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May 2013

The coolest cutting-edge technology in the world‌

www.safetytools.no


Our Cold Solutions warm customer relations Taking the heat out of grinding and cutting results in warmer relationships with our customers – and much more. Our EX Certified grinding and cutting tools will also cut your budgets – not only for equipment but also for labor costs, shipping costs and auxiliary costs such as special environment measures. You probably won’t believe us when we say that we can cut a steel pipe or grind a steel surface with little heat and no hot sparks and you can put your hand directly on the worked area one second after we lift our cool tool without getting burned. But you can. Our solutions are cool in all senses of the word and are trusted around the globe. They have been safely used for well over a decade.

Cool because our solutions are developed around Heath, Safety and the Environment and allow an end user to complete a full work shift without suffering from the harmful effects of nerve damage from vibration, inhalation of dangerous fumes and the complications of sharp harmful metal fragments. Cool because Safety Tools can be used in just about any situation imaginable. No need to build a habitat and all the associated cost with working in a hot work area because there is no need for a Hot Work Permit. Imagine the savings. Cool because you save time – your time, your client’s time and your employee’s time. That translates as cost savings – and it’s always cool to make savings wherever you can. Please feel free to call us or one of our Exclusive Importers. We’d really appreciate the opportunity to arrange a live demonstration at your convenience – that would be cool.

Cool because our solutions enable cold grinding and cutting – without a shower of molten metal. Cool because if you do it in the dark the only indication that work is being done will be the low sound.

Reidar Olsen CEO, Safety Tools Allmet


IntroductIon summary

5

around the globe

13

cost benefIts

19

hazardous work areas & safety tools

29

health, safety & the envIronment

35

safety tools cuttIng & GrIndIngsolutIons

39

InnovatIon & qualIt y control

53

traInIng & maIntenance

63


Aker Barents drilling rig - Photo Harald Pettersen - Statoil

”The work went really well with very low noise and very little vibration. We are all in all very satisfied with the tools – we saved about a week’s worth of work.” Bjørn Erik Dahl Aker Offshore Partner, Material Coordinator


Introduction summary Safety Tools Allmet specializes in unique cold work surface preparation and cutting tools. Our equipment follows ATEX guidelines and is safe to use in Ex zones 1 and 2 without a hot work permit. Safety Tools have been safely used around the world for over a decade and offer substantial health safety & environmental benefits.

Introduction / 5


there must be a better way…

6 \ Introduction


Safety Tools Allmet One day in 1986 Reidar Olsen, founder and CEO of Safety Tools, was inspecting a large tank from a fishing vessel that had recently been resurfaced. The tank was riddled with small corrosion points from conventional grinding and welding work that was just completed. Hot sparks had burned through and damaged the new surface. The exposed steel underneath was corroding and the tank needed to be completely resurfaced. Those sparks ignited Reidar’s quest to find a safe, effective way to manage maintenance and surface preparation work in the North Sea.

the Norwegian Offshore sector. This was done following strict ATEX directives and EU standards. The tool was so revolutionary just categorizing it for certification proved a bit difficult - there was no category for it. Safety Tools soon after introduced their Cutting & Weld Seem removal solutions. They were also authorized by the DNV as cold work tools. They have been an important addition to the Safety Tools revolution and are used around the world cutting cost, increasing productivity and making the workplace safer – Not to mention avoiding those costly shutdowns.

He knew, “there must be a better way”. Reidar connected with his old friend and engineer Kaj Sorensen in Denmark. Together they set out to find a new and better way. Many years were spent engineering a cold solution that would be safe & and effective. There were many challenges, but with hard work and persistence they designed a tool that would change the way surface preparation and maintenance is done around the globe. Statoil became very interested in the “cool” concept after a demonstration. They saw so many possibilities and entered Safety Tools into Statoil’s product development program - LUP. Successful testing was done on Gullfaks C platform in the Northsea. Safety Tools Allmet was further on its way to engineering the coolest cutting edge technology in the world.

Tested by experts Safety Tools were independently tested by the leading offshore explosion experts at GexCon (subsidiary of Christian Michelsen). They are known around the globe for their renowned FLACS program - that simulates a highly combustible environment. The test involved grinding and cutting different types of steel over a wide range of heated explosive mixtures. None of the test produced an ignition source strong enough to create combustion or an explosion. No Hot Sparks!

Health Safety and the Environment There are many Health and Safety advantages when using Safety Tools. They include; low vibration, low noise, no toxic fumes released (isocyanides) and no dangerous, sharp fragments.

After years of research & development the first and only Det Norske Veritas (DNV) approved Cold grinding tool of its kind was introduced to

Overview & History / Introduction / 7


Safety Tools grinding tools produce a surface profile comparable to sandblasting giving a strong adhesion level. Just grind and paint. Our cutting tools perform very clean & straight cuts.

Over the past few years Safety Tools has increased its sales and market penetration substantially. Industries using and considering Safety Tools grow every day - as our solutions are introduce to new clients around the globe.

Innovation and quality control

Safety ools offer benefits to:

Safety Tools Allmet owns STA Solutions which is operated independently. STA Solutions oversees Safety Tools product development, quality control and works directly with clients to develop and engineer custom solutions. From a robotic system to a simple adapter - STA Solutions engineers tools that simplify routine tasks. STA solution goal is to enable their clients meet new demands.

Offshore platforms Oil and gas refineries Chemical processing plants Gas pipelines and distribution centers Maritime and shipping Aircraft and railway Bridges

ork smart

Power companies

Companies have changed their workflow integrating Safety Tools further up in the job flow to reduce cost, increase safety and avoid costly shutdowns. When using safety tools many of the hidden cost disappear.

Renewable Military Automotive production Nuclear

Longevity The lifespan of one of our grinding files and disks can exceed 100 times that of a conventional high quality file or disk - All without the Hot Sparks and high heat. Safety Tools files & disks measure 9.7 on the Rockwell scale. This puts their hardness between a synthetic diamond and a natural diamond. It can take up to 24 hour just to cut the patented design of our files during manufacturing.

Applications Today, Safety Tools have expanded beyond just offshore uses. Our equipment is designed to cut the heat and reduce the risk. Safety Tools are used in many different industries.

8 \ Intr

Grain handling and storage

u t

n \ Ov rv w & H t ry

…the list is growing

Let us spark your thoughts and ignite your ideas with our cool tools. They are a safe and effective alternative for your surface maintenance and cutting jobs. Avoid complications and shutdowns – Just get the job done.

ut the heat – cut the risk


Cut the heat – cut the risk Safety Tools continuous goal is to remain the global leader in cold solutions for surface preparation and cold cutting. Always looking ahead and staying on the cutting edge of innovation & technology to meet increasing demands.

Cut the heat – cut the cost

Vision / Introduction / 9


Safety Tools Solutions Categories

Grinding Solutions Cutting Solutions Automated Solutions Air ools Safety Tools are powered by pneumatic tools that are ATEX certified as safe to use in Ex Gas Zones 1/2 and Dust Zones 21/22. our air tools can only be purchased from Safety Tools Allmet or one of our Authorized Importers.

Files & Discs Safety Tools Files & Discs are composed primarily of Tungsten Carbide. There are also special, TOP SECRET elements infused into the composite. The combination of the molecular components and the fabrication give our files and discs hardness between an industrial diamond and a natural diamond. This along with the patented design of the teeth adds longevity and the ability to grind on steel efficiently at slow speeds. The fragments produced after grinding with Safety Tools are easy to clean up, large and blunt. This offers many safety & operational benefits compared to conventional tools. All without HOT SPARKS!

Solutions that we have developed for our customers. We also offer on-demand custom solutions to meet our clients’ specific needs.

water Control Box (Cutting & weld removal) Our Cutting & Weld Seem Solutions utilize a water control box. Our water control boxes are developed by STA Solutions. The water cools our cutting and grinding tools down to a T4 rating. An added benefit is the water lubricates the grinding process and gives our discs a longer lifespan. Safety Tools Cutting & Weld Seam discs can be re-cut between 3–5 times at substantial savings. Our grinding files and disks cannot be re-cut.

Accessories All of our kits come with specially designed accessories that contribute to optimal safety and operation.

raining and Maintenance Proper training and maintenance is critical. Safety Tools conducts ongoing training at our corporate office and at our client’s facilities. We train and certify every Exclusive Importer offering Safety Tools. Along with hands on training, Safety Tools supplies detailed user manuals videos & maintenance material to enable our clients to be more self sufficient.

Grinding & Cutting Solutions

Automation from STA Solutions

Safety Tools has six standardized Grinding Solutions & three standardized Cutting & Weld Removal

All Safety Tools grinding solutions can be further engineered and developed by STA Solutions.

10 \ Intr

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Mad Dog Platform GOM – Photo Hector Maggi - Chevron

“I never imagined in my life time that I would be able to perform the type of work that involves removing steel on an Offshore producing platform without throwing any sparks. These tools have allowed us to take construction to a new era in Safety” Charles Munoz, GIS Project management Group –Gulf of Mexico, MAD DOG Offshore Platform – Chevron


round the globe Customers . . . . . . . . . . . . . . . . 14 Importers . . . . . . . . . . . . . . . . . 16


Cut the heat – cut the cost

Companies that trust Safety Tools cool technology

14 \ Around the globe


Cut the heat – cut the cost

Around the globe / 15


Offices

Safety ools Allmet Straume Næringspark Idrettsveien 113C 5353 Straume Norway Main: + 47 56 32 36 50 sales@safetytools.no info@safetytools.no suport@safetytools.no

  Safety Tools Allmet Corporate Office Exclusive Agents

Australia

Brazil

India

Atom Supply

S A Brazil

OCS Services (I) Pvt. Ltd.

Amit Fernandes

Hector Maggi Santarini

Sandeep Kotnis

137 Pilbara Street Welshpool WA 6106 Office: +61 89351 3600 Mobile: + 61 409 298 870 Email: amit.fernandes@atomsupply.com.au www.atomsupply.com.au

Office: +52 55 5545 1970 Mobile: +52 55 2129 8728 Email: info@safetytools.no www.safetytools.no

407-411 Oberoi Chambers II 645/646 New Link Road Andheri West, Mumbai Office: +91 22 267 43139 Mobile: +91 9870066787 Email: sandeep@nortrans.co.in www.ocsoffshore.com

Belgium

Denmark

Mexico

Dafco

Danbor

Fuji Air ools de Mexico S.A. de C. .

Jan Louagie

Allan Mørup

Hector Maggi Santarini

Kleimoer 7 9030Gent Office: +32 9 374 7150 Mobile: +32 475 86 70 70 Email: info@dafco.be www.dafco.be

Kanalen 1 DK-6700 Esbjerg Office: +45 7911 1966 Mobile: +45 2069 8745 Email: amo@danbor@danbor.com www.danbor.com

Kepler 144 Col. Anzures, C.P. 11590 Mexico D.F. Mexico Office: +52 55 5545 1970 Mobile: +52 55 2129 8728 Email: gnieva@fatcomexico.com www.fatcomexico.com

16 \ ArOunD tHE GLOBE \ StA OFFICES

rev. 07.2012 – please check our website for updated information.


Russia Safety Tools Russia ТРАНСИНСЕРВИС Andrei Nikitin Office: +7 (495) 926-97-24 Mobile: +7 (495) 926-97-25 Email: enterpri@mail.ru www.tuc-sta.ru

nigeria/Ghana

South East Asia

nited Kingdom

rap esources Asia Pacific Pte. Ldt.

A

Group

Perry Sim

Stewart Sim

100 Tras Street 16-01 Amara Corporate Tower Singapore 079027 Office: +65 674 2456 Mobile: +65 8382 9188 Email: admin@wrap.sg www.wrap.sg

Unit 16 Denmore Road Bridge of Don, Aberdeen, 8B23 8JW Office: +44 1224 222767 Mobile: +44 7827 950506 Email: ssim@atrgroup.co.uk www.atrgroup.co.uk

AE

SA

napmantronix & Ciscon Services

OCS Services DMCC

Napoleon Agbelogode

J. Koshy

Hector Maggi

KM 42 Eliju Village Lekki Expressway Ibeju Lekki Lagos, Nigeria Office: +234 803 304 5295 Mobile: +234 805 317 6678 Email: napoleon@napmantronix.com www.napmantronix.com

Office No. 3904; X2 Tower, Jumeira Lake Towers Dubai, UAE Office: +971 6 563 8023 Mobile: +971 50 462 3317 Email: koshy.jose@ocsoffshore.com www.ocsoffshore.com

1110 N Post Oak Road Suite 320 Houston, TX Office: +1 713 686 9400 Mobile: +1 281 755 2685 Email: hmaggi@tft-pneumatic.com www.tft-pneumatic.com

ev. 07.2012 – lease check our website for updated information.

F -Pneumatic, LLC

S A OFFICES / Ar un t

/ 17


“By using ATR Group’s Safety Tools Allmet’s grinding tools, being cold work and ATEX compliant, enabled us to successfully remove all defects while maintaining normal production saving at least a week’s worth of production.” Boris Thomas – CNNS Corrosion Engineer Shell


ost en f ts Benifits . . . . . . . . . . . 21 Real use study . . . . . . . 24 Testimonials . . . . . . . . . . . 26


Pictures above are of Safety Tools Cutting Solutions used on Gullfaks C in the Norwegian Sector of North Sea. Owned by Statoil it produces 250,000 barrels per day.

20 \ Cost benefits


Benefits afety ools goal is to help improve & simplify maintenance procedures and avoid costly accidents & shutdowns. ur old ork ools are backed by I and have been safely used around the globe for over a decade. By minimizing risks and avoiding extra costly equipment Safety Tools offer many benefits and are a solid return on your investment.

Safety tools Benefits: • No need for Hot Work Permit • No demanding Risk Evaluations • No job postponements • No need for Habitats • No need for Fireguards • No Hot Sparks • No dangerous sharp splinters • Low Heat (30C-60C average) • Low Vibration – (2.5 m/s average) • Low Noise (80-85 dB average) • Roughness Profile 40 – 75 micron’s • Disks & Files are harder than an Industrial Diamond – last long

Safety Tools Allmet has helped to save companies a lot of money and increased maintenance productivity and safety.

C

t

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Conventional Tools

Cost (Job 1)

Cost (Job 2)

Cost (Job 3)

X

Tools

Low

Low

Low

1

Job Preparation

High

High

High

2

Risk Evaluations

High

High

High

3

Personnel Hours

High

High

High

4

Clean up

High

High

High

5

HAV Limits

High

High

High

6

Hot Work Permit

High

High

High

7

Habitats

High

High

High

8

Fireguards

High

High

High

9

Surface Damage (Sparks)

High

High

High

10

Production Shutdown

Huge

Huge

Huge

11

Job Delay

High

High

High

12

Health Issues

High

High

High

22 \ Cost benefits


Safety Tools Ex 1 2 3 4 5 6 7 8 9 10 11 12

Cost (Job 1)

Cost (Job 2)

Cost (Job 3)

Tools

High

Low

Low

Job Preparation

Low

Low

Low

Risk Evaluations

Low

Low

Low

Personnel Hours

Low

Low

Low

Clean up

Low

Low

Low

HAV Limits

Low

Low

Low

Hot Work Permit

None

None

None

Habitats

None

None

None

Fireguards

None

None

None

Surface Damage (Sparks)

None

None

None

Production Shutdown

None

None

None

Job Delay

None

None

None

Health Issues

None

None

None

Cost benefits / 23


Real use study Safety Tools Allmet Cut the heat – cut the risk Summary The information below is based on work performed using Safety Tools equipment. The information & work was independently supplied by OCS Services, India. The facility is an FPSO owned by Reliance Industries and operated by Aker Floating Production. The vessel is capable of processing 60,000 b/d of oil and 15 MMcm/d of gas. It has a storage capacity of 1.3 million bbl of oil, and a liquid injection capacity of 80,000 b/d. Production operation continued during the work performed by OCS Services. Job summary Company performing work

OCS Services India Pvt Ltd

Principal client

Aker Floating Production

Type of facility

FPSO Dhirubhai 1

Where

KG Basin, Offshore Kakkinada India

Dates work performed

July 2010 – ongoing

Shutdown production time

Zero

Durability summary File / Disk A-0104 A-0105 A-0107 A-0056 A-0002 A-0003 A-0005 A-0008 A-0008 A-0009b A-0009c A-0010 A-0500

Work hours 1440 1440 2400 2040 360 360 360 1080 760 1680 990 650 1050

Approx. sq. m (Air Tool) (Air Tool) (Air Tool) 1275 40 40 40 440 210 740 395 224 276

Comments

Repaired 2 times (Rough Boy) Still usable Still usable Still usable

Same result 2 times Same result 3 times

Notes Topside maintenance is ongoing in 2012 on the FPSO Dhirubhai 1. * To avoid air tool repairs and gear breakdowns follow the recommended maintenance listed in our User Manuals on page 4 and follow a routine inspection and repair program at least every 1000 hours. 2010 Q4 Aker Floating Production has 100% commercial uptime in 2010 and passes 600 days without LTIs (LostTime Incident). 2011 Q4 Aker Floating Production has 100% commercial uptime in 2011 and passes 900 days without LTIs. The Safety Tools file and disk results above are based on information supplied to Safety Tools Allmet by OCS Services India Pvt Ltd.

24 \ Cost benefits  \ real use study


working statistics / Cost benefits / 25


Testimonials from our customers that have cut the heat – cut the cost. ”The work went really well with very low noise and very little vibration. We are all in all very satisfied with the tools - we saved about a week’s worth of work.” Bjørn Erik Dahl Aker Offshore Partner, Material Coordinator

“By using ATR Group’s Safety Tools Allmet’s grinding tools, being cold work and ATEX compliant, enabled us to successfully remove all defects while maintaining normal production saving at least a week’s worth of production. Boris Thomas – CNNS Corrosion Engineer Shell

“By using Safety Tools Allmet’s Steel Grinding Suitcase we completed the job in half the time conventional methods would have taken. In the process this saved circa £300,000 in costs. ” John Henderson Archer, Project Manager

26 \ Cost benefits


“The cutting system works excellent. We were able to cut out welds attaching equipment in an area… in one shift… without having to shut down the facility. Definitively a quality product and valuable asset. Shell-MARS Offshore Platform, Gulf of Mexico

This technology will also be very important for safety in onshore O&G plays, refineries and just about anywhere else with EX potential. It offers a possibility of doing these jobs with no shutdown or slowdown in production and increased safety for workers and infrastructure. Claudio Paschoa – Petrobras, Maintenance Engineer

“The tools are used almost daily and there is minimal wear on the teeth. I see benefits in getting work done without much delays as I do not require hot work permits. All I require now is a blanket permit for the air compressors and my team can work on the individual lines. There are significant cost savings as we get much faster turnaround.” Shell Eastern Petroleum, Singapore

Cost benefits  / 27


Mongstad refinery – Photo Øyvind Hagen - Statoil

“The Safety Tools grinding tools were tested under anticipated worst case conditions – operation within explosive mixtures of propane and acetylene. It was not found possible to provoke ignition of the explosive mixtures during any of the tests performed.” Geir H. Pedersen, Department Manager Process and Safety, GexCon


azardous work areas & afety ools afety ools are the only tools of their kind that have been safely used in azardous ork environments, around the globe, for over a decade. they are backed by the dnv and certified safe to use without the need of a hot work permit in ex Gas zones 1/2 and Dust zones 21 and 22. ATEX . . . . . . . . . . . . . . . . . . . . . . . . 30 Ex Zones . . . . . . . . . . . . . . . . . . . . . . 31 The Changing International Scene . . . . . . . 32 v


ATEX Currently there are no global standards for work in potentially Hazardous Work Environments. ATEX is an EU directive for work in explosive environments. It has been enforced in EU trade counties since July of 2003. There are many different requirements for working in explosive environments around the world.

established the use of zones in their coding to be compliant with ATEX directives. Countries & Companies around the world are increasingly following ATEX guidelines and Ex zoning when working in potentially explosive work environments.

Many countries publish their own National Standards. ATEX is highly regarded in; Australia, Saudi Arabia, South America & Asia. The US & Canada have a similar systems to ATEX but use divisions instead of zones. Many North American companies have

30 \ Hazardous work areas & Safety Tools \ atex


xplosive atmospheres

O E GAS 0 1 2

Ex Gas Zone In urope, hazardous areas are classified into three zones which are directly related to the predicted occurrence of when and the duration that an explosive atmosphere may be present in the area. hese zones are: O E 0: here an explosive atmosphere is continuously present, or present for long periods of time - ontinuous. O E 1: here an explosive atmosphere is likely to occur in normal operation - Intermittent.

xz n

O E 2: here an explosive atmosphere is not likely to occur in normal operation and if it does occur, it will exist only for a short time - bnormal. hese standards are subdivided into two groups: I and II. roup I is for apparatus to be used in mines where the danger is represented by methane gas and coal dust. roup II is for apparatus to be used in surface industries where the danger is represented by gas and vapor that has been subdivided into three groups: , and .

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Cool grinding.

The Changing International Scene Many countries publish their own National Standards. Some of these standards still exist and others have become superseded. There are differences from country to country in the way in which the standards and certification procedures are implemented. Canada follows the classification of North America; it has close links with the IEC. In Australia, the Standards Association of Australia (SAA) produces National Standards, and offers a certification/approval service by which its main requirements are very similar to the European Standards.

32 \ Hazardous work areas & Safety Tools

There are increasing reciprocal arrangements assuring the acceptance of test results between European bodies and North America and Australia. ATEX is required in Europe, of course, but because many countries follow Europe’s standards, ATEX is being increasingly required across Asia and other regions. Our Ex markings and over a decade of safe use around the world make safety tools the logical choice when you are doing maintenance work, cutting and weld seem removal in Hazardous work areas. Safety Tools can save you valuable time and money and keep your work place safe.


C S

H yT

A

Continuous

ested for misuse

or use in zones 1-2

ll 2 G c 3 ogo equipment group

Gass

ax emp. 200ºC ested for misuse

or use in zones 1-2

ll 2 G c 4 ogo equipment group

Gass

Ty

ax emp. 135ºC

ntermittent

bnormal

CEC/NEC (N. America) Division 1

Division 1

Division 2

IEC/ATEX (EU)

Zone1

Zone 2

Zone 0

the main difference between the north american and the european classification of hazardous locations is that there is currently no direct equivalent to the european zone 0 in the north american system; however, existing standards may be revised to allow an equivalent representation.

ested for misuse

or use in zones 1-2

ll 2 D c 101° ogo equipment group

Dust

ax emp. 101ºC ested for misuse

or use

in zones 1-2

ll 2 D c 185° ogo

equipment group

Dust

Safety Tools are also certified by the DNV as safe to use in dust zones 21 and 22.

ax emp. 185ºC

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Troll B platform – Photo Øyvind Hagen - Statoil

“In my 20 years’ experience, I have never before seen a new tool that has shown such promise, radically improving the HSE situation at offshore facilities. Personally I think it should be mandatory.” Halvor Erikstein, Norwegian Union of Energy Workers (SAFE)


health, safety & the Environment


Safety is our first name Safety Tools offer many health, safety and environmental benefits. Our tools are used around the globe for a variety of reasons. From low vibration – to low noise – to low heat – to no hot sparks… Safety Tools will reduce risk. Our tools produce large blunt fragments that do not spread all over a work site and damage people or equipment. The grinding and cutting fragments drop within a ¼ meter of your work area and are very easy to clean up. Compare this with conventional grinding and cutting equipment that send small sharp dangerous particles all over a worksite and have a long history of damaging people & machines.

36 \ health, safety & the Environment

There has never been a serious injury cased from using safety tools. Since there is little heat produced and no hot sparks using Safety Tools cool technology - there are no dangerous isocyanides generated. Hot conventional surface maintenance tools can release them very quick and cause long-lasting, harmful effects.


Ergonomic design winner Lyon, France 2007

Every time a new HSE / HMS person sees our tools we hear the same thing. “Why aren’t we using these tools?”

“In my 20 years’ experience, I have never before seen a new tool that has shown such promise, radically improving the HSE situation at offshore facilities. Personally I think it should be mandatory.” Halvor Erikstein, Norwegian Union of Energy Workers (SAFE)

“The noise level from Safety Tools’ cutting wheel is so low that I am able to carry out a normal conversation, while cutting through a 4-inch pipe.” Arne Veland, HSEQ Manager, Seawell Engineering

“I believe the introduction of EX-Certified tools that are classified as Cold Work by DNV is a major step forward – for safety, the environment, and the health of all personnel using this class of tools.” Arvid Skines, Main Safety Delegate, for the Statfjord Field

health, safety & the Environment  / 37


“By using Safety Tools Allmet’s Steel Grinding Suitcase we completed the job in half the time conventional methods would have taken. In the process this saved circa £300,000 in costs.” John Henderson Archer, Project Manager

Hot Tap repair - Photo info n/a - Statoil


afety tools cutt ng & r nd ng solut ons Grinding Solutions . . . . . . . . . . . . . . 42 Cutting Solutions . . . . . . . . . . . . . . 49


Safety Tools Grinding Solutions safety tools offer cutting solutions & grinding solutions (surface preparation and maintenance).

40  \  utt n & r n

n


Safety Tools Cutting Solutions ll of our rinding & utting olutions come safely packed in a custom eli case lined with pink anti-static foam and include; ertification, eclaration, ser manual, uality ontrol checklist, neumatic engine diagrams, nalysis for isk report, and of course our x tools and accessories.

  utt n & r n

n   /  41


Grinding Solutions Air ools safety tools are powered by pneumatic tools that are ATEX certified as safe to use in Ex Gas Zones 1/2 and Dust Zones 21/22. our air tools can only be purchased from safety tools allmet or one of our Authorized Importers. safety tools air tools are specially designed to safely operate with our files & discs in potentially hazardous work areas.

he feedback from many of our clients is that our files last hundreds of times longer than a conventional high quality grinding file or disc. he fragments produced after grinding with afety ools are easy to clean up, large and blunt. his offers many safety & operational benefits compared to conventional tools. ll without !

Accessories

Files & discs

ll of our grinding kits come with specially designed afety ools iles & iscs are composed primarily accessories that contribute to optimal safety and of tungsten carbide. here are also secret elements operation. infused into the composite. he combination of the molecular components and the fabrication give our files and discs hardness between an industrial diamond and a natural diamond. he hardness and the design of the teeth increase the longevity of our files and disc.

Certificates from afety ools llmet ested for misuse

or use in zones 1-2

ll2G c 3 ogo equipment group

Gass

ax emp. 200ºC

42  \  utt n & r n

n   \  r n

ested for misuse

or use in zones 1-2

ll2D c 185° ogo equipment group

n

Dust

ax emp. 185ºC


STRAIGHT grinder 3000

Prod.no. A-0107

Speed

Ref. no

3000 rpm

FG-2VX-50

ANGLE GRINDER 2000-8

(g) 894

Air inlet 1/4” NPT

Prod.no. A-0108

Speed

Ref. no

2000 rpm

FAS-1X-50

(g)

Air inlet

842

1/4” NPT

Angle Grinder 2000-4 ROTATING FILE

For STA A-0108

Prod.no. A-0009 C Big boy c

Total length

95mm

Teeth

32mm

(g)

Prod.no. A-0104

Speed

Ref. no

2000 rpm FCD-6X-51 2000

(g) 1700

Air inlet 1/4” NPT

A-0010 Rough boy

Total length

118mm

Teeth

51mm

(g)

ROTATING FILE

340g

826g

For STA A-0107 / 0104

Prod.no. A-0001 Slim

A-0002 Bow cone A-0003 Straight cone A-0004 Little papa A-0005 Round boy A-0006 Al-ti-char

A-0007 Shorty

A-0008 Big papa

A-0009 B Big boy b

Total length

65mm

Teeth

27mm

(g)

76g

Total length

70mm

Teeth

31mm

(g)

114g

Total length

70mm

Teeth

31mm

(g)

ANGLE GRINDER 1000-5

110g

Total length

65mm

Prod.no.

Teeth

27mm

A-0105

(g)

65mm

Teeth

27mm 65mm

Teeth

26mm 57mm

Teeth

17mm 72mm

Teeth

32mm

1/4” NPT

GRINDING DISC for paint FOR STA A-0105

282g

Max 1000 RPM

Total length

95mm

Teeth

32mm

Prod.no.

340g

A-0500

(g)

2400

194g

Total length (g)

FCD-10X-52

Air inlet

78g

Total length (g)

1000 rpm

(g)

168g

Total length (g)

Ref. no

182g

Total length (g)

Speed

(g) 410

Dim Ø 80 mm

Grinding  /  cutting & grinding  /  43


Safety Tools Cold Grinding Solutions Grinding Solutions afety ools has six rinding kits that we have developed over the years for our clients. e also offer on-demand custom tailored options to meet new demands. ll afety ools grinding solutions can be further engineered and developed by olutions. lease see our Innovation & uality control section for more details. 1.

ll round olution with ough boy

2.

ll round olution

3.

teel rinding olution

4.

urface rotection olution

5.

hip wners olution

6.

ough oy olution

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a l l a r o u n D w i t h r o u G h b o y SOLUTION (A-0057) 21 kg ir tools no.

ame

ile no.

ame

Kit size: 54X21X44 cm Disc no.

ame

A-0500

GDP Disc

ccessories

A-0104

Angle 2000 - 4

A-0001

Slim

A-0060

A-0105

Angle 1000 - 5

A-0002

Bow cone

A-0060RB

A-0107

Straight 3000

A-0003

Straight cone

A-0062

A-0108

Angle 2000 - 8

A-0004

Little papa

A-0065

A-0108

Angle 2000 - 8

A-0005

Round boy

A-0068

A-0006

Al-ti-char

A-0068

A-0007

Shorty

A-0068

A-0008

Big papa

A-0068

A-0009B

Big boy b

A-0068

A-0009C

Big boy c

A-0085

A-0010

Rough boy

Safety Tools optimal corrosion and surface maintenance solution.

a l l a r o u n D s o l u t i o n (A-0054) ir tools no.

19 kg

Kit size: 54X21X44 cm

ame

ile no.

ame

Disc no.

ame

A-0500

GDP Disc

ccessories

A-0104

Angle 2000 - 4

A-0001

Slim

A-0105

Angle 1000 - 5

A-0002

Bow cone

A-0060

A-0107

Straight 3000

A-0003

Straight cone

A-0065

A-0108

Angle 2000 - 8

A-0004

Little papa

A-0068

A-0005

Round boy

A-0068

A-0006

Al-ti-char

A-0068

A-0007

Shorty

A-0068

A-0008

Big papa

A-0085

A-0009B

Big boy b

A-0009C

Big boy c

A-0062

Safety Tools second most optimal corrosion and surface maintenance solution.

s t e e l G r in Din G s o lu t io n ir tools no.

(A-0058) ame

13 kg

Kit size: 54X21X44 cm ile no.

ame

Disc no.

ame

ccessories

A-0107

Straight 3000

A-0002

Bow cone

A-0060

A-0108

Angle 2000 - 8

A-0003

Straight cone

A-0062

A-0004

Little papa

A-0068

A-0005

Round boy

A-0068

A-0006

Al-ti-char

A-0085

A-0007

Shorty

A-0008

Big papa

A-0008

Big papa

A-0009C

Big boy c

A-0009C

Big boy c

Developed for contractors to remove corrosion and steel from structures.

Gr n

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su r faC e p rot eC t io n s o lu t io n ir tools no.

(A-0059)

ame

Kit size: 54X21X44 cm

ile no.

ame

17 kg

Disc no.

ame

A-0500

GDP Disc

ccessories

A-0104

Angle 2000 - 4

A-0003

Straight cone

A-0060

A-0105

Angle 1000 - 5

A-0004

Little papa

A-0062

A-0107

Straight 3000

A-0005

Round boy

A-0065

A-0009B

Big boy b

A-0068

A-0009B

Big boy b

A-0068 A-0068 A-0085

Developed for surface protection and maintenance companies as an optimal system for removing paint and corrosion from steel and producing a surface profile that is ready to paint with strong adhesion performance.

ship owners solution

(A-0055)

ir tools no.

Kit size: 54X21X44

ame

ile no.

ame

A-0105

Angle 1000 - 5

A-0003

Straight cone

A-0107

Straight 3000

A-0004

Little papa

A-0005

Round boy

15 kg Disc no.

ame

A-0500

GDP Disc

ccessories A-0062 A-0065 A-0068 A-0068 A-0085

Developed for general corrosion maintenance and surface preparation on boats.

rouGh boy solution

(A-0056)

Kit size: 43X18.5X34.5 cm ir tools no. A-0108

ame Angle 2000 - 8

7 kg ile no. A-0010

ame Rough boy

ccessories A-0060RB A-0082

Developed for general corrosion maintenance and surface preparation on larger surface areas. A replacement for spot blasting.

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Shell petrochemicals plant Singapore – Photo info n/a – Shell

“The tools are used almost daily and there is minimal wear on the teeth. I see benefits in getting work done without much delays as I do not require hot work permits. All I require now is a blanket permit for the air compressors and my team can work on the individual lines. There are significant cost savings as we get much faster turnaround.” Shell Eastern Petroleum, Singapore


Mars Platform GOM – Photo info n/a - Shell

“The cutting system works excellent. We were able to cut out welds attaching equipment in an area… in one shift… without having to shut down the facility. Definitively a quality product and valuable asset. Shell-MARS Offshore Platform, Gulf of Mexico


cutt ng solut ons

MAD DOG Offshore Platform – Chevron GIS Project management Group –Gulf of Mexico


ir ool

ater Control ox

ur utting solutions utilize our -0105 air tool. he addition of the water control box increases the rating of the air tool to a 4. ifferent disc guards are used with our eld seam disc and utting disc. ur utting disc also has additional adapters (chucks). ir tools no. A-0105-T4

ame

ef. no

peed (rpm)

Angle 1000 FCD-10X-52 1000 – 5 (T4)

ir (g) inlet 2400

1/4” NPT

Dis s

afety ools cutting and weld seam disc have the same properties as our rinding files and discs. oth our utting and eld eam discs can be recut an average of 3 times.

Disc no.

ame

Diameter

hickness

(g)

A-0502

Cutting Disc

110mm

5mm

652

A-0503

Weld Removal Disc

110mm

10mm

1420

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nique to our utting solutions is a water control box. he water cools & lubricates our utting & eld emoval olutions to a 4 rating. he purpose of the box is to regulate the flow of air and water.

Key adjustment settings: water Inlet = 4 bar minimum water adJust = 2 – 2.5 bars aIr Inlet = 7.3 bars optimal aIr outlet = 6.3 bar max ll of our utting solutions come with a 5 meter armored earthed hose for each air tool.


Safety Tools Cold Cutting Solutions Cutting Solutions afety ools has three utting olutions that we have developed over the years for our clients. ike our rinding olutions, we offer on-demand custom tailored options to meet new demands. ll afety ools utting olutions can be further engineered and developed by olutions. lease see our, Innovation & uality control section for more details. 1. Combined Solution for Cutting &

eld Seam removal

2. Cutting Solution 3.

eld Seam Solution

C o m b i n e D C u t t i n G & w e l D r e m o v a l SOLUTION (A-0300) ir tools no.

ame

Disc no.

Kit size: 80X45X64 cm

ame

ccessories

52 kg

Description

A-0105

Angle 1000-T4

A-0502

Cutting Disc

A-0310

Water Control Box

A-0105

Angle 1000-T4

A-0503

Weld Removal Disc

A-0071

Armoured hose

A-0073

Cutting Guard

A-0074

Weld Removal Guard

A-0081

Case

Safety Tools optimal solution for cold cutting and weld removals. Cut t inG solut ion

(A-0301)

ir tools no. A-0105

Kit size: 80X45X64 cm

ame

Disc no.

Angle 1000-T4

A-0502

ame

46.5 kg ccessories

Cutting Disc

Description

A-0310

Water Control Box

A-0071

Armoured hose

A-0073

Cutting Guard

A-0081

Case

Safety Tools cold cutting solution.

welD removal SOLUTION ir tools no. A-0105

(A-0302) ame Angle 1000-T4

80X45X64 cm Disc no. A-0503

ame

47 kg ccessories

Weld Removal Disc

Description

A-0310

Water Control Box

A-0071

Armoured hose

A-0074

Weld Removal Guard

A-0081

Case

Safety Tools optimal solution for cold weld removals.

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Hot Tap repair – Photo info n/a - Statoil

“The noise level from Safety Tools’ cutting wheel is so low that I am able to carry out a normal conversation, while cutting through a 4-inch pipe.” Arne Veland, HSEQ Manager, Seawell Engineering


Innovation & Quality control Overview STA Solutions. . . . . . . . . . . . . . . . . . . . . . . . . 54 Cutting Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Guides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Flange 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 PipEx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Subsea. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 STA Solutions summary . . . . . . . . . . . . . . . . . . . . . . . . 58


Overview STA Solutions STA Solutions provide creative, specialized and precision engineering – On demand. The company’s goal is to; engineer, design & develop specialized, high quality, precision products. The tools are specifically designed to be used in potentially explosive work environments. STA Solutions develops new Safety Tools products based on client demands, research & development. STA Solutions is responsible for Safety Tools Allmet’s product production & development. We work directly with clients to engineer and develop a wide range of specialized solutions. Our emphasis is on cold work solution for potentially explosive work environments. By utilizing our experience with pneumatics, electronic and hydraulic in Hazardous work Areas we are able to find solutions where others don’t.

STA Solutions is a subsidiary of Safety Tools Allmet.

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Cutting Robot the cutting robot is a automated robot that utilizes safety tools world leading ex cold cutting technology. Its main use is on decks, grating and other base surfaces. the cutting tool can be set vertical or horizontal. the cutting robot has controls and sensors that regulate, automate & guide the cutting tool. all parts are designed to be used in hot work areas (eX Gas zones 1/2 and Dust zones 21/22) without a hot work permit.

It has a cutting length of 2.5 meters and it will cut approximately 2 mm deep - each pass. Its automated design will continue cutting until the desired depth is achieved. ur robot system is designed to simplify and reduce the amount of time needed for longer straight-cuts.

Just place the robotic machine in the area you need to cut, fasten the magnets (attaching it to the surface) and press the start button.

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Cutting Guide Jr. Jr. is a smaller and more mobile cutting guide than our robot. It is designed to further automate & optimize safety tools cutting and weld seam equipment. “Junior� has been developed & enhanced over several years. It began as a hand driven guide and is now motorized for more automated & effective cutting. he length of the guide is 1.2 meters and it is approximately 0.35 meters high. he purpose of this tool is to straight-cut through grating, decks and other base surfaces. agnets are used to attach Jr. to surfaces. Its engine is powered

Product number: A-0320

by air motor and guides the cutting tool along the cutting guide. after each pass, the gear is manually released and repositioned back to the start position for another cut. In test conducted at Safety Tools Allmet using Jr. Guide we cold cut one meter (length) 8mm (depth) in less than an hour. The disc performance (lifespan) increased to a 20 to 30 meter (lifespan) at that depth. Our average without Jr. Guide at the same depth is a 12 meter disc lifespan. all of our tests using Jr. or our robot with safety tools cutting tools have resulted in increase longevity and performance of our discs. In our test the disc lifespan has more than doubled. e are very excited to add Junior to our olution enhancements for afety ools.

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Under development Flange 69 Flange 69 is designed to further automate the resurfacing of worn out leaking flanges so that they don’t need to be replaced. It is simply attached on to the flange from “behind”. Flange 69 only requires the flange surfaces to be a mere 6 cm (2.4 inches) apart while resurfacing.

PipEx The goal of PipEx is to offer a simplified and automated pipe cutting solution that adapts to a wide range of pipe sizes without the need to make major adjustments. PipEx is being designed to cut through pipelines in Hazardous work areas, utilizing Safety Tools Cutting disks. PipEx will further simplify and optimize pipe cutting in Ex zones 1 & 2.

Subsea STA Solutions has ongoing projects being developed for subsea. Currently they remain confidential. If you are interested in a Subsea solution please contact us.

Innovation & Quality control  / 57


STA Solutions Summary STA Solutions and Safety Tools believe that we can help you simplify and automate many of your cutting and grinding jobs in hazardous work areas. Our solutions eliminate all electronics and utilize Safety Tools world leading Ex cold cutting technology. We can perform cutting and grinding jobs in Ex Hazardous work areas like no other company can. Projects can be prioritized on-demand and we will customize and engineer tools based on your needs. Any questions or requests can be directed to Anders Helland at STA Solutions.

Anders Helland Project Manager Anders.helland@stasolutions.no + 47 95 87 57 75

58 \  Innovation & Quality control


Port Arthur refinery – Photo Dave Rossman – Total

“This is the best thing I have seen since sliced bread!” Total Petrochemicals – Port Arthur Refinery, Texas.


Peregrino FPSO Maersk Peregrino, Brasil – Photo Øyvind Hagen - Statoil

This technology will also be very important for safety in onshore O&G plays, refineries and just about anywhere else with EX potential. It offers a possibility of doing these jobs with no shutdown or slowdown in production and increased safety for workers and infrastructure. Claudio Paschoa – Petrobras, Maintenance Engineer


Sleipner. Photo: Kjetil Alsvik,Statoil

“Statoil UPN safety delegate services will continue its effort to get the tool implemented in all our facilities where it is performed maintenance and modification work in areas that are pressurized and in operation.� Peter Alexander Hansen, Statoil UPN (Development and Production Norway)


Statfjord C platform - Photo Øyvind Hagen - Statoil

“I believe the introduction of EX-Certified tools that are classified as Cold Work by DNV is a major step forward – for safety, the environment, and the health of all personnel using this class of tools.” Arvid Skines, Main Safety Delegate, for the Statfjord Field


Training and Maintenance afety ools have some similarities to conventional grinding and cutting tools and many differences. roper training will assure that you optimize the longevity of afety ools equipment and complete your jobs efficiently. e conduct ongoing training at our office in otra orway year-round and offer onsite training. afety ools supplies detailed; user manuals, videos & maintenance material to ensure our clients and end users have on-demand afety ools reference information. ll of afety ools rinding and utting solutions come with detailed user manuals. all safety tools authorized exclusive Importers conduct training certification (see pages 16–17) for the authorized importer near you.

Safety ools training and maintenance specialist onny erge echnical ales anager onny@safetytools.no +47 905 25 327

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Safety Tools Allmet AS Straume NĂŚringspark Idrettsveien 113C 5353 Straume Norway Main: + 47 56 32 36 50 sales@safetytools.no support@safetytools.no


Safety Tools Allmet