
Test Plan/Issue/Date
Order Number Date
Start of Test
Finish of Test
Engineer Name(s)
Related Document(s)
Customer test plan based on ANSI Z358, Clause B6 Delivered Flushing Fluid Temperature and previous temperature cycling test (July 2017)
0000201237 05 April 2018
01 May 2018
09 May 2018
Colin Hedley
Previous test data not from TÜV SÜD Product Service: Refer to Appendix B
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1.2
BRIEF SUMMARY OF RESULTS
A brief summary of the test carried out is shown below.
Section
Test Plan
Clause
Test Description Result
2.1
Customer test plan. Refer to Annex B
Clause B6 Delivered Flushing Fluid Temperature
Temperature Cycling Test
Completed satisfactorily
Satisfactory - No damage or detrimental effects were observed and performance assessments were reported as satisfactory.
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1.3
PRODUCT INFORMATION
1.3.1 Technical Description
The Equipment Under Test (EUT) was a Hughes Safety Showers Ltd passively cooled emergency tank shower as shown in Figure 1.3.1.
Figure 1.3.1 Passively cooled emergency tank shower as delivered located on wooden pallet without the stretch wrap cover
1.3.2 Test Configuration
Unpackaged product filled with 1500 litres water. Customer supplied dimensions: 1580mm (W) x 1430mm (D) x 2600mm (H). Refer to Annex A - Hughes Safety Showers Ltd - Packing List for details.
1.3.3 Modes of Operation
Non-operational.
1.3.4 Monitoring of Performance
N/A.
1.3.5
Performance Criteria N/A.
1.4
1.5
DEVIATIONS FROM THE STANDARD N/A.
MODIFICATION RECORD No modifications were made to the EUT during testing.
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SECTION 2
TEST DETAILS
Environmental Testing of a Passively Cooled Emergency Tank Shower for Hughes Safety Showers Ltd
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2.1
TEMPERATURE CYCLING TEST
2.1.1
Test Plan / Specification Reference
Customer test plan based on excerpt from ANSI Z358, Clause B6 Delivered Flushing Fluid Temperature. Refer to Appendix B Results Data from Previous Test Completed for Hughes Safety Showers in July / August 2017 (not at TÜV SÜD Product Service)
Generally, in accordance with EN 60068-2-14:2009 Test Nb Change of Temperature
2.1.2
Equipment Under Test
Description
Model Number
Serial Number
Passively Cooled Emergency Tank Shower
EXP-J-14KS/1500 with ZPC Cooler Option
ZPC0001
2.1.3
Date of Test
01 May to 9 May 2018
2.1.4
Test Equipment Used
The major items of test equipment used for the above tests are identified in Section 3.1.
2.1.5
Test Method
Install the EUT into the test chamber.
- Check the water temperature is even at +40°C.
- Use the test results chart in Appendix B as the precedented (general) test setup for the
temperature ramps and dwells. Note. This is being used as a baseline because it has been precedented and is reasonable, rather than a diurnal cycle taken from a test specification (which would give different results to those already obtained from a previous test).
Stabilise the chamber for 30 min at +25°C. 4. Adjust the chamber temperature from +25°C to +34°C in 1 hr 34 min. 5. Adjust the chamber temperature from +34°C to +55°C in 6 hrs. 6. Maintain +55°C for a period of 6 hours. 7. Adjust the chamber temperature from +55°C to +34°C in 6 hrs. 8. Maintain +34°C for a period of 6 hours. 9. Repeat steps 6 to 9 so that 5x cycles are completed in total. 10. After the final cycle is completed adjust the chamber temperature to +25°C in 1 hr 34 min. 11. Maintain +25°C indefinitely until EUT is removed from the chamber.
Notes.
The customer has already located 3 off TÜV thermocouples into the EUT. Add two further thermocouples to check the water temperature and local ambient. Connect all thermocouples to a Pico data logger. Customer has installed their own independently logging thermocouples. TÜV can remove the top lid (retained by 4 off screws). This is the filling point. Pump 1500 litres of water into the tank at +40°C. The customer advised the fill level for 1500 litres. This is a depth measured to the surface of
the water from the outside of the tank top between 80mm – 100mm.
There is a side overfill outlet (which can be connected to a drain pipe, if required). The EUT can be moved with a fork lift truck when it is half full (750 l) or full (1500 l).
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This is a non-operational test.
Figure 2.1.1 Passively cooled emergency tank shower located in walk-in chamber
Figure 2.1.2 Top thermocouple (pre-installed by Hughes Safety Showers Ltd)
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Figure 2.1.3 Middle thermocouple (pre-installed by Hughes Safety Showers Ltd)
Figure 2.1.4 Bottom thermocouple (pre-installed by Hughes Safety Showers Ltd)
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Figure 2.1.5 Additional middle thermocouple (installed by TÜV)
Middle T/C (Hughes)
Middle T/C (TÜV)
Top T/C (Hughes)
Bottom T/C (Hughes)
Figure 2.1.6 Additional middle thermocouple (installed by TÜV)
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Figure 2.1.7 Local ambient thermocouple (installed by TÜV)
Figure 2.1.8 Shows the passively cooled emergency tank shower filled with water
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2.1.6
Test Results
The EUT showed no sign of damage or deterioration on completion of the testing. The wooden pallet had deformed during the test. The temperature variation of the chamber and the water in the tank during this test is shown in Figures 2.1.9 and 2.1.10. A final inspection will be performed upon return of the EUT to Hughes Safety Showers Ltd.
Figure 2.1.9 Chamber Temperature Profile
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Figure 2.1.10 Thermocouple Temperature Profile
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SECTION 3
TEST EQUIPMENT USED
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3.1
TEST EQUIPMENT USED
Instrument
Manufacturer
Type No.
TE No.
Cal Period (months)
Calibration Due
Section 2.1 – Temperature Cycling Test
Climatic Chamber
Climatec
Walk-in
Data Logger
Pico Technology Ltd
TC-08
PFA Insulated T/C
TC Limited
Type T
2847
4428
4739
12
12
12
19-Jun-2018
08-Mar-2019
20-Jul-2018
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SECTION 4
INCIDENT REPORTS
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4.1
INCIDENT REPORTS ISSUED
No incident reports were issued during the testing.
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SECTION 5
ACCREDITATION, DISCLAIMERS AND COPYRIGHT
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5.1
ACCREDITATION, DISCLAIMERS AND COPYRIGHT
This report relates only to the actual item/items tested.
Our UKAS Accreditation does not cover opinions and interpretations and any expressed are outside the scope of our UKAS Accreditation.
Results of tests not covered by our UKAS Accreditation Schedule are marked NUA (Not UKAS Accredited).
This report must not be reproduced, except in its entirety, without the written permission of TÜV SÜD Product Service
© 2018 TÜV SÜD Product Service
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ANNEX A
Hughes Safety Showers Ltd Packing List
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Hughes Safety Showers Ltd - Packing List
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ANNEX B
Results Data from Previous Test Completed for Hughes Safety Showers in July / August 2017 (Not TÜV SÜD Product Service)
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Customer supplied test specification: ANSI Z358, Clause B6.
Beng Yang of TUV SUD PSB Singapore found that: “We noticed that appendix B6 basically states that the water needs to be maintained between 16degC to 38degC. There is no mentioning of temperature tolerances, and also no mentioning of test procedures.”
Attached is the raw data of the testing that we carried out. There are images of the extracted graphs that shows the results. Just for info, we used Gemini data loggers for the tests.
Temperature in °C
Average Highest
Lowest
Low Water r o High Water s n External Ambient e S Internal Ambient
35.773 35.82 40.456 36.762
36.36 36.36 54.78 41.35
35.14 35.31 31.06 33.06
Δ of internal and external ambient average 3.694 Δ of high and low water temperature senor average 0.77 Lowest water temperature recorded on 24/07 for both sensors Highest water temperature recorded on 04/08 for both sensors Highest ambient temperature recorded on 19/07 for both sensors Lowest ambient temperature recorded on 7/7 for both sensors
Please note the following in relation to the data attached:
Time the sensors were programmed to UK time UAE was +3 hours ahead Ambient sensors started logging 10 days before the water sensors due to a delay in getting them fitted Internal Ambient Sensor is monitoring ambient temperature inside the tank under the lid Low water sensor is approx. 30CM from the bottom of the tank High water sensor is approx. 30CM from the top of the water level - distributed to ensure any difference in high or low water temps - the difference is +/- 0.077 of a degree on average which is negligible.
The tank was moved 20M and subsequently topped up with 6 litres of water on the 3rd of August after a small loss during movement.
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File: Zero Power Cooler Datasheet.pdf
Hughes Zero Power Cooler®
Designed in collaboration with
TS Chiller ZPC
Award winning cooling option for emergency tank showers to
temper the water within the tank in hot ambient climates, without
the need for power!
EN15154 and ANSI Z358.1-2014 standards state that water
delivered by a safety shower should be tepid. In extreme
hot climates solar radiation can heat water within the tank to
dangerous levels. The Hughes Zero Power Cooler, designed
in collaboration with Celantel, uses the night time ambient
temperature to maintain the daytime temperature of the water,
ensuring the delivery of safe and tepid water.
• Perfect for remote locations, no power or electricity required • Maintenance free - no moving parts means expensive service
options are a thing of the past
• Environmentally friendly • Retrofittable to your existing Hughes tank showers
Specifications
MATERIALS OF CONSTRUCTION
EXTERNAL EXCHANGER
INTERNAL EXCHANGER
COOLANT MEDIUM
SERVICES
POWER RATING
Piping: Copper / Fins: Aluminium / Painting: Cataphoretic coating
Piping: Stainless Steel / Flanges: Stainless Steel
H2O
No power required
LOCATIONS SUITABLE FOR USE
Suitable for use in areas classified as hazardous and non-hazardous
AMBIENT OPERATING TEMPERATURE
WATER TEMPERATURE
Night-time average air temperature + 2C / 36F
MAXIMUM WATER INLET TEMPERATURE
See commissioning time table below
DIMENSIONS & WEIGHT
DIMENSIONS (WxDxH) - cooling unit (Internal and external)
1188mm (46.7in) x 1188mm (46.7in) x 1765mm (69.5in)
DIMENSIONS (WxDxH) - installed on 1500L tank shower
1420mm (55.9in) x 1495mm (58.9in) x 4274mm (168.2in)
Inlet Water Temperature
Commissioning Time - Days
60°C
55°C
50°C
45°C
40°C
3
2
2
1
1
3
2
2
1
1
3
3
2
1
1
4
3
3
2
1
4
4
3
2
1
5
4
3
2
1
6
5
4
3
1
Night Air Temperature
22°C
24°C
26°C
28°C
30°C
32°C
34°C
www.hughes-safety.comProduct Datasheet Hughes Zero Power Cooler®
TS Chiller ZPC
PROJECTION
1
1
A
PROJECTION
2
2
3
4
3
EXTERNAL EXCHANGER
4
5
5
EXTERNAL EXCHANGER
CONNECTING FLANGES FOR INNER PIPEWORK
INSPECTION HATCH
CONNECTING FLANGES FOR INNER PIPEWORK
INSPECTION HATCH
GRP/STAINLESS STEEL SHOWER ROSE
GRP/STAINLESS STEEL SHOWER ROSE
3/4 INCH BSP FEMALE WATER INLET 3/4 INCH BSP FEMALE WATER INLET
EYE/FACEWASH FOUNTAIN WITH LOW PRESSURE DEFFUSERS (OPTIONAL) EYE/FACEWASH FOUNTAIN WITH LOW PRESSURE DEFFUSERS (OPTIONAL)
I
T H G E H T E L N
PICTOGRAM SHOWER /EYE WASH SIGNS
PICTOGRAM SHOWER /EYE WASH SIGNS
SIDE & REAR GRP PANELLING (OPTIONAL) SIDE & REAR GRP PANELLING (OPTIONAL)
1496
1250
1496
1250
0 2 4 1
0 2 4 1
PICTOGRAM SHOWER / EYEWASH SIGN
PICTOGRAM SHOWER / EYEWASH SIGN
GRP TANK SURROUND
GRP TANK SURROUND
4 7 2 4
4 7 2 4
I
T H G E H T E L N
SHOWER TEST HANDLE
SHOWER TEST HANDLE
I
R E T A W 6 4 1 2
6 6 3 1
6 6 3 1
4 HOLES 18 FIXING BOLTS
A
B
C
D
E
F
B
C
D
E
F
7
7
8
8
ISOMETRIC VIEW
ISOMETRIC VIEW
6
GRP INSULATED TANK LID
6
GRP INSULATED INTERNAL EXCHANGER TANK LID
INTERNAL EXCHANGER
DETAIL A SCALE 1 : 15
DETAIL A SCALE 1 : 15
FOIL BACKED POLYURETHANE INSULATION
FOIL BACKED GRP TANK SURROUND POLYURETHANE INSULATION
MEDIUM DENSITY POLYTHENE TANK
GRP TANK SURROUND
MEDIUM DENSITY POLYTHENE TANK
SHOWER CONTROL PANIC BAR
SHOWER CONTROL PANIC BAR
A
B
C
D
E
A
B
C
D
E
ECN #
CHECKED
APPROVED
DATE
1st Rel
ECN #
CHECKED
APPROVED
NS
18/06/2019
DATE
REVISION
1st Rel
NS
18/06/2019
A
REVISION
A
A3
A3
I
R E T A W 6 4 1 2
1-1/4 INCH EYE/FACEWASH FOUNTAIN DRAIN PIPE
1-1/4 INCH EYE/FACEWASH FOUNTAIN DRAIN PIPE
STAINLESS STEEL CHAIN
FOOT PANEL CONTROL (OPTIONAL)
STAINLESS STEEL CHAIN
FOOT PANEL CONTROL (OPTIONAL)
NOTES:
REV
DRAWN
REASON
NOTES:
1500 LITRE CAPACITY TANK IN MEDIUM DENSITY POLYTHENE. ALL TUBING IN UPVC. SUPPORT FRAME AND LEGS MANUFACTURED FROM GALVANISED MILD STEEL HOLLOW SECTION(K), OR STAINLESS STEEL HOLLOW SECTION(KS). TANK LID, TANK JACKET AND SIDE PANELLING IN WHITE GRP
1500 LITRE CAPACITY TANK IN MEDIUM DENSITY POLYTHENE. ALL TUBING IN UPVC. SUPPORT FRAME AND LEGS MANUFACTURED FROM GALVANISED MILD STEEL HOLLOW SECTION(K), OR STAINLESS STEEL HOLLOW SECTION(KS). TANK LID, TANK JACKET AND SIDE PANELLING IN WHITE GRP
Whitefield Road, Bredbury Stockport, Cheshire, SK6 2SS T: +44(0)161-430-6618 F: +44(0)161-430-7928 E: info@hughes-safety-showers.co.uk Whitefield Road, Bredbury Stockport, Cheshire, SK6 2SS T: +44(0)161-430-6618 F: +44(0)161-430-7928 E: info@hughes-safety-showers.co.uk
2
1
DRAWN:
CHECKED:
APPROVED:
MATERIAL:
DRAWN:
CHECKED:
APPROVED:
MATERIAL:
SW
NS
NAME
NS
SW
NS
3
NAME
4 HOLES 18 DATE FIXING BOLTS
NS
17/06/2019
DEBUR AND BREAK SHARP EDGES
DIMENSIONS ARE IN MILLIMETRES UNLESS SPECIFIED OTHERWISE
TOLERANCES LINEAR: ANGULAR:
DEBUR AND BREAK SHARP EDGES 10mm > 1000mm / 5mm < 1000mm DIMENSIONS ARE IN MILLIMETRES 0.5 UNLESS SPECIFIED OTHERWISE
06/09/2016 DATE 18/06/2019
17/06/2019
06/09/2016
18/06/2019
TOLERANCES LINEAR: ANGULAR:
SCALE:1:2 @ A3
10mm > 1000mm / 5mm < 1000mm 0.5
DO NOT SCALE OFF DRAWING
SCALE:1:2 @ A3
FINISH:
1
2
3
DO NOT SCALE OFF DRAWING
A
REV
NS
TITLE:
DRAWN
1st Release
REASON
A
NS
1st Release
TITLE:
FINISH:
EXP-J-14K-1500-ZPC
EXP-J-14K-1500-ZPC
DWG NO.
CLEAN
SHEET 1 OF 1
EXP-J-14K-1500-ZPC-GA
DWG NO.
CLEAN
SHEET 1 OF 1
EXP-J-14K-1500-ZPC-GA
Hughes Safety Showers Ltd, Whitefield Road, Bredbury, Stockport SK6 2SS UK T: +44 (0)161 430 6618 E: sales@hughes-safety.comGeneral Arrangement Drawingwww.hughes-safety.com
File: Zero Power Cooler FAQs.pdf
Frequently Asked Questions
Hughes Zero Power Cooler® for Emergency Tank Showers
As this is the world’s first zero power cooling system you may have some questions.
Some of the most frequently asked are answered here, however if you would like to
discuss anything in more detail please don’t hesitate to contact Hughes on
+44 (0)161 430 6618 or via sales@hughes-safety.com
Why would I choose the Zero Power Cooling System rather than one of the existing chillers? Passive cooling of your emergency tank shower requires no electricity to work; if you have a remote location or area that does not have suitable power then our Zero Power Cooling System is ideal. A table comparing our Flameproof Chiller, Non-Flameproof Chiller and the Zero Power Cooling System can be viewed on our website.
How does it work? During the cooler night-time ambient temperatures, the convection process of the passive cooling system draws heat out of the stored water in the tank and reduces the water temperature to safe working limits. During the daytime, the external exchanger is heated by solar radiation and the coolant no longer circulates. This causes the coolant in the system to stratify, hot water stays to the top and cooler water remains lower down preventing the water in the tank heating up.
In what locations has it been tested? The cooling system has been tested in the UAE during the summer months where temperatures reached up to 55°C during the day and 35°C at night. There are also units currently in use in Saudi Arabia and Oman.
What temperature range will the system maintain? Testing has proven that the unit will maintain a water temperature of 2°C higher than the average night-time temperature. For example, if your average night-time temperature is 32°C in the summer the water in the tank shower will be maintained at or below 34°C. (ANSI Z358.1-2014 stipulates water should be maintained between 16-38°C)
Do you have valid results available to view? TUV, an independent laboratory based in Italy and the UK, have performed extensive tests on the Zero Power Cooling System, a summary of the results can be seen below. A copy of the full TUV test report can be found on our website.
-
Water temperature at start of test
-
Point at which water reaches a safe temperature
-
Daytime temperature level (55°C)
-
Night time temperature level (34°C)
-
Consistent water temperature (+/- 1.5°C)
Frequently Asked Questions
Hughes Zero Power Cooler® for Emergency Tank Showers
How long does it take to cool the water? Please see commissioning time table below:
Inlet Water Temperature
Commissioning Time - Days
60°C
55°C
50°C
45°C
40°C
3
2
2
1
1
3
2
2
1
1
3
3
2
1
1
4
3
3
2
1
4
4
3
2
1
5
4
3
2
1
6
5
4
3
1
Night Air Temperature
22°C
24°C
26°C
28°C
30°C
32°C
34°C
What type of locations is this suitable for? The system is designed for use outdoors and in both hazardous and non-hazardous areas.
Can it be retrofitted to an existing Hughes emergency tank shower? If so, which models? Any of our 1500 litre and 1200 litre emergency tank showers can be retrofitted to accept the cooling system. (EXP-J-14K/1500K; EXP-J-14K/1500KS; EXP-J-14K/1200K; EXP-J-14K/1200KS)
When retrofitting, is it easy for me to install or do you offer an installation service? A retrofit kit and instructions are provided allowing your engineers to fit the Zero Power Cooling System to our emergency tank showers on site. Hughes can offer further support where needed - please contact our sales team for more information.
What are the maintenance requirements? No maintenance is necessary, it is completely sealed and requires no spare parts.
Will it work for my site if the ambient night-time temperature does not drop below 38°C? Will the water available in the day still be tepid? If your location has temperatures consistently above the 38°C average at night, please contact our sales team for the best solution for your requirements.
What are the effects of black bulb temperatures or solar radiation on the cooling system? Where there is direct sunlight and solar radiation in the daytime, the cooling system is designed to benefit from this. There is a positive effect in the daytime in creating hot water at the top of the cooling system (on the external exchanger) as the hot water stratifies leaving the cooler water in the lower (internal) cooling exchanger.
The cooling cycle is not affected since it takes place during the evening/night-time when solar radiation is limited or zero. During the night phase, the temperature differential helps create the flow inside the cooling system to start the cooling process. An example of this can be seen on our website in the ‘How it works’ animation.
Can the cooling system be used where there are higher PPM chlorine levels? Yes, in this instance, the internal stainless steel exchanger can be coated with a chlorinated rubber coating that is suitable for use with safety showers with no risk of contamination of the water in the tank.
Frequently Asked Questions
Hughes Zero Power Cooler® for Emergency Tank Showers
What happens when the shower is tested and potentially hotter water is introduced into the system? Please see the example below. The impact has been calculated based on 150 litres of water (10% of the volume) which equates to 2 minutes of shower use - this is more than what would be used for normal weekly testing.
Using an extreme example where the water temperature is 36°C; in this condition, if 150 litres of the 1500 litre total is replaced with the same quantity of water at 50°C the result will be 36°C + 50 x 0.1 = 36.5°C (remaining within the tepid water requirements). Please also note that this example is during the hottest months, the remainder of the year would allow for lower water temperatures in our tank showers. As such, there are no issues when the testing is performed once a week or if the shower is tested for a longer duration.
What is the lifespan of the cooling system? The cooling system is constructed to specifications where a design life of 20-25 years is required. A 2 year warranty is offered on the system as standard.
What happens when the emergency tank shower is used for the full 15 minutes and needs refilling? Upon any emergency activation of a safety shower, we recommend that the shower is inspected and recommissioned before it is used again. Once the cooler water in the system has been depleted it will need to be replaced with fresh potable water before it can be used again. During the peak summer months, water inlet temperatures can reach above 40°C. where this is the case please refer to the commissioning times matrix on the previous page.
If you require any further information or want to discuss your requirements in more detail please contact Hughes Safety Showers directly on +44 (0)161 430 6618 or via sales@hughes-safety.com
Hughes Safety Showers Ltd, Whitefield Road, Bredbury, Stockport SK6 2SS UK T: +44 (0)161 430 6618 E: sales@hughes-safety.com
File: ZPC Test Site - Saudi Aramco.pdf
TEST SITE: SAUDI ARAMCO - KHURAIS, KSA
INSTALLATION OF 1500L GRAVITY FED EMERGENCY TANK SHOWER WITH ZERO POWER COOLING SYSTEM
- Background
Hughes Safety Showers UK (Hughes) installed and commissioned the world’s first zero power cooling system (ZPC) for emergency tank showers at Saudi Aramco in Khurais, an oil field located 300km Southeast of Riyadh. This site produces 1.5 million barrels of oil per day1. Hughes, a UK based manufacturer of emergency safety showers for over 50 years, were excited to be given the opportunity to collaborate with Saudi Aramco in testing and showcasing the new zero power cooling system for their emergency tank showers.
Emergency tank showers are essential in areas where incoming water feeds are unreliable or suffer from solar radiation that can heat water to levels above the safe limits required to supply emergency safety showers. The internationally recognised ANSI Z358.1 standard stipulates the water supplied to emergency safety showers should be tepid, between 16 C and 38 C. Cooling water within tank showers requires chiller systems to maintain water at a set point no matter where or when they are used. They provide potable water at a safe temperature to ensure no further harm is inflicted upon the casualty on activation of the safety shower.
- Products used in the Saudi Aramco project
• • •
EXP-J-14KS/1500: 1500 litre emergency tank shower with a stainless-steel frame STD-25K: GRP covered eye/face wash unit - installed inside the tank shower ZPC: Integrated Zero Power Cooling system for Hughes tank showers
All products and parts used are suitable for use in hazardous areas.
- Test data logging equipment used
• • •
Tinytag - TGP-4017 (-40 C to +85 C) temperature logger to measure ambient air temperatures Tinytag - TG-4100 AQUATIC 2 (-40 C to +70 C) temperature logger Tinytag data logger reading cables and software to extract the data stored on the sensors
Internal water temperature data logger unit located in the centre of the water tank of the EXP-J-14KS/1500 safety shower. External ambient temperature data logger unit located on the outer casing of the EXP-J-14KS/1500 safety shower.
- Test overview
An emergency tank shower (EXP-J-14KS/1500) fitted with the zero-power cooling system was installed at the Aramco site in Khurais, KSA. The unit was exposed to ambient daytime temperatures exceeding 50 C.
The shower was situated in an area exposed to sunlight from all sides, all day, without any shade. No power was supplied to the unit and there was no water connection to the tank shower.
1500 litres of water was supplied to the tank shower via a hose. The supplied water temperature exceeded 41 C from the site’s water main.
The insulation of the tank system combined with the cooling system maintains water at temperatures below the required limits of ANSI Z358.1 (less than 38 C).
The commissioning period for the tank shower unit (the time needed before the water is at a safe temperature) was expected to be 24-36 hours.
Saudi Aramco permits were obtained, and site personnel were present during the installation of the equipment and the visit to download readings from the test dataloggers.
The products used are all suitable for use in hazardous area or zones – the cooler has no moving or electrical parts.
1 1.5 mbpd production - https://www.arabianindustry.com/oil-gas/news/2018/sep/26/saudi-aramco-will-raise-production-at-khurais-field-to-15mn-bpd-5982678/
Hughes Zero Power Cooler®
Hughes Zero Power Cooler®
1500L Emergency Tank Shower with Hughes Zero Power Cooler®
5. Results
Location: Water inlet temperature at start of test: Peak daytime ambient temperature: Highest night ambient temperature: Maximum allowed water temperature: Time taken before water at a safe temperature: Testing duration: Activation 7.10.18:
Khurais, KSA oil field 41.5 C 54.2 C 33 C 38 C 16 hours 90 days - between July and October 2018 Tank shower activation released a large amount of the water - the remaining water was still maintained
TEST NOTES
NO POWER SUPPLY EMERGENCY TANK SHOWER IN OPEN SPACE 24/7 NO MAINS WATER SUPPLY NO MAINTENANCE OR USER INTERVENTION NEEDED FOR THE TEST
This document is confidential. No part of this document may be disclosed in any manner to a third party without prior consent
6. Working Principle of the Tank Shower and Zero Power Cooling System
EXP-J-14KS/1500 - 1500 litre gravity fed emergency tank shower with a stainless-steel frame
The tank of the EXP-J-14KS/1500 delivers water to the shower using gravity. The tank is located above the shower unit and will exceed the minimum delivery volume and time needed to ensure a thorough decontamination and meet ANSI Z358.1 requirements. The stainless-steel frame is structurally tested to withstand earthquakes and the weight of the water. The tank has insulation as part of its design to help maintain water temperatures. More information on the EXP-J-14KS/1500 can be found in the appendices.
ZPC - Integrated into the emergency tank shower (Patent Pending)
The ZPC cooling system uses internal and external exchangers to cool the water. It works by using lower night-time temperatures and a convection process to transfer heat out of the water tank into the air. The ZPC prevents the tank water from heating in the daytime sun by stratifying the hotter water to the top of the system allowing the cooler water to remain in the tank.
A video showing how the ZPC works can be viewed here: https://youtu.be/NGDQdXeZ4oM
More information on the ZPC can be found in the appendices.
TUV testing
A third party test report from TUV is available highlighting the testing and data of the zero power cooling system.
- Standards and Tepid Water
ANSI Z358.1-2014
ANSI states that tepid, potable water should be used when supplying emergency safety shower and eye/face wash equipment. It defines tepid water as temperatures between 16-38 C (60-100 F).
Tepid water needs to be delivered to the user for 15 minutes to ensure there is adequate showering for the user.
A minimum of: 76 litres per minute are needed for the shower and 12 litres per minute for the eye/face wash unit.
Emergency safety showers should be located so that they can be reached within 10 seconds of the hazard.
- Conclusion
Positive results were gained following the tests at Saudi Aramco’s site in Khurais. The test unit demonstrates the effectiveness of the Zero Power Cooling system when installed on the gravity fed tank shower. After just 16 hours the water temperature inside the tank was at a safe enough level to be used for the emergency safety shower. The peak daytime temperatures of nearly 55 C showed that the test unit was able to withstand the high ambient temperatures of the region. The unit successfully maintained the water temperatures well within the required ANSI Z.358.1 tepid water range for emergency safety showers. This was achieved without the need of a power source making it ideal for any location where there is a requirement for a safety shower.
- Appendices
a) EXP-J-14KS/1500 Datasheet b) Hughes Zero Power Cooler® Datasheet c) TUV Report
Hughes Safety Showers Ltd, Whitefield Road, Bredbury, Stockport SK6 2SS UK T: +44 (0)161 430 6618 E: sales@hughes-safety.com
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