P R O D U C T T R A I N I N G

INTRODUCTION This guidebook provides an overview of our complete safety shielding product range, along

with detailed information about specific models, designs and materials.

INDEX

COMPANY BACKGROUND……………...

SAFETY SHIELD BASICS………………..

INDUSTRIES & MARKETS……………….

DRIVERS & REGULATIONS……………...

PRODUCT OVERVIEW…………………...

THE FLANGEGUARDS DIFFERENCE…

APPENDIX INDUSTRY / APPLICATION GUIDE..

TYPICAL CLIENT LIST………………

PRESSURE TEST RIG………………

PHOTO GALLERY……………………

COMPANY BACKGROUND Flangeguards is a forward thinking, modern business specialising in safety shielding solutions

for a variety of industries.

Everything about the flangeguards brand is designed to be simply to understand and easy to

use. This gives us the edge over our competitors, who in this market tend to be rather old-

fashioned.

Product

With over twenty years experience, we have concentrated on four main

product materials & designs that cover the vast majority of applications

(though special designs are certainly available). All our designs are pressure

tested. This small product range makes it simple for the customer.

Website

Our website is critically important. The safety shield market is always growing,

with web-searches often being the first step for client understanding. Our site

has been carefully designed and often results in client specification work and

direct enquiries (from all around the world).

Sales & Marketing

Following on from the website, our sales and marketing material is designed

to be modern, simple and concise. our TOTAL SHIELD SOLUTIONS guidebook is

an excellent resource, and should be read in conjunction with this document.

Whilst we can influence customers around the world, it is important to have professional,

local partners. We hope this Product Training guidebook helps to learn more about our

products and markets, but hope that you will contact if you need any further information.

SAFETY SHIELD BASICS Safety Shields are designed to prevent spray-out and mist formation, from pipelines containing hazardous chemicals (acid, bases, oil, steam etc).

The primary purpose is to prevent spray or mist – but not to contain the leak indefinitely. Ideally the shield will control the leak safely, allowing liquid release vertically.

Typically leaks occur at pipe joints such as flanges, valves and expansion joints, though shields can made to fit a variety of fittings.

A variety of different shield designs exist and there is no single type which is suitable for all applications. It is critically important for the safety shield design to prevent direct and lateral (sideways) spray-outs and avoid mist formation. It is possible for a poor shield design to create a fine mist in the event of leakage.

Poorly designed or fitted shields may cause more harm than good – especially if they are held tight against the flange with not way of diffusing the pressure release.

SPRAY MIST SAFE DRIP

INDUSTRIES & MARKETS Safety Shields are now used in a wide variety of industries. The market continues to grow as incidents and accidents continue to happen. Some more common industries include:-

The mix of industries varies in different countries and regions – but generally there is always a good market for Safety Shields. See the Appendix for specific application information.

OIL & GAS; offshore, terminals, refining CHEMICAL; Chemical/Petrochem/Construction material manufacturing POWER GENERATION; from large scale power stations to small engines MARINE; Ship engine room & facilities FOOD & BEVERAGE; processing, packaging & storage sites WATER; Waste water treatment within water authority or process site GENERAL PROCESS; Any process industry using, storing or processing chemicals

(Paper & Pulp, Iron & Steel, Pharma, Automotive, many others)

DRIVERS & REGULATIONS Many different motivations exist for the installation of safety shields. Whilst most new sites require shields as ‘best practice’, the following drivers also exist:- Recent incident or near-miss on site, or associated site Very often, site incidents or near-misses will necessitate a safety review, at which time safety shields are considered as corrective or preventative action. Insurance requirement The cost of site fires, explosions and personal injury is significant. Industrial insurers now focus specifically on spray-out and oil mist prevention, and often insist on safety shielding. Hazardous area zoning issue DSEAR reclassification can create technical and commercial complications. Many customers use safety shields as part of their case to reduce zoned areas. Company-wide policy/philosophy & best practice In an attempt to reach the goal of ‘zero accidents’, many large companies create and insist upon safety policies and requirements that often include safety shielding. Other There are a variety of other reasons to fit shields, including pollution control, general site cleanliness and protection of nearby electrical equipment. Industry regulations Various regulations exist, some specifying safety shielding (SOLAS, marine industry) and others recommending shielding as a control measure (EP15 energy industry).

DRIVERS & REGULATIONS Guidelines and regulations vary depending on industry. This regulatory work is ongoing and developing as accident and incident numbers increase. SOLAS This marine industry regulation includes requirement for shielding/screening of oil spray within vessel engine rooms. EI 15 Energy Industry requirement for oil lines above 1bar pressure. Mainly focused on avoidance of oil mist prevention. DSEAR / Hazardous Area Zoning Issue Dangerous Substances & Explosive Atmospheres Regulation. Shields are recommended as a control measure to prevent spray and mist. Further, sites now use shields to reduce the size of zoned hazardous areas (since spray and mist is avoided, thus the ATEX ‘bubble’ is smaller). Industrial Insurer Regulations Many industrial insurers insist of shields to prevent spray and mist, to mitigate risk of fire, explosion and personal injury. Others Other guidelines and regulations exist in connection with those above, where leak protection should be considered;

COMAH (Control of Major Accident Hazards) REACH (Registration, Evaluation, Authorisation & Registration of Chemicals) MARPOL (Marine Pollution)

PRODUCT OVERVIEW With over twenty years experience serving the Safety Shield market, we have provided solutions for a variety of applications. The vast majority of requirements can be solved by one of these four standard designs:-

PTFE Shield Our most popular shield, compatible with practically all corrosive chemicals due to technical fabric and Teflon thread.

PTFE-CLEAR Shield This shield is generally used for applications where sight of the flange/joint must not be obscured. Thus, liquid releases can be seen within the shield, providing visual indication.

316 STEEL Shield Comprises outer 316 steel band, inner 4-layer steel mesh and external quick-release clamp. The key design feature is the internal mesh which effectively diffuses all pressure from the release, resulting in a safe drip.

PVC Shield Made from heat-sealed PVC and is designed to provide a ‘budget’ or short-term solution for low corrosion, pressure and temperature applications.

Whilst these shield are suitable for most applications, we do have a wide variety of other materials and special designs available.

PRODUCT OVERVIEW Within our standard shield range, we have two distinct designs:- PTFE / PTFE-CLEAR / PVC Shield design These are all fabric shields, made to exactly fit specific pipe joint types and sizes. The design wraps around the outside flange diameter, pulling down around the bolts to prevent direct spray, lateral spray and mist formation.

316 STEEL Shield We believe this is the most effective steel shield design available on the market. It is made to exactly fit specific flange / valve sizes and simply clamps shut using a quick-connection latch. Inside the shield, we use a multi-layered steel mesh which effectively diffuses any pressure release (direct or lateral) preventing spray & mist formation.

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PRODUCT OVERVIEW PTFE Shield The most widely used shield type throughout all industries – due to corrosion resistant materials and flexibility of fabrication. This design wraps around the outside flange diameter, pulling down around the bolts to prevent direct spray, lateral spray and mist formation.

Shield Materials: Outer Teflon-coated fibreglass Inner Central thickened scrim Thread: Teflon-coated glass thread Pull Cords: Braided Teflon Max Temperature: 232 C / 450 F * Pipeline Pressure: PN6 to PN40 Standard Pipe Sizes: DN10mm to DN600mm Leak Detection: Included via Litmus Indicator Patch Optional: Drain Nipple Assembly Typical Uses: Flanges, valves, expansion-joints, couplings, hoses, elbows, tee-pieces, non-standard sizes. Typical Applications: Acids, caustic, oil (lubrication, fuel, seal, thermal*), solvents, low pressure steam Used extensively for 98% Sulphuric, caustic and oil applications. Simple to fit and remove, without any special tools. Can be manufactured in virtually any size and shape.

PRODUCT OVERVIEW PTFE Shield Our PTFE shield uses only the highest quality materials and is designed to exactly fit, thus prevent spray and mist. Further, all our designs are tested on our pressure-test facility. Beware of shields that may look the same as ours, but use inferior materials and ineffective design. These are generally cheap copies, offering poor protection – indeed, ill-fitting shields can CAUSE lateral spray and mist formation. NOT ALL SHIELDS ARE THE SAME. WHEN THE PRICE OF FAILURE IS HIGH, DO NOT COMPROMISE ON QUALITY

1. Central Thick Scrim material Added safety. Without this, a pressure release can split the outer shield material, creating spray and mist.

2. Permeable Teflon material Ensures leaking liquid is drawn away from the flange, thus avoiding corrosion (especially if acid duty) and triggering litmus colour change . Other non-permeable shield designs can hold corrosive liquids against the flange. 3. Teflon Thread Better resistance against corrosive atmospheres. Other shields use cotton threads which disintegrate quickly.

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PRODUCT OVERVIEW PTFE-CLEAR Shield Like the PTFE shield, but with clear central ECTFE (Teflon) section, enabling visual inspection of the flange at all times, without shield removal. Comprises corrosion resistant materials.

Shield Materials: Central clear ECTFE section Side Teflon-coated fibreglass Thread: Teflon-coated glass thread Pull Cords: Braided Teflon Max Temperature: 150 C / 300 F (higher temp. available) Pipeline Pressure: PN6 to PN40 Standard Pipe Sizes: DN10mm to DN600mm Leak Detection: Visual (Litmus Indicator Patch available as option) Optional: Drain Nipple Assembly Typical Uses: Flanges, valves, expansion-joints, couplings, hoses, elbows, tee-pieces, non-standard sizes. Typical Applications: Acids, caustic, oil (lubrication, fuel, seal, thermal*), solvents, low pressure steam Used extensively for 98% Sulphuric, caustic and other corrosive applications. Simple to fit and remove, without any special tools. Can be manufactured in virtually any size and shape.

PRODUCT OVERVIEW PTFE-CLEAR Shield Our PTFE-CLEAR shield uses only the highest quality materials and is designed to exactly fit, thus prevent spray and mist. Further, all our designs are tested on our pressure-test facility. Beware of shields that may look the same as ours, but use inferior materials and ineffective design. These are generally cheap copies, offering poor protection – indeed, ill-fitting shields can CAUSE lateral spray and mist formation. NOT ALL SHIELDS ARE THE SAME. WHEN THE PRICE OF FAILURE IS HIGH, DO NOT COMPROMISE ON QUALITY

1. Central clear ECTFE material Added safety & continued visual inspection. Other shield designs use FEP as clear section, which can ‘cloud’ over time, becoming opaque, and difficult to see through.

2. Permeable Teflon material Ensures leaking liquid is drawn away from the flange, thus avoiding corrosion (especially if acid duty) and triggering litmus colour change . Other non-permeable shield designs can hold corrosive liquids against the flange. 3. Teflon Thread Better resistance against corrosive atmospheres. Other shields use cotton threads which disintegrate quickly.

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PRODUCT OVERVIEW 316 STEEL Shield The simplest and most effective shield design, made from all-316 stainless steel materials. Thus, suitable for high pressure and temperature. Critically important is the multi-layered steel mesh inner, which completely diffuses pressure releases.

Shield Materials: Outer 316 st/st band Inner 316 st/st multi-layered mesh Connection: 316 st/st quick-connection latch Max Temperature: 500 C+ Pipeline Pressure: PN6 to PN100 Standard Pipe Sizes: DN15mm to DN600mm Leak Detection: Visual Typical Uses: Flanges, valves Typical Applications: Oil (lube, fuel, hydraulic, thermal), steam, acids Used extensively for high pressure & temperature applications, or where simple installation and removal is an advantage.

PRODUCT OVERVIEW 316 STEEL Shield Our 316 STEEL shield uses only the highest quality materials. This simple design outlasts all other shield types/materials in our in-house pressure testing. Most important is the internal multi-layered steel mesh, which effectively diffuses pressure releases – thus preventing spray and mist formation. More than any other shield in our range, beware of cheap copies without adequate mesh or any form of testing. NOT ALL SHIELDS ARE THE SAME. WHEN THE PRICE OF FAILURE IS HIGH, DO NOT COMPROMISE ON QUALITY

1. Multi-layered steel mesh Critical for safety, to avoid spray and unwanted mist formation (which is a consequence of ill-fitting shields with no mesh)

2. Quick-connection latch Enables simply fitting & removal without any special tools. This is very useful for harsh environments where gloves, chem-suits and other conditions make installation difficult

3. All 316 stainless steel, standard No weak points or opportunities for error, by ordering the wrong material

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PRODUCT OVERVIEW PVC Shield Two-layer PVC shield, offered as low-cost alternative, where process conditions allow. Typically used for low corrosion applications for ambient pressure and temperature conditions.

Shield Materials: Two layers of red PVC (available in other colours) Thread: Cotton Max Temperature: 65 C / 150 F (higher temp. available) Pipeline Pressure: PN6 to PN16 Standard Pipe Sizes: DN10mm to DN600mm Leak Detection: Included via Litmus Indicator Patch Typical Uses: Flanges, valves Typical Applications: Water, low concentration acid. Used if only a short-term solution is required or in the event of budget constraints.

PRODUCT OVERVIEW Summary This quick reference guide shows the relative strengths of each shield type:-

PRODUCT OVERVIEW Summary Note these important differences between ours, and competitors shields:-

Permeable, Teflon Coated Fibreglass Leaking liquid drains away from flange, better leak indication Teflon Thread Best resistance against corrosive environments Central, Thickening Scrim Prevents pressurised leak breaking through shield ECTFE Clear Material Remains transparent, stronger material 316 STEEL With Mesh Diffuses Pressure entirely, no spray/mist Pressure Tested All our shield designs are pressure tested, with proven fitness-for-purpose

Non-Permeable Materials Liquid held against flange, creates corrosion Cotton Thread Disintegrates within industrial environment No Scrim No resistance to pressure release, can cause spray & mist FEP Clear Material Becomes opaque, difficult to see through STEEL Band Only Can create mist & lateral spray Untested The vast majority of shields are untested & therefore unproven

FLANGEGUARDS

OTHERS

THE FLANGEGUARDS

DIFFERENCE

NOT ALL SHIELDS ARE THE SAME We only use highest quality materials & most effective designs.

With over twenty years Safety Shielding experience, we have developed a product range delivering the highest degree of safety and quality. TESTED UNDER PRESSURE

All our shield designs have been pressure tested on our Leak-simulation test facility

CUSTOMER-FOCUSED, EXPERT SUPPORT Over twenty years experience, large stockholding and quick turn-around for urgent requirements

TAILORED SOLUTIONS Comprehensive product range, with ability to solve unique client shielding requirements with special designs

APPENDIX

INDUSTRY / APPLICATION GUIDE..

TYPICAL CLIENT LIST………………

PRESSURE TEST RIG………………

PHOTO GALLERY……………………

INDUSTRY / APPLICATION GUIDE A number of common applications exist within industries such as Chemical

Manufacturing, Oil & Gas and Marine. However, new requirements for safety shields

continue to be discovered, as incidents / accidents / near misses occur.

The Industry / Application matrix overleaf, is a list of the more common areas where

shields are used. But this is by no means a definitive list, and we routinely find new

requirements wherever hazardous substances are used or stored.

INDUSTRY / APPLICATION MATRIX

Other significant industries include:-

Construction Materials, Paper & Pulp, Iron & Steel, Waste Water Treatment, Packaging, Film & Fibre, Renewables.

Typical Contact Job Titles End-User Sites: Mechanical Maintenance Manager Engineering Manager Plant Manager Process Eng.

EPC Contractors: Piping Engineer Process Engineer Technical Procurement Loss Control Engineer

TYPICAL CLIENT LIST

A variety of routes-to-market exist for safety shields, and sometimes more than one

organisation needs to be aware of the requirements:-

End-User Sites Engineering, Procurement & Construction Contractor (EPC) 3rd Party Consultant Practices Pipe Fabricators OEM suppliers System Integrators Buying Houses

What follows is a list of some companies, broadly split by industry who we have

supplied with safety shielding solutions.

Oil & gas related

Associated Petroleum Terminals BP Expro BP Hamble BP Refineria de castellon BP Refinery Kwinana CB&I Centrica Costain Dof Referi Dragon LNG Essar Stanlow Refinery Exxon Mobile GE Energy GE Oil & Gas Jacobs KDG Murco Oil Neste Oil Nexen NuStar Terminals POS Perenco Petroplus Phillips 66 PT Nippon Qatar Oilfield Supply Reliance Robbins & Myers Shell Bacton Shell Polska Sp Stell St Fergus Subsea 7 Sumed Arab Petroleum Pipelines Co. Tengizchevroil Turner EPS TYCO Metito

TYPICAL CLIENT LIST

Chem, Petrochem

ABB ADM AG Fluor Polymers Akcros Chemicals Associated Octel BASSF Celanese Chemoxy Covidien Cristal Global / Millenium Croda Chemicals Dynea EPC F2 Fine Organics Geo Specialty Chemicals Growhow Hexcel Composites Huntsman Pigments Icopal INEOS Innospec Jacobs Engineering Johnson Matthey Koppers Lotte Chemical MEL Chemical Nufarm Perstop Polimeri ENI Proctor & Gamble PZ Cussons Rhodia Robionson Brothers SAFC Hitech SAMI Silberline Simon Storage Springfield Fuels Stanbet Syngenta Victrex Whelan Refining William Blythe Marine

BP shipping Babcock Marine Andrew Weir Shipping Anglo Eastern BAE Systems Bluewater Shipping CalMac Ferries Carnival Cruises Dubai Drydock Exxon shipping Ferguson Shipbuilders Fincantieri Hoverspeed IMTL Italian Navy MAN Diesel P & O Ferries Princess Cruise Royal Navy Saga Shipping SBM Marine Stena Subsea 7 Wartsila

TYPICAL CLIENT LIST

General / Other

ADM Bluestar Fibres British Salt Cadbury Cammell Laird Cargill CEL Christ Kennicott Water Technology Climax Molybdenum Coryton Energy Costain Daewoo E&C Korea Dairy Crest Dof Management Durr Easton Aerospace Ecolab Ecolutia Eli Lilly Ford Motor Company Gatwick Airport Genzyme Green Fuels Hyundai Heavy Industries (HHI) Kaefer Kimberly Clark Kittiwake Kodak Lenzing Fibres Mercedes AMG Morrison Bowmore Distillery North British Distillery Company Novacyl Thailand Ostensjo Rederi AS Ovivo PB Gelatins Sellafield Sites Siemens Water Technology St Regis Paper TATA Steel Tate & Lyle ThyssenKrupp Bilstein Worley Parsons Power

Borg Warner Cummins Turbo Technologies DRAX Power EDF EON National Nuclear Laboratory Nuvia Medway Power Phoenix Natural Gas Rolls Royce RWE SITA SSE

PRESSURE TEST RIG

Uniquely, we have our own Pressure Test Facility where all shield designs can be

assessed. Whilst this represents a considerable investment, we feel it is necessary to

prove fitness for purpose (virtually all other shield manufacturers rely on data from

their suppliers of individual materials, thus the whole shield is NOT physically tested in

pressure-leak conditions).

All our shield designs have been tested under pressure, backing-up our product

specification data-sheets. Further detail on test rig, procedures, success criteria is

available upon request – as is our test video.

This ability to test the product can and does result in our shields being specified

no-equal.

Our test facility can also be modified to accommodate specific client test

requirements. Contact us for details.

PHOTO GALLERY

This is a small collection of safety shield pictures, either on their own on in-situ. Notice

the variety of non-standard shield configurations available.

Standard Shields:-

Flange

Union / Coupling

Elbow

Tee piece

PTFE PVC PTFE-Clear

PHOTO GALLERY

This is a small collection of safety shield pictures, either on their own on in-situ. Notice

the variety of non-standard shield configurations available.

Valve Shields:-

Bonnet / Gate

Other Shields:-

Expansion joint Flow Indicator Drain Guard

Pump Shield

Ball

PHOTO GALLERY

This is a small collection of safety shield pictures, either on their own on in-situ. Notice

the variety of non-standard shield configurations available.

Fitted PTFE Shields:-

PHOTO GALLERY

This is a small collection of safety shield pictures, either on their own on in-situ. Notice

the variety of non-standard shield configurations available.

Fitted 316 STEEL Shields:-

PHOTO GALLERY

This is a small collection of safety shield pictures, either on their own on in-situ. Notice

the variety of non-standard shield configurations available.

Fitted PTFE-CLEAR Shields:-

PHOTO GALLERY

This is a small collection of safety shield pictures, either on their own on in-situ. Notice

the variety of non-standard shield configurations available.

Special Pump Shields, Aviation Fuel Application (Airport):-

Large pump sets can have multiple potential leak paths. Flanges, valves, seals are often in close proximity which means conventional flange guards are unsuitable. The Pump Guard uses the same woven Teflon material that we use for flanges guards but is fixed to a metal frame that completely encloses the pump shaft, seals & flanges. It is easily removed for maintenance and features a transparent Teflon hood for visual inspection of the pump. For pumps transferring corrosive chemicals, the Pump Guard will offer effective personnel protection, but in the case of hydrocarbon applications it will also eliminate the possibility of a hydrocarbon vapour cloud. The Pump Guard can therefore be used as a “Control Measure” in the compliance to DSEAR regulations because it significantly reduces the size of the hazardous area surrounding the pump. This will have added advantages in reducing the cost of local instrumentation.