Custom 10’ explosion-proof paint storage unit for offshore oil & gas sector

Green Box Containers was engaged by Penta Global to design and manufacture a specialised 10-foot explosion-proof paint storage unit for use in a highly hazardous offshore environment for ADNOC. The client required a solution that complied with Zone 2 hazardous area standards to ensure the safe storage of flammable paint materials on the offshore platform.

Client Requirements

The client outlined a clear set of requirements to ensure the unit complied with ADNOC’s safety and operational standards:

• Compliance with ATEX Zone 2 standards for hazardous environments
• Safe and secure enclosure for storing flammable and hazardous paint materials
• Integration of explosion-proof electrical fittings, fire alarm, and fire suppression systems
• Inclusion of a UPS system, despite the challenge of sourcing explosion-proof variants
• Full documentation and technical validation prior to production

Challenges

• Sourcing Explosion-Proof Components: All electrical fittings had to be imported from Europe, which required us to manage extended lead times and deliver within the project duration.
• Fire Safety Systems: Identifying suitable fire alarm, suppression systems that met offshore safety standards, and approved vendors to supply these systems.
• UPS Integration: The client requested a UPS system, but explosion-proof models were unavailable within the project duration.
• Restricted Offshore Access: Posed a challenge to validate performance and compliance of project equipment and solution.

Solutions

• Sourcing Explosion-Proof Components: Despite extended procurement timelines, Green Box ensured timely sourcing and integration of all explosion-proof electrical fittings.
• Fire Safety Systems: Certified vendors were engaged to supply fire alarm and suppression systems that fully met offshore safety requirements.
• UPS Integration: To address the UPS challenge, Green Box proposed alternative safety measures that achieved the intended operational requirements without compromising safety.
• Restricted Offshore Access: A comprehensive pre-dispatch inspection was conducted in coordination with the client and ADNOC to validate performance and compliance.

Execution and Outcome

• Detailed drawings, specifications, and technical documentation were submitted and approved prior to production.
• The unit was manufactured and completed on schedule, with final inspection conducted at Green Box’s facility.
• Although the inspection and pickup process took longer than expected, the client expressed high satisfaction with the quality and performance of the unit.
• The client indicated future demand for similar units, validating the success of this first-time explosion-proof project.

Key Features and Benefits

The unit was equipped with a range of specialised features to ensure safe, compliant, and reliable offshore operation.

• Explosion-Proof Construction: Engineered to contain and prevent the ignition of flammable materials.
• Fire-Resistant Materials: Built with certified non-combustible materials to minimise fire risk.
• Advanced Ventilation: Designed to control flammable vapours and maintain safe internal conditions.
• Spill Containment: Integrated systems prevent environmental contamination.
• Weatherproof Design: Suitable for harsh offshore conditions including extreme temperatures and humidity.
• Fire Suppression Systems: Equipped with certified systems for rapid response in case of fire.
• Electrical Safety: All fixtures and wiring are explosion-proof to ensure operational reliability.