Hex 17 07

hazardexonthenet.net

Food & beverage plants Safety challenges Dust explosions Risks and mitigation

UK Process Safety Forum

Dairy industry fires

Sharing experience across high hazard sectors

Prevention, protection and mitigation

Process Safety The importance of plain language

July 2017

the journal for hazardous area environments

The 2018 Hazardex International Conference and Exhibition will be taking place once again at the Holiday Inn Hotel in Runcorn, Cheshire, UK, on February 28 and March 1.

The two-day Conference & Exhibition, which also includes workshops, a networking dinner and awards ceremony, aims to strengthen and expand the community that looks to the Hazardex website and journal for industry intelligence and information.

New for 2018 will be the Industry 4.0 village & workshop, which will focus on the safety and security aspects of this key global issue.

The other main areas of interest at next year’s conference will be systems, procedures, competence, human factors, legislation, non-electrical, risk and asset management, but anyone with an original take on any aspect of hazardous area operations or process safety is encouraged to get in touch.

The conference committee has also issued a special request for end user/ operator experiences, particularly relating to regulation, cultural change, ageing plant and decommissioning.

Sponsorship or exhibitor queries should be addressed to the Event Director Russell Goater at russell.goater@imlgroup.co.uk or phone +44 (0) 1732 359990.

Please contact Hazardex Editor Alan Franck – alan.franck@imlgroup.co.uk – to submit presentations for consideration or for any queries about the conference.

www.hazardexonthenet.net

contents july 2017 Waking up on the morning of June 9 to the news that the UK had a hung parliament, where no political party has a majority to push through its legislative agenda, senior figures across a number of industries may well have been scratching their heads and wondering what the future has in store.

None, perhaps, more so than those in the food and beverage industry. With a quarter of its workforce and a large majority of imports and exports coming from the EU, according to the Food and Drink Federation (FDF), rapid progress on the main issues thrown up by Brexit is vital for the sector, which is responsible for 16% of the

14 16

UK’s manufacturing turnover, annual sales of £83.7bn and 400,000 employees. With the two main parties having radically different views on the deals needing to be made with the EU, any period of uncertainty ahead seems likely to do this vital industry few favours.

In this issue, one area of focus is food and beverage sector safety. On page 22 we have an overview of specific safety issues in food processing plants and breweries, and on page 27 we look at the problem of fires in dairy plants, as well as prevention and protection solutions.

High hazard sector organisations have much to gain from sharing safety information with others

22

…Alan Franck, Editor, Hazardex

in this issue Hygiene, continuous operations and high staff turnover are just some of the issues facing the food and beverage industry

News Extra

5

• Second fatal explosion in Colorado puts safety of state oil and gas operations in question • Dust explosion follows major toxic waste leak at Taiwanese-owned steel plant in Vietnam • Explosion kills at least 29 illegals in South African gold mine

27

• Chinese authorities punish more than 30 over 2016 power plant explosion • Researchers in Canada find methane in groundwater poses safety risk • SpaceX launch programme achieves further milestone after September rocket explosion

15

Standards: Harmonisation of standards

16

UK Process Safety Forum - Sharing experience across high hazard sectors

20

Getting on the same page in process safety

22

Safety challenges in food and beverage processing plants

27

Dairy industry fires and explosions: prevention and protection

30

Dust explosions: risks and mitigation

34

Dust detection in the workplace

36

Event previews

37

Datafiles & Buyers Guide

Fires and explosions in the European dairy industry are becoming an increasing problem

30

if you are using powdered ingredients anywhere in your process, the possibility of a dust explosion exists

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

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News Extra

5

the evacuation, which affected about 25 people.

The East Cheyenne Gas Storage facility is owned by Midstream Energy Holdings and is located near two major pipelines, offering gas storage to meet demand peaks.

In response to the Firestone explosion, Governor Hickenlooper ordered a statewide review of all oil and gas lines in the state that lie within 1,000 feet (300 metres) of an occupied building.

The Colorado Oil and Gas Conservation

Second fatal explosion in Colorado

puts safety of state oil and gas operations in question O

n May 25, workers upgrading an Anadarko Petroleum Co. oil tank

facility were caught in a fire that killed one and injured three in Mead, about 65 kilometres) north of Denver, Colorado.

The incident took place only a few kilometres from the site of the Firestone home explosion which killed two and injured a third in April, and was linked to a leaking Anadarko gas pipe.

Anadarko, the Colorado Oil and Gas Conservation Commission (COGCC), the Mountain View Fire Protection District, the Occupational Safety and Health Administration and the National Transportation Safety Bureau (NTSB) will investigate the incident.

Colorado Governor John Hickenlooper said there was no reason to believe that the circumstances behind the Mead oil tank facility explosion were similar to those that caused the Firestone incident.

This follows a report from COGCC and Anadarko, delivered to Firestone residents on May 24, which showed that a new

ground, located within 1,000 feet of occupied buildings.

methane cloud had been discovered just west of the home explosion site during

“At this initial stage, the COGCC believes that industry is taking compliance with the

testing in early May, and that the methane levels were even higher than those at the site of the explosion.

order seriously. It will take further review, however, to develop firmer details about overall compliance,” said Todd Hartman,

Anadarko said it was permanently shutting in three wells in that neighbourhood, including the one that led to the explosion.

The company said it believed the three wells were safe but was closing them down because of the “special circumstances and sensitivity surrounding this equipment.”

This comes as a class-action lawsuit was filed against Anadarko by shareholders who claim the company failed to disclose its knowledge of risks involving its vertical wells in Colorado.

Also on May 25, an evacuation order was issued for all residents within a two mile radius of the East Cheyenne Gas Storage facility in Peetz, north-eastern Colorado, after equipment failure led to a gas leak.

In late May, Anadarko distributed free gas detectors to home-owners near its oil and gas infrastructure in Firestone.

Commission (COGCC) said that operators were for the most part complying with the review and had submitted 129 reports by May 30 covering 16,514 wells. The reports detail the GPS coordinates of risers, or the part of the flow lines that come out of the

a spokesman with the Colorado Division of Natural Resources.

Operators also had until May 30 to inspect all flowlines, regardless of location, to ensure any not in use complied with state rules on abandoned lines. Those rules require abandoned lines or their risers to be clearly marked with fluorescent paint, all operating valves be removed and the lines capped until they can be cut off below ground.

State inspectors will have to visit those sites to confirm compliance.

Hartman said determining compliance with that part of the order will take more time.

He also said a small number of operators had not submitted the required information and that the COGCC would be contacting them.

The town has opened a shelter for evacuees and the company said it would reimburse evacuated homeowners for their expenses.

The second part of the order, with a June 30 deadline, requires operators to pressure

There was no explosion or fire associated with the leak, but the growing plume of natural gas forced the authorities to order

test all active flowlines within 1,000 feet of a building to ensure they are not leaking or damaged.

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News Extra

7

The Environment Ministry said the disaster had been caused by Formosa disregarding a series of commitments it had made to the government in securing approval to build the plant.

According to a Reuters report, the ministry said the company had deliberately changed many of the contents of the two environmental impact assessment reports approved in 2008 including using a wet coking system, instead of a dry one which is far less polluting but more expensive.

Wet coking uses water for cooling and

Dust explosion follows major toxic waste leak at Taiwaneseowned steel plant in Vietnam

the resulting waste water contains toxic chemicals that include cyanide. Despite denials of responsibility over a period of months, the company was found to be piping this waste water into the ocean nearby.

The environment in the area has seen some improvement and was expected to be fully restored within 10 years if sufficient rehabilitation work was carried out, the

A

dust explosion rocked Taiwanese conglomerate Formosa Plastics Group’s new steel plant in Vietnam

ashore in the central provinces of Ha Tinh, Quang Binh, Quang Tri, and Thua Thien-Hue.

on May 30, a day after it resumed test operations for the first time since causing one of the country’s worst environmental disasters last year. The explosion was

Nguyen Xuan Phuc, the Prime Minister of Vietnam, said that the destruction of marine life was the most serious environmental disaster Vietnam had ever faced.

displays of public outrage against both the company and the Hanoi government over its handling of the issue, only partly assuaged by the announcement of the $500 million

The provincial People’s Committee in Ha Tinh

In mid-May, Deputy Prime Minister Truong Hoa Binh said fishing would continue to be banned up to 20 nautical miles offshore of the affected provinces. Species highlighted as unsafe by the ministry included aquatic

compensation package. There have been rallies in major cities and an outpouring of social media anger in a display of dissent on a scale not seen during the Communist Party’s 41 years of tight control of the country.

confirmed that the explosion, triggered by limestone dust, had caused some physical damage but no injuries or environmental harm.

animals infected with phenol, a harmful chemical which affected creatures living near the bottom of the sea such as shrimp, crabs, squid, and rays.

The company said the blast would have little impact on preparations for the launch of production at Formosa Ha Tinh Steel, but the incident is likely to raise fresh concerns about

Formosa paid $500 million in compensation to affected communities and in March said it would boost investment by about $350 million in the steel project, amid public outcry against

the safety of the $11 billion plant, the biggest steelworks in South-East Asia.

the company and the government’s handling of the spill.

In April 2016, toxic waste from the plant polluted more than 200 km of Vietnam’s

The fresh investment will go into improving environmental safety measures, raise working

Local media also highlighted other allegations against Formosa, saying it had dumped toxic waste in illegal dumpsites.

And in 2015, a scaffolding collapse at the

coastline, devastating sea life and local economies dependent on fishing and tourism.

An estimated 100 tonnes of dead fish washed

capital, buy materials and build a dry coking system for introduction by June 30, 2019, at the latest.

plant’s construction site caused the deaths of 16 workers, which trade unions ascribed to a lack of adequate safety measures.

caused by the combustion of fine dust particles in the air as a result of an equipment malfunction, the company said

ministry said.

This disaster has caused the most sustained

Protesters allege the Vietnamese government was slow to respond to the disaster because of the importance of the Formosa Ha Tinh Steel project to the country’s economic development programme. Future plans at the complex include the construction of a deepwater port and 1,500-megawatt thermal power station.

www.hazardexonthenet.net

8

News Extra

Known locally as Zama-zamas, illegal miners enter mine workings to dig gold on their own account or for criminal gangs.

Explosion kills at least 29 illegals in South African gold mine

In 2014, the former Minister for Mineral Resources, Susan Shabangu, estimated that there were about 14,000 illegal gold miners working in about 6,000 abandoned mines, mainly around Johannesburg, often in very dangerous conditions.

n explosion on May 11 reportedly killed dozens of illegal miners in Harmony Gold’s Eland mine in Welkom,

“This is an unused mine and it is very dangerous,” Molale said.

Free State, in central South Africa. A week later, 29 bodies had been recovered from the closed mine, local media said, with some dragged for 13km through underground tunnels by rescuers to bring the bodies to the surface.

The miners had forced their way into the St

The bodies of 76 illegal miners were brought to the surface at the Eland shaft in 2009 following a fire and in 2014, 23 died in the disused Durban Deep mine in Roodepoort, near Johannesburg.

Helena shaft before the explosion. The rescue team travelled a distance of up to 25km from St Helena to the Eland shaft to get some of the bodies out of the mine, the police said.

There are even so-called ‘ghost’ workers in the larger open mines, such as the deepest gold mine in the world, Mponeng. Here,

Harmony Gold spokesperson Marian van der Walt said the matter had been handed

crime syndicates smuggle illegal miners into the many abandoned tunnels up to four kilometres below the surface where they stay

over to the police and the SA Department of Mineral Resources, which would carry out an investigation.

for months in the most primitive conditions imaginable, recovering gold from abandoned seams before being smuggled out again.

A

Police spokesman Major General Lerato Molale said there were rumours that still more bodies were trapped underground. He said 11 illegal miners survived the explosion, and more could still be inside the mine.

News Extra

9

The report says another fourteen are awaiting trial or are under investigation.

Yu Huaqiang, general manager of Huaqiang Chemical Group, the parent company, and eight others are currently awaiting trial.

Workers were testing a high-pressure steam pipe when the accident happened, according to Xinhua. Workers did not follow standard procedure when testing the pipes, and supervision was lacking, it said.

Chinese authorities punish more than 30 over 2016 power plant explosion A

ccording to a report by the Xinhua

news agency on June 2, more than 30 people have been punished after their responsibility was highlighted in an investigation into a power plant

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blast in the city of Dangyang in central China’s Hubei Province on 11 August 2016. The explosion killed 22 and seriously injured another four.

“The shoddy quality of a pipe nozzle caused a leak which ultimately led to the blast,” according to a statement from the Hubei Provincial Work Safety Bureau. The factory design did not meet safety standards, and the control room was not properly reinforced to protect people inside, it said.

China has vowed to improve safety at such facilities. President Xi Jinping has said authorities would learn the lessons paid for with blood after chemical blasts in the port city of Tianjin in 2015 killed more than 170 people and injured hundreds more.

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10 News Extra

Researchers in Canada find methane in groundwater poses safety risk

P

otentially explosive methane gas leaking from oil and gas wells may travel extensively through

groundwater and pose a safety risk, according to a new study by academics at the University of Guelph, Ontario.

Researchers at the university-based G360 Institute for Groundwater Research found the gas travelled far beyond the shale wells where it is drilled to threaten explosion risk some distance away.

Besides posing an explosion risk and degrading groundwater quality, methane can contribute to climate change when released to the atmosphere, said G360 director and principal investigator Beth Parker.

The researchers injected methane over 72 days into a shallow sand aquifer and monitored it for more than eight months at Canadian Forces Base Borden in Ontario. They found the gas travelled through the ground, was sometimes released into the atmosphere and dissolved extensively into the groundwater, where it changed water chemistry.

“If this water is extracted, say, by a farmer, the dissolved gas can be released and form an explosion risk or change the taste of the water,” Parker said.

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“Depending on conditions of groundwater and aquifer minerals, microbes can ‘eat’ the methane and generate undesirable byproducts such as hydrogen sulphide, and induce the release of trace metals into the water.”

The study found only small changes in water quality, said lead author Aaron Cahill, a former U of G post-doctoral researcher.

He said the study covered only a short time period and used only small amounts of methane.

“For larger leaks over longer times and greater areas, these findings would indicate that the groundwater would become unusable,” he said.

Leaky wells could pose a significant danger to the environment in a number of ways, said Cahill, who is now at the University of British Columbia.

“Methane is 30 times more potent than carbon dioxide at trapping heat when in the atmosphere, so we need to consider both the air and the groundwater when monitoring for leaks. The impact to groundwater is likely to be long-term and persist long after a methane leak is fixed,” he said.

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News Extra 11

Sealing energy wells thoroughly can be extremely challenging, said School of Engineering adjunct professor John Cherry, co-author of the study.

“When energy wells are constructed, the cement used might not seal fully, or will initially seal but as it matures little cracks can form, allowing gas to escape. While drilling is better than ever before, leaky wells are still common and represent a large liability for the oil and gas industry,” Cherry said.

Monitoring of groundwater for methane leaks is rarely done. That needs to change, he said.

“The industry needs a level playing field where the rules and reasonable expectations are clear. The gas will spread up and out in groundwater, so it is the responsibility of government to set sciencebased groundwater monitoring standards for all companies to meet.”

The findings were published recently in the journal Nature Geoscience.

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News Extra 13

SpaceX launch programme achieves milestone after hiatus caused by September rocket explosion

O

n June 3, a SpaceX Falcon 9 rocket

given a new heat shield and parachutes, a few

The rocket exploded while it was being fuelled

successfully launched a Dragon spacecraft for the company’s eleventh

other modifications and was tested extensively.

in preparation for an engine test, leading to the loss of both the launch vehicle and

Commercial Resupply Services mission (CRS-11) to the International Space Station (ISS). This mission marked

Each Dragon can probably safely fly about four missions to and from the ISS, Hans Koenigsmann, SpaceX’s vice president of

its payload, the $200 million Israeli Amos 6 communication satellite. Accident investigators determined that a canister of helium burst

the first reflight of a Dragon, having previously flown during the fourth CRS mission in September 2014.

build and flight reliability, said during a press conference on June 3.

inside the rocket’s second-stage liquid oxygen tank, triggering the explosion. The canister has since been redesigned.

Following stage separation, the first stage of Falcon 9 successfully landed at SpaceX’s Landing Zone 1 (LZ-1) at Cape Canaveral Air

The first stage booster flown on this mission was brand new, and as is now the custom, returned to Cape Canaveral for a vertical touchdown. Each Falcon 9 first stage is

The accident affected the company’s aggressive agenda, which includes taking US astronauts into space. Later this year, SpaceX will launch

Force Station, Florida. Dragon arrived at the ISS on June 5 to be installed on the Earthfacing side of the Harmony module for its month-long stay.

designed to fly 10 times with no hardware changes, and at least 100 times with only moderate refurbishment, SpaceX owner Elon Musk said in late March.

its Crew Dragon (Dragon Version 2) spacecraft to the ISS in automatic mode, without people on board. A subsequent mission with crew is expected to fly in the second quarter of 2018.

The reflight of the recycled Dragon cargo ship is

The booster’s return was the fifth successful

SpaceX is currently contracted to perform

a further milestone in the company’s commercial space programme and marks the first time one has been reused on a second mission. It was

landing by SpaceX since the explosion of one of its Falcon 9 rockets on the launch pad at Cape Canaveral, Florida, on 1 September, 2016.

an average of four Dragon 2 missions to the ISS per year, three carrying cargo and one carrying crew.

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In November 2016 SGS Baseefa appointed their new Operations Manager Phil Oates. Phil has an extensive background in the explosive atmospheres industry. He explains ‘Since 1975 I have worked in the Explosive Atmospheres industry, primarily within manufacturing. As the vast majority of our customers are manufacturers I feel I can relate to the issues that they have, especially regarding the interaction with test and certification bodies such as SGS Baseefa.’

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Standards 15

Harmonisation of Standards a later edition of the standard is published.

There are exceptions, but there is normally a three year overlap between the new edition being published and the old edition losing harmonisation status.

Ron Sinclair MBE gives his perspective on the latest developments in the world of standards

A

lthough many readers may be familiar with the term “Harmonised Standard”, it is a sometimes a concern how little understanding

The purpose of the overlap is to allow equipment being designed to the earlier edition of the standard, at the time the new edition is published, to continue through to certification without the manufacturer being forced to make technical changes at the last minute. It has never been intended to allow manufacturers to put forward new designs that do not comply with the “state of the art” at the time of development.

give the information required by Annex X of the directive, including correctly identifying the status of the standards used to support the EHSRs, along with a justification for the use of any nonharmonised standard. Without a correct DoC, the equipment is non-compliant and should not be installed.

It is easy to justify the use of the new edition of a standard when the immediate previous edition is harmonised. This is “state of the art” and all that needs be stated is that it is anticipated that the new edition will be harmonised.

Both a new standard that has not yet been

Use of a standard that has lost harmonisation status requires more

there is of the significance of the

listed in the OJ, and an old standard that

consideration. Equipment may remain in

harmonisation process. Whether you are a manufacturer anywhere in the world, or a purchaser, an installer or a user of ATEX Equipment in Europe,

has lost harmonisation status, do not give an automatic presumption of conformity.

Yet they can be used under specific circumstances, subject to full justification

production for a number of years. Essentially, it is up to the manufacturer to decide if any of the changes between the two editions materially affects his product. If the answer

it is important to understand what harmonisation means to you.

being given in the manufacturer’s Declaration of Conformity (DoC).

is yes, he must do something about it. If the answer is no, he can self-declare on the DoC that he has conducted such a review

Simply, a Harmonised Standard is a standard (usually from CEN or Cenelec) which has received legal acceptance by

Although many manufacturers understand the harmonisation process, and make the necessary adjustments to their DoCs,

and that the older standard remains “state of the art” for his particular product.

the European Commission as a means of demonstrating conformity with the Essential Health and Safety Requirements (EHSRs) of one of the EU Directives. ATEX Certificates issued by European Notified Bodies, as required by the directive, certify conformity to the EHSRs but list the standards that have been used to support the assessment.

Provided they are harmonised, they give the legal “presumption of conformity”.

there are undoubtedly a large number who either do not fully understand the process, or are willing to issue DoCs with incorrect information, typically listing standards as harmonised when they are not or, if correctly identifying non-harmonised standards, fail to give the required justification.

The European notified Bodies Group for ATEX has provided detailed information on this process in ExNB Clarification Sheet ExNB/CS/10/397, which can be downloaded from the Ex-NBG Clarification Sheets link on the EU Commission web site http://ec.europa.eu/growth/sectors/ mechanical-engineering/atex_en

A standard becomes “harmonised” through the simple action of the European Commission publishing the number of the standard in the Official Journal of the European Union (OJ). Until listed, the standard is not harmonised, even if it represents the “state of the art” which, according to the ATEX Directive, must be implemented as soon as possible.

A standard, once harmonised, can also lose that harmonisation status, for example when

And this is where purchasers, installers and users in Europe need to be aware of their duties under the ATEX User Directive 1999/92/EC and its various legal incarnations throughout Europe – for example, the Dangerous Substances and Explosive Atmosphere Regulations (DSEAR) in the UK. It is a DSEAR requirement that all equipment within the scope of the Equipment Directive, 2014/34/EU, should actually meet the requirements of that directive, before it is installed and put into service. In order to satisfy the Equipment Directive, the DoC supplied by the manufacturer must

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 Process safety

UK Process Safety Forum - Sharing experience across high hazard sectors S

haring lessons from incidents and near-misses has always been challenging. We live and work in an increasingly litigious society, one where caution can mean giving away as little as possible. Sharing information can be stifled by different legal situations, for example where there may be a pending criminal prosecution. Despite this, organisations have much to gain from sharing safety information with others.

The explosions and fires in 2005 at the Buncefield oil storage terminal in the UK highlighted the importance of communicating key findings quickly, and understanding that these lessons may be equally relevant to other industrial sectors outside of bulk petroleum storage.

The Major Incident Investigation Board (MIIB) which looked into the Buncefield incident recommended that: “The sector should put in place arrangements to ensure that good practice in <high reliability organisations>,

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incorporating experience from other high hazard sectors, is shared openly between organisations”

At the centre of the PSF is the ability to share information.

This has always been, and will always be, the primary objective.

The principles of process safety leadership which followed the MIIB report and its recommendations also stated that good leadership should: “Share best practice across industry sectors, and learn and implement lessons from relevant incidents in other organisations … to maintain the currency

these recommendations was to form a new body, the Process Safety Forum (PSF).

PSF formation In understanding that many companies had developed mechanisms for sharing information within their own sector through relevant trade associations, it was logical that the PSF should engage with these trade bodies. The PSF first met in the summer of 2009 with representation from the offshore oil, refining, chemical, bulk liquid storage & warehousing and nuclear sectors.

Selection of a chair was critical to its success – a leader was needed with a background in hazardous industries and a strong and deep understanding of safety.

Rear Admiral Paul Thomas CB was elected later in 2009, and remains Chairman of the forum today. Paul has a wealth of knowledge having held senior positions in the Royal Navy, AEA Technology, British Nuclear Fuels and the Rail Safety & Standards Board.

of corporate knowledge and competence” The response of several UK industries to

In responding to the MIIB recommendations and developing a mechanism through which

Process safety 17

good process safety leadership could be demonstrated, the PSF committed to: • understanding current initiatives and

PSF today

immediate future plans for sharing of process safety learning across all sectors; • identifying barriers to sharing of best practice and incident learning across sectors, and facilitating the development of recommendations for improvement;

dozen trade bodies, ranging from Aerosol manufacturers to Scotch Whisky producers.

• identifying initiatives to enhance process safety leadership across sectors; • sharing understanding of effective process safety performance indicators; • promoting these initiatives through using relevant media.

between its members and externally: • Learning Briefs are published to promote key learnings from widely publicised incidents (such as the Alton Towers rollercoaster crash in 2015) and to highlight new guidance or standards that have

Since its inception, the PSF has grown to include representation from over a

The forum meets three times a year and uses a variety of resources to share relevant information on incidents and good practice

www.hazardexonthenet.net

18 Process safety been produced by industry, for example those published by the Chemical and Downstream Oil Industries Forum (CDOIF).

• Safety Alerts are published to raise awareness relating to a specific incident reported by one of the forum members.

These incidents tend not to be those that are widely covered by the media, but may include important lessons for a wide range of industry sectors, for example highlighting additional test procedures for breathing apparatus.

• PSF Newsletters are published after each meeting. These distil and highlight key discussion points raised during PSF meetings.

PSF Learning Brief

Given the many and diverse sectors with an interest in process safety there are inevitably many sector-focussed discussion groups and committees. The PSF provides an important role in sharing relevant outcomes from these various fora – providing a mechanism for propagating good and best practice and highlighting future planned changes to the legislative regime, for example: • The Control of Major Accident Hazards (COMAH) Strategic Forum (CSF) is a joint industry/regulator group working to improve major accident hazard management and raise standards across business regulated under COMAH. PSF provides means by which relevant learning can be shared more widely than simply the COMAH sector • The Process Safety Management Competence Programme Board (PSMCPB) seeks to ensure safety throughout high hazard industries by raising awareness of Process Safety Management, providing regulation of training solutions and courses to improve process safety knowledge and understanding. PSF encourages this work to be more widely publicised, raising awareness of process safety competency training to those businesses not directly involved with the training development.

These resources provide invaluable information for participating trade associations to highlight with their own members these key developments in process safety – enabling them to look beyond their own sectors.

www.hazardexonthenet.net

PSF Safety Alert

PSF future

and seek to include other relevant safety

At the centre of the PSF is the ability to share information. This has always been, and will always be, the primary objective.

This is achieved effectively by using the resources and networks discussed above.

However, the PSF is continually looking for

aspects?

These topics will continue to be discussed and, whatever the outcome, PSF members will ensure that they remain true to their core values. Any changes that are made will

ways in which it can improve this process, for example by asking: • Are we using the correct language and terminology to make what we do attractive to business?

• How can we better engage with Small and Medium Sized Enterprises (SMEs)?

• How can we expand our membership to include other relevant sectors?

ensure that PSF members remain fully engaged and the sectors that they represent continue to receive accurate, informative and relevant information.

• How can we more formally link with other relevant bodies such as the COMAH Strategic Forum and Process Safety Management Competence Board?

Should we reach out to other bodies

a need to avoid complacency. The PSF only functions because of the involvement and engagement of its members, and they will only continue to contribute whilst there is a benefit to be gained. It is also important

such as government departments and agencies?

• Should we look beyond process safety

to ensure that the PSF does not become exclusive because of the language that it uses or that topics become stagnant

Conclusion Can we say that the original MIIB recommendations have been met?

Emphatically Yes. However, there is always

Process safety 19

because the same sectors contribute the same material. Continual review and

Association, Mineral Products Association, Oil and Gas UK, Rail Safety Standards

development is therefore essential and working with other groups and fora will be ever more important to ensure inclusivity.

Board, Scotch Whisky Association, Tank Storage Association, UK Petroleum Industry Association, UK Liquified Petroleum Gas Association, UK Onshore Pipeline Operators Association and Water UK.

Past incidents and changing regulation highlights the importance of sharing and learning, the PSF has an important role in helping to make sure that this happens.

More information

If your organisation is interested in joining the PSF, or for more information visit the website at www.p-s-f.org.uk or contact the forum secretary, peter.davidson@ tankstorage.org.uk.

PSF members currently include: British Aerosol Manufacturers Association, Chemical Business Association, Chemical

(N.B. Membership of the forum is limited to

Industries Association, Explosive Industries Group, Engineering Construction Industry

trade associations representing the interests of a sector.)

PSF Members

About the author

Peter Davidson is Chief Executive of the Tank Storage Association, representing the interests of over 22 companies which operate around 300 terminals in the bulk liquid storage sector. He is also Secretary of the Process Safety Forum.

Prior to joining TSA in April 2016, Davidson was the Director of Safety, Commercial and Projects at the UK Petroleum Industry Association and, before that, Regulatory Compliance Manager for ABB Automation in the UK, specialising in the delivery of automation systems to highly regulated industries, including the Oil and Gas, Petrochemical, Pharmaceutical and Nuclear sectors.

20 Process safety

Getting on the same page

in Process Safety T

he complexity and technical jargon that surrounds process safety in many organisations can be a barrier

a blatant disregard for safety precautions; especially as many who bear the full impact are the front-line workers who are

The term ‘process safety’ does not conjure up a shared understanding. It has tended to be the preserve of safety professionals

to effective understanding of major hazard risks. In this article, based on a presentation at the StocExpo Europe 2017 Conference, Ian Travers, Principal Consultant (Process Safety) at Lockheed Martin UK Information Systems, looks at how to focus on the most important issues in the prevention of a catastrophic incident.

so frequently blamed as the cause for not following the rules or procedures.

and engineers who frequently describe this aspect of risk management in complex language; using phrases such as safety barriers, bow ties, as low as reasonably practicable, ALARP, SFIRP, Safety Integrity Level, SIL, HAZOP, HAZID and more.

In catastrophic risk management the hazardous properties of materials, substances and energy never take any time off to allow us to figure out how to contain and manage the associated risks. We fully know how to effectively manage such risks through a system known as process safety management. So why do major catastrophic accidents keep occurring?

Such events don’t usually occur because of

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Understand and describe risk in plain language The answer lies in the education and understanding of major hazard risks and in presenting the concepts of process safety management in plain and simple terms for all those involved. Delivering safety and environmental protection involves people at all levels within an organisation and is not just the responsibility of a small dedicated professional team. We all have to get involved in the same way, because the hazards are always present, no matter how inconvenient for us. Confusion, misunderstanding and misaligned priorities can all lead to catastrophic consequences.

No wonder that ordinary workers and senior executives lose interest within the first few minutes into a discussion. A simpler, plain language approach is needed.

Simple questions The way to manage catastrophic risks can be broken down into simpler solutions, agreed and communicated throughout an organisation: • How could it go catastrophically wrong?

– Hazard Identification.

• Where/when will the process most

Process safety 21

likely go wrong and what will the consequences be?

• What controls or systems are there

that control of major hazards is not degraded.

They can operate with a ‘no surprises’ asset performance through effective KPIs and positive confirmation that critical safety

to prevent a major accident or to limit escalation? – • Which of these are most vulnerable to failure?

• What information is available to show these control systems continue to

Regrettably, many well-meaning employees have not been involved in the system design or had the relevance of the procedure properly explained to them.

Most people have no concept of the hazard, let alone of process safety risk.

systems, including human performance, are intact and delivering the desired safety outcomes.

operate to the desired performance standard?

Driven from the top Implementing and maintaining a process safety management system does not occur spontaneously. It has to be driven and led by senior executives from Board level down through the organisation. Strong process safety leadership is required.

Controls need to fit the risk like a glove

Implementing and maintaining a process safety management system does not occur spontaneously Get on the same page

High reliability and no surprises High reliability major hazard business can be readily achieved through simplifying and demystifying process safety management; engaging everyone within a high hazard organisation by using common plain language descriptions of risks and control measures so that the importance of critical procedures and control measures are distinguished from other activities, understood and accepted.

Make risks and performance of critical control measures visible and describe them

Unfortunately, there is no ‘one size

Use plain language – after all people ‘do’ safety, not systems. My proposal for everyone involved in major hazard risks is

fits all’ solution to the control and mitigation measures required to prevent the catastrophic failure of plant and its equipment. Controls have to be closely

to ‘get on the same page’. This ensures that everyone working at such risk fully understands the hazards they are exposed to, and accepts the associated control

alongside an integrated asset management programme and a highly effective, reliable and profitable business will be achieved.

tailored to the risks, the way the plant or equipment could fail, and the profile of the organisation. If key measures are missed

measures and procedures. A degree of differentiation and visibility is also required against a backdrop of ‘proceduralisation’

a major hazard challenge might not be effectively controlled. Overdoing it will lead to ‘gold plating’, incurring unnecessary

of business activities.

expense in design and operation.

Cover asset management at the same time and stay in business

A great deal of thought and effort is

The good news is that effective asset

required to design and implement the right system, tailored to the risk profile of the organisation.

management and good process safety management are one and the same thing.

Both aimed at effective containment of hazardous substances or energy, and both rely on accurate information on the status of the plant, process conditions and of control systems.

But then it all goes wrong from day one?

Most effort and resource is applied during the design and implementation stage, and subsequently the system is expected to run without failure – like a modern high-tech automobile.

Unfortunately, systems of control start to deteriorate immediately they are implemented. This is mainly due to modification and change, but also human ingenuity to work outside documented procedures and systems to get the job done, save time and improve performance.

This endeavour is to be welcomed provided

using simple language. Undertake this

About the author

Knowledge and understanding of how such systems degrade and fail is essential. Get this combination of asset management and process safety right and not only will the plant be safe but it can be run efficiently, with costly activities, such as maintenance, being precisely targeted to avoid unnecessary expense. Achieving this goal of safe operation, reliable plant and reduced operational costs is now well understood, and has been increasingly the practice of high reliability organisations.

Ian Travers is Principal Consultant (Process Safety), Lockheed Martin UK Information Systems and Global Solutions. He spent over 25 years with the HSE, latterly as Deputy Director, Chemicals Regulation. He led the joint HSE and industry response to the Buncefield incident, set up the UK Process Safety Leadership Group and chaired the panel to develop the OECD Guidelines on Process Safety Governance.

www.hazardexonthenet.net

22 Food & beverage

Safety challenges in food

and beverage processing plants I

n 2014, in the UK, a large food manufacturer had to pay an £800,000 fine after a serious industrial accident. An engineer was trapped by the machinery while examining a conveyor belt and suffered major injury and ongoing nerve damage. Accidents such as this are widely reported, but many

In Europe, the Machinery Directive 2006/42/

In the 1970s, the increase in heavy machinery such as the creation of the steel press led to

people are unaware of the number of hazards found in food and beverage processing plants. Here, Jörgen Saxeryd, safety products and functional safety advisor to ABB’s

EC requires machinery to be designed and built so that it can be used safely. In food processing plants, there are many dangerous machines for which plant managers should follow safety regulations,

increased safety guards. Since then, many safety conscious companies undertake a risk analysis in the initial stages of machine development. In the case of decanters, it is not possible to remove the risk, but it is

food and beverage program, explains some of the safety risks in these facilities.

or face the consequences. Machines such as decanters exhibit high centrifugal forces during operation and it is not unknown

possible to mitigate the risk to an acceptable level by putting safety guards such as enclosures or emergency stops into place.

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Across the globe, there are a variety of different regulations for food processing plants. In particular, North America and Europe have strict regulations for safety in these potentially dangerous environments.

Those companies that put the safety of their employees at risk can face severe sanctions.

for the machine’s g-forces to reach many hundreds of times normal gravity. This is clearly a dangerous environment for employees to work in, however as these machines are essential for use, the key concept is the management of risk.

Food & beverage 23

Robots and other moving equipment need to be shielded to repair equipment themselves. They

becoming trapped. Hazards are present

may override safety guards to reach into machines and risk injury in the process.

It is therefore vital that despite high

throughout the plant, from the handling of the raw material, to production — where industrial ovens can often reach very high

production targets, employees are well educated in the company’s safety policies.

temperatures — to the final packaging of the product.

Despite overall labour turnover falling in Britain over the last five years, there is a notoriously high turnover of staff in food and beverage processing plants. This presents an additional complication in high risk areas. Employers are often reluctant to spend much time training staff on safety procedures if they will not be with the company for long, but this makes for a vulnerable workforce.

The hazardous nature of a food processing plants is especially affected by the need for hygiene, the continuous working of the plant and the high turnover of staff. To comply with hygiene regulations, plants need to be constantly washed down, meaning that despite safety guards, equipment needs to be accessible, which adds additional risk.

In Europe, the Machinery Directive 2006/42/EC requires machinery to be designed and built so that it can be used safely

The UK’s food processing industry employs 117,000 migrant workers from the EU, which can add language barriers to the list of safety hazards. It is vital that plant managers communicate safety measures effectively to reduce the risk to non-English speaking employees. This can be done by using visual displays or by placing new

Breweries show a number of the hazards present in the beverage industry. The dust generated in the conveying, sieving and milling of malt grains can form flammable dust clouds. This creates a potentially explosive environment, officially classifying the environment as a hazardous area. This

Due to the high demand on food and beverage production facilities, plants often run 24 hours a day. Continuous operation means there is little time for downtime and repairs to be carried out. In the food

staff members alongside more experienced employees.

means that ATEX ratings must be observed on all equipment used in this environment.

Safety systems need to put in place from the very start of the food chain,

Later down the line, carbon dioxide, a dangerous by-product of the fermentation

industry, it is during breakdowns when injuries occur. Workers, faced by high targets and strict deadlines, will attempt

such as in the milking process. In milking parlours, exposed platform rollers must be guarded to avoid any clothing or employee

process, can be fatal if inhaled. Workers have died while trying to perform repairs or checking fermentation tanks, becoming

www.hazardexonthenet.net

24 Food & beverage

Packing areas can be particularly dangerous overwhelmed by CO2. This means that

will arise. Although it may seem instinctive,

companies should use suitable sensors and locks to separate workers from the tanks, while also educating workers on the

where there is a dangerous moving machine, the safest answer is not always to shut it away behind an enclosure or barrier.

dangers.

In the beverage industry, the filling process has to be managed carefully. Bottles and

Equipment such as light grids, for example, can perform a local controlled safe stop when actuated. These devices can be more

cans are usually filled at high speed and high pressure, which can lead to explosions if things go wrong, showering glass or metal all around. It is vital that companies use sensors to monitor speed and other variables, and have emergency stops in

appropriate for the food processing sector than using physical guards or barriers as they allow easier access for maintenance and washdown, which is essential for hygiene in food processing plants.

place in case of a breakdown. If receptacles need to be changed on the production line, there should be a slow running option allowing the operator to change the bottle or can.

In the beverage industry, particularly in breweries, packaging and filling stations can be particularly dangerous places. The speed

Functional safety experts are also able to advise on the use of safety programmable logic controllers (PLCs), rather than traditional PLCs. Safety PLCs are designed to help companies comply with functional safety regulations such as IEC61508 and IEC61511. Safety devices can be connected directly to the PLC, which monitors equipment such as light curtains.

of operation and high quantity of goods being moved increase the risk of things going wrong.

By using the PLCs, companies can meet the rigorous standards required in the food industry.

As companies become more knowledgeable

Managers of food and beverage processing

Given some of the unique issues facing the sector, successfully identifying risks and

about regulations and regulations become more stringent, the need for retrofitting old equipment with additional safety measures

plants have a duty to protect their employees and comply with all the relevant regulations governing their operations.

ensuring adequate mitigation and protection will safeguard staff and production into the future.

www.hazardexonthenet.net

If the expertise to do this is not available in-house, it may be useful to call in external consultants with the background knowledge and experience to advise on which steps to take to make plants safe for workers and fully compliant.

Food & beverage 25

In breweries, glass bottles are filled at high speed and high pressure

About the author

Breweries face dust explosion and CO2 risks, amongst others

JĂśrgen Saxeryd is safety products and functional safety advisor to ABBâ&#x20AC;&#x2122;s food and beverage program.

www.hazardexonthenet.net

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Food & beverage 27

Dairy industry fires and explosions: prevention, protection and mitigation T

here are more fires than explosions in milk dryers. Traditionally, these units produced a basic whole milk or

that five of these incidents experienced an explosion, with another three explosion-like effects without any damage that could be

By studying the plant details, internal mechanical and/or outside introduced ignition sources were ruled out. So the

skim milk powder, although customised formula and ingredients are now more common. The milk powder was

traced to pressure effects of an explosion.

The remaining incidents were fires only, with damage ranging from medium to total loss of

problem can be solved if an appropriate method can be found to detect heating before it turns into a fire. And if a fire does

prone to sticking to the walls of the chamber, while stalactites on the vortex of cyclones and nozzle build-up was not uncommon. Cyclones were more

the drying unit.

develop, a range of protection systems are needed to mitigate its effect.

common than bag filtration to separate the air from the powder. Cleaning was not as thorough then, when only producing single products, especially in cyclones.

processes within the drying installation.

The five to eight explosions were found to have been a consequence of the fire - not the other way round.

More than 90 % of these incidents could be traced directly back to self-heating

Another analysis looked at 240 incidents that

Prevention In spray driers the fuel (milk powder) and oxygen cannot be removed, but the ignition source could be controlled. Operating experience shows that the primary source of ignition for fires or dust explosions in drying installations for milk, or in secondary

Cleaning of plant frequently involved manual access due to blockages and wall build, although automated CIP is now used more in dryer plant. The increase in the use of filter bags, although not acceptable for all products, is more popular to reduce exhaust emissions which has increased the risk of fire and explosions. The risks involved in the use of internal and or external fluidbed is

occurred in spray driers in the food industry from 1953 to 1993. 20 incidents were reported to have experienced an explosion while 210 were fires only, and here too It was believed that fire was the initiator of the explosion. The result of the statistical analysis defined that further steps are needed for a new approach.

installations such as filters and dust precipitators, are smouldering spots or selfigniting milk products.

a big talking point at the moment with the increased use of fines returns highlighting the need for an improved isolation policy.

In the Irish dairy industry between 1980 and 1987, 12 incidents were reported involving fires in spray drying plants, and in five of these cases explosions were reported. In the UK dairy industry from 1972 to 1982, seven

of damaging events, however, shows that these devices are not always sensitive enough to recognise small smouldering spots on time.

Fires and explosions in the European dairy industry are becoming an increasing problem: An analysis of 116 incidents in the milk powder processing industry showed

explosions were reported in spray drying plants.

Up to the present time, early-warning fire detection in such facilities consisted of installed temperature measurement devices, infra-red sensors or sniffing lines through which the smell of fires could be detected. The frequency

Early-warning fire recognition through CO detection An early recognition of smouldering fires at an initial stage is possible through inspection

www.hazardexonthenet.net

28 Food & beverage of the exhaust air from drying installations for the presence of carbon monoxide, a

recognition of smouldering fires must be guaranteed, while false alarms should be

Detection of a smouldering fire

gas which is the product of the thermic decomposition of milk products. Due to high volumes of air, the CO would be diluted so the system had to be very sensitive. Also it had to use differential readings between the inlet (reference) air which can be excessively CO loaded from boilers, trucks, forklift etc.

kept to a minimum.

fire detection system, it was concluded that an unusually steep increase in CO content in the exhaust air can best be used to trigger a pre-alarm. With such an advance warning, the operator would have sufficient time to localise and remove the smouldering spot, without having to

and the exhaust air (sample) which would add anything burning inside the drying process.

such a way that the sum of all exhaust gas flows is measured, if at all possible, at the same time. Because the exhaust gases are loaded with dust and have a high dew point temperature, a dust and water removal system is required at the sampling point and

accept long-term shutdowns.

absorber, a measuring principle is made available, which is suitable for detecting traces of carbon monoxide. NDIR CO gas analysers, with a measuring range of 0 to 10 ppm, have been tested in the area of emission control and under harsh conditions,

over the gas sample line.

exceeded.

The reaction time of the system is a cumulative combination of the time during which the air is present in the system, the residence time in the gas sampling lines

Next generation CO early fire prevention systems

and can be considered as reliable for this type of measuring task.

and the response characteristics of the analyser. To avoid a false alarm caused by

conditions outside of the dryer. Now, a new generation of CO monitoring

An early-warning fire detection system consists of the following main components:

a sudden rise in CO content in the intake air (for instance as a result of heavy traffic), the transit time in the sampling lines must

systems are available that are designed to compensate for internal and external environmental and flow conditions. To do

be balanced. The gas sampling lines to the analyser should be kept as short as possible, in order to avoid unnecessary delay times.

this, all CO fluctuations are measured at the same point in time so the effects of the dryer process on the sample are taken into account.

The use of an early-warning fire detection system as the primary safety measure in spray drying systems in the milk industry

This proved to be an insurmountable task when considering direct fired dryers. Since infrared gas analysers are very sensitive to contamination, the gas samples must

requires a high degree of reliability and availability. An unambiguous and quick

be carefully pre-conditioned, by removing humidity and product residues.

Infrared gas analysis With NDIR, the non-dispersive infra-red

1. gas sampling probe 2. sample gas preparation 3. analyser

The locations at which gas samples are taken and the place of installation must be carefully selected at the time of installation.

The location for the gas sampling probe in the exhaust gas canal must be chosen in

During the test phase of an early-warning

The initiation of a forced shutdown, or the activation of fire extinguishing installations, should occur automatically, after a certain individually determined threshold has been

In the past, effective CO systems had false signal potential based on environmental

About the author

Declan Barry is the Owner of ATEX Explosion Hazards Ltd, which specialises in fire and explosion protection for food and beverage sector companies in the UK and Ireland.

www.hazardexonthenet.net

Food & beverage 29

Top 10 Tips in Milk Dryer Safety 1. Explosion versus Fire For a fire, you have a hazard in milk dryers that is milk powder, oxygen, usually 100K m3/hour of hot air, and an ignition source. With dispersion in a confined space, you then have

0.3 to 0.7 barg. Fluidbed and cyclones can be very strong with filters usually 0.5 to even 1 barg.

8. Protection

5. Select the appropriate Zones/Equipment

Once the explosion starts, you need to mitigate the consequences. Venting is the preferred option but only if you can vent the flame outside, usually only feasible on the chamber and bag

the potential for an explosion. This can happen in the dryer chamber, the fluidbed and/or cyclone/filter. Fires typically happen in these vessels and the silo.

Simple things like a viewing lamp have caused fires and explosions in dryer plant. Obviously, do not use any equipment, instrumentation or tools which generate an ignition source.

Electrical apparatus like hand dryers

filter. If you cannot find a safe vent area outside, the flame from such large vessels can do a lot of damage in a congested site. With product upgrades, flameless vents are now being accepted into the dairy industry

Explosions only happen in silos when being filled. There can also be secondary explosions in auxiliary equipment, such as the bag off plant.

and insect killers are unwise in a bag off area. Halogen lamps inside or outside can cause overheating.

for small vessels venting inside the building.

2. The Hazard is milk powder This requires a typical dust

If there is a potential risk of an explosion at the workplace, this also implies that the work organisation must meet

concentration Lower Explosion Level (LEL) of 30 to 60 g/m3, enough fuel to sustain an explosion. You cannot see the hand on the end of your arm at 30

certain requirements. Organisational measures must be taken where technical measures alone cannot ensure and maintain explosion protection at

rotary valves if Atex approved. Barriers using hot water and powder between the chamber, fluidbed, cyclones and bag filter are common.

g/m3; it is not a light dust loading. The explosibility KST of skim milk powder is typically160 bar m/s or less. That is 160

the workplace. In practice, the work environment can also be made safe by combining technical and organisational

9. Maintenance

bar/s in a 1-m3 vessel reaching typically a Pmax 9 barg. The milk powder normally has a particle size less than

measures.

Installing lances on the top of dryer

while the plant is running, especially blockages and hot work. Proper risk and method statements even for

150 micron.

chamber should be secure so to avoid spraying onto obstructions in the dryer atomiser. One operator decided to

regular maintenance should be in place supervised and signed off by a competent person. Ensure the dryer

sterilise the sample scoop with alcohol.

To be extra clean he lit the alcohol on the scoop with a flame, then he thought he had blown it out, before inserting it in the fluidbed. You cannot always see an alcohol flame.

plant is returned to the operator in safe condition.

3. Ignition sources The minimum ignition energy MIE is >30mj with a minimum ignition Temperature of >460 C. The layer temperature can be lower at <350 C but an exothermic event can happen at even lower temperatures creating a smouldering spot. This is the most common ignition source in spray dryers.

6. Train your staff

7. Prevention

It is important to know the strength of the plant, so that one can design the

Outside the above, there are systems that can minimise the probability of a fire or subsequent explosion. Temperature sensors are useful to control process

protection system within that vessel containment. Take care of transition points and socks. The weakest part of a drying plant is the dryer chamber roof.

In old plant this could be lower than 0.1barg, but in modern dryers typically

conditions but tend to be too slow to detect a fire. Spark detection can cause more trouble than it is worth. Contact a specialist supplier or consultant to learn about the best systems for your application.

4. Strength of vessel

Explosion suppression is an alternative when venting is not feasible, using hot water or powder fast fire extinguishing usually in the fluidbed and cyclones.

Explosion Isolation is possible using

Maintenance, should never be done

10. Changes!

Many dairy companies are now in the business of multiple ingredients where the properties and hazards of each product are different and have different safety implications. Some dryers can be drying three different products in one week, so which product is the worst case scenario? Is one product stickier, or does it have a higher CO content leading to smouldering nests?

Many operators are changing from cyclones to bag filters, which can blind easily and accumulate product. Review the safety assessments.

www.hazardexonthenet.net

30 Dust

Dust explosions: risks and mitigation Perhaps the first dust explosion was recorded in a flour warehouse in Turin in 1795 - it injured two boys but did not kill anyone. As the scale of industrial

A brief review of dust explosion properties shows that even small items are capable of generating a spark that can ignite relevant powders.

processes has grown, so, sadly, has the size of dust explosions. In this article, Keith Plumb of BPE reviews the conditions required for a dust explosion to take place and provides a risk reduction road map.

In 1878, the Washburn â&#x20AC;&#x2DC;Aâ&#x20AC;&#x2122; Mill , then the largest flour mill in the USA, exploded and claimed 18 lives and destroyed a large area.

This explosion led to reforms in the milling

industry to reduce the dust in air during milling and to improve housekeeping.

In view of the lessons learned you would have expected that matters would have improved significantly but this has not always been the case. For example, in 2008 there was a dust explosion at the Imperial Sugar Company in the USA that killed 14 people and injured 36.

The first of a series of explosions took place in an enclosed steel belt conveyor located under the sugar silos, where recentlyinstalled covers had allowed explosive concentrations of sugar dust to accumulate.

A secondary explosion arose because of sugar dust accumulations, and this explosion propagated through large parts of the site.

Figure 1 - Minimum ignition energy table

www.hazardexonthenet.net

Figure 2 - Static table

Dust 31

Imperial Sugar Company after the explosion on 7th February, 2008 – Image: CSB This illustrates how new risks can be introduced when making modifications and that poor housekeeping is still a problem after 130 years.

Figure 3 shows the number of incidents in the USA rose significantly between 1980 and 2003, and the number of injuries and fatalities accordingly.

A 2006 report by the US Chemical Safety Board (CSB) (1) suggests that this may be due to under reporting in earlier years, or it could also be due to an increase in overall industrial activity.

There are no comparable statistics for the UK or Europe. However, the HSE data presented

by Lunn (2) for the years 1979 to 1988 show 136 explosions occurred giving an average of 15 explosions per year, which is comparable to the US data.

Figure 3 – Dust explosion incidents, injuries, and fatalities, 1980-2005 Source: CSB

Zeeuwen, writing in 1997 (3), suggested that the data available then did not indicate a trend but did suggest that - ironically - the increased use of dust extraction as a result of the desire to protect workers from dust was probably causing a rise in explosions in the dust collection equipment.

Recently, good practice from Europe and elsewhere has been incorporated into IEC standards. The IEC 60079 series of

Figure 4 – Sources of ignition in dust explosions - Source: BIA Report 11/97

www.hazardexonthenet.net

32 Dust standards cover such subjects as hazardous area classification, the design and testing of electrical equipment and the selection of

elsewhere. This datum shows that electrical equipment is a minor source of ignition and that other sources are of much greater

electrical equipment. PD IEC/TS 60079-32-1 providing guidance on electrostatic hazards is particularly useful.

importance. Data presented by Lunn (2) for the UK gives a very similar picture.

However, the statistics from Germany summarised in Figure 4 (4 & 5) suggest that

In Europe, the ATEX directive requires that non-electrical equipment must also be certified and this should be having an

whilst these IEC standards on electrical hazards are important, the focus should be

impact on the sources of ignition shown in the 1997 data from BIA. Also there is a new

ISO 80079 series of standards including BS EN ISO 80079-36 which covers the nonelectrical equipment shown in Figure 4.

A report on combustible dusts (1) by the US Chemical Safety Board (CSB) has a number of important findings: • Workers and managers were often unaware of dust explosion hazards, or failed to recognise the serious nature of these hazards.

BPE Dust Explosion Risk Reduction Road Map

B

PE’s Hazardex award-winning approach to dust explosion risk is used by IChemE in its training on the topic. Below is the company’s road map, which helps to identify risk and take necessary precautions.

Steps 1 and 2 Steps 1 and 2 should be completed as an intergral part of a Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) risk assessment. To do this you need to check if any of the powdered components used are combustible.

Where possible, elimination of a combustible powder is the best way to reduce risk.

Step 3 – Are There Any Dispersion Mechanisms?

Dispersion mechanisms include leakage from the equipment and dispersions created inside equipment by processes such as milling, conveying etc.

Reduce risk by eliminating as many dispersion mechanisms as possible and, where this is not possible, minimise the amount of dispersion as much as is practical.

Figure 5 - Dust Explosion Risk Reduction Road Map Step 4 – Carry Out Hazardous Area Classification (HAC) Carry out the HAC using BS EN 60079-101. Use examples in the BS to help decide the size of each hazardous zone.

weight poured. So for a powder with an MEC of 45 g/m3 a zone of 1.5 m radius could be created if the contents were poured into a large space.

Step 5 – Minimise Sources of Ignition

Figure 5 shows a simple way to estimate the size of a hazardous zone. The mimimum explosive concentration (MEC) of a dust lies in the range 15 to 60 g/m3 and literature sources suggest pouring a powder disperses between 0.5% and 3% of the

Regulation 6 of DSEAR requires the risk of ignition to be minimised. BS EN 1127-1 lists all the possible ignition sources for explosive atmospheres.

Step 6 – Assess Explosion Severity/ Consequences (Detrimental Effects) Regulation 6 of DSEAR also requires the consideration of the detrimental effects of an explosion, these will depend on: 1. The level of confinement. For fully contained explosions the pressure can reach up to 10 bar. For unconfined explosions the pressure rise is much less

Figure 6 - Estimate Size of Zone

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and the result is only a flash fire.

2. The amount of powder dispersed.

Dust 33

• Management often failed to conform to NFPA standards that would have prevented or reduced the effects of the explosions.

• Dust collectors were often inadequately designed or maintained to minimise explosions.

One other observation in this report was that 41% of Material Safety Data Sheets reviewed did not warn users about explosion hazards.

• Some facilities contained unsafe accumulations of dust and housekeeping was inadequate.

• Procedures and training to eliminate or control dust hazards were often inadequate.

• Warning events were accepted as normal

• Process changes were made without adequately reviewing them for the introduction of new potential hazards.

• Government enforcement officials, insurance underwriters, and health and safety professionals inspecting the

The author would concur with this finding.

and their causes were not identified and resolved.

3. The number of people working in the vicinity.

Step 7 – If Necessary, Reduce Risk Using Simple Measures The following simple measures can be used to reduce the risks of an explosion and should be considered in detail.

facilities failed to identify dust explosion hazards.

ignition. So, for example, a Zone 20 with a high level of ignition protection but high consequences, the residual risk would be unacceptable.

risks associated with your facility.

References: (1) Report 2006-H-1, November 2006, US Chemical Safety and Hazard Investigation Board (2) Lunn G., Dust Explosion Prevention

Steps 9 and 10 - Can the Oxidant (Usually Air) be Excluded? If so, Provide Such a System.

1. Reduce the inventory of fuel 2. Eliminate/reduce dispersion mechanisms

If the residual risk is unacceptable then further protection measures are required.

3. Increase process containment.

4. Provide ventilation – local extract or general.

For hazardous zones inside equipment the use of an inerting gas such as nitrogen to exclude the oxidant is a proven method to

5. Ensure good housekeeping.

6. Provide segregation between equipment.

7. Move the process to a location where

reduce the risk.

there are fewer people or exclude personnel from the processing areas.

8. Avoid hybrid mixtures of flammable vapours and dusts.

Where the residual risk is unacceptable and the oxidant cannot be excluded e.g. outside of the equipment then other measures are required to mitigate the consequences.

Step 8 – Is the Residual Risk Acceptable?

The next step is to consider if the residual risk is acceptable. Figure 7 shows one approach. The ignition protection level is

The additional measures that could be used include: 1. Explosion venting of equipment 2. Building blast relief and blast proof walls 3. Explosion suppression in equipment

the protection afforded by the measures provided to minimise ALL sources of

4. Explosion resistant design of equipment.

Figure 7 - Assess Residual Risk

So if you are using powdered ingredients anywhere in your process, then the possibility of a dust explosion exists. The Road Map (below left) will show you how to reduce the

Step 11 – Mitigate Consequences

and Protection, Part 1 – Venting, 2nd Edition, IChemE (3) Zeeuwen P., Dust Explosions: What is the risk? What are the statistics?

Euroforum conference, Paris – March 1997 (4) BIA Report 11/97 Dokumentation Staubexplosionen – Analyse und Einzelfalldarstellung (5) BIA Report 13/97 Combustion and explosion properties of dusts About the authors

Keith Plumb is process and equipment consultant at BPE. He has more than 30 year’s experience in the pharmaceutical, biopharmaceutical, fine chemical and allied process industries, is a member of the Pharma Subject Group of IChemE committee and a fellow of IChemE.

www.hazardexonthenet.net

34 Dust

Dust detection in the wo D

Under the Control of Substances Hazardous to Health regulations (COSHH) in the UK,

are given specific limits under Workplace Exposure Limits regulations, commonly

a hidden killer. In the United Kingdom during 2015-2016, 13,000 deaths were reported as a result of past exposures

the levels of inhalable dust in the workplace should not exceed 10mg/m3 and the level of respirable dust must not exceed 4 mg/

referred to as WELs. For example, cobalt metal has an exposure limit of 0.1 mg/m3 and silica is 0.1 mg/m3, meaning workers

at work, primarily to chemicals and dust. Annually, there are an estimated 14,000 new cases of lung disease and

m3. Employers are advised to control levels constantly to ensure such maximums are never reached.

can only be exposed to a small amount before the substance potentially becomes hazardous to health. If such substances are identified in the working environment, employers must be familiar with the relevant exposure limit figures.

ust in the workplace continues to receive international attention as

breathing illnesses believed to be caused by the working environment.

In petrochemical, pharmaceutical, mining and some manufacturing environments, there is also an added risk of dust explosions. In this article, Tim Turney of Casella look at some of the wider ramifications of exposure to dust at work and the role of personal dust sampling pumps in safeguarding staff.

Health matters There are a wide range of substances in the workplace that have the potential to cause harm to health if ingested, inhaled, or come in contact with skin. These can lead to irreversible respiratory diseases, asthma or eczema, amongst a long list of potential health problems.

www.hazardexonthenet.net

From the thousands of substances that can be found within a working environment, 500

Dust 35

from an external occupational hygienist inspecting the workplace provided evidence of dust levels.

Personal pumps offer an enhanced monitoring system able to provide continuous data records. Data can be collected throughout seasonal and weather changes - in the summer months there may be better ventilation, where windows might be open, as opposed to winter months where lower ventilation can make for a dustier environment. Based on the findings, dust control measures can be modified. Workers may be required to wear additional respiratory protective equipment, or the location may need to be fitted with ventilation systems.

When new processes are introduced,

orkplace Accurate measurement

When dealing with asbestos, a filter with grids is used which allows for the asbestos fibres to be counted by microscope in a laboratory. The sample is analysed after the shift has ended ensuring personal exposure is below the level allowed, providing an essential historical record.

The latest personal sampling pumps are both small and light, with Bluetooth connectivity giving the ability to access data collected remotely. They should also have a smooth surface for easy cleaning.

limits are kept to a minimum. Ultimately, this allows workforces to become more engaged, providing staff with concrete information on how their health is being

Those being used in environments where there is a risk of explosion, such as the petrochemical, pharmaceutical or mining industries, will also need to be intrinsically

safeguarded in the workplace.

safe and certified to ATEX or other explosion protection standards, depending on where they are being used.

Asbestos monitoring

dust sampling pumps is the preferred method of measuring dust exposure levels in the workplace, allowing employers

The World Health Organisation estimates that 107,000 workers globally die every year from exposure to asbestos, with many

to remain compliant with government standards of safety by providing an accurate record of individual exposure

succumbing to fatal respiratory diseases such as mesothelioma.

levels.

The 1999 Asbestos Prohibitions Amendment Regulations officially banned the importation, supply and use of all forms of asbestos in the UK, but it can still be found in industrial or residential buildings built or refurbished before the year 2000.

Asbestos has been used in 70% of countries around the world.

risk. To ensure personal sampling pumps accurately measure inhalable dust levels, filters connected to the devices are worn near the breathing zone (mouth and nose) absorbing air and catching particles,

For the many workers involved in asbestos removal, personal sampling pumps are increasingly being used to measure individual exposure alongside room monitors, giving a more accurate indication

mimicking the way a human breathes.

When required, the particles collected are sent to a laboratory for further testing.

of specific risks workers are exposed to. Tests are required to ensure the air quality of the contaminated area is safe for individuals to remove the substance and to measure airborne exposures.

In some instances, this is replacing traditional methods whereby reports taken

carefully monitored. For this specific task, the pumps must be worn on the body as part of their protective clothing, which is then sprayed down after working in the contaminated area.

such as new machinery and ventilation equipment, the personal pumps enable tests to be made to ensure exposure

Personal monitoring in the form of personal

Personal pumps are efficient, practical and adaptable, offering tailored features depending on individual requirements.

The pumps provide information on temperatures and dust levels, alerting employers about harmful levels of dusts in the atmosphere and potential explosion

With personal sampling pumps, workforces can continue with removal of asbestos knowing that their overall exposure is being

About the author

Tim Turney is Technical Product Manager at Casella. Previously he worked for SMC Pneumatics (UK) as a Sales Engineer and THSP as Sales and Marketing Manager.

He has a B.Eng in Aerospace Material Science from Queen Mary University of London.

www.hazardexonthenet.net

36 Event preview

Process Safety Congress at EUROCORR Date: 5-6 September 2017 Location: Prague, Czech Republic CCPS is pleased to announce that it will be holding the 2017 Process Safety Congress in conjunction with the 2017 EUROCORR and 20th International Corrosion Congress in Prague, Czech Republic.

The 2017 Process Safety Congress will take place during the conference, September 5-6, 2017.

The 2017 Process Safety Congress will be organised by AIChE/CCPS and volunteers from industry and academia. CCPS conferences promote process safety by identifying emerging

process safety issues and advancing leading process safety management practices. It is dedicated to managing process safety systematically, locally, regionally and internationally.

The 2017 Process Safety Congress will cover the following general themes, with special emphasis to share process safety learning from corrosion in the Process Industries.

• Process Safety Case Studies and Lessons Learned • Process Safety Leadership and Culture • Process Safety Integrity Management • Human Factors Analysis

• Hazard identification and risk analysis/ management • Process Safety Management Implementation There will be a special emphasis to share process safety learning from corrosion in the process industries www.aiche.org/ccps/conferences/processsafety-congress-eurocorr/2017

SPE Offshore Europe Dates: 5-8 September 2017 Location: Aberdeen, UK

than 1,500+ suppliers on the exhibition floor, from international market leaders to new innovative technology companies, to source and compare

SPE Offshore Europe is recognised by offshore E&P professionals as Europe’s leading E&P event.

effective solutions.

Attending will ensure you are up to date with the most significant technologies and can connect with a global network of 56,000 attendees.

Expand your technical knowledge with exceptional insight and best practice in the industry’s largest free to-attend Conference. Produced in association with the Society of Petroleum Engineers (SPE), four

An extended preview of this event will be included in the August issue of Hazardex

Engage directly with technical experts from more

days of cutting-edge content will ensure you and

www.offshore-europe.co.uk

your company stay informed and competitive.

4th CCPS Global Summit on Process Safety Date: 12-13 September 2017 Location: Okayama, Japan

• Academia Panel Dicussions on Process Safety A novel feature of the Summit is a Leadership Forum,

Over the past several years Process Safety has taken on increased importance. Today companies large and small, in the traditional process industries and in emerging areas, all put a premium on improving their Process Safety performance.

Organised by AIChE/CCPS, 4th GSPS highlights will include: • Pre-conference short courses on Process Safety • Invited World Class International Process Safety Speakers • Leader’s Panel Discussions on Process Safety entitled “How I drive Process Safety in my Organization”

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where 10-12 Industry leaders participate in open discussion, where they express their vision on the future of process safety and share their experiences on how they drive Process Safety within their organisations. The outcome of the discussions in the leadership forum will presented to the delegates in a plenary session announcing a call for action. There will also be an exhibition over the two days.

Theme of the 4th CCPS Global Summit on Process Safety is “Process Safety Vision 2020”.

Global Summit provides a common platform to Process Safety leaders and experts from Industry,

government, regulators and academia to share advancements in the field of Process Safety, both through formal paper presentations and informal discussions.

Perceived outcomes include knowledge sharing, awareness and uniting for the common cause of process safety. www.aiche.org/ccps/conferences/ccpsglobal-summit-on-process-safety/2017

Product Datafiles 37 New Timer and Clocks: control the moment and last for years

An Engineer’s 3 Step Guide to selecting a static grounding solution

BEKA associates’ extensive new range of Timers and Clocks simplify process timing in both hazardous and non-hazardous areas. Including panel and field mounting models which can be configured to function with most sensors, they feature easy to read dual displays.

These versatile instruments can be configured on-site as a Timer or as a Clock. As a Timer they can measure and display the elapsed time between external events using sensors connected to one or both inputs.

Optional dual control outputs enable the instruments to control external devices.

Control cycles can be repeated continuously or a specified number of times with a configurable delay between each cycle.

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.

www.beka.co.uk Tel: +44 (0)1462 438301

For more information please contact Newson Gale. www.newson-gale.co.uk

ATEX Certified Humidity/ Moisture & Temperature Sensors

Now available in stainless steel: The 7501 Field mounted HART temperature transmitter

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.

The PR 7501 allows for safe and easy temperature monitoring, even in harsh and hazardous environments. Now customers, especially dealing with corrosive process environments, have the option of choosing a stainless steel housing.

With the brand-new stainless steel version now available, the PR 7501 is now also an excellent choice, when it comes to the additional challenges offered by harsh and corrosive process environments. Customers in the marine, offshore and chemical industries, for example, will now be able to take full advantage of the many benefits of the PR 7501’s unique design.

Technical datasheet available Tel: 01293 571000 Email: instruments@rotronic.co.uk Web: www.rotronic.co.uk

T: +45 8637 2677 www.prelectronics.com Follow us on LinkedIn

New Ex square shaped beem LED floodlight by Cortem Group

Connecting you to Global Markets

Thanks to the “square shaped beam” optics, the SLED series of explosion-protected floodlights from Cortem Group ensures a uniform illumination over large areas, 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 sodium vapour or metal halide floodlights, ensuring quality of the light, energy saving and visual comfort.

Features include: 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, colour temperature 6.500 K; Long Term Performance; Zone 1, 2, 21, 22; ATEX/IECEx/TR CU certificates; and IP66.

For more information visit www.cortemgroup.com or write to saleseurope@cortemgroup.com

CSA Group is a global organization dedicated to safety, social good and sustainability. We provide testing, inspection and certification services for products in industrial and hazardous locations.

We realise our customers need access to global markets and they need it quickly.

As such, we’ve evolved our processes to respond even better to the pressures our customers face, while offering the marks needed to access markets around the world.

Our large team of certification engineers are focused on completing projects within agreed-to timelines and we consistently start and finish projects with some of the best lead-times within the industry.

T: +44 (0) 1244 670900 E: ukinfo@csagroup.org

W: www.csagroup.org

Stand & Sponsorship packages now available For more information

Go to www.hazardexonthenet.net or email events@imlgroup.co.uk

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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

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Tel.: 0161 6336431

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Advanced batteries and protection whatever the environment

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Call 0161 727 3860 for further details

SAFETY PLUGS PROTECT FROM ARC FLASH

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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

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Explosion Proof Cranes

Conventional venting Flameless venting Explosion isolation Explosion suppression Testing services Expert advice

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We flash test as standard, we also offer injection testing & more

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Contact the HazardEx sales team on +44 (0)1732 359990 or events@imlgroup.co.uk

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www.dekra-insight.com www.chilworth.co.uk +44 (0) 23 8076 0722 DEKRA Insight represents the collective expertise of our member companies, each an institution in safety.