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Decommissioning: Preparing for retirement Asset management: Cable identification – the latest technology
Standards:
Functional safety:
Decommissioning:
IECEx Management Committee Meeting – New Zealand
IEC61511 Ed 2.0 Overview (Part 2)
The importance of safety culture for incident-free projects
December 2015
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contents december 2015 President Barack Obama’s rejection of the proposed Keystone XL pipeline, which would have carried oil 1,200 miles from Alberta’s oil sands through the shale fields of the Dakotas to Gulf Coast refineries, is a significant blow to those who want to see continued expansion in the US oil industry. Green groups have now said they will take the battle to other fossil fuel interests. They have already won an impressive list of other victories in the last year, most notably helping persuade Shell to abandon its multi-billion dollar Arctic drilling programme. Keystone’s defenders argue that its opponents have scored a hollow victory, insisting the crude will still reach US refiners by rail, a transport method
suffering regular derailments and which was responsible for the deaths of 47 in Lac Megantic, Quebec, two years ago. Activists have vowed to increase efforts to block crude oil moving by train as well, but given the likely dependence of the US and Canadian economies on hydrocarbon extraction for years to come, it is clear oil products will continue to be transported from oilfield to market somehow.
President Obama’s rejection of the Keystone XL pipeline is a serious blow to North American oil interests
13
The main argument, surely, has to be over which is the most safe and environmentally secure way to transport those oil products until such time as fossil fuels have been replaced by reliable and clean energy alternatives. ...Alan Franck, Editor The right choices made late in a production facility’s life will lead to successful, cost effective and safe decommissioning
in this issue 19
News Extra
4
• US rejects Keystone XL pipeline and claims leadership on climate change • NASA issues report on Orbital Sciences Antares rocket launch failure • Wildlife thriving around Chernobyl nuclear plant despite radiation • US Environmental Protection Agency overseer says Chemical Safety Board must improve employee morale • Tension between Venezuela and Guyana exacerbated by oil and mineral exploration
11
Standards: IECEx Management Committee Meeting in New Zealand
13
Decommissioning - Making the most of late life and preparing for retirement
19
The importance of safety culture in ensuring incident-free decommissioning projects
22
The evolution of cable identification: Understanding new technology
26
IEC61511 Ed. 2.0: Functional safety – an overview (Part 2)
32
Datafiles & Buyers Guide
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Gaps in operators’ safety culture need to be addressed to deliver successful and safe decommissioning projects
22
Installers need to understand those developments that are making the job of cable identification easier than ever before
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News Extra
5
Trudeau, though ostensibly a supporter of Keystone, had opposed Harper’s aggressive lobbying for the project. This decision comes at a time when North American pipeline projects are at a crossroads. Until recently the sector was expanding rapidly, but prospects have been undercut by a 50% slide in oil prices and tough environmental reviews. Also, oil producers are cutting back investments, so there is less crude to carry.
US rejects Keystone XL pipeline and claims leadership on climate change
Other companies have also delayed pipeline projects. Sunoco Logistics, part of US pipeline giant Energy Transfer, is slowing development plans for an expansion project in West Texas, while Blueknight Energy Partners LP has delayed building one in East Texas.
O
When TransCanada first proposed the
Obama announced that he would reject the $8 billion Keystone XL
project in 2008, Keystone XL was seen as one of just thousands of pipelines across
Also, a day before Obama rejected its Keystone XL line, TransCanada said it
project, which would have involved the construction of a 1,200-mile pipeline to carry crude from the tar sands of
North America, but over the years, because of its size, it became a symbol of the fight against climate change.
was scaling back plans for its Energy East project, which would carry crude from Alberta to Canada’s east coast, another
Alberta to refineries on the Texas Gulf coast. This ends seven years of political arm-wrestling, is a significant victory
The President said his decision followed the State Department’s assessment that
for environmentalists and a serious blow to North American oil interests.
the pipeline “would not serve the national interests of the United States”.
“America is now a global leader when it
Obama said the State Department
comes to taking serious action on climate change,” Obama said from the White House. “Frankly, approving that project would have undercut that global leadership, and that is the biggest risk we face: not acting.” He added: “Today, the United
review, which sought public opinion and consultation with other agencies, concluded that the pipeline would “not make a meaningful long term contribution to our economy”, especially as lower oil prices and a recovering labour market had already
States is leading on climate change.”
helped boost job numbers and cut gasoline costs.
n November 6, President Barack
project vocally opposed by environmental groups. Its rival Enbridge saw its Northern Gateway project in British Columbia blocked by green and First Nation groups, and Trudeau’s election is likely to finally bury the project. The difficulties facing the pipeline sector could provide some respite for railway transportation of crude and oil products in the USA and Canada. This transportation method has been in decline over the last two years since the July 2013 Lac Megantic disaster in Quebec, when a crude train derailed and exploded in the town centre, killing 47.
TransCanada, the Canadian company behind the pipeline, said it was disappointed with Obama’s decision. “Today, misplaced symbolism was chosen over merit and science – rhetoric won out over reason,” Russ Girling, the chief executive, said in a statement.
But the Canadian company published a lengthy statement disputing the findings and arguing that the pipeline would also carry domestic oil from North Dakota shale. TransCanada later said it would continue its efforts to push the project through.
He said Keystone’s rejection would be bad for jobs and the economy in Canada and the US and the project’s (mainly Republican) supporters in Congress vowed to continue fighting to take the decision out of Obama’s
The timing was also dictated by events in Canada, and the swearing-in earlier this week of a new Liberal prime minister, Justin Trudeau, who has moved swiftly to distance himself from the pro-oil stance of his
Wisconsin, spilling an estimated 1,000 gallons of crude oil and causing local homes to be evacuated. The previous day, another crash at Alma in Wisconsin led to tanker cars leaking more than
hands and force through approval of the project.
predecessor, Stephen Harper, and commit to fighting climate change.
20,000 gallons of ethanol into the Mississippi River.
Further oil train crashes have happened regularly since then, with the most recent on November 8 when a Canadian Pacific Railway train derailed at Watertown in
6
News Extra
NASA issues report on Orbital Sciences Antares rocket launch failure A
NASA report into the October 2014 loss of an Antares rocket shortly after liftoff, released by the agency on
AJ-26 engine, including failure history dating back to its Soviet origins. “A lack of design and operating insight into the AJ-26 engines
October 29, concluded there was an explosion in the liquid oxygen turbopump in one of the two engines in the first
creates a low level of confidence in loss-ofmission predictions made by Orbital ATK and Aerojet Rocketdyne,” the report stated.
stage about 15 seconds after ignition. The vehicle lost thrust and crashed to the ground near its launch pad at the Wallops Island facility in Virginia.
Orbital’s own Accident Investigation Board agreed with NASA’s conclusion that elements of the turbopump came into contact and ignited the fire that caused the explosion.
The explosion destroyed 2,250 kilos of supplies destined for the International Space Station and wrecked the launch pad. NASA said the explosion was triggered when rotating and stationary components in part of the turbopump came into contact. “This frictional rubbing led to ignition and fire” in the turbopump, and thus the explosion, the report states. The cause of the explosion remained unclear, but was due to either poor engine design, debris in the engine, or a manufacturing defect. The Orbital Sciences Corp. rocket was powered by two AJ-26 engines, made in the former Soviet Union more than 40 years ago and refurbished in the US by Aerojet Rocketdyne. The report found that both Aerojet and Orbital lacked sufficient information about the
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The Orbital report, though, identified a single highly probable technical root cause of the failure: a machining defect in turbine assembly of the turbopump that dates back to when the engine was manufactured decades previously. An adjacent piece of the engine, recovered with little damage after the explosion, showed a “clear defect” in its machining, according to the report. Aerojet announced on September 24 it would pay Orbital $50 million to end the dispute between the companies about the accident. Orbital is replacing the AJ-26 engine with the more recent Russian RD-181 design, and a static test of the first Antares equipped with RD-181 engines is scheduled for early 2016. The first launch is planned for May, with ISS resupply flights resuming later in the year.
Antares rocket explosion, 28 October 2014 - Images: Joel Kowsky, NASA
News Extra
Rare Przewalski’s horses in the Chernobyl exclusion zone
7
At Fukushima in Japan, site of the world’s second worst nuclear accident, there have also been reports of wild boar thriving in the evacuated area. Professor Tom Hinton of Fukushima University is a co-author of the new research and said: “These remarkable data from Chernobyl will help us understand the potential long-term environmental impact of the Fukushima accident.”
Wildlife thriving around Chernobyl nuclear plant despite radiation
After the nuclear disaster at Chernobyl in 1986 the region’s 116,000 residents were
the researchers found the number of large mammals, including elk, roe deer, red deer, wild boar and wolves are similar to those in four uncontaminated nature reserves in the region.
permanently excluded, and animals in the area were exposed to extremely high doses of radiation. The research shows that their populations recovered within a few years. Wild boar reached very high population densities then dipped, which
which found wildlife was thriving. The results pose profound questions about
Professor Smith said: “We know that radiation
the researchers say was caused by the soaring wolf population and a disease
both the effect of humans on nature and of the safety for humans of sites devastated by nuclear accidents.
can be harmful in very high doses, but research on Chernobyl has shown that it isn’t as harmful as many people think.
H
umans are worse for wildlife than nuclear disaster, according to the first long-term study at Chernobyl, site of the world’s worst nuclear accident,
An international group of scientists coordinated by Professor Jim Smith from the
“There have been many reports of abundant wildlife at Chernobyl but this is the first large-
University of Portsmouth’s School of Earth and Environmental Sciences published their findings in Current Biologyy in early October.
scale study to prove how resilient they are. It’s very likely that wildlife numbers at Chernobyl are much higher than they were before the accident.
It is the first large scale study of mammal populations in the 4,200 square kilometre human exclusion zone around Chernobyl. The zone was exposed to chronic radiation following the 1986 accident but, 30 years later,
“This doesn’t mean radiation is good for wildlife, just that the effects of human habitation, including hunting, farming and forestry, are a lot worse.”
outbreak not linked to radiation. Increases in the area’s wildlife are in stark contrast to a decline in elk and wild boar populations in other parts of the former Soviet Union in the 1990s, as major socioeconomic changes brought rural poverty and poorer wildlife management. The census data covers 20 times the area of previous studies of mammal populations in the area and was repeated in different years, to result in the most in-depth analysis of the zone’s animal numbers to date.
8
News Extra
US Environmental Protection Agency overseer says Chemical Safety Board must improve employee morale He told Bloomberg BNA the EPA IG could have been trying to help House Republicans persecute the CSB in exchange for political support for a bigger IG budget. “This report reinforces the notion that their work has been politically targeted in a way that is not helpful in terms of the larger issue of chemical safety,” Ruch said. The unsettled times at the agency culminated in the resignation of chairman Rafael MoureFinally, the report said the CSB should
Eraso in March, amid allegations of general mismanagement and use of private email
Investigation Board (CSB) must improve employee morale and carry out a higher number of investigations, the
determine the need for a chemical reporting regulation under the Clean Air Act Amendments of 1990. The board’s ability to
for official board business to circumvent the system. When the White House asked Moure-Eraso to leave under growing
Environmental Protection Agency (EPA) Inspector General (IG) Arthur Elkin said in a report published on October 22. The report
do so has been hampered by congressional budget cuts and sequestration, the Inspector General conceded, but the CSB should also
pressure from Congress, it appeared that the controversy would die down.
draws on a House Republican committee hearing from 2014 alleging a “toxic work environment” and friction between staff and former chair, Rafael Moure-Eraso.
revisit its rulemaking effort.
But in June, shortly after CSB board member Rick Engler was granted temporary administrative authority for the board, CSB’s managing director Daniel Horowitz and
T
he US Chemical Safety and Hazard
general counsel Richard Loeb were suddenly placed on administrative leave.
The report was critical of past CSB retaliation against whistleblowers and Moure-Eraso’s “disregard for proper board governance.”
In Loeb’s absence, Raymond Porfiri – who had worked at CSB for about 16 years and was the organisation’s deputy general
Although the agency has a new chairwoman, Vanessa Sutherland, the IG said the Chemical Safety Board’s new leadership “needs to assure that the CSB functions as intended and restores open communication among staff, the board and the chairperson.”
counsel – was left as head of the CSB legal department. However, evidence then came to light that Porfiri was suing the agency. CSB chair Vanessa Sutherland – Image: CSB
His lawsuit against the CSB alleged various incidents of discrimination and failure to accommodate his injuries resulting from an April 2011 accident at his home, according to documents released by PEER.
The report also said the CSB, an independent federal agency charged with investigating serious industrial chemical accidents, was not investigating all the events that fell within
But Jeff Ruch, executive director of the Public Employees for Environmental Responsibility (PEER) watchdog group, was critical of the
its legal jurisdiction. It should increase the number of investigations, as well as develop a protocol for closing investigations that remain open for longer than three years, although it admitted some steps have already been
report. He said the IG basing its morale claims on a Republican staff report was inappropriate and unreliable, and said the recommendation to do more investigations ignored the fact that the CSB lacked the
This meant Porfiri was supervising the CSB attorney who was defending the agency against his own lawsuit, according to PEER, although this was denied by Engler, who insisted at the time there was no conflict of
taken in this area.
budget to take on any more or complete them in a more timely manner.
interest.
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News Extra
9
At the same time, several Republican-led congressional committees had been calling
governance and collegiality and address pending accident cases so the board can
for reforms to the CSB and its governance. In addition, the Senate Appropriations Committee “sent the CSB an unmistakable message” in June by slashing $300,000 from its proposed budget of $11 million in fiscal year 2016. The committees cited issues related to the board’s records
“‘be a voice domestically and internationally in workplace safety.”
management, contracting, personnel management and general lack of credibility, the CSB said.
have an opportunity to seize the day and agree that some of the [governance rules] are out of date.”
President Obama had originally requested that the CSB receive a 10% increase in funding to $12.27 million in FY2016.
Tensions among CSB board members “have been a challenge for many years,” she said, “so board order needs to be revisited. But with four new members, we
Former CSB chair Rafael MoureEraso – Image: CSB
Many of the employees who “left in a huff” over the past few years are still in
100-day listening tour amongst CSB staffers and outside stakeholders, and brought a number of key employees under her direct supervision in a bid to clarify reporting lines and improve staff morale.
government, Sutherland noted. “We know some of them and would welcome them back as consultants or full-time employees.”
just morale but investigations’ status,” she said. “With four of five board members, we
Only by gaining her own understanding of how the 40-employee independent
watchdog, the Transportation Department’s Pipeline and Hazardous Materials Safety
now have a great opportunity to get things done in these exciting times.”
investigative body operates “will we be able to distill a set of priorities and execute the mission as effectively as possible,”
Administration. Before that, she was a corporate executive at Philip Morris/Altria Client Services and held legal roles at MCI/
In September, Sutherland embarked on a
Sutherland said. She will seek to improve
WorldCom.
At a public meeting on October 21, Vanessa Sutherland said she had met with the IG and had received a favourable response. “We will focus on organisational health, not
/ isual .com/v
Sutherland is an attorney whose last position was with another public
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10 News Extra
Tension between Venezuela and Guyana exacerbated by oil and mineral exploration
Venezuelan land (yellow) and sea (green) claims to Guyanese territory
the “extraordinary military activity in eastern Venezuela” was a “hostile and aggressive”
The company has been developing the Aurora mine since 1996 and announced its first gold
move. His government responded by conducting military exercises of its own, including operations by parachutists near the border.
production in August. It expects to produce between 30,000 ounces and 50,000 ounces of gold in 2015, which would make it one of Guyana’s most productive gold producers.
The border dispute between the two countries goes back over a hundred years but had been
Granger has said that Venezuela’s claims are scaring away investors from his country.
on the backburner for decades until recent oil exploration off the Guyanese coast, with Exxon Mobil’s Deepwater Champion rig announcing significant discoveries in May.
In October 2013, Venezuelan naval vessels seized a US-chartered oil research ship from Guyanese waters and detained the crew, following which no further research activity has taken place in that sector.
Venezuela has long claimed a huge tract of land known as the Essequibo, which comprises nearly 40% per cent of Guyana’s current territory adjacent to Venezuela. On top of this, following Exxon’s discoveries, Maduro’s government published maps showing that Venezuela now claims much of Guyana’s
Venezuela already sits on some of the world’s largest oil supplies while Guyana is one of the poorest countries in the region, second only to Haiti in terms of GDP.
the Guyana border. “I call on the people of Venezuela to stay calm because we are
continental shelf and maritime exclusion zone.
to close its border with Colombia. Maduro’s critics claim he is using both border disputes
seriously preparing ourselves,” he said in a TV broadcast.
On October 23, Canadian mining company Guyana Goldfields said it had received a notification of possible legal action by
to distract from the dire economic problems faced by his country following decades of populist misrule by him and his predecessor,
President David Granger of Guyana said
Venezuela over its operations in Guyana.
Hugo Chavez.
I
n September, Venezuelan President Nicolas Maduro confirmed his country’s armed forces were conducting military exercises in the east of the country, near
Venezuela recently also used military forces
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Standards 11
IECEx: a view from the chair
As usual, the week started with meetings of TAG, the organisation of all IECEx Test
• The appointment of a new Chairman of the Ex PCC committee dealing with the
Labs and Certification Bodies. It was the first time Prof. Xu of NEPSI China took the chair, stepping into the shoes of Ron Sinclair MBE of SGS Baseefa in the UK, who has done excellent work in this role over the years.
certification of personal competencies. The membership elected Peter Thurnherr from Switzerland to become the new chairman. For many years Peter has been the convenor of the Maintenance Team for IEC 60079 – 14 (Selection and Installation) and with his
Amongst a wide range of topics, the following issues were discussed: • The use of documents other than standards as the basis for certification of equipment. It was recommended to ExMC to review the current IECEx rules
election, we should achieve a good combination of the standardisation and the certification of people who have to follow the standard specification. • The long-time Chairman of that committee, Ralph Wigg from Australia,
to allow the use of any publication of TC31 such as Technical Specifications (TS) for that purpose. • The preparation of the next round of Ex proficiency testing dealing with the electrostatic charge test.
remains the Deputy Chairman. For his outstanding contribution to the success of the IECEx System, the ExMC proposed to the IEC Executive that he be awarded the 2015 Edison Award.
• The new decision sheets, developed by Ex TAG and published on the IECEx
• The new committee for the Ex-Service facility scheme (Ex SFC) also got a new
homepage. The intention of these documents is to provide a uniform interpretation of the TC31 standards.
chairman in the shape of Ron Sinclair. The Deputy Chairman will be Marco Erdhuizen from the Netherlands.
The Ex TAG meeting was accompanied by a training workshop for IECEx Prof. Dr. Thorsten Arnhold
T
he IECEx chairman gives his account of the organisation’s
Management Committee Meeting in Christchurch, New Zealand, in September 2015. During my six weeks in New Zealand I became a passionate fan of rugby union, culminating in the ‘All Blacks’ glorious victory! But this was not the only positive result of my long trip to the other end of the world - the IECEx Management Committee Meeting (ExMC) was definitely another highlight. Our hosts from Standards New Zealand did a great job and provided perfect organisation for the event.
assessors, another standard item of our annual meetings. The assessors are very important individuals within the organisation, ensuring the highest quality
chairman, the secretary, and the chairmen of the different schemes, is responsible for all important matters and necessary decisions between the
for Ex Certification Bodies and Ex Test labs. It is essential that all assessors have a high and uniform level of competence to make the right decisions.
ExMCs. A very important issue for the coming months will be a survey on how strictly the IECEx rules are followed in member countries.
Finally, the highlight of the week was the
Another task for the Executive group will
IECEx Management Committee. The importance of our organisation inside the IEC community was underlined by the fact that both the immediate past Chairman of IEC, Prof. Klaus Wucherer, and the acting Vice Chair of IEC and Chair of the Conformity assessment board (CAB), Dr. Ullrich Spindler, came all the way to New Zealand to join our meeting.
be the organisation of the next IECEx regional promotion conference. In April 2016 it will take place in New Delhi, India, a decision that pays respect to the very impressive development of the Indian process industry. We have noticed a steadily growing demand for IECEx certificates in India and want to support this development. As usual, a number of excellent experts will give presentations
Some highlights of this event were: • The first time participation of our 33th member country, Israel, and the endorsement of the first Certification body and Ex Test Lab of this country,
about different aspects of explosion protection and there will be sufficient time for detailed discussions on many topics. The details of the conference will be published soon on our IECEx webside.
This year, more than 100 delegates from 31 countries joined the series of meetings during the second week in September. A very positive fact was the strong participation of industry: more than 30% of the participants had an industrial background.
• The role of the Executive group was defined. This group, consisting of officers of the system such as the
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Decommissioning 13
Making the most of late life and preparing for retirement T
he aspiration in the headline is
The economic turmoil over the last 12
recovery can be made economic through
something that many of us will strive for towards the end of our working lives, but it is also a good recipe for assets, say Dai Richards and Philip Lawson of
months has accentuated the situation with the cut point for economic recovery coming forward, or being passed, by many assets.
reducing costs or Enhanced Oil Recovery (EoR) techniques. However there are many factors dictating whether recovery is economic or not and these factors constantly
ABB Consulting.
Forecasting the actual timing of Cessation of Production (CoP) further complicates the picture and depends very much on maintaining economic recovery. There is a real benefit to extending the CoP date, if
change, often driven by events which are hard to predict. This lack of certainty of CoP makes it harder to plan late life operations and any plans must be flexible enough to accommodate these changes.
As production facilities approach the end of their economic operating lives two conflicting priorities come to the fore: maximising production while maintaining safety and reliability, and reducing operating costs to make economic operation viable. Successful operation during this phase of the asset’s life means walking a very fine line between overinvesting in supporting the asset and not carrying out some maintenance that results in a production loss, or worse still, a safety or environmental incident. Late life is also the phase of an asset’s life when the foundations are laid for decommissioning: the right choices leading to successful, cost effective and safe decommissioning - the wrong choices leading to overspend or incidents that could damage an operator’s reputation.
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14 Decommissioning
Des esspit pite e the the dif diffficult fific cu ultties e of es o do doing ing ng sso o itt is vitittal to o mai ma a nta ttain a cohe coh ere ent nt pla p n for for o man a agi g ng late lifife lat ieo op peratio eratittio era ion nss iff ec eco c nom omic om ic re rec ec cove o ryy iss to o be em max axximi m sed d an a d tthe he prepar pre pa a par atitions ns fo forr succ su uc ucc c ess sssful fu u decomm dec ommiss omm iss ssion ion on oning nin ing ng ar are e tto o be com be comple pleted ple ted d. This This ar a tic ticle le wilill high w high ghlig gh lig ght som s e of of the he e e ess en ent n ial a el e eme e nts n for for fo suc ch a pl plan. a an
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She Shelf helff (UK (U UKCS) C e CS en nco ncou cou ourrag age mini ag n mal ni ma all sp a spend en n ing ng ng on o n pre p par pa paring a ing ng fo ng forr deco ecommi mmissi mm mmi ssioni ss on ng g dur during du ing ng lat ate liife at fe e op opera opera r tio t n. n H How ow weve evvve er not o c com omp ple etin ng som some ome of th he e key ke ey pr preparat ep epa e pa arrat ation at tion o st on s eps ep a an n nd d takking ta g the th he key key dec decisi ssiions o s co ons c uld u si signi g fic gn gni ficant ficant n lyy inc increa ncrea ea e ase the t co ostss an a d diffi fficu c ltit es cu e o off the t fifinal n na nal decomm dec ommiss om omm mmission iss ssion ioning ing pr p oce cess ss. s
red edund ed dant an n eq quip u pmen ment and pre prepar pa par a ing ng n g fo or de o dec om omm mmiss mis isssion ission o ing; ing ng g; an nd d finall fina fin alllly coll coll o abo ol borat ra ration rat ation on o n.
T e in Th ngred edient ie ents off a go good o app od ppro roac ro ach ac h This secttiion This on wi willlll dis discus c s some cus me off th he keyy el men ele ments ts tha thatt need need e d to o be be co con nsid ns nsi de der e ed d
Sma m rte rt r M Main a ten ain e anc en n e is abou nc bo out chal ha a len engi e gin ng the he cu urre rrent ntt p pra r cti c cess to t m miinim mise se e tth h he e cost osts ts of m mai ainte a nt n nt nan a ce an ce whi w le wh e pro p tec ec ctitin ing inte nteg ntegri grrityy gri and n re nd r llia ia abil b ity bi bil ty. y. The e sta start rt p po poi o ntt iss to o foc fo ocuss on susstai ta ainin ng th he e ass asssett d dur uring ing ng g itits ts la att ttter err yea ears rs off ope pe p erat attion o to on o en enabl able ab abl e maxi maxi ax mum m ec eco conom nomic nom ic c rec ecove e ovv ry, y which which wh h rre e equi q res sa qu qui safe fe and re rel e iab ab ble e ope operat rat ation at on. Equi o quipme q pment n re nt retire emen entt datte ess bas ased sed d upo upon the th he e CoP da date nee e d to to be est be esstima m ted t . Base ase ed on on the he cur urrent urren ren ent sstat tat atus a o the of he eq quip u men m t the me em min inim imu mum leve m leve velss off
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Decommissioning 15
ma nte mai enan nance, ce an and d insp s e ect c io ion on ne neces ce ces e sar a yy,, to ar o sup u por po p o t the the equ equipm ipm pmen pment ent e n u up p until until th un he proj oject ec ed ect ed
wherre wh whe e goo good go d main ntten en nance anc a nce reco e ords rds ds ex e ist st. The st. he benefi ben efits efi fits are e no nott only do down wn w n to o the he d diirec re ectt c cost ostt
fo for or ea each ch rel ch rele re eva ev vant n iite t m m,, the he ap he ppro ro opri pr ate ap approa app p roa ro oa o a ach ch c hd dep ep pen pend end nding n nding ing on n th he cons n equ q en enc n es es
retire ret re etire e re emen m t dat me ate tte can can then ca th hen en nb be e de determin ter e min er mined. ed ed. When Whe he en con ons n ide ns derin de ring g the h mai ma ntenan ma nttenan nte an a nce c and nd d ins nssp pe pec ecttio e on requ requ q ire remen remen e tss tthe he h ere wil wi l be ma any n opp op po ort or rtuni tun uni nitie ie es to re edu duce d e the th he h e fr frequ eq enc ency or or s pe sco e of of the e ma maint maint in ntena n nan nce in nce nterven terven ter v tio tio on nss ns.
sa ing sav in ngs from n from om m re reduc duc d cing ng n g ma maint nttenance ena en nance na nce e ta tasks skkss, bu but ut th the he work o loa or lo oa ad re ed edu d cti cttion o ffre on ee ees ess up p bed ed e d spa p ce ce to to all a ow al w peo people ple le to wo worrkk on on hig h gher he pririori p orityy tas asks as asks. ks ks.
A chal hallen ha len len nging gin i g proc proc cess es ca an resu res esu s ltt in n sig gnifi nifica ca ant
Whe W h n cons o side ide derrin de in ng equi quipme pme pm pme m ntt re ret ettire irre remen me entt dat da ae ess itt iiss imp m ort mp ortant tant ant tto o co c nsi nsider derr th he
of equ of quipm qu pm men ent ent n fa faililu failu llure ea and nd d the th he op pttions pti ns fo n or rep re ep e pair ai or or re repla pla p lace cem ment ent.. Ano An nother ther cons the onside iderat ide d rat ra ation at on o whe whe hen n dete e erm etermi rmi minin m niin ng late ate lliife at fe mai ma nte ma ena nan n an nc ce e iiss the he eve eve eventu entu ntu uall fat fa ate of the a h equ equ eq uipm pm pment ment, en ent e n nt, whe het ethe her err iitt wi e w llll be dis d sman mantle man ttle ed, d so so sol old for for or sscr ca cr ap p or o pre pre eser ervved e ed fo for o rre or esal sale. sa e.. Add e A itititiona tiona al m main a nten ain tenanc te an anc nce may may be b jjus ustifi ififified ed d to oh he elp elp pm max aximi mise se e ass asset ett val e value. va ue. ue e
reduct red re uc ion o s in in main inten ten nanc nce e and d ins nssp pec ectio on tas tasks, a ks, ks as illlus ks lustra usstra ate ted e by ed by th he foll foll o owi ol ow w ng exa amp mpl ple p ess A rrevview es. ew e w of of pr p esssu urirrised se eq equip uip i men ipmen mentt me ins nssp n pec e tio t ns ns car carrie ried rie ed ou utt acr across ac o s ei oss eight gh of ght offsh fsh shore ore and three th hree re ee on nsho ho ore e ffac cili ilitie ttie es dete es t rmi rm ned ed th ha att over 50% ove ov 50% 0 of o the t ittems em m re revie viewed vie ewed we we were re e sui su tab ab ble e
re u req uiireme uir ments m tss fo f r equi equi qu u pme pm pment ment to to ope op pe erat r e b ond bey o d Co on CoP, P eitthe P, her e as as itt iss re requi quired qu red tto o fac acili a il ta ttat ate deco a ecommi commi mmissi s o ssi oni ni ning, ng, ng g or o as as itt iss ne eede d d to o mai ma nt ma nta tain aiin n the he es e sen se titia ial al syst ystems em ems e m rre ms equi quired qu red ed e d while whi le e th t e assset the sett iiss ma aint ntain nt ain ne ed d as as a Norm Norm mall ay al Un Unm n ann nm a ed an ed In Ins nstallat n ta llat tal ation o (N on NUI)I)), p prio riorr to rio
L e life La Lat e op pera err tio eratio io on brin brin rin ngs g new e ma maint nttena nance n nce ch cha halle enge ng g s, s du due ue e pa parrtl rttlyy to chan hangin gi g oper operati pe per erat atit ng condit con dittion ions ons and and d par partly tlyy du due to equi q pment qu pm pme m nt nt age eing g. Typi ypical ca cal ca al ex e a amp m mples ess of o so some me of me of th the he h e the these hese e cha alle eng nge ges incl ges nc u ude de d e:
for o No N n Inva nvasiv s ve siv e Insp spect e ion ect on n (N (NII) II), mean II), II) a ing tha ha at tthe he ite t ms cou ould ld be ins n pec ns pected ted d on onlin line lin e and n withou wi wit hou out the o h nee ed to to o open pen up up th the e equipme qu pme qui pment pm n nt fo for o in inspe specti spe c on. ct cti on n NI NIII help e ps redu redu educe c the ce he frrequ quenc uenc ency o tur of turnar naroun nar ounds oun ds (TA ARs) s),, one one n off the he e ma ain n con ontri t but tri b ors to lo ower we w er pr produ oducti odu ctiton effi effici cienc ci e y, enc
dec ecomm o omm iss ssion ss ion oning on ing g. The h ope op pe erat ating n pe ng perio rio iod a ass a NU co NUI c uld d be e se sevver erral al yea years ye rs and an n th the he requ equire iire re red d equipm equ ipment ipm ment e wi willll nee e d to to have a ma maint ntena nt ena nan nce ce c a mo an and monit niti ori o ng g pla plans l nss in n place pla ac ce e tthr hrroughou ou oug ughout ho t hou that tha hat time me.. Iden me Iden entif ntifi yin ying g re etitirem et ire rem em me en ent nt dates da ate tes es al also also o provid pro v es a so vid ollid basi oli asiss ffor as orr the he e evvent en ual a
* acceler cce eler l ate le atte ed corr orrosi os on osi o d dam mage g to o3 30 0 year yea ear old d equipm equipm equ p ent en nt wi with th low ow wm me ea asu ssu ured re ed d co ros cor ros o ion on ra rates ttes es, due e u to oc cha ha ange ange ng ge g es in flui flui uid com c mp pos ossiti it ons nss * dete et rio et r rating ra rat a ing ng g co condi n tio on of of smal m l bore ma orre pip pewo wo orkk and an n branc nd branc br an nches e , giv ivi vviing ng gp po pot otent en ia ial al
and nd n d reduc re educ d ess the the e works wo w orks rkkscop rkscop co e for o pla planne lanne nned d eve ev events vents nt .
decomm dec omm mmiss mm is ion iss o ing on n pllans an ns. n
failur fai lur urres u es and a a losss o an off co ont ntainmen ain nme me men ent * poo oor or rre elia elia ia abil b ity of compr bi compr co mp m press ess ssion ion ion n tr tra train ain in ns, s, due e tto o
Thiss redu Thi redu ducti c on cti n in n wor worklo kload klo ad a allllo ows ws fo or either eit ther he sh hor ort o rter TAR TA durat durat du r ion ionss or ffor or oth or otherr
O e of the One th he c comm omm m on n iss ssssues sues u im ue mpac pactin pa tin ing in rel re e iab el ble e pro pro od duc uc ctio t n duri tio uring ng lat ng ate at e life life iff iss ob obsol bso sol o ete et et equipm equ iipm pment ent. nt. When id dent en ifying ify fying ng g re retir t reme tir eme ment entt
red e u ed uce uc ce c ed pres presssur sures, s re red duc u ed flow uc flow ra flo attes a ate and nd n d differ dif fer ferent erent en ntt mo molec le ula ularr weig weig eig gh htt ran ange ge ge * a la ack ck o off pow owerr ge ge gen en nera eration tio tio on capa cap apa pacit p city due ue to to
m ntenan ma mai nte enan n ce tas tasks ks to o be be sub bsti stitut st utte ed, d wh which ch c h can a he help lp to add ddres resss the res the inc in rea easin ea sing g back a lo og of mai m nte ma ntenan nan ance e in in the he No he N rth th h Se Sea. a. In ano no oth the he er
d e dat es, s a an ny equi equi u pme pment tha pm at will i be b ob bsol s e so ete te e prir or p o to oC CoP oP P sh s oul ould be iden de tifi ifified fied ed. A An n obs b ole bs esce scence nc ce strat sttrat a egy at eg gyy is g is then th hen en req requir equirred e
additi add ittiona ititi onall equi quipme qu pm p me ent ntt hav a ing av aving i g be been en ins en in nstal t led ta tal ed * redu duc ctttions cti on in n th the reliabi eliiabi eli ab a b llitiitty ty of of uttil tiilliti itties, iti es e. e.g. g g. coo oo olin ng wat ate t r syyst yss em ems, due ems u to o age ageing ing ng g.
exampl exa mp mpl ple, e, the th he e te testi s ng sti ng fr fre rre eque que que qu ency nc cy of cy o pr press essssure es ure ur ure saf affet ety ty va valve valve vess wass rev ve evie ev iew iew wed we ed acr ac oss osss si sixx o sho off sh hore ho re p pla la atf ttfo form rms ms an m and an on-s and n shor nsh ho hor or o ore e term rmina rm mina ina in al.l. The Th he h e rriisskk ba bas b a assed sed d re rev e iew ew e w re resul su ted su sul d in in the the aver th errage e inspe ins pec pec ctio tio on inte inte t rval rva va al bein ein ng incr c eas eas a ed d byy 27% %, res esu es ulltlting ult ng in in si s gni n fic fican ant n c co ost ost st sav sa avving ing gs. s. The The Th These hesse e sor ort or rt of redu ed c ctittions o ar on are achi ch eva evvable vable b pa parti rrtititicul rt cul ua arlrlly
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16 Decommissioning
Identifying these new factors and ensuring they are considered as part of challenging the maintenance regime is critical as they can have detrimental impacts on the
Further advantages come from freeing up deck space, reducing topsides weight and providing a source of critical spare parts. The cost savings can be very significant,
These range from the construction and condition of the asset, the efficiency of demolition techniques deployed, logistical issues such as the availability of lifting vessels
equipment’s likelihood of reaching the required retirement date.
with examples of the maintenance savings equating to over 2% of of overall
and port facilities. The overall schedule for decommissioning, the various methodologies
Asset life extension has not been mentioned above, but there are many situations where it
maintenance spend. This exercise brings benefits not only during late life, but reduces the overall decommissioning task.
to be deployed for different stages, project estimates, project risks (including safety, environmental, reputational and commercial
remains desirable to significantly extend the operating life of an asset. In these situations, a comprehensive review of the asset’s equipment and maintenance approaches is required to identify the actions required to assure the continued safety and reliability of the production facility. Such a study would provide a forward view of the investments required to support the asset and would provide a robust starting point for the decommissioning plans.
Collaboration is possibly the most important element in a successful decommissioning project
risks), the contracting strategy and the availability of key lifting and disposal facilities are some of the key project elements that should be developed during late life operation. Late life is also a good time to ensure that the key information required for successful decommissioning is captured and secured in order to make it easily accessible during decommissioning. Uncertainties about the condition of equipment, the state of decontamination, structural integrity, the health of safety and emergency
Managing redundant equipment and
Determining which items of equipment are required post CoP requires many of the key decisions about the decommissioning plans to be made. The length of time after
preparing for decommissioning is a vital element that should be starting up to 10 years before CoP. During the maintenance challenge process described above equipment will be identified that can be retired early, or indeed is already redundant. Clearly continuing to maintain redundant equipment is a cost that should be avoided, but there are examples of this happening when redundant equipment is not fully
CoP that dismantling will actually start, the choice of dismantling approach (single lift or piece small or piece large or a combination of all) and the systems that will continue to operate during NUI operation are three of the key decisions that will impact the retirement dates of equipment. While there are financial benefits from delaying development work on decommissioning projects the overall risk of making poor decisions necessitates
systems etc. will increase the risks during decommissioning and therefore the contingencies allowed for the project. Determining critical information will help to manage and reduce the project risks. Capturing this data during late life is easier as people with much of the unrecorded knowledge are available, the operating and maintenance systems are live and active.
isolated or maintenance records updated.
some planning and preparation work being done. This is consistent with the regulatory requirements to complete decommissioning plans and estimates prior to CoP.
Collaboration
There are many factors that will influence the optimum strategy for decommissioning.
decommissioning successfully. Collaboration is certainly a current hot topic in the
Removing redundant equipment not only reduces maintenance costs, but also reduces safety and environmental incidents caused by, for example, inappropriately isolated dead legs that are prone to leaks.
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Collaboration is the final element to be discussed here, but it is possibly the most important element in helping the UKCS operators to manage late life operation and
Decommissioning 17
industry, however Maximising Economic Recovery requires collaboration to actually
around the liabilities arising from use of used components in uncertain condition.
happen in a meaningful way. Many of the topics discussed earlier in this article can be improved or made easier through collaboration.
Navigating this concern in a one-off situation, possibly involving a breakdown, is not easy. Tackling the issue across the industry and developing an approach that all operators can accept would be a significant task, but if accepted could make the sharing of spares acceptable and bring significant
There are a number of areas that will benefit from collaboration during decommissioning. Developing standard procedures for decommissioning that everyone accepts will save time and costs compared to these being developed for each and every project. Standard forms of contract will simplify the contracting process. Commonly agreed
benefits to all. This is the sort of issue that collaboration could address.
ways of working and offshore operating procedures during the decommissioning phase will assist with contractor compliance and reduce costs. Collectively establishing estimating norms for piece small demolition will make project estimates more robust
approaches are adopted must be flexible enough to adapt to constantly changing demands. Having an up-to-date understanding of the most likely retirement date for equipment and the interventions required to maintain equipment’s fitness
and faster to develop. These are just some examples.
for service will go a long way in helping to make the right decisions during late life
The ‘wave’ of decommissioning activity will create bottlenecks in areas such as heavy
and decommissioning. This understanding will help balance the conflicting pressures of safety, maximising production, reducing
About the authors:
Conclusion Finding the right balance during late life operations is not easy and whatever
lift vessels and port capacity. Coordinating the demand for scarce resources and using them efficiently will benefit all operators,
costs as much as possible and maintaining flexibility.
but will require collaboration and some compromise. During late life operation, collaboration
There are sustainable ways of responding to the current cost pressures without compromising safety, integrity, reliability or future decommissioning costs. However
around sharing critical spares and making these available from redundant assets would help with some of problems created by obsolescence. One-of the blockers to sharing spares is concern
the industry will have to continue to change and adapt traditional ways of working by looking at new approaches, often well tried and tested in other sectors, and by truly collaborating.
Dai Richards is currently the Marketing Manager for ABB’s Consulting business. He has worked for 30 years in the oil & gas, chemicals and petrochemicals industries and his operational experience includes engineering maintenance, turnaround management, project management and consultancy.
Philip Lawson manages ABB’s Aberdeen Service & Consultancy. He has over 15 years’ experience in the oil, gas and process industries working with key North Sea operators. Most recently, he has been responsible for delivering a number of asset life extension studies for operations and developing economical solutions for managing redundant or obsolete equipment.
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2015-2016
February 24th & 25th, Runcorn, Cheshire, UK
Protecting Plant, Process & Personnel
HazardEx 2016 International Conference & Exhibition 24th & 25th February 2016 Contact Russell Goater on +44 (0)1732 359990 or email russell.goater@imlgroup.co.uk k for details of the current early-bird & 2-for-1 delegate package offers now before they expire!
Running alongside the exhibition will be our varied conference programme. This will concentrate on the experiences of leading end-users in the oil and gas sector, both upstream and downstream, energy, chemicals and other process industries where hazardous areas exist and safe operational procedures must be adopted. As always, there will be a strong contribution from regulators, safety consultants and industry associations, as well as detailed standards and legislation updates directly from those responsible for creating them. The HazardEx biennial conference and exhibition has become the must-attend event for the hazardous area sector. It offers networking opportunities with government agencies, regulators and certiďŹ cation bodies as well as senior engineers and safety managers from all the process industries, who all come together to share their experiences.
For further information on delegate or exhibiting options contact: +44 (0)1732 359990 hazardex@imlgroup.co.uk www.hazardexonthenet.net The organisers welcome contact for delegates: Tel +44 (0)1732 359 990 or Email us hazardex@imlgroup.co.uk for more information on all enquiries
Decommissioning 19
Case study: The importance of leadership in building safety culture on decommissioning projects
W
ith the pace of decommissioning
activity accelerating, Mark Walker of Optimus Seventh Generation, a behavioural change consultancy, discusses the vital need for leadership to help ensure projects are as safe as possible.
Key findings from this year’s Oil and Gas UK activity survey state that the annual average expected spend on decommissioning on the UK Continental Shelf (UKCS) over the second half of the decade has increased to £1.8billion from £1.5billion. With the low oil price, rising costs and ageing infrastructure, the huge task of removing redundant installations from the North Sea is gathering momentum.
In high hazard industries, and specifically the
It is clear that those organisations whose
energy sector, we talk about safety culture and understand the importance of it but do not always understand how we can assess it and, therefore, how we can improve it.
culture is underpinned by strong values will create a workforce willing to engage with new safety processes and will therefore be best equipped to protect both their people and their assets. If these values have been socialised within the business and are
Many operators are seeking less expensive alternatives to deliver decommissioning work, but want to ensure that safety remains a priority. However there needs to be the acknowledgement that there may be gaps in their safety culture that should be addressed to deliver successful, safe projects. Incident-free projects are delivered by motivating the workforce to follow the rules and to intervene, while educating leaders so they understand the influence
used by leaders at all levels in an authentic manner then the safety culture in our industry will create the resilience it needs.
they have over their teams.
Case Study Our organisation has developed an approach to safety culture assessment, drawing upon High Reliability Organisation (HRO) principles, seeking a diagnostic as a means of providing the assurance that
With over 600 offshore oil and gas installations in the North Sea, of various sizes, and more than 10,000km of pipelines, wells and accumulations of drill cuttings, the biggest
Resilience is assured not just by the behaviours of people but also by the consistent application of processes and
things are as they should be. We ask the diagnostic to identify the most significant safety issues confronting the organisation or site, gathering evidence of safety culture by a combination of observation and audit
concern is how the infrastructure can be removed in a safe and cost effective manner.
procedures as well as the functionality of safety critical equipment.
of work products and perception-based surveys and interviews.
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20 Decommissioning
health and safety advisors to support the safe decommissioning of a floating production, storage and offloading vessel in the North Sea. When embedded by the presence of our safety advisers, Induction Plus helps influence the decision-making of all involved, ensuring rules are being followed and incident-free projects are being delivered. The four-hour induction is aimed at projects experiencing a large influx of new, often subcontracted, labour during decommissioning and construction projects or shutdowns. It educates the attendees on the company’s expectations with respect to compliance with the company’s safety rules, alongside a motivational element to engage the project team with ‘why’ compliance is important and how they can raise their awareness of the hazards specific to the asset. We work with leaders to educate them with the understanding that their decision making is key in the project’s success, increasing workforce engagement, which helps ensure that the work force remained focused and motivated, creating a safe environment.
The diagnostic seeks to establish the aspects of resilience that are present, such as:
Our coaches encourage our clients to turn that statement around and ask; what do
• The ability of the business to stop something bad from happening • The ability to stop something bad becoming worse
followers want? One of the principal roles of a leader is to create an engaged workforce or, more simply expressed, to create followers. Without an engaged workforce, there is no
The work is based in the North Sea, and we will be providing specialist safety support services to decommission a floating production, storage and offloading vessel, in
• The ability to recover something bad once it has happened
relationship and no leadership.
a safe and environmentally responsible way.
The diagnostic is also looking for what barriers there are and how many are in place, with the use of personal protective
our industry - to incorporate authenticity as an assessment criterion for our current and future leaders during selection and to re-design our
equipment (PPE) at one end of the scale as the weakest defence and the elimination of hazards at the other end of the scale as the strongest. Between these we would hope to see others that give the business the ability to detect hazards by fixed detection systems, hazard spotting and management processes, adequate planning and active monitoring.
leadership training to establish authenticity as an outcome of such programs.
We recognise that this poses challenges for
The glue that would hold all of the above
Working with safety leaders in individual companies or in our open course – Leading Safety Performance – we have witnessed many “light bulb moments” when leaders have realised what skills they require to be authentic and have left with a strong desire to be that authentic person and to lead based
together is the leadership.
on their values.
When we deploy our leadership and workplace safety coaches in the field, our clients and their workforce often ask; what
In May 2015, Optimus Seventh Generation was awarded its first decommissioning contract with a major North Sea operator
does an authentic leader look like? How will we know them when we see them?
to supply induction training, through its programme Induction Plus and back to back
www.hazardexonthenet.net
About the author:
Mark Walker is Client Partner at Optimus Seventh Generation, an international behavioural change consultancy focused on the high hazard industries.
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22 Asset management
The evolution of cable identification:
Understanding new technology and innovations U
sing cable management solutions
to identify wiring, long-running cables and components is vital. Clear identification aids future maintenance and reconfigurations, as well as providing reassurance to those responsible for health and safety.
However, as the technology and methods of cable management evolve, it is important for installers to understand how and why they should use certain products and, most importantly, what developments are making the job of identification easier than ever before.
for both short and long-term use, cable
Looking at identification markers, one
identification has evolved in leaps and bounds over the past few years, resulting in a range of differing solutions that can potentially save time and money.
of the downfalls is that the markers can be damaged and readability can be affected. The danger here is that a code can be misinterpreted which could lead to incorrect handling and might put safety at risk. One of the more important aspects
RFID technology and labelling has taken great leaps forward in recent years
In the beginning‌
is choosing the right material for each application. Markers are available to suit a range of environments and situations, including being fire resistant and zero halogen. Cable management that meets certain criteria ensures that any labelling is protected and the risk of illegible information is reduced by simply choosing the correct material.
John Banks of HellermannTyton, looks at the solutions available and the
Identification has come a long way since we began manufacturing solutions. Markers that
innovations shaping the future of cable management. Cable identification is a crucial part of any installation and it needs to be clear and
slide on to the label were applied one-byone, with separate letters and numbers used to provide a readable label. Just like a bar code the marker held significant information, yet, although tried and tested for many years
However, since the humble beginnings of identification, data technology has emerged as an efficient backup for the physical marker and such innovation has an important role to play in creating an
correct to ensure readability and meet health and safety regulations. Essential
this solution has proven time-consuming, repetitive and can produce a potential risk.
easier identification process.
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Asset management 23
A Thermal Identification Printing System, or TIPS to most, is the next step up
legends using individual cable markers and the tubing shrinks to fit around cables and
from the simple slide on markers or adhesive labelling systems. Consisting of a thermal printer, ribbon and easy-to-use software, TIPS products make it possible to have multiple lines of text with images and even bar and QR codes, and with the accompanying software, creating
wires to become a permanent marking. This once again ensures no tampering or removal and provides a safe way to avoid human error. It is advisable to use a product that has a good resistance against solvents and chemicals, as this will ensure cables and wires remain properly identified in a
data tables that consist of hundreds of automatically sequenced idents takes just seconds.
range of environments, including industrial settings.
A system such as this is ideal for companies that have large scale, regular cable or component identification projects that would benefit from having their own on-site printing capability due to the complexity and variety of their identification needs. TIPTAGs are ideal for easy and convenient identification and they are
An additional benefit of heat shrink tubing is its ability to work in extreme temperatures between -55°C up to +225°C, which again is ideal for arduous and unpredictable environments.
Time-saving software TIPS is an effective and efficient way of identifying cabling, however without the
clearly visible, resilient and can be fastened with cable ties with ease. This type of
advancement in software, the process wouldn’t be the streamlined system it
identification is trusted by the likes of UK Air Traffic Control, who rely on such a system to identify long runs of cabling that run
is today.
under several rooms and provide resistance to chemical, fire and other potential risks, as well as mobile phone mast installers who
since our first printing system was designed over ten years ago. Users no longer have to enter each product individually or type
require a clear and long lasting product that can survive all weather conditions.
out new labels with each new project, and, human error is significantly reduced thanks to pre-programmed and bulk print functions available on the market.
Tubing technology
For those seeking to mark a variety of
In today’s world, there is a need to get more and more information onto cable or wire identification sleeves or labels, and traditional single cable markers are not always able to satisfy this demand.
cable sizes and find an even simpler way to apply information, heat shrink tubing is an option to consider. Essentially printable sleevings, the tubing significantly reduces costs by eliminating the need to make up
Labelling software has come a long way
This software within printing systems is essential for those keen to save time and investment. A printing system needs to produce identification labels as and when required and by owning the right software the installer can take control of their output. Benefits produced by new software also result in high quality labels with bar codes or QR codes, text, images and graphics that improve on production and allows users to create the labelling they want. Integrating data also helps to save time and costs without losing past settings, while systems offering pre-loaded size order spreadsheets eliminate spelling errors and incorrect data entry. This means that less time is now spent on producing labels and more time is concentrated on the installation job at hand without any compromise on quality or safety.
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24 Asset management
The bi bigge ggest st imp mprov mp rov ovem eme ent in n ter terms ms of ide denti nt fic nti ficati ation tion sof softw wa are com om mes es in in th th the he form off Rad Radio io Fre Freque quency ncyy IId den dent ntifi ifificat cation ion (R (RFID FID D)
th the h insta ta alllle le er with a sec cure e an and d reli reliabl ablle ide tifificati identi ide cati ation on sys ysttem tem tem.
proce pro esss shou uld db be e con con co onsid s ere ed care ca are eful ful fu u ullly. lyy. ly The h be est ad adv dvice dv ic ce e is is to o ta ake ke all co compo po onen nen nts ts in iint ntto acc n ccount cco un when when ch wh choosi cho osi si n si ng g sol olut ol utititons an ut and d
technolog techno logyy whic which hp provvide es la larg arg gerr cap paci city ty and pr produ oducti ctivit vityy, wor workkkin in ng in in ssync ync wi with th existi exi isti sting ng g sys system temss.
Ben enefi efits inc nc clu lud ude ud e taki taki akin k ng ng awa aw y man anu nual al rea adin din ng mist stak ake kes, s the e ab abiility ility to pre re epro ogra gramm mme me a ser serial ial numbe er to prov prov rovide ide a di dire ect lin linkk to a netwo two work wo rk withou outt huma h ma man n
app app plyy the th sam sa ame dil diilige gence ence e to to ca able manage manage man gemen ge mentt prod product uctts as to uct to tthe he e lar l ger ger ge elements. ele ts. ts s. By By se selec lec ctin titi g the ting he rig right ht ma mat a eri at er all and nd d solution ion fo or each each a ap application n, inst sta st alllers
RFID tech RFID tech echnol nology nol ogy an and d labe labe abelli lling lli ng has has ta taken tak ken great leaps forward in recent years. Although not a new concept, RFID works with existing coding and software and provides a foolproof way to ensure cable management is safe, secure and readable.
contact and com om mpatibi pattibi ibilit lityy wi lit with ith ex exiisting systems.
can be be co confi nfident in their workk, ensu nsurin ring g end-user risk is minimised and time on a project is being spent wisely.
Intelligent, ideal for use within all sectors and compact, RFID data technology is being used within the industry to collate and register products that can talk to a network system – essentially it’s a tracker that can be read even when the labelling can’t. This use of RFID within cable management
Identifying future trends RFID tags won’t entirely replace traditional identification methods such as printed labels and heat shrink tubing. However, as time goes on we will see more use for RFID, with an increased focus on seamless wireless installations and registration within cable and wire applications. Going forward there will be exciting developments in data collection, how we utilise this to benefit identification even further and new products, such as products with integrated RFID transponders. Yet, no matter how
means that not only can each cable be identified, but the tags can potentially be changed, updated and locked, with risk of damage and marks being accidentally removed greatly reduced. Although there
much progress is made, technology will always be an additional complement and quality check to traditional methods and straightforward labelling solutions.
is still a wider scope of opportunities for using RFID technology, it has provided
When considering cable management and identification solutions, the specification
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About the author:
John Banks is National Product Manager at HellermannTyton and was formerly Sales Manager at Unipart Rail.
2016
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Simo Si mon n Brow Brown n – co cons nsul ulta tant nt, t, IE EC 61 6151 511 1 wo work rkin ing g gr grou oup p 2nd ed IEC 2nd C 615 1511 11 – Prroc oces esss sect ctor tor fun unct ctio iona ona nall sa safe fety fe ty T no Vande Ti an nde Cap apel elle el le e – GMI Safe Sa fety fe ty cul ultu ture re & func fu nctition onal al saf afet etyy et
Riichard Da R Rich avis viis – Cl Clev vel elan lan nd Fi Fire e M ltltiMu i Ta iT nkk fifirrefi efig fight htin ing g st stra rate tegy te egy gy;; risk skk asses essm es ssmen smen nt & an anal alys y is Steve Pe St Pear arso s n – Ph so P us usio io oniim Five tip ipss to mak ake ak e yo your ourr haz a ardo ardo dous uss are ea equiipm pmen nt in insp spe sp ectit on ec onss mo more re efffic ciien entt & ef effe fecti cttive ive Elaina Har arve veyy – Du ve DuPo DuP Pont How to assess elec ec ctr tric ic c arc rc hazar azards arrds ds and protec ct st stafff Intertek k What’s next for ageing ng g ass sset ets? et s? Future-proofing for deco omi miss ssio io oni n ng g
Co C olin ol lin Ea East ston on – Pro rosa sallus lus Functtion Fu Func tion onal al saffet etyy appl appl plie ied ie d to age to g in ing g asse asse as sets ts Pa P aull Reeve ve – Sillmetr tric tr ic c How is jud Ho udge ge g eme ment nt of fu func func ctiion onal al safe sa fety tyy bei e ng made? ad d ? A n Ro An Rosb bro rook ok k – Head d off Saf afet fet ety y Engi En g neer gi erin ing, g, Total otall E&P ot P UK S fe Sa f tyy Critica call Ta T sk sks: ks: s: Ide d nttiifificat a io ion on o Hum of uman an Err rror orr to Co Conttrol Ri R sks sk ks fr from om m M jo Ma jorr Ac A ci cide de ent Hazar ards ar dss
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26 Functional safety
IEC61511 Ed. 2.0 : Functional safety – Safety instrumented systems for the process industry sector (Part 2) his article by Functional Safety Senior Expert Tino Vande Capelle presents a general overview of IEC
Unfortunately, too often people consider this a formality and use uncalibrated tools or wrong risk definitions.
Phase 2 (Clause 9, Allocation of safety functions to protection layers)
61511 – Functional safety – safety instrumented system (SIS) for the process industry sector - Normative
Risk management consists of three main tasks: 1. Identify the hazard, 2. Analyse
Once the safety functions are identified, each is assigned to protective layers. There are prevention layers and mitigation
Part 1: Framework, definitions, system, hardware and software requirements, edition 2.0. This is based on the CDV version (65A/691/CDV - 2014-05-09,
the hazard & 3. Reduce the risk. A HRA (Hazard and Risk Analysis) team identifies the potential hazards using accepted methods, analyses the consequences and frequencies,
layers. The risk reduction allocated to a basic process control system that does not conform to IEC 61511 must be less than 10 and any layer must be
CDV=Committee Draft for Vote) of the standard and the author’s interpretation of the changes in relation to edition 1.0.
and when the frequency is higher then the tolerable criteria, there will be a need for risk reduction – a safety function achieving a certain SIL band performance or RRF (risk reduction factor).
independent and separate from the initiating source to avoid common cause, common mode and dependent failures. The safety functions allocated to the safety instrumented system (SIS) are called safety instrumented functions (SIF). The risk
New in Ed. 2.0 is that there SHALL be a Security risk assessment carried out on the SIS and the associated devices to identify the security vulnerabilities of the SIS, with guidance from ISA TR84.00.09 and IEC62443-2.
reduction is the safety integrity level (SIL) for each SIF or the average frequency of dangerous failure (PFD or PFH) to that SIF. See Figures 3 and 4 below. (ref. IEC61511 Ed. 2.0 part 1)
T
When the article was written, the forecasted publication date of IEC61511 Ed. 2.0 – Part 1 has been postponed to 2016-01. Please note that there may be additional or different changes to the final published version of the IEC 61511 Ed 2.0. This is the second part. The first was published in the November 2015 issue of Hazardex.
4a Lifecycle phases overview Phase 1 (Clause 8, Process hazard and risk assessment) This is probably the most crucial phase in the lifecycle, because if the team fails to identify the hazard, then there will not be a safety function in place to reduce the potential risk.
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Figure 3 – Safety integrity requirements: PFDAVG
Functional safety 27
- Environmental conditions likely to be encountered, EMC limits - Survival requirements for any SIF by a major accident event
Figure 4 – Safety integrity requirements: PFH
Phase 3 (Clause 10, SIS safety requirements specification, SRS)
requirements shall take into account the safety planning requirements and the safety manual of the chosen architecture, such as limitations and constraints of the hardware and embedded software. There is of course a close relationship between the SIS
The objective of this phase is to specify the requirements for the SIS including any application programs and the architecture of the SIS. Many consider this document to be the primary document in the lifecycle. However despite the fact that IEC61511 Ed. 1.0 was released over 10 years ago, experiences from international projects prove that not many people or organisations are capable of describing a SIF as summarised in IEC61511-1. Therefore, I include the detailed list below – reference IEC61511-1, 10.3.1. The specification of the SIS safety requirements SHALL include: - SIF description - List of plant input and output devices - Common cause failure requirements
The SIS application program safety requirements shall be derived from the SRS and chosen architecture (arrangement and internal structure) of the SIS. The
hardware and the SIS application program requirements, as shown in Figure 5. (ref. IEC61511 Ed. 2.0 part 1) The SIS safety life cycle of the application program starts in phase 3 and ends in phase Figure 5 – Relationship of system, SIS hardware and SIS application program
- Mean time to repair - Identification of dangerous combinations of output states
10 with the functional safety assessment. Each phase of the application program safety life cycle (see Figure 6) shall be defined in terms of its elementary activities, objectives, required input information and output results and verification requirements.
- Definition of the safe state - Assumed sources of demand on the SIF - Proof test intervals and implementation requirements (e.g. proof test coverage) - Response time within the process safety time - Mode of operation (low, high or continuous) and SIL - SIS process measurements, range and accuracy - SIF process output actions - Functional relation between process inputs and outputs - Requirements for manual shutdown, resetting SIF - Energise or de-energise to trip for each SIF - Maximum allowable spurious trip rate - Requirements for start-up or restarting the SIS - Interfaces between SIS and any other system - Application program safety requirements - Bypass requirements and compensating measures - Specification of any action necessary to achieve or maintain a safe state of the process in case of a fault detection
Figure 6 – Application program safety life cycle and its relationship to the SIS safety life cycle (ref. IEC61511 Ed. 2.0 part 1)
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Functional safety 29
program development requirements in edition 2.0. The application program of the safety instrumented system SHALL be in accordance with the SRS from phase 3 – clause 10, up to and including SIL3.
Clause 13, describing Factory Acceptance Testing (FAT) was in IEC61511 – part 1, edition 1.0 and was the only ‘INFORMATIVE’ clause in part 1 as all other clauses were
The application program SHALL allow a functional safety assessment to be carried out.
‘NORMATIVE’. Although edition 2.0 made this clause NORMATIVE, it is not referred to in Figure 2 - SIS safety lifecycle phases and FSA stages.
Furthermore there are new requirements for verification (review and testing) by a competent person NOT involved in the original program development. Application program development SHALL comply with the constraints in the applicable safety manual(s).
This special note is based on the author’s personal opinion that clause 13 (FAT) could be listed under phase 5 of
vendors provide checklists or installation recommendations to help the end user minimise potential installation failures.
The objective of a FAT is to test the
activities should be initiated.
devices including the application program of the SIS to ensure that the met. The need for a FAT SHALL be
starting from the SIS safety requirements to the final testing as SIS safety validation
has a list of prescriptive requirements
8 below.
The installation of the SIS should be done as per the design and installation plan. Any deviation should be properly reviewed with the project team to ensure all the design requirements are still satisfied. Many
Once the SIS has been properly installed, it should be fully commissioned and validation
requirements defined in the SRS are
V-model was available in IEC61511-part 1 Ed. 1.0, but has been revised and moved into IEC61511-part 2 in Ed. 2.0. See Figure
Clause 14: SIS installation and commissioning
the SIS life cycle model.
The use of a V-model life cycle for the development of an application program
(by FAT or SAT) is highly recommended to minimise potential systematic failures that might cause program malfunctions. A similar
Phase 5 (Clause 14 & 15)
specified during the safety planning and in the standard. The FAT also requires competent test personnel and preferably also the people who will
Installation and commissioning planning SHALL define all activities required including: - Procedures, measures and techniques to be used - When and how this work will be done - Responsibilities of persons, departments and organisation involved in this activity All must be recorded and documented.
operate the process, since this will give them some early training on the operation of their SIS.
Clause 15: SIS safety validation Validation is to demonstrate that the SIS achieves the requirements as described in the SRS and needs to be completed prior to the SIS being brought into operation. A full validation could be referred to as a Site Acceptance Test (SAT), whereas a partial validation at the manufacturers site or system integrator could be referred to as a FAT. Validation planning of the SIS SHALL be carried out throughout the SIS lifecycle and SHALL define all activities and equipment required for validation. The standard describes a list of requirements to fulfil. Validation planning of the application program as an integrated test SHALL fulfil a list of requirements from the standard and be documented. After the SIS validation and before hazards are introduced into the process, the following activities SHALL be carried out: - All bypass functions shall be returned to their normal position - All process isolation valves shall be set in
Figure 8 – Application program V-Model
the correct position according to start-up requirements and procedures
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30 Functional safety
- All test material shall be removed - All commissioning overrides and force permissives shall be removed
Phase 6 (Clause 16, Operation and Maintenance) The objectives of this phase are: - To ensure that the required SIL of each SIF is maintained during operation and maintenance - To operate and maintain the SIS so that the designed functional safety is maintained at all times. Operation and maintenance planning
- Impact analysis of the required modification
Phase 9 (Clause 7 & 12.5)
- Safety planning for the modification, reverification, and re-documentation
Clause 7 Verification
New in edition 2.0 is that any modification activity SHALL not begin until a functional safety assessment (FSA) is completed. The following information SHALL be available: - Detailed description of the modification - The reason for the change - Identified hazards and safety instrumented system potentially affected - Impact analysis of the modification - The approval required before the
The objective of this clause is to demonstrate by review, analysis and/or testing that the required outputs of that activity or phase fulfil the defined requirements for the appropriate phases (Figure 2). Verification SHALL be planned and documented so it can be later used for the functional safety assessment. See Figure 9 below Basically no matter which phase of the lifecycle you are responsible for, every single phase, before moving to the next phase,
SHALL be carried out with a document that describes routine and abnormal activities, proof testing, preventative maintenance, maintenance after failure, techniques to be used for operation and maintenance, verification of adherence to operations
modification starts - Test details and records - Appropriate configuration history and log book
and maintenance procedures, when these operations and maintenance activities shall
competent, qualified and trained personnel.
A competent person not involved in the original development SHALL review
take place and the persons, departments and organisations responsible for these activities.
Phase 8 (Clause 18, Decommissioning)
the application program including its documentation. The approach used for the review and the review results SHALL be
All modifications SHALL be performed by
This clause requires similar actions to Clause Procedures SHALL be made available. Additional requirements in edition 2.0 cover proof testing efficiency and consistency, for
17 (Modifications): - Procedure, analysis and authorisation. - The required SIF(s) must remain
data collection, for compensating measures during bypass (repair and testing). Particular focus is on the procedure for proof testing and inspection and the documentation
operational during decommissioning activities. Typically an example would be during an
records of those activities, which are absolutely necessary for functional safety assessments or audits.
upgrade of a SIS, parts or all SIFs may be decommissioned when the upgrade is required.
Operator and maintenance personnel SHALL be trained to sustain full functional
As with the modifications, decommissioning activities SHALL not begin without proper
performance of the SIS, both hardware and software, to meet the target SIL of the SIF.
documentation and authorisation.
This clause objective is: - To ensure that modification of any SIS is properly planned, reviewed, approved and documented before a change is made. - To guarantee that the functional safety and required safety integrity of the SIS are maintained despite the changes being made to that SIS
documented.
Phase 10 (Clause 5, Management of functional safety) Besides verification, the management of functional safety - including assessments and audits - remain keystones in achieving functional safety. Management of functional safety is the ‘non-technical’ or ‘management’ requirement from the standard that is unfortunately disliked by many users / engineers, mainly because of the documentation requirements and duties.
that ‘everyone’ claiming functional safety compliance SHALL have a functional safety management system in place.
Prior to carrying out any modification to a SIS, a procedure for authorising and
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Clause 12.5 (Requirement for application program verification review and testing)
The objective for functional safety management is to document, monitor and assess those requirements necessary to ensure that the functional safety objectives are met by those responsible for them. Functional safety management SHALL be planned. The plan or procedure may be in conjunction with the organisation’s quality management system. New in edition 2.0 is
Phase 7 (Clause 17, Modification)
controlling SHALL be in place, containing elements like, but not limited to:
must be verified. This is one of the key principles of functional safety.
Besides responsibilities, every person, Figure 9 – Relation between Verification and Assessment
department or organisation involved in SIS safety lifecycle activities SHALL be
Functional safety 31
competent to carry out the activities for which they are accountable. New in edition
Phase 11 (Clause 6.2, Safety lifecycle structure and planning)
IEC61511: - IEC61508 Part 2 (Hardware) and Part 3
2.0 is that there SHALL be a procedure in place to manage competence of all those involved in the SIS life cycle and periodic assessment SHALL be carried out documenting the competence of individuals against the activities they are performing and on change of an individual within a role.
A SIS safety lifecycle incorporating the requirements of the IEC61511 SHALL be defined during the safety planning. New in edition 2.0 is that it also now addresses application programming.
(Software) - IEC TS 6100-1-2 Ed. 2.0 (Technical Specification EMC) - IEC 62682 Ed.1 (Alarm Management in the Process Industry)
The safety lifecycle requirements include an
Clause 3, Abbreviations and definitions
The functional safety assessment (FSA) team SHALL include at least one senior competent person not involved in the project design team for stages 1-2-3 or not involved in the operation and maintenance of the SIS for stages 4 & 5: - Stage 1 - After the hazard and risk assessment has been carried out, the required protection layers have been identified and the SRS has been developed. - Stage 2 - After the SIS has been designed. - Stage 3 - After the installation, precommissioning and final validation of the SIS has been completed and operation and maintenance procedures have been developed. (This is sometimes called PreStartup-Safety-Review - PSSR)
objective and detailed description of each phase activity, the inputs needed for the phase and the output generated by the phase. Each phase SHALL be verified and documented as per the requirements of the standard. A graphical explanation of the phases is shown in Figure 2 – SIS safety lifecycle phases and FSA stage.
4b The remaining clauses not directly referenced in the lifecycle phases
(These five stages are shown in Figure 2 – SIS safety lifecycle phases and FSA stages)
as an application-specific standard for the process sector implementation of IEC61508. See Figure 10 for the relationship between IEC61511 and IEC61508
Besides those stages and new in edition 2.0 is that functional safety assessments
be defined and executed for auditing compliance with the requirements.
Declares that compliance with IEC61511 requires demonstration that each of the requirements outlined in clauses 5 through 19 have been satisfied and therefore the clauses’ objectives have been met.
About the author:
Defines the requirements of the specification, design, installation, operation and maintenance of a safety instrumented system (SIS) so that it can be confidently entrusted to achieve or maintain a safe state of the process. IEC61511 has been developed
New in edition 2.0 is that functional safety audits SHALL be performed by an independent person not undertaking work on the SIS, and procedures SHALL
Clause 4, Conformance to this International Standard
Clause 1, Scope
- Stage 4 - After gaining experience in operating and maintenance. - Stage 5 - After modification and prior to decommissioning of a SIS.
SHALL be carried out periodically during the operations and maintenance phase (typically one of the longest phases in duration) to ensure that everything is still being carried out according to the assumptions made during design, and that the requirements within IEC61511 for safety management and verification are still being met. This assessment is typically called a functional safety audit.
This clause contains abbreviations and definitions and is quite comprehensive with approximately 20 pages of definitions.
Figure 10 - Relationship between IEC61511 and IEC61508 IEC61508 is also often used by safety instrumented designers, integrators and users where directed in IEC61511.
Clause 2, Normative references The following referenced documents are indispensable for the application of the
Tino Vande Capelle was educated in Belgium, where he specialised in Automation and Critical Control Systems. During his 30-year career, in a variety of areas such as the LNG, Petrochemical, Refining and Petroleum Industries, he gained significant experience of technical management, marketing and technical consultancy, hardware and software engineering, process control engineering, troubleshooting and field instrumentation using advanced control, distributed control, SCADA, emergency shutdown, fire and gas, compressor control and PLC systems. He is a Senior Functional Safety Expert (TÜV Rheinland 109/05) and Trainer for Safety Instrumented Systems (SIS) with the International TÜV Rheinland Functional Safety program.
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33 3
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www.hazardexonthenet.net
Hazardous Area Specialist
Heaters
Isolators
Training
Problem Solvers
Certified opto Couplers for use in hazardous environments, tubular, Surface mount and high Speed.
Complete one-stop ne stop in-house in house solutions sol for Hazardous Area Installation, /ŶƐƉĞĐƟŽŶ Θ dĞƐƚŝŶŐ ŝŶĐůƵĚŝŶŐ͗ Control Systems; Reporting; Electrical Systems; Maintenance
ATEX conforming to: EN60079-0 EN60079-11 EN60079-26
z-tech.co.uk
01223 653500
IECEx Conforming to: IEC60079-0 IEC60079-11 IEC60079-26
Hazardous Area
engineers@z-tech.co.uk
Training Courses & Consultancy for Industrial & Hazardous Areas
www.epitgroup.com
SAFE TRUSTED RESPONSIVE & PROFESSIONAL
Heaters
Intrinsic safety
Trace Heating
&
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Raychem
WORKING IN PARTNERSHIP Q Q Q Q
CONTACT US! www.gmintsrl.com sales@gmintsrl.com
Q Q
SIL 3
Design Supply Installation Maintenance Commissioning Thermal Insulation Tel: +44 (0) 1792 813231 Fax: +44 (0) 1792 321816 www.rdtraceheating.co.uk email: sales@rdtraceheating.co.uk
To advertise in the Product Datafiles or Buyers Guide contact
Quote ‘Hazardex’ for a 15% discount on CompEx01 to EX04 and refresher courses
Kathryn Startin
01642 770310
on +44 (0)1732 359990 or kathryn.startin@imlgroup.co.uk
www.tte.co.uk
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