hazardexonthenet.net
Downstream Safety performance in Europe Safety culture Leadership and incident prevention
Safety culture
Standards
Event review
Effective use of Behavioural profiles
Ex Equipment Marking
Hazardex 2017 Conference & Exhibition
May 2017
the journal for hazardous area environments
be ready for an extra-ordinary new world
• Extra-competitive • Extra-light • Extra-compact • Extra-flexible With the MAXIMUS MMX cameras, a new world of cost effective solutions is available for monitoring tasks in the most challenging conditions in onshore, offshore, marine and heavy industrial environments.
maximus mmx camera VIDEO SECURITY PRODUCTS www.videotec.com Made in Italy
contents may 2017 As the impasse over North Korea’s nuclear and ballistic missile tests continues with a powerful US Navy battlegroup now on manoeuvres off the Korean peninsula, it seems that China is finally ramping up the pressure on its recalcitrant ally. China ordered ships laden with North Korean coal to return home full on April 10, Reuters reported, in accordance with a United Nations Security Council resolution passed in February meant to punish the country and its authoritarian leader, Kim Jong Un, for the tests. Coal is North Korea’s biggest export and China is, by far, the product’s biggest buyer. The fossil fuel accounts for up 40% of the country’s exports and remains a financial lifeline for the isolated dictatorship.
14 16
society would approve of severe restrictive measures, such as restricting oil imports to the North, if Pyongyang engages in further provocative activity. Given North Korea’s lack of alternative sources of oil, this would rapidly bring the country to a standstill. It might also make the regime understand that its policy of nuclear blackmail is no longer tenable.
The Hazardex 2017 Event saw attendance up 10% and exhibitor numbers up 25% on 2016, with the Awards ceremony a highlight
22
Following on from our successful Hazardex 2017 main event (see review on page 16), we will be running a oneday Hazardex in the Regions event on November 29th in Antwerp, Belgium, co-located with the PEFTEC conference, seminars and wider exhibition. If you are interested in presenting a paper, exhibiting or attending this event, please contact: russell.goater@ imlgroup.co.uk or phone +44 (0)1732 359990.
And the next step could be to restrict the flow of oil to Kim Jong Un’s regime. The Global Times, an influential Chinese publication, said in an editorial in mid-April that Chinese
…Alan Franck, Editor, Hazardex
Accident frequencies in the European downstream oil industry are generally at low levels and the 2015 data continues this trend
in this issue
28
News Extra
5
• Alaska operator shuts production at two platforms over gas and oil leaks • UK carbon dioxide emissions fall 7.4% in 2016 • EU successfully displacing fossil fuels through increased use of renewables • Workplace safety improving in China, but coal mines still a problem • Ukraine ammunition storage facility fire causes evacuation of 20,000 • World coal plant construction fell significantly in 2016 – report • Canada First Nation makes history with LNG terminal vote
Behavioural profiling of individuals, teams and managers can help map safe and unsafe behaviours in the workplace
15
Standards: The hazardous world of Ex Marking
16
Hazardex 2107 Conference & Exhibition – Event review
22
Concawe European downstream safety trends
28
Behavioural profiles and influencing decisions around safety
32
Integrating culture and leadership into process incident prevention
37
Datafiles & Buyers Guide
32
Each organisation needs to assess the cultural impacts on existing systems for catastrophic event prevention
Hazardex is a controlled circulation journal published monthly. Completed print or online registration forms will be considered for free supply of printed issues, web site access and online services. Annual subscription for non-qualifying readers is UK £84.00, EU €113.00, Airmail £178.00 and single copy price is £17.00 plus P&P.
Hazardex content is the property of the publishers or relevant content providers. The publishers and sponsors of this magazine are not responsible for the results of any actions or omissions taken on the basis of information in this publication. In particular, no liability can be accepted in respect of any claim based on or in relation to material provided for inclusion.
Editor Alan Franck alan.franck@imlgroup.co.uk
Group Publisher Russell Goater russell.goater@imlgroup.co.uk
Sales Executive Kathryn Startin kathryn.startin@imlgroup.co.uk
Circulation subscriptions@imlgroup.co.uk Tel: +44 (0)1732 359990
Production and Events Sara Clover sara.clover@imlgroup.co.uk
Design Graham Rich Design www.grahamrichdesign.co.uk
IML Group plc Blair House, High Street, Tonbridge, Kent TN9 1BQ, UK Tel: +44 1732 359990 Fax: +44 1732 770049 Email: events@imlgroup.co.uk ISSN 1476-7376
Register for weekly email newsletter & up-to-the-minute news at www.hazardexonthenet.net
II 2GD Ex de IIB+H2 method of protection for environments with the presence of hydrogen High luminous efficiency Energy saving Optimization of plant engineering and maintenance costs Cool White LED, color temperature 6.500 K Long Term Performance
Square shaped beam LED floodlights collection SLED-600 30.800 lm
Thanks to the “square shaped beam” optics, the explosion-protected floodlight SLED series of Cortem Group ensures a uniform illumination over large spaces, both indoors and outdoors. Characterized by high light output with a white light and a colour rendering index greater than 70, they are able to replace the sodium vapour or metal halide floodlights, ensuring the quality of the light, energy saving and visual comfort.
SLED-400 20.750 lm
SLED-250 13.050 lm
Zone of installation 1, 2, 21, 22 | ATEX/IECEx/TR CU certificates Class temperature T5 (100°C) T6 (85°C) | Degree of protection IP66 Power supply 100-277 Vac ±10% and 120-277 Vac ±10%
cortemgroup.com IML Advert QSTX.pdf
1
2017/03/17
10:19
News Extra
Cook Inlet, Alaska
5
On April 2, Alsaka Governor Bill Walker issued a statement saying the DEC was keeping him updated on the situation. “It has been less than a week since Hilcorp agreed to temporarily shut down oil and gas production as part of its response to a leaking gas supply line,” he said in the statement. “Now, Hilcorp has reported a separate leaking oil line — which is significantly more harmful than natural gas. I am deeply concerned about the potential impact to the environment.”
Alaska operator shuts production at two platforms over gas leak, discovers new oil leak
O
n April 1, Hilcorp Alaska said it had discovered a crude oil leak from one
As regards the gas leak on the other side of the Cook Inlet, the PHMSA told Hilcorp to fix it by May 1 or shut the pipeline down. The agency also ordered the company to inspect the oil line between Anna and Bruce in mid-March, before the sheens were seen on April 1.
representatives from Hilcorp, the US Coast Guard and DEC, according to the report.
PHMSA said the pipelines, originally installed in the 1960s, were at risk from pipe vibration,
of its undersea pipelines near the Anna production platform in the Cook Inlet southwest of Tyonek. The oil leak is on
In response to the oil leak, Hilcorp said it would flush crude out of the pipeline,
ice and rock damage – particularly those not supported by the seabed. Although the cause of the ongoing gas leak was unknown, past
the west side of the inlet and is unrelated to the company’s ongoing natural gas leak on the eastern side of the basin near
assemble appropriate support vessels and send a diving crew down as soon as it was safe to do so. On April 4, following the flushing
leaks on the pipeline have occurred due to these outside forces, most recently in 2014, the agency said.
Nikiski.
operation, no further oil sheens were seen on the surface.
Oil and gas production was temporarily suspended a week earlier on both the Anna Platform and the nearby Bruce Platform because of the gas leak. The oil leak was noticed after workers on the Anna Platform “felt an impact” and spotted an oil sheen, according to the Alaska Department of Environmental Conservation (DEC).
The Anna Platform was originally constructed in 1965 by Amoco and has changed hands several times. Chevron was the last owner before Hilcorp took over. Infrastructure on and supporting the platform has had regular failures. When BP forced air
Hilcorp detected the gas leak in February when a helicopter flying above the pipeline route spotted water disturbance. The company indicated the leak began in December, according to PHMSA. Hilcorp said pan ice and strong tides in Cook Inlet present dangers for repair divers. The company does not expect to begin finding and
“In looking over the side of the platform to see what was going on, personnel observed sheen and bubbles coming up from near one of the platform legs where the 8-inch line is located,” the state agency said in a situation report, adding that the sheen and bubbles had not been seen on the previous day.
into a pipeline to the Anna platform in 2002, it sprung several leaks, causing crude oil to leak and create sheens as large as 200 yards wide and five miles long. Eight years later, in 2010, Chevron chose to suspend crude oil operations from the Anna platform after the US Pipeline and Hazardous Material Safety Administration (PHMSA) refused a waiver to allow a corrosiondamaged pipeline to be used.
fixing the leak — about 80 feet underwater — until the ice clears.
On an overflight, Hilcorp staff observed six sheens on the water, according to DEC’s report. The company’s response contractor sent a ship out to the Anna Platform but did
Hilcorp took over the platform in 2011 after Chevron pulled out of operations in Cook Inlet. The company bought up the area’s ageing infrastructure as other companies
The PHMSA said Hilcorp needed to introduce “smart pig” internal inspections of the pipelines on top of the side-scan sonar, multibeam
not see any sheens. A Unified Command has been set up in response to the spill, with
withdrew and is now the Cook Inlet’s dominant producer.
echo-sounder surveys and diver inspections it currently undertakes.
The notice said environmental harm from an oil leak could be “significantly greater” than from the gas leak, while the company’s ability to respond could be severely hampered in winter, and could have a serious impact on the 340 endangered Cook Inlet beluga whales, as well as birds and fish.
www.hazardexonthenet.net
Timer or Clock?
...time based
It starts with the connection...
indicators
The Ralston Quick-test™ system is the ideal connection system for pressure calibration, testing and checking pressure
•
Connect up to 10,000 psi / 700 bar without a wrench or thread sealant
•
Connect safely in hazardous locations
•
Adapters for almost any process connection
n
Dual function Timer or Clock
•
Low volume, high pressure micro-bore hose requires very little compressed gas or fluid
n
Timer - displays the interval between two events
n
Clock - shows local time in 12 or 24 hour format
NEW Now with adapters for Pete’s Plugs™* for natural gas distribution applications
n
Timer event initiation by pulse input
n
Optional control outputs
n
Field or panel mounted versions
n
Hazardous area or general purpose models
•
* Pete’s Plugs are trademark of Peterson Products
Visit ralstoninst.com/hx or scan the QR code to find out more
www.beka.co.uk
+1-440-564-1430 | (US/CA) 800-347-6575 ISO 9001:2008 Certified
Hitchin, Herts. SG5 2DA,UK sales@beka.co.uk Tel +44 (0)1462 438301
Made in the U.S.A.
timers_124x86.indd 1
4/6/2017 10:39:18 AM
News Extra
7
website estimated that UK consumption of coal fell by a record 52% in 2016 from the previous year as use of the fuel was affected by cheaper gas, higher domestic carbon prices, the spread of renewables and other environmental policies. In November 2015, ministers announced plans to phase out coal power by 2025, and the UK may be closer to reaching this target than previously thought. The UK is legally obliged to cut its overall greenhouse gas emissions by at least 80% from 1990 levels by 2050, under the 2008
UK carbon dioxide emissions fall 7.4% in 2016 T
Climate Change Act. Beyond the UK, new figures showed emissions regulated under the EU’s Emissions Trading System (ETS) carbon market fell for the sixth straight year in 2016, in part due to lower coal-fired power production.
he UK Government published provisional 2016 greenhouse gas emissions figures on March 30 showing
In 2016, an estimated 30% of carbon dioxide emissions were from the energy supply sector, 32% from transport, 16%
Data published by the European Commission and examined by analysts
net emissions of carbon dioxide came to 374.1 million tonnes (Mt), 7.4% lower than the 2015 figure of 403.8 Mt. Carbon
from business and 18% from the residential sector. This is the first year the energy sector has not been the largest emitter of CO2
at Thomson Reuters showed emissions totalled 1.75 billion tonnes of CO2 equivalent (CO2e) last year for companies under the
dioxide (CO2) is the main greenhouse gas, accounting for over 81% of total UK greenhouse gas emissions.
Emissions increased by 4.5% (2.8 Mt) in the residential sector due to an increase in the use of natural gas for space heating, and
The decrease in emissions was mainly caused by: • Reductions in carbon dioxide emissions in the energy supply sector, down 18.7% (25.4 MtCO2e – Mt CO2 equivalent) driven by a large decrease in power station
there was also a small increase of 0.9% in emissions from the transport sector.
emissions due to a change in the fuel mix for electricity generation, with less use of coal (as a result of reduced capacity and conversion of a unit at Drax to biomass) and increased use of gas. • A decrease of 10.3% (7.1 MtCO2e) in the business sector, driven by a reduction in emissions from manufactured solid fuels, following the closure of SSI steelworks at
fuels being used for electricity generation, including the growth of renewables, together with greater efficiency resulting from improvements in technology and a decline in the relative importance of energy intensive industries.
Redcar in September 2015.
Since 1990, UK carbon dioxide emissions have decreased by 37%. This decrease has resulted mainly from changes in the mix of
Overall energy consumption is provisionally estimated to have decreased by around
Total carbon dioxide emissions on a temperature adjusted basis for 2016 were 378.2 Mt, 1.0% higher than actual emissions.
10% since 1990 (although it increased up to 2001 and has decreased since then). If this figure is adjusted to allow for the effect of temperature, energy consumption has fallen by around 13% between 1990 and 2016.
This reflects the fact that temperatures in 2016 were slightly higher than the long term average.
In a separate report, the Carbon Brief
ETS excluding airlines, down 2.7% on the previous year. The data showed capped emissions from power and heating generation were down 4.4% while emissions from industrial manufacturers were down 0.5% year-onyear. Emissions in the aviation sector rose by 8% in 2016 to 61.6 MtCO2e. Around 45% of Europe’s greenhouse gas emissions are regulated by the ETS, the bloc’s flagship policy to cut emissions by charging for the right to emit carbon dioxide. The ETS caps the emissions of around 11,000 power plants, factories and airlines, forcing them to surrender one carbon permit for every tonne of carbon dioxide emitted annually by the end of April of the following year. It is expected to contribute around two thirds of the reductions needed to meet the bloc’s target of slashing emissions 20% from 1990 levels by 2020, and 80% by 2050.
www.hazardexonthenet.net
8
News Extra
EU successfully displacing fossil fuels through increased use of renewables
T
his is the conclusion of a new report from the European Environment Agency which details how renewables’ share of the European energy mix is approaching 17% and has led to a reduction in greenhouse gas emissions across the bloc of around 10% since 2005. The report, entitled Renewable energy in Europe 2017: recent growth and knock-on effects, provides data on how the EU’s transition to a cleaner energy mix has evolved in recent years, as the bloc’s reliance on coal has reduced and energy developers have increasingly focused on bringing renewables projects online. Renewables share of the energy mix in the EU
The report calculates that the surge in renewables capacity means that since 2005, EU greenhouse gas emissions have fallen by 10% - equivalent to the domestic emissions of Italy.
acceleration after 2030, when tough decisions about phasing out internal combustion engines and oil supplies will have to be taken. Another recent report from the International Renewable Energy Agency (IRENA) provides some detail on which EU countries are moving ahead fastest with renewables.
It said progress was unevenly spread across Europe, with renewables expanding to take up 30% of the power load in many Scandinavian countries, but only 5% in Malta. The UK had Europe’s seventh best record for the intensity of its greenhouse gas emissions, but was a mid-table performer in terms of emissions per capita, according to figures compiled by the European Environment Agency (EEA).
rose from 15% in 2013 to 16% in 2014, before then rising again to 16.7% in 2015. Renewables
The EEA’s report suggests that the EU is
accounted for 77% of all new electricitygenerating in 2015 - marking the eighth year in a row renewables provided the majority of
broadly on track to achieve its goals of 20% emissions cuts and 20% renewable energy share by 2020.
new capacity.
But a more challenging target for 2050 – of reducing emissions by at least 80% – will require
In the EU, solar energy capacity reached 104 GW, up 5 GW on 2015. The biggest expansion took place in Germany and the UK, with 1,200 MW and 2,063 MW of additional capacity respectively, compared to 2015. Spain was up 15 MW, similar to Portugal (+13 MW) and France (+12 MW). As regards wind energy, the top performers in the EU were Germany (+5 GW) and Spain, which saw 49 MW growth. In Europe, only Germany is ahead of Spain in terms of total wind energy capacity. According to the IRENA report, hydropower growth in Europe was a little less than 2 GW.
Dixon Petrochemical Products Fluid transfer products for upstream, downstream and refining Products: • API certified products • Zero emission valves • No-spill couplings • Safety breakaway fittings • Blow Out Prevention Couplings • Hydrocarbon Hoses and Hose Assemblies • Vent lock Safety Cam & Groove • Petroleum tanker overfill systems • Hydraulic Fracturing: Low Pressure System
Services: • Global Inventory and Locations • Sales and technical support worldwide • ISO9001 accredited • Pressure Equipment Directive (PED97/25/EC) Through innovation and application expertise, Dixon is committed to improve end user productivity and reduce environmental and safety related incidents within the Petrochemical industry
For further information please contact us now on: +44 (0)1772 323 529 sales@dixoneurope.co.uk www.dixoneurope.co.uk
News Extra
9
Official 2016 statistics show workplace safety improving in China, but coal mines still a problem
A
ccording to a report by Xinhua, workplace accidents continued to decline in China in 2016 after the government took “iron-fisted” efforts
Most of the accidents happened on building construction sites, chemical factories and coal mines, according to the administration.
mines, where nearly 80% of severe coal mine accidents happened. In addition, illegal small coal mines re-emerged in a number of regions as local governments loosened
to curb illegal operations. The State Administration of Work Safety (SAWS) reported 60,000 workplace safety accidents in 2016, down 5.8% on a year earlier.
Xinhua said 200 of those responsible for severe incidents have been punished and 97 sent to judiciary departments for investigation, citing the administration.
oversight in pursuit of economic interests, Huang told the SAWS annual meeting.
Despite improvements, the safety situation
To ensure safety improvements, SAWS launched a nationwide programme of checks on coal mines in March which will
Those accidents killed 41,000 workers, down 4.1% on the death total reported in 2015, Yang Huanning, head of the administration said at its annual meeting.
at small coal mines remains dire, SAWS said, with severe accidents at small pits on the rise.
last until the end of the year. It will cover both operational mines and those previously ordered to suspend production.
SAWS highlighted the substantial decline in the number of severe workplace accidents,
Huang Yuzhi, director of the State Administration of Coal Mine Safety, affiliated with SAWS, said 60% of the nation’s coal
The move comes after a string of fatal incidents so far in 2017, Xinhua said, including one where a gas explosion killed
defined as those resulting in at least 10
mines are small collieries with production
seven people and injured 11 in southwest
deaths. The number of severe accidents fell by 15.8% year on year to 32, while deaths declined by 25.7% to 571.
capacity less than 300,000 tonnes a year.
China’s Guizhou province in early March.
Outdated equipment, lack of technicians and loose management have plagued those
Coal mine safety was “complicated and grim,” SAWS said, according to Xinhua.
Offering diversity. Ensuring protection. Perfecting performance. Electrical Explosion Protection Equipment
Wide range of terminal boxes, control units and stations, Ex d/Ex de control
and distribution panels as well as many more products and solutions Covering Ex d, Ex e, Ex p, and Ex i types of explosion protection and
combined Ex de solutions Highest degree of protection for all applications from the leading authority
on explosion protection www.explosionprotection.com
10 News Extra Ukrainian bomb disposal specialist in Balakliia – Image: SESU
The Balaklia facility, which held about 138,000 tonnes of ammunition, covers 370 hectares and is located about 100 km from the frontline of Ukraine’s war against Russianbacked separatists. It was guarded by around 1,000 soldiers and civilians, some of whom reportedly heard the sound of an aircraft just before the explosions.
Ukraine ammunition storage facility fire
causes evacuation of 20,000
A
Military spokesman Oleksander Motuzyanyk said security around other bases was being reinforced. Saboteurs previously tried to destroy the same base using drones in 2015, military spokesman, Yuzef Venskovich, told the 112 TV channel. On March 27, the State Emergency Service of Ukraine (SESU) said all fires had been extinguished and bomb disposal units were in the process of clearing explosive ordnance
round 20,000 people were evacuated from the area around the Balakliia ammunition storage facility in the
dump is being evacuated, the Interfax news agency quoted an aide to President Petro Poroshenko as saying. Around 600
and remnants of ammunition from the affected area, with 1,092 pieces removed to date. Some 75 bomb disposal specialists
eastern Kharkiv region of Ukraine after it caught fire on the morning of March 23. Defence Minister Stepan Poltorak accused the Russian military or its
firefighters struggled to douse the flames and explosions at the tank and artillery ammunition storage site, sending clouds of thick grey smoke into the sky.
in 27 special vehicles were involved in the clean-up. More than 10,000 people have been killed
A third of the base is still burning and all airspace within 50 km has been closed off,
in the conflict between Ukraine and the separatist rebels since 2014, and a ceasefire agreed in Minsk in 2015 is routinely violated.
separatist rebel proxies of setting off the fire, possibly via a drone attack. Everyone within a 10 km radius of the
Poltorak said two days later.
Indonesia to sue Thai oil company over 2009 oil spill
I
ndonesia is preparing to sue the Australian subsidiary of Thailand’s PTT Exploration and Production (PTTEP) over alleged environmental damage from the
Montara drilling rig off Australia’s northwest coast in 2009.
Montara oil spill in 2009, the country’s Maritime Affairs Ministry said. This follows the Indonesian government’s December 2016 decision to freeze the licenses and assets of PTTEP operations in Indonesia.
offshore drilling accident and an Australian government inquiry blamed the spill on systemic shortcomings at the Thai oil giant. PTTEP was fined A$510,000 by a Darwin court in 2011 after pleading guilty to four charges relating to workplace health and safety and failure to maintain good oilfield practice.
Attempts at negotiation between both parties stalled in 2012, with PTTEP Australasia
The Montara incident was Australia’s worst
Tenggara Province was polluted in the incident and in the first year after the incident
maintaining that no solid evidence had been supplied that any of the oil from the leaking well had reached the Indonesian mainland.
PTTEP said that inquiry and fine concluded all government legal matters in relation to the Montara incident.
A total of about 30,000 barrels of oil were
The Indonesian Government says an area
Indonesian seaweed farmers started a separate class action suit in August 2016
estimated to have leaked into the Timor Sea over 74 days after an explosion at PTTEP’s
spanning some 70,500 square kilometres of the Timor Sea bordering the East Nusa
seeking more than A$200 million from PTTEP Australasia to cover damages from the spill.
www.hazardexonthenet.net
fish catches from Timor Sea waters dropped by 80%.
DTR120ZEX-Hazardex-05-2017_124x178mm 11/04/2017 09:54 Page 1
Optimal solutions for TV survey of Ex hazardous sites ECA group offers a range of ATEX and IECEx certified TV cameras for the survey of hazardous sites such as drilling rigs, offshore platforms, petrochemical plants, gas storage areas. Masterpiece is the DTR 120Z Ex, a night & day Ex colour TV camera with an 18x zoom and a swivelling head for panoramic survey; incorporates an IP server for access and control of a network of cameras, thus permitting a large area surveillance.
fotolia
Discover our Solutions for Ex areas survey
eca-hytec@ecagroup.com | www.ecagroup.com
Lighting under Harsh Conditions
PXLED - Ex-Power-Floodlight Series Robust flameproof enclosure for use in harsh & hazardous areas Zone 1, 2, 21 and 22, even for Gas group IIC Modular design 5,000-32,000 lm - just use the size you need to replace Sodium lamp fittings up to more than 600 W High efficient power LED Module with 110 lm/W For ambient temperatures from -50 °C up to +55 °C Highest corrosion protection and mechanical resistance
SFY Functional Safety Frequency-to-DC Transmitter Put a fortress of protection around your process with FS Functional Safety Series instrumentation from Moore Industries. You can be confident that it will safeguard your processes when you need it the most. Our STA, SSX, SST, SRM, STZ and the NEW SFY Functional Safety Frequency-to-DC Transmitter have been designed and built to strict IEC 61508 standards, ensuring safe and reliable function – particularly in environments where hazardous or emergency situations are likely to occur.
For further information: Eaton, Crouse-Hinds Division Phone: +44 247-630-89 30 E-mail: sales5@eaton.com www.Crouse-Hinds.de www.Eaton.com
Demand Moore Reliability To learn about our Functional Safety Series, To learn moremore about our Functional Safety Series, call +44(0)1293 514488, or go to: (800) 999-2900, or go to:callwww.miinet.com/safetyseries www.miinet.com/safetyseries
News Extra 13
station. Realistically until a project breaks ground it should not come as huge surprise if plans do not go ahead. Look no further than the woes of the nuclear infrastructure in the UK. “Yes, China, is reducing the number of coalstations but not because it’s transitioning away from coal, instead the new dynamics is a signal of a more developed economy. Contrary to the picture being portrayed by certain quarters, China’s climate pledge suggests that coal will continue to be central to its energy solutions, albeit through efficiencies, including the use of new coal technologies.”
World coal plant construction fell significantly in 2016 - report C
onstruction of new coal plants fell sharply last year according to a report published on March 22 by
unprecedented and far-reaching restrictive measures by China’s central government,” the report says.
environmental groups Greenpeace and the Sierra Club, and research company CoalSwarm. The report
To tackle air pollution and curb excess supply, China has pledged to close 800 million
Sporton disagreed with the report’s claim that in India, renewables were displacing coal. “The IEA has said that India’s coal demand will see the biggest growth over next five years, with annual average growth rate of 5% by 2021,” he said. The Sierra Club, a US-based environmental group, says 35 GW had been retired in the US and 29 GW in the EU over the last two years’ alone.
claims that 2016 saw a 48% drop in pre-construction activity, a 62% drop in construction starts, a 19% drop in ongoing construction, and a 29% drop in
tonnes of outdated coal capacity by 2020. It has already exceeded its 2016 goal to eliminate 250 million tonnes of coal capacity.
“Once a project has started construction, there is a massive economic incentive to complete it. The fact that projects are now being halted underscores how dire the
completed projects.
Over 300 GW of Chinese projects in various stages of development have been put on hold until after 2020, including 55 GW already under construction, the report says.
situation is for the coal sector,” it said on its website.
According to the report, called Boom and Bust 2017: Tracking The Global Coal Plant Pipeline, in January 2017 there was 570 gigawatts (GW) of coal power capacity in pre-construction, down from 1,090 GW in January 2016. Projects under construction came to around 273 GW, 19% lower than in Jan. 2016, and those put on hold surged by 164% to 607 GW from 230 GW. In China and India, where industry once forecast unending, exponential growth in coal demand, 68 gigawatts of construction is frozen at over 100 project sites.
India also experienced a slowdown in coal plant development due to the unwillingness of banks and other financiers to provide more funds, the report said. The International Energy Agency (IEA) said in December that growth in coal demand globally would slow over the next five years due to lower consumption in China and the United States and as renewable energy sources gained ground. In India, however, demand was expected to increase.
“The good news is that, despite his blustering rhetoric, Donald Trump cannot change reality. The coal industry is collapsing, with clean energy overtaking coal across the US In 2015, solar and wind accounted for two-thirds of new generating capacity across the country, with the (Republican-voting) states of Texas, Oklahoma and Kansas leading on wind.” Nevertheless, in the USA, the Energy Information Association (EIA) said it
“Globally, more construction is now frozen
Reacting to the report, World Coal Association CEO Benjamin Sporton said:
expected growth in coal-fired electricity generation to contribute to a 4% increase in coal production in 2017. According to its March forecast, it also said coal production should remain unchanged across 2018. EIA
than entering construction in the past year ... The main cause of the shrinkage in the coal plant pipeline was the imposition of
“Developing energy infrastructure is complex particularly for huge projects like a large coal
estimates the delivered coal price, which in 2016 was 5% down on the previous year, will rise again in 2017 and 2018.
www.hazardexonthenet.net
14 News Extra Sarita Bay LNG plant site – Image: Steelhead
for 25 years. The main target market is Asia, and the next stage will be to plan the infrastructure required to collect natural gas from across Western Canada and pipe it to Sarita Bay Assuming the final investment decision is taken in 2019 or 2020, the facility could begin exporting in 2024.
Canada First Nation makes
history with LNG terminal vote
I
n late March, citizens of the 750-strong Huu-ay-aht First Nation in western British Columbia voted in favour of a
Many First Nations across North America have been vocal in their opposition to hydrocarbon pipeline and infrastructure projects on or near their lands in recent years, most notably the Standing Rock Sioux and other US tribes who have fought a vocal battle against the Dakota Access Pipeline.
that will have three seats saved for Huu-ayaht representatives. The First Nation will also get a seat on Steelhead’s corporate board.
Representatives of the Coldwater Indian Band, the Tsleil-Waututh Nation and the Squamish Nation filed lawsuits in the
proposed liquefied natural gas (LNG) export project on Vancouver Island.
“An incredible opportunity is on our doorstep
Canadian Federal Court of Appeal in late 2016 against the expansion of the Trans
This represents a major step in the development of the proposed Sarita LNG facility, which would source natural gas
and we want to pursue that opportunity,” said Huu-ay-aht Senior Chief Councillor Robert J. Dennis. “We’re seizing it…to make things
Mountain pipeline, which runs 1,150 kilometres from Edmonton to a marine terminal in Burnaby, near Vancouver.
from northeastern British Columbia and northwestern Alberta via existing and new pipelines.
better for the Huu-ay-aht people.” According to the chief councillor, the
The Trans Mountain project would triple capacity of the pipeline and has been given
Project developer Steelhead LNG of Vancouver sought early involvement of the First Nation when it looked into the
Huu-ay-aht are not facing as severe an unemployment problem as some First Nations, but at the press conference to announce the deal, he said there was a wide
federal and provincial approval, but is being opposed by these communities due to environmental and health risks.
construction of a proposed liquefaction and export facility located on Huu-ay-aht-owned land on Sarita Bay near the Vancouver Island community of Bamfield.
gap between the prosperity in his community and that in the rest of Canada and they would be looking to take an initial 15% of the jobs created on the project.
Key to the acceptance of the project by
Steelhead LNG CEO Nigel Kuzemko said
Nevertheless, a total of 51 First Nation communities – 10 in Alberta and 41 in British Columbia – have signed mutual-benefit agreements with project developer Kinder Morgan, with 12 signing on after the federal government approved the project, with
the community has been the idea of comanagement between the partners. The project will have a six-person oversight board
Canada’s National Energy Board has granted the company four licenses to export up to 24 million tonnes of LNG per annum
conditions, in late November. The mutualbenefit agreements will see $400-million shared between the communities.
ZONE 1/21
ZONE 2/22
ZONE 1/21
ZONE 2/22
Android is a trademark of Google Inc. The Android robot is reproduced or modified from work created and shared by Google and used accordingto terms described in the Creative Commons 3.0 Attribution License.
IS320.1
ISM_MA0004_170410
Powerful, rugged, key-operated phone. With AndroidTM 4.4, Wi-Fi, NFC, LED torch, amplified loudspeaker and SOS button.
IS730.2
Industrial smartphone which combines high performance technology (Android 6.0. LTE, wireless charging) with robustness and modern design.
IS-MP.1 IS-MP.2
Handheld readers for easy and efficient reading of RFID/NFC TAGs that are located closely together or positioned in areas that are difficult to access.
YOUR EXPERT IN COMMUNICATION AND MOBILE SOLUTIONS
WWW.ISAFE-MOBILE.COM
Standards 15
The hazardous world of Ex Marking
Ron Sinclair MBE gives his perspective on the latest developments in the world of standards
60079-1, with the other concepts and ideas forming subsequent part numbers, until we are now talking about introducing IEC 60079-40 With each new type of protection,
Which brings us back to the Sydney discussion. With the publication of ISO 80079 Parts 36 and 37, we now have IECEx certificates issued for the first time
a letter “code” was allocated, so that people operating on a plant would be able to tell the type of protection and be able to inspect and maintain accordingly. This letter code was used to determine the suitability of a particular item of equipment for installation in a given
for non-electrical equipment. The symbol “h” has been allocated to indicate the protection of non-electrical equipment, whatever the detailed method applied.
zone. Simple – or at least it was at first.
be used at the international level, since it was intertwined with the legal marking of the ATEX Directive. Although used as shorthand within the standards, the letters “c” constructional safety, “b” control of ignition sources and “k” liquid immersed, do not appear as part of the marking.
Now we have single standards covering individual types of protection, but for various levels of protection, so the letter “m” for encapsulation, for example, is always followed by a second letter indicating the level of
The marking from EN 13463-1 could not
protection, giving us “ma”, “mb” or “mc”. Equipment now is more commonly protected by more than one form of protection. For example a typical fluorescent luminaire may
When a single item of equipment with both electrical and non-electrical protection is considered, questions arise how it should be coded. There is a view
subject of the marking of Ex Equipment. There is not much disagreement about the need to identify the equipment
have the lamps and terminals protected by increased safety “e” with the ballast encapsulated “m” or powder filled “q”, while
that the electrical and non-electrical marking should not be mixed, with two separate lines of code used (as with a
type, its operational parameters and its manufacturer, but everyone seems to have an opinion on how the hazardous
the isolating switch is flameproof “d”.
product suitable for use in either a gas or a dust hazard).
area code should be expressed.
whether the first letter should represent the type of protection applied to the wiring terminals, or should represent the protection
T
he one subject guaranteed to get everyone hot under the collar is the
The discussions at the recent IEC TC31 standards meetings in Sydney, Australia were no exception, and I will return to this later. But first, we need an historical perspective. In the beginning there was only the need to confirm that a piece of equipment was intended to be installed in a hazardous area. It was pretty obvious if it was either flameproof or intrinsically safe, and everybody knew the difference. Then we started to divide our hazardous areas according to how severe we thought the hazard might be: originally into Divisions (still maintained in the USA) and then Zones, with Zone 0 indicating the greatest risk and Zone 2 the least risk. Flameproof protection was originally IEC 60079, but as it was later decided to put all the forms of protection in the same series, flameproof became IEC
For a long time, there was an argument
applied to the largest part of the equipment. Eventually, the decision was taken that the letters would be listed in alphabetical order so that no one would be able to read the wrong significance into that order. It was also agreed that the equipment would be marked with the Equipment Protection Level (EPL) a single, short form two-letter designator that explicitly indicated the overall level of protection and, therefore, the Zone for which it was most suitable. The current published edition of IEC 60079-0 also requires that marking for hazardous gas or vapour atmospheres and marking for hazardous dust atmospheres should not be combined. This is to indicate two separate possible uses of the equipment, and not that the equipment is suitable for use in a hybrid mixture of gas and dust.
I do not subscribe to that view, but consider that there should be just one line of code, with the letter “h” taking its alphabetical place in the marking string. That way, there will just be one EPL, one Group and one Temperature Class marked, putting the potential use of the equipment beyond doubt.
About the author SGS Baseefa Technical Manager Ron Sinclair MBE is chairman of BSI Committee EXL/31, responsible for the UK input to both European and International standards for Electrical Equipment for use in potentially explosive atmospheres. He is chairman of Cenelec TC31, represents electrical standardisation interests on the European Commission’s ATEX Standing Committee and chairs the IECEx Service Facility Certification Committee.
www.hazardexonthenet.net
16 Hazardex 2017 Review
Hazardex 2017 Conference & Exhibition - Another great success T
he Hazardex 2017 Conference & Exhibition for hazardous area and process safety specialists, which
was up almost 10% on 2016, itself up by a third on the previous edition in 2014.
and services to the assembled professional audience, up by a quarter on 2016.
took place on March 2 & 3 in Runcorn, Cheshire, was judged a great success by attendees and saw an increase in
Compared with the last event in 2016, the conference programme was longer and delegate numbers were also well up.
Exhibitors ran the gamut from process control electronics and software to consultancy, certification and training, with a
visitors on the previous edition, itself up significantly on the previous year.
For more information on the conference, see the ‘Thoughts from the Chair’ section overleaf.
number providing niche technical solutions to the hazardous area industry. See the full list on the opposite page.
The Conference & Exhibition aims to strengthen and expand the community that looks to the Hazardex website and journal
Although the main focus of the packed-two day event is the conference, the attached
A large majority of exhibitors expressed satisfaction with the quality of contacts
for industry intelligence and information, and the 2017 event seems to have achieved this across the board. Attendance
exhibition is also an important element, and the 2017 event saw 44 hazardous area sector companies display their products
they had made, to the extent that a large majority indicated they intended to rebook stands in 2018.
www.hazardexonthenet.net
Hazardex 2017 Review 17
the journal for hazardous area environments
hazardexonthenet.net
The event offered exceptional opportunities
entertainment provided by the well-
in 2017, with announcements on likely
for networking, with attendees from government agencies, regulators and certification bodies meeting up with senior engineers and safety managers from the high hazard and process industries to share their experiences.
received stand-up Jamie Sutherland.
formats and venues available in the next few months on www.hazardexonthenet. net.
The 2017 event also saw a revival of the Hazardex Awards, designed to recognise excellence in the hazardous area sector. A full list of winners and runners-up is provided on page page 20-21.
These opportunities came to a climax at the drinks reception and Gala Dinner at the end of the first day, with after-dinner
The organisers are looking into holding further Hazardex regional events later
Dates have also been announced for the next international Hazardex Conference & Exhibition, which will take place at the same venue, the Holiday Inn Hotel in Runcorn, Cheshire, on 28 February and 1 March, 2018.
2017 EXHIBITORS ABB Consulting Anamet Europe Banelec Barrier Ex Beamex
CMP Products Cogent Skills Cordex Crowcon CSA Group
Extronics FES Ex Glamox Hornbill Engineering IHS Research
Moore Industries Mutech Nightsearcher PEI Genesis R&M Electrical
Roxby Training Rugged Mobile Systems SGS Baseefa STS Bespoke Handling Tempa Pano
Beka BSI C&P CCG UK
Dekra Insight Draeger Exheat Exloc
Industrial Interface Inspec Systems Lewden Palazolli Mobexx
R Stahl Randall & Daniels RAS Rheintacho
Vega Controls WEG Xplore Technologies
www.hazardexonthenet.net
18 Hazardex 2017 Review
Thoughts from the chair Quite possibly the presentation which provoked the most questions from the Hazardex audience was that on application of Energy Institute guidance and the potential for generation of flammable
safe and then invite experts to confirm this. However, when they learn, for example, that they are failing to follow their own safety critical procedures, then disbelief and denial can set in.
mists during release of high flash point materials. In this case, kerosene stored at airport fuel storage sites. The speaker explained that as a result of a recent study that blanket zoning across such sites has been rolled back by taking a more Hazardex Conference Chairman Lee Alford
O
n the drive to Hazardex 2017 I notice a couple of gorillas standing in a front garden no more than a stone’s throw from the venue. A pair
conservative approach to flammable mist generation. It is certainly a fascinating development to observe conservative approaches be applied to formation of hazards rather than their control measures. Nevertheless as new evidence
of inanimate life sized models to be exact. The bizarre sighting reminds me
is unearthed, new opportunities to do just this will undoubtedly emerge across the
of that video where a gorilla wanders into centre shot amongst a group of basketball players. Most viewers fail
hazardous environments sector.
to make the obvious spot because they have been instructed to count the number of ball passes and in effect the
up on day two was that it is preferable to design with people rather than design for people. Typically it is engineers who design
One speaker pointed out that the process industry has much to learn from the manufacturing sector with respect to
gorilla is hidden in plain sight. Bemused I arrive at the venue a few minutes later, start chatting with friends and get on with the job in hand.
the plant and process but it is the operators who make the day to day decisions which impact safety. For example, in a ship to shore oil transfer, a serious spill
standard operating procedures (SOPs). It may well be that the process industry considers itself a sector of such complex technology that the major risks arising
For the second year I was delighted to be chairing Hazardex 2017 on the topic of essential intelligence for changing times. And what changing times! Since the last conference we have experienced
can result from use of a defective hose. However, opinion on what constitutes a defective hose can differ between those same engineers who conceivably possess only modest experience in the field and the operators who need to make that
from its seemingly more basic operations are under-appreciated. That said, SOPs not only result in safer practices but also improved productivity through reduction of variation across individual operators and shift teams.
a whirlwind of unforgettable and barely foreseeable happenings such as BREXIT, Trump and Leicester City Football Club. Some will have long- lasting and irreversible impacts.
judgement call. Unless opportunities exist for both groups to jointly clarify then this uncertainty is likely to remain dormant until it reveals itself, possibly with devastating results.
As a result of what I heard in the first conference session on standards and regulations it is clear that post-BREXIT
There is no doubt that decision-making in safety-critical activities is better based on objective criteria rather than left to
there will be minimal impact to the UK’s role in international standards at ISO and IEC level. Furthermore the expectation is that post-BREXIT UK experts will continue to play an undiminished role in
common sense by default. So again, for a ship to shore oil transfer the assessment of hose quality can be made with reference to photos or graphics illustrating various aspects of defective and defect free hoses.
the governance and technical work of European standards bodies such as CEN and CENELEC
Nevertheless, as one speaker observed there are organisations in the major hazards sector which believe they are almost always
www.hazardexonthenet.net
IECEx Chairman Thorsten Arnhold
One memorable piece of advice to crop
Sarabjit Purewal, ECI Acting Head of Operations - HSE
Hazardex 2017 Review 19
BP Downstream Human Factors Advisor Simon Monnington
Rob Magraw, Operations Manager, BakerRisk Europe
RAS Process Safety Specialist Carolyn Nicholls
Yet another conference theme to emerge was the currently fashionable topic of cognitive biases which one presenter explored through accident investigation.
Hazardex 2017 also saw a sharing on the development and application of technical standards across various industries, including whisky distilleries and
are entirely invulnerable in this area.
Confirmation bias, for example, is a tendency for an investigator to seek
fuel storage sites. Away from technical areas, standardisation was also a theme
professionals to gather together and discuss the opportunities and challenges
evidence which supports and fits with their mental model of accident causation. This can result in evidence to the contrary
for presentations on development of procedures and national training standards for process safety. Perhaps one area
which are currently relevant to the industry.
being dismissed or relegated in importance, in contrast to that which reinforces the original notion. Another important bias
that continues to defy the march of standardisation is that of safety culture and human factors, which one speaker
I shall be again on the lookout for the Runcorn gorillas.
is known as fundamental attribution bias which can lead investigators to attribute the behaviour of those involved in the lead up to an accident to perceived character flaws
pointed out enjoys multiple meanings. Hazardex 2017 also saw the stakes being raised on cyber-security with the imminent publication of HSE operational guidance
Hazardex Conference Chairman Lee Alford was Operations Manager at the European Process Safety Centre for six years until December 2016. In a varied career he
rather than pertinent external factors. It is certainly true that investigators need both the understanding and time to arrive at a balanced and considered view of what led to an accident.
on the topic. Several incidents have been linked to malicious cyber-attacks and no doubt industry will need to place this topic right to the top of its risk register in future years. Few organisations claim that they
has worked as an Operations Manager at Vivendi, Quality Manager at Diageo, Plant Superintendent at RTZ Chemicals and was trained and started his career as a chemical engineer.
It was satisfying to see Hazardex 2017 provide an opportunity for over 400
I look forward to Hazardex 2018, when
www.hazardexonthenet.net
20 Hazardex 2017 Review
Hazardex 2017 Awards:
Excellence in the hazardous area sector risk of an explosion occurring and the severity and consequences of a dust explosion. The launch of the Tool Kit has been a success, demonstrated by its use to reduce dust explosion risks at major pharmaceutical, metal and plastic parts plants, has been presented as IChemE-approved training and has also been
Keith Plumb, BPE (Winner - Contribution to Safety Award) with Adam Garner, CSA Group
A
total of 20 nominations were shortlisted across four categories for
the Hazardex 2017 Awards, designed to recognise excellence in the hazardous area
used to develop an in-house training programme for Jaguar Land Rover. Runner-up: Moflash – BC150 Explosion proof beacon Runner-up: BS&B Safety Systems – System V chemical suppression & isolation system
Dr Geof Mood, CCG (Winner - Best User Application Award) with Jenny Banner, Banelec
For a number of years installers in hazardous areas have been relying on barrier glands with a two-part epoxy-based putty as a means of stopping explosive gases and liquids from
sector. Winners were announced at the Hazardex 2017 Conference and Exhibition Gala Awards dinner on March 2nd and are
2. Technical Innovation An innovative product or system that has brought significant advantage to hazardous area
The mixing process can take several minutes
listed below.
operations Winner: CorDEX – TC7000 Thermal imaging camera
depending on the volume of putty required and the insertion of the putty between the individual cores of multi core cable. This is not only time
The TC7000 is the world’s only Intrinsically Safe, Fully Radiometric Thermal Imaging Camera. Tough, safe and accurate, TC7000 is the thermal
consuming but there could be additional risks in that the putty may not have been mixed correctly or packed correctly around the cable conductors, which could result in the potential
imaging camera of choice for oil, gas mining, marine and dust environments.
of voids and gaps for gas or liquids to migrate through.
Features • Intrinsically safe certified. Safe, Reliable and above all, Rugged.
CCG’s QuickStop-Ex Barrier Gland, with an instant mixing and injecting resin, has all but eliminated the problems surrounding the
• High speed, articulating lens. Shoot high quality images over, under and around obstacles. • Onboard RFID tag reader. Assign images to RFID tags and automatically create reports, manage data and create trends. • CorDEX CONNECT™ enabled. Runner-up: Rheintacho – ATEX Certified system for stationary stroboscopes
preparing, mixing and applying of compounds/ resins in Barrier Glands. The QuickStop-Ex Injection Resin system is instantly and 100% accurately mixed, whilst being simultaneously
1. Contribution to Safety A product, system or service that has made a significant contribution to safety in the last two years Winner: BPE Design & Support Ltd – Dust explosion risk reduction tool kit The aim of this project was to develop a rigorous approach to dust explosion risk reduction to be incorporated into a Tool Kit that would allow professional engineers and other safety professionals to easily follow the approach. The comprehensive research and development programme came up with a more scientific approach to the hazardous area classification of dusts, with a true risk assessment covering the
diffusing down unfilled cables.
Runner-up: ION Science - Titan benzene specific monitor
3. Best User Application An application story highlighting the benefits of a Marcus Halliday, CorDEX (Winner - Technical Innovation Award) with Adam Garner, CSA Group
www.hazardexonthenet.net
product or service for hazardous areas Winner: CCG – QuickStop injection resin barrier gland
Danielle Abbott and Alistair McKean of Forth Valley College (Winner - Overall Award) with Alan Franck, Hazardex Editor (Centre)
Hazardex 2017 Review 21
injected into the barrier gland in one single action.
With our large team of certification engineers around the world focused on completing your
Runner-up: Pepperl+Fuchs – HiC2441 Smart universal IS barrier Runner-up: Eaton Crouse-Hinds – Clamped EBMX Series explosion proof motor
project within agreed to timelines, and our streamlined processes, we consistently start and finish projects with some of the best leadtimes within the industry.
4. Best Customer Service
As such, our customers have scored us 90% in overall customer satisfaction, with 4 out of
An account of customer service best practice within the hazardous area sector Winner: CSA Group CSA Group is a global organisation dedicated to safety, social good and sustainability. We provide testing, inspection and certification services for products in many market sectors, including industrial and hazardous locations. We know that for many of our customers, time to market is critical and that dealing with a Certification Body is typically the last step
5 clients saying they would recommend CSA Group to a colleague, according to December 2016 customer feedback results. Runner-up: – Ex Veritas Runner-up: – LGM Products
5. Overall Delegate Vote Winner The best hazardous area sector product, system or service introduced over the last two years, with voting restricted to delegates and attendees at the Hazardex 2017 Conference and Exhibition Winner: Forth Valley College - Hazardous
Clare Wilson, CSA Group (Winner - Best Customer Service Award) with Jenny Banner, Banelec
Hazardous Area Safety, Electrical Safety and many other courses for well over 20 years and within the last five years we have been recognised by our governing bodies and industry in Central Scotland for the professional and passionate approach we take. Recently we led the way training the new Ex14 Responsible Person course, the first in Scotland,
in a long product development process. Over the last 12 months, CSA Group has evolved
Area Safety Training Team
with our close Petrochemical allies INEOS & Petroineos. The course has been featured in
its processes to respond even better to the pressures you face, while offering you the marks you need to access global markets.
We are a small dedicated team of Trainer/ Assessors and administrators with a passion for teaching safe working practices in hazardous
Hazardex magazine and many other publications due to the very positive feedback it received both from the attendees and the governing body
areas. The centre has been training CompEx,
representative in attendance.
NEW Gas-Pro IR
New Hazardous Area Equipment Market report – 3 Jan 2017
Provides rapid detection of hydrocarbon gases
IHS Markit is pleased to announce it has commenced a new edition of its world-wide Hazardous Area Equipment Market report. As with previous editions, the new edition will be conducted in co-operation with HazardEx and is scheduled for publication Spring 2017. The report covers a wide range of products in terms of revenues, unit shipments and average selling prices. The company collects data and opinions from many sources including interviews with leading suppliers, enabling the general health of the market and trends to be assessed. A five year forecast and estimated market share of leading suppliers is also provided. IHS Markit works in association with Hazardex on this report which has become an important source of information for all companies that manufacture or are associated with the supply products approved for use in explosive atmospheres.
Fail-safe technology
Crowcon Gas-Pro multi-gas detector is now available with IR technology to detect hydrocarbon gases. IR sensors provide fail-safe operation and are resistant to poisoning. They are low maintenance, and provide reliable protection over many years.
John Morse – Snr Market Analyst IHS Markit 3-5 Huxley Close Wellingborough NN8 2UL UK t: +44 1933 408077 e: John.morse@ihsmarkit.com w: http://technology.ihs.com
Detecting Gas Saving Lives www.crowcon.com
22 Downstream
European downstream oil industry safety performance
improvement continues
C
oncawe, the European pipeline and downstream health, safety and environmental monitoring organisation, published a statistical summary of
In 2015, the total number of fatalities (7) was equal to that recorded for 2014 with the fatal accident rate (1.27 per hundred million hours worked) being marginally lower than in 2014
reported incidents in 2016 covering the period 1993-2015. The information was provided by 38 Concawe Member
(1.32 per hundred million hours worked) due to an increase in recorded working hours. These results remain at historically low levels.
Companies, together accounting for 97.1% of the available refining capacity in the EU-28, Norway and Switzerland.
Of the 7 fatalities, 4 occurred as the result of one incident (3 Staff and 1 Contractor), a fire
but one less than in 2013 (32 Companies) and two less than the peak in 2012 (33 Companies). The 2015 data represents 86% of the respondents and 96% of the reported
The article below quotes key passages from the report and reproduces select graphics, and a link to the full report is
during refinery shutdown. The remaining 3 Fatalities were Marketing Contractors, 2 as a result of ‘road accidents’ and 1 resulted from
hours worked. Up until 2012 the number of respondents was increasing each year, but it now seems to have plateaued.
provided at the end of the article.
being ‘struck by’.
The collection and analysis of safety data are widely recognised by the oil industry as an essential element of an effective safety management system. The report is the twenty-second Concawe review on safety, compiling statistical data for
Accident frequencies in the European downstream oil industry are generally at low levels and the 2015 performance continues this trend. Standing at 1.0, the Lost Work Injury Frequency (LWIF) indicator for 2015 is slightly lower than that achieved in 2014 (1.1), and is the lowest recorded since 1993,
the European downstream oil industry. This latest version incorporates key performance indicator (KPI) data for 2015 and gives a full historical perspective from 1993. It also includes comparative figures from other
which maintains the positive trend of being less than 2.0, as has been the case since 2007. The responsible management of safety in the oil industry has resulted in a low level of accidents despite the intrinsic hazards of the
related industry sectors. For 2015, the results are reported mainly in the form that has been adopted by the majority of oil companies operating in Europe as well as by other industry sectors.
materials handled and the operations carried out.
www.hazardexonthenet.net
Background For the seventh consecutive year, Concawe Member Companies were asked to provide
Process Safety Performance Indicator (PSPI) data which describe the number of Process Safety Events (PSE) expressed as unintended Loss of Primary Containment (LOPC). Thirtyone Companies provided data in 2015, two more than in 2014 (29 Companies)
The term “Downstream” represents all activities of the Industry from receipt of crude oil to products sales, through refining, distribution and retail. Not all companies operate in both the manufacturing and marketing areas but all those who do, collect data separately for “Manufacturing” (i.e. refining) and “Marketing” (i.e. distribution and retail, also including “head office” staff) and this split has also been applied in the Concawe data. Additionally, the data are split between own personnel and contractors, the latter being fully integrated in all of the companies’ safety monitoring systems. The purpose of collecting this information is twofold: • To provide member companies with a benchmark against which to compare their performance, so that they can determine
Downstream 23
the efficacy of their management systems, identify shortcomings and take corrective actions; • To demonstrate that the responsible management of safety in the downstream oil industry results in a low level of accidents despite the hazards intrinsic to its operations. From the outset, a majority of Concawe member companies have participated so that the sample has always represented a large portion of the industry. By 1995 virtually all Concawe members participated, representing about 93% of the European refining capacity (somewhat less for distribution and retail). Over the years this level of participation has peaked to >97%, although the actual number of participating companies fluctuated in line with the structural changes and mergers occurring in the industry as did
Safety Events (PSEs) and are expressed as the number of unplanned or uncontrolled
fatalities is certainly no guarantee of a safe operation. The safety pyramid of H.W.
releases of any material, including nontoxic and non-flammable materials from a process with the severity defined by the consequences experienced or released amount thresholds.
Heinrich implies that for every fatality there have been many other incidents with less serious injury outcomes. These less severe incidents provide the opportunities to address equipment, standards, training, attitudes and practices that may prevent both the less, and
the percentage of the refining capacity represented. For 2015, 38 Member
The report also provides statistics for the All Injury Frequency (AIF), Lost Workday Injury
Companies responded with the submission of a completed questionnaire, although not all companies could supply all the requested
Severity (LWIS) and Road Accident Rate (RAR).
data. The statistics presented represent all except two EU-based refineries covering 97.1% of the refining capacity in the area where Concawe operates.
1. Safety performance indicators A number of safety performance indicators have become “standard” in the oil industry and in many other industry sectors. They are mostly expressed in terms of frequency of the injury or incident - the number of hours worked being the common denominator
Fatalities and Fatal Accident Rate (FAR)
the more serious incidents.
Lost Work Time Injury (LWI) Causes The analysis of the data collected on causes
Because of their very low numbers, fatalities, and therefore FAR, are not necessarily
for fatalities and injuries has generated much interest amongst the membership. In 2013, Concawe members agreed to
reliable indicators of the safety performance of a Company or Industry. A single accident can produce several fatalities and cause an abnormally high result in the indicator
adopt 16 cause categories to describe both fatalities and lost work time injuries. These cause categories are aligned with other organisations (e.g. IOGP). A total of 556 LWIs
for a certain year. Conversely, the lack of
were reported in 2015.
representing the level of activity. Such parameters have the advantage of relying on a small number of straightforward inputs, which allows meaningful statistical analysis even when the data sets are incomplete. The performance indicators considered in this report are: • The number of work-related fatalities and the associated Fatal Accident Rate (FAR) is expressed as the number of fatalities per 100 million hours worked. • The Lost Workday Injury Frequency (LWIF) is calculated from the number of LWIs divided by the number of hours worked expressed in millions. • The Process Safety Performance Indicators (PSPI) measure the number of Process
Figure 1 - Visual representation of LWI causes 2015, 2014 & 2013
www.hazardexonthenet.net
24 Downstream the improvement in the personal safety performance of contractor staff is catching up with that of own staff. For the LWIF, the performance even appears to be better for contractor staff. Therefore, it can be concluded that the sector is finding the balance between managing the safety performance of both contractor and own staff. However, further performance improvement for both groups remains a feasible target. In 2015, the road traffic accident rate was again 0.3, consistent with the rates achieved over the last few years. Road safety has been a major focus for the industry and it is
Figure 2 - Historical evolution of main performance indicators for the European downstream industry
pleasing to see the sustained reduction in the number of accidents being maintained. These accidents essentially occur in the Marketing activity where the bulk of the driving takes place. However, there were still 2 fatalities as a result of a road accident in 2015.
As this is the third year of using the new 16
are shown in Figure 2 (above).
categories for all incidents, a summary of the 2014 and 2013 results has been included in the table for comparison. The outcome in
2. Process safety performance indicators
As reported above, the total of 7 fatalities were reported for 2015, with 4 fatalities
The American Petroleum Institute (API) has recommended the adoption of Process Safety
terms of the % allocation of causes is very consistent from 2013 through 2014 and 2015. This consistency in the causes will
resulting from one incident, which occurred during a refinery shutdown, and the other 3 being the result of separate incidents. The
Performance Indicators (PSPI) in addition to personal safety performance indicators such as those contained in this report. This
clearly aid in identifying areas of concern for all Companies. After only 3 years of collecting the new data it is already possible to draw some limited conclusions about the causes of
absolute number of fatalities and the FAR have been at consistently low levels since 2004 and this continues in 2015. In 2015, 4 fatalities (3 employees and 1 contractor)
is intended to better address the potential causes of major process safety incidents, which can have catastrophic effects in the petroleum industry. In 2010, the Safety
LWI which could suggest areas of focus. ‘Slips & trips (same height)’, 29.5%, ‘Struck by’, 11.9%, ‘Overexertion & strain’, 13.9%, ‘Falls from height’, 8.6%, ‘Explosions or burns’, 6.0% are the major causes of LWIs in 2015 and together account for 79% of all LWIs.
occurred in Manufacturing while the 3 fatalities in Marketing were all contractors. 4 of the 7 fatalities were contractors. As discussed above, it should be kept in mind that the FAR is notoriously prone to large variations.
Management Group of Concawe decided to expand the scope of industry wide safety performance indicators to address process safety, following the reporting guidelines that were developed by the API. Combining a focus on process safety in conjunction with
The LWIF of 1.0 recorded for 2015 is the lowest value since the collection of this data commenced in 1993 and maintains the trend of less than 2.0 for the ninth consecutive year, the longest consistent period since Concawe started to collect safety data. This indicator initially had greater reductions in Manufacturing than in Marketing, however, since 2006 figures for the 4 categories
the personal safety factors collected thus far will contribute to a further reduction in serious injury rates in the industry.
‘Explosions or burns’ also accounted for 4 fatalities in one incident while ‘Road accident’ caused 2 fatalities and ‘Struck by’ a further 1 fatality for a total of 7 fatalities in 2015. The causal data is relatively consistent across the 3 years of collection. Figure 1 (previous page) provides a visual presentation of the 2015 causes recorded compared to those over the previous two years.
Historical trends The performance indicators are of particular interest when considering their evolution over the years. The historical trends for the European downstream oil industry as a whole
www.hazardexonthenet.net
continue to remain very close.
The Concawe Membership was requested to report their PSPI indicators as defined by the API in 2008 and as further refined in the ANSI/API recommended practise that was published in 2010.
Definitions
The figures suggest that AIF peaked around 1996-97 but this is likely the result of improved reporting standards. Since this time
LOPC - Loss of Primary Containment (LOPC) is an unplanned or uncontrolled release of any material from primary containment, including
the trend has been slowly downward.
non-toxic and non-flammable materials (e.g., steam, hot condensate, nitrogen, compressed CO 2 or compressed air).
Furthermore, it can be concluded that
Downstream 25
PSE - A Process Safety Event is an unplanned or uncontrolled LOPC. The severity
to €2,500 of direct cost to the Company’.
was a slight increase versus that reported for 2014. In this seventh year of data collection a
of the PSE is defined by the consequences of the LOPC.
PSER - Process Safety Event Rate (PSER) is calculated as the number of PSE (Tier 1, Tier 2 or Total) divided by the total number of hours worked (including contractor hours) expressed in millions.
total of 86% of the Manufacturing operations and 77% of the Marketing operations provided the requested information. The results for 2015 are included in this report and continue to show a significant reduction in the number of Process Safety Events (PSE) and in Process Safety Event Rates (PSER)
• Tier 1 PSE - A Tier 1 Process Safety Event (T-1 PSE) is a loss of primary containment (LOPC) with the greatest consequence. A T-1 PSE is an unplanned
Process safety statistics
or uncontrolled release of any material, including non-toxic and non-flammable materials (e.g., steam, hot condensate, nitrogen, compressed CO 2 or compressed air), from a process that results in one or more of a list of consequences
The data provided suggests that one Tier 1 PSE in the Manufacturing sector resulted in 4 fatalities. The number of LWIs resulting from the PSEs is not established, as this information is not available.
versus prior years. This is demonstrated in the range of graphs for Manufacturing and Total PSPI (Process Safety Performance Indicator) responses presented in Figures 3 (below) and 4 (overleaf) which show the results recorded by this survey over the 7 years of Concawe
including: ‘An employee, contractor or subcontractor with days away from work injury and/or fatality’ or ‘Fires or explosions resulting in greater than or equal to €25,000 of direct cost to the Company’.
The extent of reporting of Process Safety data
reporting and the associated trends.
• Tier 2 PSE - A Tier 2 Process Safety Event (T-2 PSE) is a LOPC with lesser consequence. A T-2 PSE is an unplanned or uncontrolled release of any material, including non-toxic and nonflammable materials (e.g., steam, hot condensate, nitrogen, compressed CO 2 or compressed air), from a process that results in one or more of the consequences including: ‘An employee, contractor or subcontractor recordable injury’ or ‘A fire or explosion resulting in greater than or equal
Figure 3 - Manufacturing Total PSEs 2009-2015
www.hazardexonthenet.net
26 Downstream
Figure 4 - Total PSERs 2009-2015
Comparison with other sectors Most of the safety performance indicators used in the oil industry, and particularly LWIF, have also been adopted in many other sectors
and production activities. For 2015, IOGP recorded somewhat lower safety metrics to those collected by Concawe for the 2015 data for European downstream activities. The
so that meaningful comparisons are possible.
‘upstream’ operation recorded a higher FAR
Table 1 - Comparison of the safety performance of the downstream oil industry IOGP - International Association of Oil & Gas Producers CEFIC - Conseil Européen des Fédérations de
but somewhat better results for the other safety metrics across the globe.
l’Industrie Chimique API - American Petroleum Institute (1) Own staff and contractors IOGP 2015 (2) Estimated from 2.1 injuries per 100 FT oil and gas workers (own & contractor staff), API WIIS-report 2003-2012
The 2012 data for the EU chemical industry (CEFIC), the 2015 data for IOGP and the 2013 data for API have been shown as these reports are publicly available.
The IOGP statistics concern the “upstream” oil industry covering oil and gas exploration
www.hazardexonthenet.net
For the report on which this article is based (12/16), and others relating to the European downstream oil industry, go to www.concawe. eu/publications/concawe-reports
@P E R F T E C
Antweep 2017
In the regions hazardexonthenet.net Protecting Plant, Process & Personnel
We are pleased to announce the next Hazardex in the Regions event will take place in Antwerp, Belgium on November 29th 2017 and will be co-located with PEFTEC, the event for petroleum refining & environmental monitoring technologies.
The underlying philosophy of Hazardex in the Regions is to bring the latest safety-related intelligence to process plant and hazardous area specialists at a venue near their workplace, reducing travel time and expense. The conference will be supported by an exhibition of products and services relevant to those working in hazardous environments, and offers free access to PEFTEC conferences, seminars & the wider exhibition.
Following on from the success of the decade long series, this is another opportunity for all those interested in process plant safety in Belgium and the surrounding countries to participate in one of our hazardous operationsfocused one-day conference & exhibitions.
These events will be useful for engineers, safety managers, directors with corporate liability and other members of the hazardous area community from all the process and high hazard industries, including oil & gas, petrochemicals, fine chemicals, pharmaceuticals, mining, manufacturing and the food & beverage sector, amongst others.
If you are interested in presenting a paper, exhibiting or attending the event, please contact:
russell.goater@imlgroup.co.uk or phone + 44(0) 1732 359990 www.hazardexonthenet.net
CONFERENCE EXHIBITION & SEMINARS 29th - 30th NOVEMBER 2017 - ANTWERP, BELGIUM
29th & 30th NOVEMBER
2017
ANTWERP
BELGIUM
Antwerp was chosen as PEFTEC’s location as it is situated in the World’s second largest cluster of Petrochemical Industry activities and the largest outside of the USA. Antwerp is an ideal location for visitors as it is placed in the heart of Europe with easy access by car and by rail with excellent Air links for visitors from the Middle East, Africa, Asia and the Americas.
Peftec 2017 is a focused international Conference and Exhibition for Companies specialising in monitoring and analytical technologies for the Petroleum, Refining and Environmental Industries. Peftec offers international visitors and experts an extensive conference and seminar programme on case studies, CONFERENCE EXHIBITION & SEMINARS regulation, standards and analytical techniques with a focussed exhibition of product and service providers.
29 - 30to th NOVEMBER 2017 - ANTWERP, BELGIUM Thethneed produce accurate analytical and monitoring data is essential to industry.
For more information email: info@peftec.com Hazardex will be staging a one day high hazard process safety conference within PEFTEC, contact events@imlgroup.co.uk for attendance and exhibiting options.
www.PEFTEC.com
Topics and products featured at Peftec 2017 will include: • Laboratory Testing and Measurement • Petrochemical Analysis • Emissions Monitoring in Air, Water and Soil • Portable and Field Sampling • Process Monitoring • Reference Materials • Oil Analysis • Calibration • Regulation and Standards
Organiser: International Labmate Ltd, Publisher of Petro Industry News, International Environmental Technology, Asian Environmental Technology, International Labmate and Lab Asia.
28 Safety culture
How to influence decisions
around safety P
rocesses, procedures and hard controls alone cannot provide a complete safety solution. Even best–
85 - 95% of accidental acute injuries. It is also well known that when people made these critical errors they were in one or
proposed for how to control, change or improve human error and human performance. It is known that human
in-class processes and systems may not be effective because not everyone interprets and acts on them in the same way. Companies spend millions on behavioural based safety programs, consultants and training, often with little
more of the following four states; rushing, frustration, fatigue, or complacency.
performance can be affected by many factors such as age, state of mind, physical health, attitude, emotions, propensity to make certain common mistakes, errors and cognitive biases, etc.
return on investment. In this article, Lyn Fernie and Mike Warren of Zento Global Solutions discuss the missing element - people’s natural behaviours and how these contribute to an individual’s decisions around safety, which ultimately influence safety performance.
go wrong and how to prevent failure] found that 85% of the failures of control systems were shown to be a direct result of people and the processes they followed. The study acknowledged that failures in control systems are not due to technical aspects alone; human and managerial factors are extremely important. Issues such as conflicting managerial priorities
However, most behavioural based safety and safety culture programs focus on training people to avoid error, thereby preventing injury.
Workplace related injuries cost the Australian economy an estimated $60.6 billion each year 4.8% of GDP) with other countries following a similar pattern.
and incentives, lack of safety engineering training, absence of a ‘safety culture’ and poor contract procedures etc may contribute significantly to an eventual failure that has a technical cause.
& safety expenditure is directed towards creating a safer working environment and the human factors are largely ignored. Procedural controls are introduced and rules put in place for people to follow.
It is well known that there are four critical errors that people make that contribute to
Human behaviour has been extensively studied, and many models and hypotheses
These programs all miss one important factor - natural human behaviours.
www.hazardexonthenet.net
A study in the UK by the Health & Safety Executive in 1995 [Reference HSG 238 2003, Out of Control: Why control systems
Companies spend millions on such programs and systems, consultants, training and advice, only to find the return on investment is limited. Most workplace health
Safety culture 29 Human behaviour
Natural behaviours and safety
Research into human behaviour can be
individual’s perception of the environment as either antagonistic or favourable.
traced back to the time before Christ. Hippocrates (400 B.C.) was an observer of people. He noticed the effect of the climate and the terrain on the individual. Defining four types of climates, he categorised behaviour for each climate, even suggesting which people would conquer others in battle, based
The profiling or measurement system derived from Marston’s work analyses these factors and reveals one’s strengths and weaknesses, one’s actual behaviour, and tendencies toward certain behaviour. Behavioural profiles measure personality traits that have been
procedures and programs, it can be seen from behavioural research that many factors play a part in the decisions people make. These factors also play into the decisions people make around safety. It is therefore logical that mapping people’s natural behaviours can assist with understanding
recognised since the ancient Greeks and validated by extensive research over the last century. Behavioural profiling is not impacted by experience or education, it is a scientific indicator of core human preferences.
how those natural behaviours influence safe and unsafe behaviours in the workplace, and this understanding can provide leaders with opportunities to improve safety performance.
identified and described four “types”. These four types are primarily oriented by the four psychological functions: thinking, feeling, sensation and intuition. These four are further divided into two divisions that Jung called “libido” or “energy.” These two divisions
Behavioural research suggests that the most effective people are those who understand themselves and others. The more one understands his or her personal strengths and weaknesses coupled with the ability to identify and understand the strengths and
Understanding how an individual responds to problems and challenges, interacts and attempts to influence others, responds to change and pace of their environment, and responds to rules and procedures provides insight into how that person would react in
are “extroverted” and “introverted.” Jung believed the extroverted and introverted
weaknesses of others, the better one will be able to develop strategies to meet the
different scenarios, such as: • Under pressure during an emergency;
types were categories over and above the other four functions.
demands of the environment. The result will be success on the job, at home or in society at large.
• Performing routine tasks; • Following rules and procedures; • Handling detailed reporting requirements;
Dr William Moulton Marston published Emotions of Normal People in 1928 in which he described the theory that people behave
Equally this theory holds true in the safety space. The decisions people make about
• Leading a team; • Making safety interventions; and • Making the right decisions around safety
along two axes with their actions tending to be active or passive depending upon the
safety are influenced by their core natural behaviours.
on the environmental conditions in which they were raised. Hippocrates believed the climate and terrain affected behaviour. Much later, Carl G. Jung (1921) published Psychological Types in Germany. He
People do not respond identically to
versus production.
www.hazardexonthenet.net
30 Safety culture Our own company uses special behavioural profiling of individuals, teams and managers to help understand how natural behaviours
information about an individual’s strengths, weaknesses, communication style and their motivators. The one-to-one coaching, report
colleagues, how best to work with them, and the best approach to achieve strong safety performance as a team.
play into safe and unsafe behaviours in the workplace, and how this understanding can provide opportunities for improved safety performance through better communication, trust, motivation, empowerment and teamwork.
and workbook provides a clear roadmap with information on how to maximise their own potential and achieve safe outcomes. In a workshop environment team members learn what over-arching
Good safety leadership can positively impact safety behaviour by up to 86%. Managers therefore have a huge part to play in determining the success or otherwise of a behavioural safety
Individual profiles provide detailed
behaviours exist in their team, what behaviours they might expect from
process. The executive style coaching and reports provide managers with
Case study Zento Global Solutions were invited to run a program for an open cast mine site in Australia. The site had been operating for 7 years and had successfully maintained a good safety culture, driving down the total recordable incident rate (TRIF) through a
The operational team-based workshops provided a platform for members to learn: • What overarching safety behaviours exist in their team; • What behaviours they might expect from colleagues and how best to work with
the final step was to work with the site’s leadership team to design a safety strategy for the organisation. This guidance on how to influence safety culture within the organisation provided tools that the leadership team could use in a volatile
series of focused initiatives on the site. However as the site entered the final
them; and • How to achieve strong safety
environment, thereby providing a measure of sustainability.
phases of mining prior to closure, a number of problems had been encountered: • Demotivation and disengagement
performance as a team. The workshops were based on the
The language and shared understanding provided high levels of cooperation
throughout the operations teams • Difficulty with maintaining the good safety culture
rostered site teams, allowing the existing teams to develop trust and understanding.
and commitment from everyone from shop floor to board room and this endorsement and belief in the program
• Supervisors struggling to motivate teams and turn the rising TRIF around • Personnel unhappy with allocation of tasks
The coaching for supervisors focused on how the knowledge they had gained from the team workshops would allow them to optimise their teams’ safety performance
generated measureable improvements very quickly, including: • Measurable and sustained reduction in total recordable injury frequency rate
• Generally poor safety performance
and allocate tasks more effectively, taking behaviours into account.
(27% reduction over 12 months); • Significant reduction in incidents caused by behavioural choices; • Improved safety culture – awareness and understanding of safety behaviours;
Zento Global Solutions designed a 6-month program for the site comprising: • Zero profiles© provided for all personnel; • Operational team based workshops; • Coaching provided to supervisors; • Executive style coaching and reports provided to managers; and • Support to the leadership team to design a safety strategy for the organisation. It is well known that most teams never make it to high performance without both training in a behavioural model and commitment to using it from the top management down. For this reason, the Zero profiles were completed for all staff and contract personnel on the site, including the leadership team and the managers/supervisors.
www.hazardexonthenet.net
The executive style coaching and reports provided to managers provided a snapshot of the site’s behavioural biases, allowing strategies to be developed to balance weak spots throughout the organisation. In order to drive improvements in safety culture and performance from the top,
• Improved team interdependence – no longer rely on rules and processes for safety; and • Increase in productivity due to better task allocation.
Safety culture 31
direction and support with how best to manage individuals and teams to optimise their safety performance and influence
• Increase in productivity due to better task allocation.
safety culture within the organisation.
Conclusions
Our experience of profiles has demonstrated the following benefits: • Significant reduction in incidents caused by behavioural choices.
Processes, procedures and hard controls alone don’t provide a complete safety solution. Even best-in-class processes and systems may not be effective because not everyone interprets and acts on them in
• Improved safety culture – awareness and understanding of safety behaviours. • Improved team interdependence – reduce reliance on rules and processes for safety.
the same way. Companies spend millions on behavioural based safety programs, consultants and training, often with little return on investment. The last piece in the jigsaw is to understand
people’s natural behaviours and how these contribute to an individual’s decisions around safety which ultimately influence safety performance. Behavioural research suggests that the more an individual understands his or her personal strengths and weaknesses and the strengths and weaknesses of others in the team, the better one will be able to develop strategies to meet the demands of the environment. This theory holds true equally in the safety space. The decisions people make around safety are influenced by their core natural behaviours.
About the authors She has international experience with both capital projects and operating assets. Lyn is certified by TÜV Rheinland as a Functional Safety Expert in Process Hazard & Risk Analysis and was awarded the Frank Lees medal in 2005 by the Institution of Chemical Engineers for her contribution to Safety. Lyn is also the Module Director for the Functional Safety Module on the University of Sheffield’s Masters Degree in Process Safety and Loss Prevention.
Lyn Fernie is VP Consulting at Zento Global Solutions and has 25 years’ experience in process and functional safety. She has worked with companies around the world, across most industry sectors, helping them improve their safety culture and performance.
Mike Warren is Director and Principal Consultant at Zento Global Solutions and his passion is inspiring Behavioural Change within individuals and teams. Having been involved in a workplace accident early in his career, Mike has dedicated his career to help companies achieve sustainable success, maximise business performance and reach their safety goals through Behavioural Change.
For more than 25 years Mike has worked with organisations worldwide across sectors such as mining, rail, power generation, construction, healthcare, oil & gas, and engineering.
www.hazardexonthenet.net
32 Safety culture
Integrating culture and leadership into process incident prevention T
he implementation of process safety management (PSM) has
outcomes and positive consequences. A common example relates to operating
and that had been the basis of hazard assessments. When lack of availability of
received significant attention in the last 25 years, with major incidents (e.g., Piper Alpha and Bhopal) giving rise to
procedures. It is not uncommon to find that across time operators and their supervisors deviate from the letter of the
a replacement hose caused replacement time to be delayed to two months and no safety incident occurred, the replacement
new rules and practices. But despite this attention, major catastrophic incidents have continued to occur.
written procedure, finding ways to do the job more quickly and efficiently (at least in their perception). They are praised,
cycle was informally changed to every other month, and later to quarterly. This eventually led to a chemical release when
Retrospective views on these events have consistently shown organisational cultures that resulted in systems breakdown.
reinforcing the belief that efficiency and speed are valued, and do not experience adverse consequences (e.g., injuries or chemical releases) reinforcing the belief that their practice is sound. In this situation leaders would probably say that operating procedures are important and operational discipline is valued, but shortcuts become the norm.
a hose failed – not due to poor hazard assessment or a mechanical integrity programme that was flawed on paper, but because various individuals allowed the programmes to slip based on perceptions of risk derived from their recent experience.
In this article, R. Scott Stricoff of DEKRA Insight says this pattern tells us that process safety must make the same migration as that of personal safety in recent years – that systems are only as effective as the culture in which they operate. Culture is often described as “the way we
Because ultimately all of our PSM systems are implemented through the behaviour of engineers, managers, supervisors, front-line workers, and/or others within
do things around here” or “the unwritten rules.” Culture arises from shared values and beliefs held within the organisation, which lead to shared norms of behaviour. These behavioural norms are reinforced over time as they lead to successful
the organisation, the behavioural norms created by the culture have a direct impact on the effectiveness of the PSM systems. In one recent instance a transfer hose was to be replaced monthly according to the procedures that were in place
www.hazardexonthenet.net
We also know that the culture of an organisation and the organisation’s leadership are inextricably linked. Leaders have the ability to create and drive change in a culture through what they do, and through what they do not do. For example a leader who never asks about resolution of safety audit items but requests frequent updates on installation of new production equipment helps create a culture that values production but may take safety shortcuts to achieve it.
Safety culture 33
To advance beyond the level of safety achieved through process safety management systems alone, we have
across various types of data. In many organisations there is a wealth of information collected, but different types
early warnings and reinforce the analysis of these indicators, even when this does not result in identification of serious risk. These
found that organisations should adopt a Comprehensive Process Incident Prevention (CPIP) approach that builds on the foundation of PSM to create a safety process integrating culture and leadership characteristics critical to catastrophic event
of information cannot be integrated and effectively used.
leaders understand that supporting the detection and investigation of many false positives is worth it if it results in just one catastrophic event avoided.
prevention. This approach includes four major components, Anticipation, Inquiry, Execution, and Resilience, to build a strong safety culture that supports effective technical and management safety systems.
Anticipation An organisation that is strong in Anticipation will have mechanisms to capture information from a variety of sources. Process deviations, unusual maintenance requests, and even front line workers detecting differences in
Even when systems are in place, it is incumbent upon the organisation to assure that the systems are used. Individuals will not bring forward information if they perceive that nothing happens or, even worse, that raising a concern is considered to be a nuisance. It is important for leaders to encourage individuals to be alert for weak signals and reinforce this behaviour. Finally the information gathered must be used effectively. This requires having people with appropriate skills who are given appropriate encouragement and
Inquiry Inquiry involves making effective use of information to analyse, understand, and plan mitigation of risks. Traditional PSM includes a number of elements (such as process hazard analysis, pre-startup safety review, management of change) designed to evaluate and plan for control of hazards and risks. However there are common (but often undetected) cultural characteristics that can undermine the effectiveness of these efforts and leave the organisation vulnerable.
sounds can potentially be meaningful early
attention. Early warning indicators will not
indicators of change to exposure. If there are not systems to seek out and capture this information it can easily be lost.
always lead to actual findings of increased exposure; by its very nature, sensitivity to weak signals will result in numerous “false positives.� It is easy for the organisation
Cognitive bias refers to the tendency we all have to rely on intuitive rather than analytical thinking in order to process information efficiently. Our knowledge and
Once captured, the various types of information that can be early indicators must be accessible and structured in
to begin to discount early warnings in the manner of the boy who cried wolf. Organisations with strong cultures have
experience allow us to reach conclusions and make decisions quickly and efficiently in many circumstances. However this can
a way that allows analysis of patterns
leaders who visibly value the search for
also trap us in poor decisions. Recency
www.hazardexonthenet.net
34 Safety culture bias is a common example – we tend to overweight our recent experience in
Execution As seen in the examples cited earlier in
of written progress reports, review of appropriate metrics, etc.
assessing data and situations. Confirmation bias is another example – we tend to give more weight to data that supports our intuition and belief than to data that refutes it. These and other cognitive biases have been researched and demonstrated to be present in everyone.
this article, excellent hazard identification and assessment, as well as hazard control efforts related to mechanical integrity, safe operating procedures, and management of change, can be undermined if the programmes and practices are not followed as intended. While many organisations
Reinforcement involves providing feedback that recognises good performance. This communicates the importance and priority of the catastrophic event prevention activities and maintains focus on consistent execution. Effective reinforcement is based
use periodic audits to provide a check on implementation, the key to assuring consistent and on-going activity is leaders who monitor, reinforce, and verify effective programme execution.
on effective monitoring, which provides the leader with specific data on which to base reinforcement, avoiding the vague and ineffective “good job” type of feedback to subordinates.
underestimate or even miss entirely potential failure scenarios. In addition, the routine operational decision-making that occurs day-to-day can be influenced by cognitive bias, leading to unintended increases in risk.
Monitoring involves regularly acquiring information on what subordinates are doing, how they are progressing toward achievement of goals, and what issues or problems they may be encountering. This is not micromanaging; rather it is assuring
Verification is similar to monitoring, but where monitoring is focused on the performance of subordinates, verification is focused on activities and programmes. Assuring that audit findings are resolved in a timely manner is an example of verification,
While awareness of cognitive bias helps to
that the leader has sufficient information to meaningfully recognise good performance,
and leaders who do this effectively are more likely to have organisations in which
counteract its effect, the best way to guard against the insidious effects of cognitive bias is to have an organisational culture that
provide support when subordinates need it, and providing corrective feedback on those hopefully rare occasions when subordinates
consistent execution is valued as part of the culture.
combats it. There are specific leadership behaviours (for example, encouraging the voicing of dissenting opinions) that promote
fail to fulfil their responsibilities.
Resilience
A leader’s monitoring behaviour may take
Upset conditions occur from time to time in any system.
a culture in which the effect of cognitive bias is minimised. There are also specific skills involved in asking the right question in the right way to get the right data.
many forms. Depending on the situation and the leader, these may include walking around
Resilience refers to the organisation’s ability to react in ways that prevent upset conditions from becoming catastrophic
Organisations should promote and measure the use of these leadership behaviours and skills.
and observing, informal conversations at the front line, periodic meetings with subordinates to review progress, use
events, and then learning from the experience. This has a major influence on ultimate results.
Where cognitive bias becomes particularly problematic for catastrophic event prevention is that our methods for systematic hazard analysis can be influenced and can cause us to
www.hazardexonthenet.net
Safety culture 35
Even where automated control systems are designed to handle upset conditions, it is important that workers understand when and how to intervene, and are not only able but also willing to make appropriate interventions early. An organisation that is strong in resilience is more likely to prevent a small process disruption from becoming a major incident. One requirement for strong resilience is knowledge; that is, do people at various levels have a broad enough understanding of the operation so that they can make good judgments in case of emergency. Some organisations approach this through use of extensive sets of rules and procedures. That approach is intended to assure consistency and avoid having to rely on technical knowledge at the operating level. However two problems arise with that approach. First, the range of possibilities that must be planned for results in a proliferation of procedures and rules that become impractical for anyone to know. Second, this approach assumes that all possibilities (with all variations in every scenario) can be identified in advance – something that is unlikely to be true. The alternative is to develop an organisation in which people are knowledgeable and are taught to make good judgments based on their knowledge and the information at hand. The second requirement for resilience is willingness, and this relates directly to culture. Simply put, people are less likely to take action on their own initiative if they are not confident that the organisation will support them. Perceptions of the culture’s support for resilience are formed over a long period and are based on many small actions taken and not taken by leaders. An organisation desiring strong catastrophic event prevention will be sensitive to this and intentionally create the culture that supports resilience.
Creating comprehensive process incident prevention The discussion above emphasises the importance of supplementing systems with specific leadership behaviours to create and sustain the culture that leads to prevention of catastrophic events. Focused initiative is
www.hazardexonthenet.net
36 Safety culture A common misconception is that leadership behaviours and culture can be changed through training. While training may be part of the effort, creating a CPIP-supporting culture requires a process that creates understanding of the need for change, elucidates for each individual the leadership behaviours on which he or she must focus, provides new skills and knowledge where necessary, provides structured reinforcement to help establish the new culture, and measures progress. Through a focused initiative individual leaders can be helped to understand their role in catastrophic event prevention and learn to communicate commitment to that objective. With knowledge of the key behaviours that support Anticipation, Inquiry, Execution, and Resilience and appropriate measurement tools, leaders can receive individual feedback on their use of the behaviours. Leaders can improve their ability to use the key leadership behaviours, and through a variety of both personal and virtual methods receive reinforcement and guidance in adopting new leadership practices. About the authors
often needed to introduce these leadership behaviours in a way that will integrate them
functioning characteristics it is important to assess the extent to which Anticipation,
effectively with other safety efforts and assure their use in day-to-day activities.
Inquiry, Execution, and Resilience are present and consistent in the organisation. This assessment will help the organisation understand its strengths and improvement opportunities in creating the cultural foundation to optimise technical and management systems.
An important starting point is to assess the cultural impacts on existing technical and management systems for catastrophic event prevention. There are key organisational characteristics indicative of culture that can be objectively measured
Based on the assessment findings, an
and that will predict the effectiveness of catastrophic event prevention programmes. One example is Perceived Organisational Support. This measures the extent to which individuals feel that they are valued
organisation can take steps to ensure that it has a Comprehensive Process Incident Prevention approach. This may involve strengthening the technical and management systems themselves,
by the organisation. When this dimension is strong individuals are more likely to take initiative to support the organisation’s objectives, which is critical to strong Anticipation and Resilience. In addition to measuring these key organisational
improving communication, and/or implementing and using new metrics. However it most often also involves creating the framework of leadership behaviours that drive CPIP-supporting culture.
www.hazardexonthenet.net
R. Scott Stricoff is president, process safety and Americas region for DEKRA Insight. He has over 40 years of experience in safety performance improvement and today helps organizations build strong safety leadership and culture, working with senior executives to enhance safety performance. He has worked in the chemical, railroad, utilities, and metals industries, as well with NASA following the Columbia space shuttle accident.
Product Datafiles An Engineer’s 3 Step Guide to selecting a static grounding solution
ATEX Certified Humidity/ Moisture & Temperature Sensors
Hazop assessments, and the reports that follow on from them, are a great way of capturing and identifying processes and practices that could lead to the ignition of flammable atmospheres through discharges of static electricity. What Hazop reports are not so great at doing is identifying what the grounding solution to eliminate the risk should look like. This 3 Step Guide is about helping you get started on the right path and can be best described as a door opener to the subject of hazardous area static control.
ROTRONIC Intrinsically Safe sensors and measurement transmitters with analogue outputs are suitable for use wherever there is a risk of explosion due to dust or gas in the environment. They were developed for the pharmaceutical, biotechnology, grain & sugar, petrochemical, and oil & gas industries. HygroFlex5-EX transmitters and probes from ROTRONIC conform to the latest international ATEX standards. The transmitter is Intrinsically Safe (secondary side) , there are two channel outputs, the housing is heavy duty. Interchangeable probes are available for all applications, including those at pressure and low dew point. Technical datasheet available Tel: 01293 571000 Email: instruments@rotronic.co.uk Web: www.rotronic.co.uk
For more information please contact Newson Gale. www.newson-gale.co.uk
STA Functional Safety Trip Alarm – Effective Alternative to Safety PLCs
High-End Humidity and Temperature Transmitter with Multi-Functional Display
It is a standalone SIL 3 capable functional safety single loop logic solver. It is approved for single use in Safety Instrumented Systems (SIS) up to SIL 2 and in redundant architectures (1oo2, 2oo3, etc.) up to SIL 3. The STA is easier to use and significantly more affordable than a typical safety PLC and can work as an extension of a larger control system or perform localized operation in safety settings. It acts as a single loop logic solver that: • Warns of and acts on unwanted or potentially hazardous process conditions • Provides emergency shutdown in Safety Instrumented Systems • Provides on/off control and traditional alarm trip functions • Locally displays and retransmits PV status Visit www.miinet.com/safetyseries or contact us at +44(0)1293 514488 and info@miinet.com
(Engerwitzdorf, 22.2.2017) The highly accurate EE310 humidity and temperature transmitter from E+E Elektronik is dedicated for demanding process control. The modern multi-functional display with data logging function enables intuitive operation and offers an optimum overview of the measuring task. Extensive settings and diagnostics can thus be performed directly on the device.
Ex-rated enclosures ejb for hazardous areas Trusted Industrial-Grade IP CCTV System for Hazardous Oil and Gas Environments Oil and gas have a major impact on the global economy. New oil platforms, rigs, and pipelines are constantly being constructed to meet the demand for oil, with a corresponding growth in the number of factories and control centers used to process and manage crude oil. To maximize safety and increase reliability, Moxa’s IP surveillance systems have an intrusion detection alarm system (IDAS) and are easily integrated with SCADA systems for process CCTV monitoring. Moxa’s rugged hardware ensures system reliability 24/7, even in -40 to 75°C oil & gas environments, without the need for a heater or fan. This reduces maintenance costs and has a longer MTBF. Remote monitoring allows operators to easily maintain field sites, detect system problems, and reduce manpower costs. http://www.moxa.com/product/VPort_36-2L_Series.htm
www.ee310-humidity-transmitter.com
Asecos Q range – proven fire resistance of 90 minutes Labtex’s Asecos Type 90 storage cabinets provide extremely safe, regulationcompliant storage of hazardous materials in laboratories and other work spaces. Each cabinet variant is furnace tested in accordance with EN 14470-1 and proven to give fire resistance of 90 minutes. Extremely robust in construction for maximum torsional rigidity and with tamper proof lock and indicators built in, every ASECOS cabinet has GS approval and CE conformity. In addition the Q range is offered in range of scratch-resistant paint colours and with extensive interior equipment options Warranty cover is available up to 10 years. Tel:+44 (0)1484 600200 Please contact Greg Smith at greg@labtex.co.uk
NEW WEBSITES FOR THE MARECHAL ELECTRIC GROUP
Stand & Sponsorship packages now available For more information
Go to www.hazardexonthenet.net or email events@imlgroup.co.uk
MARECHAL ELECTRIC launches its new global website. A site that reflects the image, values and solutions of a major player in Low Voltage LT electrical connection systems in industrial environments with or without the presence of an explosive atmosphere. MARECHAL ELECTRIC launches its new website, a professional showcase for the group’s activities. It offers an optimized organization and easy access to all the information needed by its various customers and markets. Both on the Group and on all the solutions offered by its two brands MARECHAL® and TECHNOR®, surfers will access to multiple online services: configurator, downloads, interactive map, online videos. Renewed design, responsive experience, and ergonomics: everything is thought for a user-friendly and fast access to institutional or technical information. Contact: Phill RADFORD, Tel: 03330 124 048 sales.uk@marechal.com marechal.com
www.hazardexonthenet.net
38 Buyers Guide
For a complete range of hazardous area solutions Intrinsic Safety Isolators • Zener Barriers • Zone 1&2 Remote I/O • Fieldbus Exe Enclosures • Exd Control Panels • Ex Lighting • Purge Solutions • Zone 1 & 2 HMI’s PC’s
www.pepperl-fuchs.co.uk Batteries
Tel.: 0161 6336431
Consultancy
sales@gb.pepperl-fuchs.com
Electrical
Electrical Distributor
®
Powerful New ATEX-Approved Batteries
RANDALL & DANIELS ELECTRICAL LTD n n n n n n
Your Source Onshore For Everything Electrical Offshore R&M is the UK’s largest independent electrical group serving the Oil and Gas industries.
023 80341 444
www.rm-electrical.com
Tel: +44 (0) 1792 813231 Fax: +44 (0) 1792 321816
Advanced batteries and protection whatever the environment
www.rd-electrical.com email: mail@rd-electrical.com
Call 0161 727 3860 for further details
SAFETY PLUGS PROTECT FROM ARC FLASH
Control Panels Cable Glands
Instrumentation Trace Heating Electrical Control Panels Leak Detection ATEX Inspections
Explosion protection
Total Explosion Protection ■ ■ ■ ■ ■ ■
J.B. SYSTEMS LTD EExd & EExe enclosures Custom built panels, terminal boxes & control stations
DECONTACTOR™ Switch Rated AC-23 Socket ATEX/IECEx rated up to 200 A Compliant to ISO OHSAS 18001
Tel: 01296 489967 Fax: 01296 393515 Email: sales@jbsystems.co.uk Website: www.jbsystems.co.uk
Tel: 03330 124 048 sales.uk@marechal.com
Explosion Proof Cranes
Conventional venting Flameless venting Explosion isolation Explosion suppression Testing services Expert advice
Contact us today! ike i E
E one
ee en
: E: info@fike.co.uk www.fike.co.uk
Hazardous Area Specialist
Control Panels
HazardEx_43x60_0117_v2.indd 1
09/01/2017 18:28
In Control
EXd & EXe Control Systems Design Using the Latest AutoCAD software, based on your specification
Manufacture Drawings approved, we then build the system in-house
Test
Your total solutions provider
t-s-e.co.uk Trant System Electrical Southampton SO40 9AH 023 8042 8700 HAZARDOUS AREA PRODUCTS info@t-s-e.co.uk
www.hazardexonthenet.net
Specialist in design and custom build of a wide range of high-quality, hazardous area enclosures, terminal boxes & control stations
We flash test as standard, we also offer injection testing & more
Delivery All around the world, Packaging to suit your Circumstances
Install & Commission Our engineers are fully qualified and we have carried out successful works in over 50 countries On & Offshore
Tel: +44 (0) 1384 48 48 05 Email: sales@banelec.co.uk Web: www.banelec.co.uk
BARTEC MCC
CONTROL PANELS
PLC
SCADA
APPROVED OEM INSTALLER FOR CORTEM EXD ENCLOSURES
Approved Partner
-perts in Hazardous Area Automation... Consultancy Design Installation Commissioning Maintenance Atex Inspection
01482 898080 inspecsystems.co.uk
Explosion Proof Cranes
Heaters
Training
Training Courses & Consultancy for Industrial & Hazardous Areas
www.epitgroup.com
Hazardous Area Specialist Trace Heating
&
Raychem
WORKING IN PARTNERSHIP n n n n n n
Design Supply Installation Maintenance Commissioning Thermal Insulation
Sponsorship & exhibition stands now on sale
Tel: +44 (0) 1792 813231 Fax: +44 (0) 1792 321816
www.rdtraceheating.co.uk email: sales@rdtraceheating.co.uk
Contact the HazardEx sales team on +44 (0)1732 359990 or events@imlgroup.co.uk
To advertise in the Product Datafiles or Buyers Guide contact
10% OFF all CompEX Courses • Foundation • EX01 to EX04 • EX01 to EX04 Refresher
Kathryn Startin
• Dust EX05 to EX06 • Mechanical EX11
Quote Code: HAZ10
on +44 (0)1732 359990 or kathryn.startin@imlgroup.co.uk
+44 (0) 1642 770310
www.tte.co.uk/accredited
ATEX – IECEx
MACHINES AND EQUIPMENT Zone 1 and Zone 2 DIESEL POWER PACKS Zone 2 GENSET Ex e Stainless Steel BATTERIES Ex d Stainless Steel and Light Alloys CONTROL PANELS MATERIAL HANDLING EQUIPMENT For All Zones Ex e BATTERIES excen_190x45.indd 4
sales@excen.it
www.excen.it
DIESEL POWER PACKS 14/07/15 15.02
FOR ALL OF YOUR
CERTIFICATION REQUIREMENTS SGS Baseefa is the leading globally recognised certification body for explosion protected equipment, delivering certification and associated services to customers around the world. • • • • •
Improved project timescales North American certification capabilities Delivery driven certification process Facilitation of global certification marks World class training courses
visit www.sgs.co.uk/sgsbaseefa email baseefa@sgs.com phone +44 (0)1298 766600