Explosion proof sounders for FPSO safety
12 March 2025
When you’re standing on the deck of a Floating Production Storage and Offloading (FPSO) unit, the sheer scale of these maritime marvels is breathtaking. These vessels, which have revolutionised offshore oil and gas operations, serve as floating facilities that extract, process, and store hydrocarbons.
The growth in FPSO deployment tells an interesting story. From the waters off Brazil’s coast to the maritime zones of West Africa and Southeast Asia, these vessels are increasingly dotting our oceans. The economics make compelling sense. FPSOs offer remarkable flexibility in deployment and can be repositioned as needed, making them particularly valuable for marginal fields that might not justify permanent platform installation.
And like all offshore oil and gas applications there is a responsibility to ensure the safety of both personnel and assets in some of the world’s most challenging operating
However, the potentially explosive atmospheres ever-present in oil and gas processing applications, means standard sounders are simply dangerous. That’s because they could ignite any flammable gases or vapours.
This is where explosion proof sounders or ATEX/IECEx sounders come into play, serving as reliable guardians that can raise the alarm without risking ignition.
Explosion proof sounders for alarm systems and more
These explosion proof sounders perform several vital functions aboard FPSOs. Beyond the obvious emergency alerts for fire and gas leaks, they’re the voice that guides the multi-lingual crew members during evacuations, signals equipment malfunctions, and manages routine operations like shift changes. These sounders have evolved to incorporate sophisticated sound patterns that help crew members instantly distinguish between different types of alerts, a crucial feature in emergency situations where every second counts.
The material question when specifying explosion proof sounders
When it comes to choosing materials for explosion proof sounders, offshore engineers face a choice. The first is 316L stainless steel, praised for its remarkable strength and resistance to corrosion. However, as any experienced offshore worker will tell you, even this robust material demands regular attention to combat the relentless assault of salt-laden air.
The alternative that’s gaining traction is glass-reinforced polyester (GRP). The appeal is clear: they offer impressive durability while significantly reducing maintenance requirements. For FPSO operators grappling with tight maintenance schedules and cost pressures, this presents an attractive proposition.
The maintenance implications of material choice extend beyond simple durability. In the harsh offshore environment, where access to equipment can be challenging and weather windows for maintenance are limited, the reduced maintenance requirements of GRP can translate into significant operational advantages.
Paul Madden, Ex-tech Signalling’s Product Manager, shares an interesting perspective from his years of experience: “The choice of sounder material isn’t just about immediate durability, it’s about long-term operational efficiency. We’re seeing a shift in how FPSO operators approach this decision, with maintenance requirements becoming increasingly central to the selection process. The industry is moving towards solutions that offer both reliability and reduced lifecycle costs. However, many tenders and company policies explicitly demand stainless steel, often with SIL2 as standard.”
SIL2 sounders built to endure: meeting offshore challenges
Considering the punishing conditions these sounders must withstand, it’s no surprise that IP66 or IP67 ratings are considered essential. These ratings ensure protection against the constant onslaught of rain, waves, and salt spray that characterise offshore environments. But the challenges don’t stop at weather resistance – these devices must also maintain their functionality in extreme temperatures, high humidity, and potentially explosive atmospheres. The manufacturing process for these sounders involves rigorous testing that simulates the harsh conditions they’ll face in service. Manufacturing plays a crucial role in maintaining high standards, with stringent quality control measures ensuring compliance with ATEX and IECEx certifications. Each unit must undergo extensive vibration testing, salt spray exposure, and thermal cycling to verify its resilience. And with a SIL2 (Safety Integrity Level) rating, FPSO operators can be sure of the reliability of the sounders if or when they are needed.
Integrating explosion proof sounders with modern safety systems
Today’s explosion proof sounders form part of larger integrated safety systems. They can be networked with gas detection systems, fire alarms, and emergency shutdown protocols to provide automated responses to various scenarios with control over sound patterns and volume levels.
These systems mean FPSO operators are able to create distinct audio signals for different scenarios, from general alerts to specific emergency protocols. The ability to programme different tones and patterns helps prevent alarm fatigue while ensuring that critical warnings remain easily distinguishable. This integration enhances overall safety while reducing response times in critical situations.
Explosion proof sounders by Ex-tech Signalling
Ex-tech Signalling’s journey in developing explosion proof sounders has been shaped by significant experience, thousands of successful deployments, proven technologies and countless conversations with offshore professionals. We understand that every FPSO presents unique challenges, which is why we offer both GRP and 316L stainless steel options. Our sounders aren’t just designed to meet standards – they’re built to exceed expectations in the most demanding offshore environments.
Our manufacturing facility in the UK serves as a centre of excellence, where each sounder undergoes rigorous testing to ensure it meets both safety regulations and practical operational requirements. The testing regime includes extended exposure to salt spray, extreme temperature cycling, and rigorous vibration testing to simulate the demanding offshore environment.
For FPSO operators seeking reliable, high-performance signalling solutions, we offer not just products, but a partnership built on years of offshore expertise. Our team of engineers works closely with clients to understand their specific requirements and recommend solutions that balance performance, maintenance requirements, and long-term operational costs.
We welcome you to reach out and discuss how we can support your FPSO’s signalling needs, drawing on our extensive experience in providing safety-critical equipment for the offshore industry.
