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Founded in 2017, ExRobotics was created to commercially produce robotics technology for use in environments that are potentially explosive, usually in gas and oil production and processing plants.
These facilities are frequently located in remote areas inside challenging environments. Human presence is normally still required for standard inspection work, even in facilities that are mainly unmanned.
The deployment of Ex certified robots (IECEx Zone1 and ATEX) can have a significant positive influence on safety by reducing the field trips of workers, which in turn strongly decreases running costs.
The ExRobotics ExR-1 robot features microphones for sound monitoring, gas detectors for the detection of leaks and cameras for visual inspection. An alarm to the control room is transmitted when a leak has been identified.
The ExR-1 moves through installations and terrains independently and is able to find its way back to its docking station for recharging. This means that inspectors and operators can reduce their trips to dangerous and/or remote areas, greatly enhancing their safety at work.
Our robots are used in the oil and gas industry mainly for first response, fugitive emission and preventative maintenance. The introduction of more stringent fugitive emission regulations and the subsequent opening up of new markets prompted the need for a fixed gas detection instrument that could be incorporated into our remotely operated ExR-1 robot.”
Ian Peerless, Operations Director, ExRobotics
When setting up the robot in this way, it is employed as a first responder and for monitoring at remote locations that are potentially dangerous. The operator is located in a central control facility, where each robot is driven, utilizing its sensors as the ears and eyes of the operator.
When the robot is configured in this way, it is utilized for auditable and continual operations rounds at remote and/or hazardous locations. The robot is installed with microphones for the monitoring of sound and cameras for visual inspection. The robot can autonomously travel between and on inspection premises.
This setup provides optimized emission management as the robot is furnished with various leak-detectors for pre-entry safety checks.
The robot features microphones for sound monitoring, a range of gas detectors for leak detection and cameras for visual inspection. If a leak is identified, it sends an alarm to the control room.
The Ion Science Falco VOC monitor was recommended by a significant player in the oil industry who conducted extensive performance tests and trials at a large refinery where the Falco came out on top. When ExRobotics did testing of its own, we found the PID instrument to be robust and reliable.
Ian Peerless, Operations Director, ExRobotics
Image Credit: Ion Science
Image Credit: Ion Science
Ion Science’s Falco showcases efficient response times and several innovative design features. The ‘typhoon technology’ of the instrument stops condensation from being formed on the sensor, making it ideal for deployment in challenging weather conditions and high humidity.
Simple to use, the Falco’s inherently safe sensor is located externally, which allows efficient and simple servicing where a hot work permit is not required.
The Falco PID features Ion Science’s patented Fence Electrode Technology which protects against contamination and removes the impact of airborne humidity.
This advanced capability supports total accuracy and reliability in the field while reducing drift problems and extending run time. The Falco range includes eight models providing detection ranges as high as 0 – 3000 ppm or as low as 0 - 10 ppm with parts per billion (ppb) sensitivity.
The Falco’s external sensor is certified to EX ib IIC T4 Gb II, and its explosion and flame proof enclosure is certified to EX d IIC T4 II.
A 4 – 20 mA analog output allows the Falco to be simply integrated into a DCS control system to manage or provide warnings of high VOC levels in the workplace. It can be connected remotely, thanks to the two relay outputs.
An RS485 output with Modbus protocol is also provided as standard, which enhances network connectivity.
The Operations Director at ExRobotics, Ian Peerless, stated, “So far, feedback from customers using the ExR-1 gas detection robot with Falco PID has been very good. It has fulfilled the urgent need for a remotely operated VOC monitor in line with the tightening of fugitive emission regulations.”
The key advantages of the Falco PID are flexibility of communication channels, adequate power requirements and importantly, certification. ExRobotics supply the only Ex robot for this kind of application so it was vital the instrument was accredited for use in hazardous zones and atmospheres. Importantly, the Falco is also able to detect those VOCs commonly found in the oil industry and offers high sensitivity to a broad range of gases.
Ian Peerless, Operations Director, ExRobotics
“It is still early days for the ExR-1 gas detection robot as it is an emerging market and an entirely new concept. However, many oil majors currently have them on test making it highly likely we will purchase more Ion Science’s Falco fixed PIDs going forward. We are also excited about the option of a FalcoTAC instrument as benzene monitoring is becoming a bigger and bigger requirement.”
“ExRobotics is already recommending the Falco to other oil companies. Our robots are used all over the world so end users can see just how good the instrument is. We are also optimistic that there is likely to be a wider use for the ExR-1 gas detection model across the chemical, mining and energy industries.”
“Our relationship with Ion Science is very good and we are happy to work alongside them to explore future joint opportunities.”
The usability of the Falco is realized through its intuitive user interface with an OLED display and five magnetically activated LED switches – down, left, up, enter and right – which are back-lit to confirm the right button has been pressed.
For additional ease of use and convenience, brightly colored amber, red and optional pulsing green status indicators are clearly presented in sunlight, allowing assessments to be carried out from a distance of up to 20 meters.
This information has been sourced, reviewed and adapted from materials provided by Ion Science.
For more information on this source, please visit Ion Science.
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