Case Study: How CPCL’s Hazardous Area TRUs de-risk industrial processes

Across a wide variety of industrial facilities, from petrochemical to fuel storage, cathodic protection power supplies often need to be installed in hazardous zones.

A common approach is to place transformer rectifiers (TRUs) in a safe area and run long DC cables to the protected asset. This method creates a set of inefficiencies that compound over the life of the system – significant voltage drops, increased cable costs, slower commissioning and ongoing power waste.

Cathodic Protection Co. Ltd’s range of ATEX, IECEx and UKEx TRUs are a highly effective solution to these issues, and ensures plant expansion can be carried out safely and efficiently. Many facilities are now pre-planning for changing plants and ever-widening ATEX areas - ensuring that each plant expansion doesn’t result in an expensive refurbishment.

Read on to discover the positive impact of Hazardous Area TRUs in safeguarding investments across the globe.

The Product

CPCL have developed the TRUst™ range of Transformer Rectifiers, specifically designed to meet the most exacting of standards in terms of quality, versatility and cost-effectiveness.

The range covers Thyristor, Switched, Variac and Switch Mode power supply technology across flameproof (Ex d) and liquid immersion (Ex o) – ranging from 1mA through to 1000A outputs.

  • Thyristor – in terms of range and features, this is the most flexible system available and meets the most arduous of specifications. Oil or air-cooled configurations are available in the following control types: Constant voltage control, constant current control, auto potential control.
  • Variac – ideal for industrial solutions that require robust, trouble-free operation. Oil or air-cooled configurations available in the following control type: Constant voltage control, allows for smooth infinite adjustment between 0-100%.
  • Switch Mode Power Supply – the best option for low power applications, particularly concrete CP systems. Air-cooled configurations available in the following control types: Constant voltage control, constant current control, auto potential control.

CPCL’s in-house developed remote monitoring and control system (RMCS), across a variety of communication mediums, can assist with ongoing compliance to international standards.

The Impact

Due to the unmatched capabilities and versatilities of the TRUst™ range, CPCL have in excess of 300 installed units worldwide. These units have been operating for over two million hours across four continents – the sites include LPG Compression Trains, Offshore Gas Platforms, Onshore Fuel Storage Depots and Chemical Plants.

A number of the world’s leading energy companies have purchased hazardous area units from the TRUst™ range, including Technip, Tecnicas Reunidas and Saipem – with end users such as SABIC, Total, Enquest, ADNOC, North Oil Company, Sonatrach and BP.

All surveying, installation, design, production and management staff carry relevant certification to ensure customer requirements meet the highest possible standards.

The Result

The success of CPCL’s Hazardous Area TRUs has been resounding in creating safe, efficient solutions for essential cathodic protection systems. The first step was to perfect the implementation of Ex d TRUs, and then to support our customer’s growing needs, CPCL developed Ex o units.

The company is committed to the continuous enhancement of Ex o TRUs, and CPCL is already on the third revision of this certificate. Since the first Ex o installation in 2022, the company have sent units of this new variety to several major plants internationally, including:

  • 187 to Qatar, with more units in progress.
  • 19 to Poland.
  • 15 to the United Arab Emirates.
  • 7 to Nigeria.

All of these units utilise CPCL’s proven control technology from our well-established safe area equipment.

The global demand for CPCL Hazardous Area TRUs is testament to the overall safety and reliability of the TRUst™ range, proving highly effective in protecting structures in extreme environments from corrosion.

To learn more about Hazardous Area TRUs or to make an enquiry, get in touch with the CPCL team on +44 (0)1476 590666.