hazardexonthenet.net
October 2017
the journal for hazardous area environments
Renewables Wind turbine acoustic monitoring Process safety Sharing lessons across the EU
Hazardous Area Equipment IEC 60079-19
Renewables
Cybersecurity
Industrial fans in biomass applications
The lessons from history
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contents october 2017 The aftermath of Hurricane Harvey highlights some of the problems facing high hazard industry regulation in Texas and the USA. The International Business Times has reported on how Arkema, which owns the plant on the outskirts of Houston where a number of explosions and fires broke out after the floods, was one of a number of companies to lobby the Trump administration to delay Environmental Protection Agency rules that would have required it to report more extensive information to first responders in case of a disaster. The state began allowing companies to shroud their operations in secrecy in 2013, after the deadly fertiliser plant explosion in West, Texas, increased media scrutiny. That year, Texas Attorney General Greg Abbott, now the governor, declared that state and local agencies could
14 16
prevent the public from knowing the contents of inventories under a 2003 law meant to prevent terrorist attacks. The Trump administration and Republican leaders in Texas have blocked potentially life-saving information being made available about toxic chemical releases, explosion risk and other dangers.
Offshore wind turbines are subject to considerable stresses and loads from sea and air movements, which can cause cracks
This could prove costly for those companies that are hiding behind these rule changes. Barely a week after the Arkema explosions, a lawsuit alleging gross negligence was filed on behalf of first responders to the incident who were incapacitated by the toxic fumes emanating from the site. The Texas Tribune says this could be the first of many cases filed against companies that have chosen secrecy over honesty.
21
…Alan Franck, Editor, Hazardex In biomass applications, fans and other equipment should have IP55 protection against dust and liquid ingress
in this issue News Extra
5
• Houston plant explosion highlights efforts to block access to information on chemicals • Total acquisition of Maersk Oil demonstrates French group’s confidence in North Sea • US mining deaths down to record low in 2016 • Putin pardons imprisoned director of Russian mine where 110 were killed in 2007 • Prominent geologist expresses pessimism over likely size of UK shale reserves • Fukushima operator hit by second multi-billion dollar US lawsuit • Investigation highlights allegedly unsafe practices at Florida power station
15
Standards: The start of the IECEx season
16
Acoustic Emission monitoring of wind turbine monopiles
21
Industrial fans in biomass applications
25
IEC 60079-19: What is it and what does it mean to me?
29
Sharing lessons in process safety across the European Union
33
Cybersecurity - The lessons from history
36
Event previews
41
25
An important section of IEC 60079 specifically covers equipment repair, overhaul, reclamation and modification
29
• ADIPEC preview - 13 to 16 November 2017 – Abu Dhabi • Gas Asia Summit & Exhibition (GAS) - 25 to 27 October 2017 - Singapore • OPITO Safety and Competence Conference - 8 November 2017 - Kuala Lumpur, Malaysia • Offshore Decommissioning Conference - 27 to 29 November 2017 - St. Andrews, UK
To facilitate information sharing, a cloud-based SharePoint is used where guidance, safety alerts and other data can be posted
Datafiles & Buyers Guide 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
dangerous substances held on their sites after the fertiliser plant explosion at West in Texas in 2015, which killed 15. For decades, the state made these reports available upon request to homeowners, the media or anyone else who wanted to know where dangerous chemicals were stored.
Houston plant explosion highlights efforts in Texas to block access to information on chemicals
O
But in 2014, Abbott ruled that state agencies could withhold such information. Texas leaders have pushed for more secrecy on another front. Following the West explosion, the EPA began drafting a rule that would have, among other provisions, eased public access to chemical plants’ risk management plans for worst-case scenarios. The EPA identified 466 chemical facilities across the country that each put 100,000 or more people at risk of a poison
ne of the most damaging aspects of the major flooding in and around Houston after Hurricane Harvey has
But at a news conference in Washington, DC, Brock Long, of the Federal Emergency Management Agency, said he considered
been its effect on the many chemical and oil facilities across the city. ExxonMobil
plumes from the explosion “incredibly dangerous”.
said there had been leaks from its two refineries in the area and there have been reports of ‘unbearable’ chemical smells across the city. But the most
Confusion as to the toxicity of chemicals released across Crosby and Houston is widespread as the authorities and plant
visible effect of the flooding on local high hazard industry has been the explosions and fires at the Arkema plant in Crosby,
owners are not always giving concerned citizens details about the chemicals stored in the many flooded and damaged high hazard
including Arkema.
where the floods caused the electrical supply to fail taking out the refrigeration systems vital for the safe storage of
plants in and around Houston.
the rule would have required “unprecedented public disclosure of facility information that will threaten local communities and
organic peroxides on the site.
homeland security.”
On August 31 two trailers containing the
Arkema plant, for example, the company refused to voluntarily release two documents critical for assessing the potential fallout.
chemicals exploded at the Arkema plant, causing a fire and thick column of black smoke that led to the evacuation of everyone within 1.5 miles of the plant. On September 3, Arkema carried out a controlled burn of the six other trailers containing organic peroxides
In the past, information contained in such filings has proved useful in helping journalists and outside experts assess public health risks at refineries and chemical plants, or discover what went wrong in the wake of a disaster.
“to balance the public’s right to know with the public’s right to be secure” in his decision to keep some information on the Crosby plant secret. The company has released a list of the chemicals used at the site, but not their quantities or on-site
to enable emergency staff to access the site and establish the extent of the damage. Earlier, 15 police officers were taken to hospital after being exposed to toxic vapours from the site and were treated for eye irritation.
After the first of the explosions at the
The two documents — a federally mandated risk management plan and a detailed account of the chemicals on site, called a Tier-II inventory — are technically considered
gas disaster. But Scott Pruitt, the EPA chief under President Donald Trump, scrapped the rule earlier this year, at the request of the state of Texas and manufacturing companies
Texas and 10 other states complained that
Rich Rowe, Arkema’s CEO, cited the need
locations — crucial data for assessing likely effects on the plant’s neighbourhood. More than 12 hours after the initial explosions, the EPA finally provided reporters
public records. But current laws and policies make them difficult to access.
who asked with a partial version of Arkema’s Crosby risk management plan.
Texas Governor Greg Abbott was vocal in the campaign to restrict this information, claiming this would prevent terrorists from targeting volatile plants. He was a major
In the absence of any clear guidelines, the courts could end up as final arbiters over what is disclosed. On September 7, a lawsuit was lodged against Arkema
figure in the Republican-led campaign to oppose then-President Obama’s push to make companies publish inventories of
alleging gross negligence in its failure to disclose details of the toxic chemicals that incapacitated first responders on the site.
The Environmental Protection Agency said in a statement: “EPA has emergency response personnel on the scene and the agency is currently reviewing data received from an aircraft that surveyed the scene early this morning. “This information indicates that there are no concentrations of concern for toxic materials reported at this time.”
www.hazardexonthenet.net
6
Image: Maersk
News Extra
Total acquisition of Maersk Oil demonstrates French group’s confidence in North Sea T
he $7.45 billion takeover of Maersk Oil by French group Total makes the latter the second largest operator
supermajor has concluded since oil prices crashed in 2014. Royal Dutch Shell agreed to buy BG Group for $52 billion in 2015
60,000-90,000 boepd following its launch in 2019. Maersk also owns a 8.44% stake in the Johan Sverdrup project in the Norwegian
in the North Sea after Statoil. Total CEO Patrick Pouyanne said last month that he was ready to make acquisitions to grow production, taking advantage of a fall in
and has been reaping the benefits since the transaction closed the following year. In January, Exxon Mobil agreed to pay $5.6 billion in shares, plus a series of contingent
sector, which is led by Norway’s Statoil and is due to start pumping 440,000 bpd by 2019, with peak output of 660,000 bpd anticipated by 2022.
company valuations, the cost of drilling and other equipment during the threeyear industry downturn.
cash payments totalling as much as $1 billion, for drilling rights in the Permian shale region of Texas.
Subject to approval by the Danish Energy Ministry and competition authorities, the deal
“The combination of Maersk Oil’s North Western Europe businesses with our existing
Energy deals have picked up pace more broadly in recent months as the industry puts
portfolio will position Total as the second operator in the North Sea with strong production profiles in UK, Norway and
the worst of the slump behind it, although major oil companies have tended to be sellers. BP has offloaded assets including a
The deal boosts the share of eight global oil majors in the North Sea - Statoil, Total, Shell, Exxon Mobil, Conoco, ENI, BP and Chevron -
Denmark … Internationally, in the US Gulf of Mexico, Algeria, East Africa, Kazakhstan and Angola there is an excellent fit between Total and Maersk Oil’s businesses,” Pouyanne said.
$1.7 billion stake in a Chinese petrochemical venture and Shell exited its Irish venture for $1.2 billion.
to back above three-quarters of total output.
The acquisition gives Total about 1 billion barrels of oil equivalent of proven and probable reserves, about 80% of which are in the North Sea, according to the group. It will add output of about 160,000 barrels a day of oil equivalent (boepd) to Total next year, rising to 200,000 a day by 2020. The group said
Pouyanne said the acquisition would make the group more competitive and was a good fit, having earlier decided against moving into the US shale sector because of the high expense of assets there. He said that with Maersk’s assets, the Total group was well on its way towards its target output of 3 million boepd by 2019. The deal had not changed
it anticipated achieving financial synergies of more than US$400 million per year, with the combination of assets in the North Sea in particular enhancing efficiency.
the group’s forecast for capital expenditure of $15 billion to $17 billion next year, he added.
The deal ranks among the largest that a
sector with a forecast peak output of around
www.hazardexonthenet.net
Maersk Oil’s UK North Sea assets include the US$4 billion Culzean gas field in the UK
is due to be completed in the first quarter of 2018.
Several oil majors have been actively looking to divest fields in the North Sea - one of the most mature global oil provinces - where future developments will be complicated by high decommissioning costs of old infrastructure. The transaction will see Total take over all of Maersk’s decommissioning obligations in the North Sea, which are estimated at close to US$3 billion. Maersk said the sale was an important step in its strategy to create an integrated transport and logistics company, and it would contribute significantly to strengthening the group’s capital.
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News Extra
US mining deaths down to record low in 2016
A
ccording to data compiled by the Mine Safety and Health Administration (MSHA), part of the US Department of Labor, 25 miners died in work-related accidents in
MSHA has encouraged mine operators to put effective safety and health programs in place that address specific conditions and hazards; conduct thorough examinations of the workplace to assure
2016, against 29 in 2015. This is the lowest number of mining deaths ever recorded and only the second year that mining deaths dropped below 30.
that conditions and hazards leading to deaths and injuries are identified and fixed before they pose a danger to miners; and properly train miners on hazards and conditions that could cause injury, illness, or death as they perform their duties.
Sixteen of the 25 fatalities were reported in metal/non-metal mines — two in Mississippi and Texas, and one each in Arizona, Arkansas, Florida, Georgia, Iowa, Kentucky, Michigan, Nevada, North Carolina, Tennessee, Utah, and Virginia. The leading causes of the fatalities were machinery accidents (four) and
use of strategic enforcement tools, including targeted impact inspections that address problem mines, pattern of violations regulation for chronic violators, special initiatives aimed at preventing common deaths, compliance
Employment has been in long term decline in the mining sector over the last few decades. Total employment was 317,369 in 2015, the last year for which figures are available. This compares with 327,204 in
powered haulage (three). None of the 16 deaths occurred in underground mining operations. In
assistance, training, and outreach, along with improved compliance by the mining industry.
2010, 421,617 in 2005, 439,159 in 2000, 388,689 in 1995, 410,869 in 1990, 378,876
2015, 17 metal/non-metal miners died. The remaining nine fatalities occurred in coal mines — four in West Virginia, two in Kentucky, and one each in Alabama, Illinois, and Pennsylvania. The leading causes of death were powered haulage and machinery, which
in 1985 and 459,717 in 1980. “While these deaths show that more needs to be done to protect our nation’s miners, we have reached a new era in mine safety in the past few years,” Main said in an MSHA press release. “Each year since 2009, injury rates have dropped, and the number of mining
The 2015 total comprises 47,794 in underground coal mines, 50,711 in surface coal mines and facilities, 22,731 in metal and non-metal underground mines and 196,133 in MNM surface mines and
accounted for six of the deaths. In 2015, there were 12 coal mining deaths.
deaths and fatality rates were less than in all prior years in history except in 2010, when the Upper Big Branch mine disaster occurred. We
facilities.
Joseph A. Main, Assistant Secretary of Labor for Mine Safety and Health, credited the agency’s
have created a new roadmap to protect our nation’s miners.”
recorded 18 fatalities, 7 in metal and nonmetal mines and 11 in coal mines.
In the first eight months of 2017 the MSHA
MSHA says no US mining operation eligible for toughest enforcement measures over last year On August 2, the US Mine Safety and Health Administration (MSHA) announced that – for the third consecutive year – none of the nation’s more than 13,000 mining operations met the criteria for a Pattern of Violations notice. The screening period started on July 1, 2016, and ended on June 30, 2017. notice to mine operators that demonstrate a
implemented corrective action programs to address specific hazards at their mines to improve miner safety and health, and those efforts are paying off,” said Deputy Assistant Secretary of Labor for Mine Safety and Health, Patricia W. Silvey. “Throughout the year, MSHA works with mine operators and miners to identify and correct recurring hazards.”
The POV provision in the Federal Mine Safety and Health Act of 1977 is one of MSHA’s toughest enforcement tools. The agency reserves the provision for mines that pose the greatest risk to the health and safety of miners,
disregard for the health and safety of miners through a pattern of significant and substantial violations. It requires mines that receive POV notices to be issued withdrawal orders – temporarily ceasing operations until the violation
In January 2013, MSHA published its final POV rule to strengthen safety measures in the nation’s most dangerous mines. The regulation enables MSHA to consider mitigating circumstances
particularly those with chronic violation records.
is abated – for all significant and substantial, or “S&S” violations. “A number of mine operators have proactively
before issuing a POV notice and encourages mine operators to implement a corrective action program if they are approaching a POV.
The Mine Act authorises MSHA to issue a POV
www.hazardexonthenet.net
News Extra Russian President Vladimir Putin
I
n mid-August, President Vladimir Putin signed a decree to pardon the
The Ulyanovskaya investigation found that safety equipment had been
former director of the Ulyanovskaya coal mine, who was sentenced to six years in prison in 2015 by the Novokuznetsk District Court for violating security rules in explosive areas. Several others were also sentenced to terms
tampered with deliberately to decrease the readings of methane levels in the mine. According to Kemerovo Oblast governor Aman Tuleyev, this was done “consciously in order to increase coal production”. Five mine inspectors were
of imprisonment following the 2007 incident, the worst mining disaster in Russia for at least 50 years.
subsequently dismissed for allowing the mine operator to “breach safety rules in order to make a profit.” The explosion was said to have been caused by sparks from an exposed cable igniting methane gas, which then ignited coal dust.
According to Pravda, Putin’s pardon on the official legal website reads: “Guided by principles of humanity, I herewith pardon Andrei Ivanovich Funk, ... having released him from the need to further serve his sentence of imprisonment.”
Putin pardons imprisoned director of Russian coal mine where 110 were killed in 2007 disaster
9
Among those killed were 20 top mine
The Ulyanovskaya mine is located in the Kuznetsk basin in southern Siberia, which contains some of the world’s richest coal reserves. The heart of the area is called the Kuzbass, where many of the
officials, including the chief engineer, who had been inside checking a British-made
population work as miners or in miningrelated industries.
hazard monitoring system. British citizen Ian Robertson was also killed in the blast, along with his interpreter. Robertson worked for the British-German mining
The mine was relatively modern at the time, having only been opened in 2002, and is owned and operated
consultancy group IMC and was there performing a coal reserves audit. There were around 200 miners and other
by Yuzhkuzbassugol, Russia’s largest underground coal mining firm. Yuzhkuzbassugol is an affiliate of the
personnel in the mine at the time.
Russian coal and steel company Evraz Group SA.
In its investigation, the federal Russian industrial safety agency Rostekhnadzor said that there were no gas monitors in the 270 metre deep pocket where the methane
Since the Ulyanovskaya tragedy, other major mining disasters have included the Raspadskaya mine explosion where 91
gas accumulated, and the large number of people in a restricted space could have accounted for the high fatality count.
were killed in May 2010 and the Vorkuta incident in February 2016 where 36 died in a methane blast.
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10 News Extra retained their thickness and integrity, retaining plentiful reserves. The British Geological Survey found in 2013 that there were likely to be 1,300 trillion cubic feet of gas buried beneath the ground, but said nothing about how much of it might be accessible. Underhill argues the amount
Prominent geologist expresses pessimism over
likely size of UK shale hydrocarbon reserves
P
in suitable areas may be much less. “My challenge is: does the geology stack up?” he said. The body representing the UK’s shale gas industry, UK Onshore Oil and Gas (UKOOG),
rofessor John Underhill, Chief Scientist at Heriot-Watt University in Scotland, has said the UK’s potential shale deposits are likely to be far smaller than originally forecast because of fundamental geological realities that
based on seismic imaging of the country’s underlying geology, pockets of hydrocarbons were likely to be small and fractured, because most of the areas in which deposits of onshore unconventional gas and oil are likely to be found were affected by tectonic activity
said more exploration was needed. Ken Cronin, the chief executive, said: “The industry is currently in the process of seismic surveying, core drilling and flow testing in various parts of the country to determine a number of questions including the extent
have not been taken into account up until now. In the light of this, he said the
along the Atlantic plate about 55m years ago.
of the geology and whether gas will flow commercially.”
government would be wise to formulate alternative plans to fracking for future gas supplies.
This process has buckled and depressurised these pockets, making them cooler than the optimal temperatures for oil and gas production. In the USA, shale structures
Poland, once thought to have plentiful shale hydrocarbon reserves, has seen exploration programmes come to an end following
Prof Underhill said that, according to research
are far from tectonic plate edges and have
disappointing results from test wells.
News Extra 11 USS Ronald Reagan at anchor in Yokosuka, Japan
homes, many of whom will not return, and destroyed businesses, fisheries and agriculture. In June, a federal appeals court cleared the way for a group of US military personnel to file a suit against Tepco over radiation exposure that they say occurred during recovery efforts on board the aircraft carrier USS Ronald Reagan.
Fukushima operator hit by second multi-billion dollar US lawsuit
J
Shareholders of Tepco are suing the utility’s executives for a record 5.5 trillion yen ($67.4 billion) in compensation in a long standing case. The company’s former chairman and other
apanese utility Tokyo Electric Power Co Holdings (Tepco) said another lawsuit had been filed in a US court seeking $5 billion in compensation over the 2011 Fukushima nuclear disaster, the second filed against the utility in a US court. Tepco is being sued
of medical tests and treatment after efforts to support the recovery from the world’s worst nuclear disaster since Chernobyl in 1986, including personnel involved in Operation Tomodachi, the US military relief effort.
executives of the company appeared in court in June to answer charges of professional negligence, in the first criminal case after the meltdowns at the plant. They all pleaded not guilty.
over improper design, construction and maintenance, claiming compensation for
Tepco has been the target of more lawsuits than any previous Japanese contamination case
The criminal and civil legal cases do not threaten financial ruin for Tepco, which is
physical, mental and economic damages, the company said in a statement.
following the meltdown of three reactors at its Fukushima Daiichi plant north of Tokyo after a massive earthquake and tsunami in March 2011.
backstopped by Japanese taxpayers. The company faces nearly $150 billion of costs to decommission the Fukushima plant and clean
Radiation forced 160,000 people from their
up the surrounding area, according to the latest government estimate.
The suit was filed by 157 individuals seeking to set up a compensation fund for the costs
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12 News Extra Big Bend power station – Image: Wikipedia
underway to see whether it should be changed. The investigation unearthed the fact that after a similar incident at another TECO plant in 1997 when four workers were seriously injured, clearing blockages in the slag tank with the boiler above still in operation was banned at Big Bend, but was allowed again despite union objections sometime after 2007. The Times speculates that one reason for this might be the expense of shutting down
Newspaper investigation highlights allegedly unsafe practices at Florida power station
O
n June 29, molten coal slag spilled
To understand the accident, Times reporters
and restarting the boiler, estimated at up to $250,000 a time. Despite the cost, many other US coal-fired plants of similar design are shut down when there are blockages to be cleared or maintenance work is carried out below. It quotes a station manager at Nebraska Public Power District’s Sheldon Station saying that working at the bottom of a slag tank with the boiler online has not been
onto six workers as they tried to clear a blockage in a tank during routine maintenance at the Tampa Electric Co (TECO) Big Bend power plant at
interviewed 14 current and former TECO employees, examined the company’s safety manual, reviewed textbooks on power plant operations and analysed hundreds of pages
allowed in the 30 years he has been at the plant, and this was confirmed by three other managers at different US power stations.
Apollo Beach, south of Tampa. Two of the six died immediately, three others succumbed to their injuries over the
of records filed with the state Public Service Commission and the US Energy Information Administration.
TECO officials said they had done similar work hundreds of times with the boiler online, including six maintenance jobs on slag
They then spoke with 11 power plant experts and operators from across the country, all of
tanks this year, but the CEO confirmed to the Times that no worker would be asked to clean out a slag tank with the boiler running
In a major investigation, the Tampa Bay Times has looked into operational practices at the Big Bend power plant in Florida and
whom said working at the bottom of a slag tank with the boiler online is dangerous, and most coal-fired plants ban the practice.
until the company and the Occupational Safety and Health Administration (OSHA) had finished their investigations.
concludes that the incident that resulted in the deaths of five contractors in June is particularly dangerous and may have been carried out in a bid to save TECO money.
They also interviewed TECO CEO Gordon Gillette, who acknowledged the procedure’s risk and said a major safety review was
www.tampabay.com/projects/2017/ investigations/tampa-electric/big-bend-
following weeks and a sixth is still in hospital with serious injuries.
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Standards 15
The start of the IECEx season attraction of IECEx CoCs. After the first 6 months of certifying non– electric products, we have the first 20 CoCs of this type in the database! • The development of the IECEx Certified Service Facilities Scheme can also be considered a success: 227 certificates and 13 accepted ExCBs are the current numbers. During the IECEx MC Meeting in Washington the membership will decide on whether to support the next major project, the certification of service providers for inspection and maintenance. The updated versions of the respective set of Operational Documents (OD) are ready for approval by the member countries.
Every two months, IECEx Chairman Prof. Dr. Thorsten Arnhold provides an update on developments within the organisation
E
very year at the beginning of August, email traffic and telephone calls inside the IECEx
• With the IECEx Certificate of Personnel Competence (CoPC) Scheme we could reach the next
On the one hand, this is welcome as any effort to increase efficiency within IEC systems will enable new CAs to be established quickly according to market needs. On the other, however, every CA system has specific requirements from its major stakeholders and therefore needs elements of freedom and flexibility. To accommodate this, the basic document has a general section, the Harmonized Basic Rules (HBR) in the CAB document CA 01, which contain the general specifications, and a supplementary section for individual CA systems. The system stakeholders are responsible for the matters inside their organisations and have the right to make all necessary decisions as long as they are in line with these basic documents. Another item fast rising up the agenda
level over the next 12 months. As per end of August 2017, 1,622 CoPCs have been published. There are 10 accepted CBs and 6 applicants.
is cybersecurity. IEC is developing certification procedures covering this critical issue and IECEx is playing an active role in this process. We are well
The Recognised Training Provider (RTP) Program is well established and 17 RTPs are listed on the IECEx
aware of the fact that process plants are safety-critical facilities and therefore need effective protection against cyber
community and the number of working group and national committee meetings rises sharply.
homepage. Apropos the IECEx homepage, this is one of the main benefits for our global
attacks.
This is a good indication that the IECEx Management Committee (MC) meeting and other major
customers as through it we provide almost complete transparency. All rules and documents are available free of
be a short break of three days at home and after this the IEC General Meeting, which will be held in Vladivostok, Russia.
annual events will be upon us soon. In 2017, the IECEx MC will take place in Washington DC.
charge 24/7 and the same with all our certificates. In 2017 we launched an updated version of the homepage, www.iecex.com, which now has a better
At this event, my current Vice Chair, Dr. Alexander Zalogin from Russia, whose second term will end on December 31, will be honoured with the IEC’s
A look at our annual report card, which is updated before the MC meeting, shows that the IECEx system is in a really good shape: • In the equipment scheme there are 55 accepted Certification Bodies (CBs) and 62 accepted Test Laboratories (TLs). As per end of June 2017, we
structure and is much more user friendly.
What do I expect of the coming MC Meeting? One major topic will be the
Thomas Alva Edison Award. For me, this will be a good opportunity to thank him for his valuable contribution over the last six years. Last year, our Ex PCC Chair, Ralph Wigg from Australia, won this award in Frankfurt for his outstanding contribution to international standardisation and the development
have 28,624 Certificates of Conformity (CoC) and 26,188 Test Reports (TR) in our online database. The share of ‘Issue 0’ certificates, brand new certificates for new products, is more
introduction of new basic documents. The Conformity Assessment Board (CAB) of IEC, which rules the four Conformity Assessment (CA) systems, including IECEx, is trying to harmonise
of the IECEx Personal Competence Certification Scheme. The whole IECEx family is proud of these honours and considers the awards an appreciation of the efforts and successes of the whole
than 40%, which shows the ongoing
the basic rules of the different systems.
system and its members.
For all who are interested in the current status of IECEx and in future developments, it is well worth visiting.
After the week in Washington there will
www.hazardexonthenet.net
16 Renewables
Acoustic Emission monitoring of
wind turbine monopiles O
ffshore wind turbine monopiles, single tube turbine supports, are
Vibration monitoring is another method often used to detect problems in monopile
subject to considerable stresses and loads from sea and air movements, which can cause cracks or other
structures. This involves looking at the resonance (low frequency movement) of the structure to see if any changes occur.
structural defects. Tim Bradshaw of Mistras UK highlights one method of early detection, continuous Acoustic Emission monitoring, which can provide
However, a defect may be required to be of a significant severity for the resonance to change, which means it can be difficult to detect problems early.
an early warning to wind farm operators when the structural integrity of their offshore assets is threatened.
Acoustic Emission Acoustic Emission (AE) is the term used
Due to their relatively simple design and ease of installation in shallow-to-medium
to describe the high frequency signals (not audible to the ear) that result when material cracks or yields. These signals
(0-40m) water depths, monopiles are the most commonly used foundation structures for offshore wind turbines.
are usually short transients and can be detected using high frequency sensors in the same way that earthquakes are detected using low frequency sensors.
The monopile structure itself is a cylindrical steel tube that extends above the waterline and down into the seabed. The pile penetration depth is adjustable to suit the actual environmental and seabed conditions. The tower is supported by the monopile, either directly or through a transition piece. A limiting condition of this type of support structure is the overall deflection (i.e. lateral movement along the monopile) and vibration, as the structures are subjected to large cyclic, lateral loads and bending moments (due to the current and wave loads) in addition to axial loads (e.g. vertical loads due to the structure being supported). The diameter of a monopile can range to over 7 metres, with wall thickness as much as 160mm.
www.hazardexonthenet.net
Current monopile inspection methods A number of methods can be used to inspect for defects in monopile structures. These include diver and/or ROV (remotely operated vehicle) based inspection. However, both of these methods are time consuming, costly and can be unreliable. A diver or ROV has to visually inspect for cracks or other defects, which is challenging due to potential issues with visibility and marine growth. There are also the inherent safety risks when using a diver.
The advantage of the AE monitoring approach is that the technology is able to provide information on when these defects are active (i.e. under what load conditions) and their location on the structure being monitored. AE is used worldwide to monitor offshore structures, bridges and pressure vessels as part of inspection and risk-based inspection schemes.
AE monitoring of monopiles MISTRAS has developed, and successfully deployed, a continuous structural monitoring system to provide fatigue crack detection capability within the monopile foundations of offshore wind turbines.
Renewables 17
Prior to developing the AE system, MISTRAS identified the following factors as critical: • Simple to install as possible, with minimal impact on the asset and enabling easy access for maintenance. • Provide 100% coverage of the monopile for any active sources within the installed sensor array (water’s surface to the mudline). • Collect AE signals, process and store the data on a specific AE data acquisition system. • Filter potential noise sources from day-today operation on the asset.
The AE system is permanently installed on the asset, continuously monitoring the AE signals
• Have the potential to interface with SCADA to collect additional parameters used during AE data analysis. • Monitor movement of the asset for correlation to AE activity. • Be remotely interrogated via a network connection to allow system and data management.
being generated by the monopile to provide real time detection and location capability for any active gross fatigue crack sources.
• Automatically provide statistical updates to the customer via direct or website interface on the status of all assets being monitored.
• Provide vertical position (+/- 0.5m) of any active sources within the monopile.
The Solution The system utilises a string of underwater AE sensors immersed in the monopole water column. This allows signal transmission from any active discontinuity on the monopole structure (that is within the sensor array) to be transmitted to the sensors through the water column. The physical setup of the complete system is defined by verification trial measurements of the system performance to ensure sufficient sensitivity. The AE system comprises the following separate components: • The sensor string. • The data acquisition system. • The website.
www.hazardexonthenet.net
18 Renewables Linear array sensor string
information on the inclination of the tower. This gives some indication of the movement of the structure to correlate to the AE activity.
The sensor string is the array of sensors that are distributed down the centre of the monopile water column. This array is delivered to site as a manufactured component ready for installation. The use of a string
Each DAQ system is set up to continuously monitor signals on all the AE sensors and inclinometer
of sensors within the water column in the monopile is utilised for both ease of installation and for coverage. The installation, inspection and maintenance of the sensor string can be completed without any requirement
simultaneously, undertaking real time location of signals and rejecting any signals that do not locate linearly along the length of the sensor array. This helps to minimise noise signals and therefore minimises the size of
for access into the water. In addition, the ability to monitor the whole circumference of the monopile with the same sensitivity but a minimal number of sensors. The number of sensors and spacing are defined by Mistras to
data files collected. The system is also capable of identifying if the sensors are working correctly. The Mistras AE system has alarms defined within its software to identify activity on the monopile that is of interest and requires further
provide sufficient sensitivity to active discontinuities. monitoring system enclosed in an IP65 case. The DAQ system and industrial PC are designed specifically for acquisition of
investigation. In order to minimise false alarms, the system is programmed to identify the signature received from a boat pushing
AE data, providing 16 channels of AE data acquisition in order to provide spare channels and the capability to monitor the 3D array if required. A second DAQ system is provided
on to the structure. In this event, the system will inhibit the release of alarm messages in the form of emails or website messages.
The data acquisition system (DAQ) is installed in the Transition Piece in an
as backup. A battery back-up unit and UPS is also provided for the DAQ system. A two-axis inclinometer is also mounted
In addition to the raw data files collected, each DAQ system generates statistics files that summarise the data collected every
available area. The DAQ consists of an AE
internally in the DAQ system, which provides
30 minutes. These files are small text files
If a suspected active source is identified, a 3D array can be installed, the objective of which is to provide a 3D source location, providing not just vertical but circumferentially source position information.
Data acquisition system
www.hazardexonthenet.net
Renewables 19
The website clearly shows the status of all AE monitoring systems in a systems status grid. An alarm log is also provided, whereby alarms can be reviewed, acknowledged and managed.
A monthly report can also be produced to summarise the performance of all systems over the last month.
About the author
The website also provides access to all historical statistical monitoring data up to data that is at maximum 1 hour old. Cumulative alarms for an asset against time can also be displayed, as well as the ability to view cumulative events/hits. Access to historic reports can also be accessed in a format that can be searched.
Reporting designed to be used for data transfer to a website while minimising bandwidth demand on the network. These files are automatically transferred by the system to the Mistras servers for processing and to allow data display on the customer’s secure website.
Website
Various levels of reporting can be provided. The first level includes the automatic reporting by the system via alarm emails and the data displayed on the website. In addition, Mistras can provide a daily check on each system using remote desktop to view each system and reporting on the time of test, activity since last inspection and any activity of interest. Hardware tests such as automatic sensor tests can also be
To allow the customer to have visibility of alarms and trending data generated by the monitoring systems, Mistras provides a
conducted at this time.
secure website. This interface is designed around customer requirements. Access to the website is through a secure log in using
acknowledge the alarm on the website and communicate the system of interest. The data from the alarm period can be recovered
HTTP SSL security protocol.
over the network for further analysis.
If an AE alarm is triggered, Mistras can
Tim Bradshaw is the General Manager of the Mistras UK Cambridge Office and joined Mistras Group in 2002 working on the development and operation of advanced inspection services and condition monitoring solutions in a wide range of industries and environments. He works with BSI and the British Institute of Non-Destructive Testing (BINDT) on condition monitoring certification and development of codes and standards.
www.hazardexonthenet.net
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Renewables 21
Industrial fans in biomass applications A
s the demand for an efficient form of renewable energy increases,
biomass is now very much in the spotlight. Axair Fans Sales Engineer Andrew Ward explains the importance of industrial fan selection. Biomass energy is produced using matter from vegetation and waste, typically including wood chips, trees, manure, sewage and mulch. Due to the nature of the matter harnessed, the energy is classed as renewable as it can be regrown and used again.
In biomass generation from wood, the process begins when logs are sourced from regulated woodland areas The method can be seen as expensive due to the costs involved in growing living things. However, a huge advantage of using biomass energy is that it reduces the growing problem of landfill waste.
By using waste products and turning them into energy, the process reduces the dependency on fossil fuels. Biomass is a key energy production method in a world that is increasingly demanding sustainability. New technology to increase the efficiency of this plentiful resource is under constant development. One important technology is industrial fans, ranging from low to high pressure which can be used in a number of separate areas within the biomass operation.
www.hazardexonthenet.net
22 Renewables The simplest biomass heaters burn chipped or palletised materials such as wood, straw
boiler runs efficiently and reliably. If the woodchip is too low in moisture it will burn
and elephant grass and use low to medium pressure blowers to provide combustion air. The energy produced can be used to heat water or air and in the latter case, low pressure centrifugal fans are useful for space heating.
too quickly, while too much moisture could make the burner cut out.
In biomass generation from wood, the process begins when logs are sourced from regulated woodland areas. These logs are turned into woodchips of the required size, but will at this point contain 60% moisture.
Pressure
The woodchips are then loaded into an air vented drying bin that has hot air blown through. The drying bin has a walking floor which moves the woodchip through the bin and onto the conveyor, carrying the now 30% moisture chips into a dry building. To achieve this level of moisture removal a
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In biofuel applications, there are a number of other important factors to consider when selecting industrial fans.
heavy duty single inlet centrifugal fan with high performance, all steel backward curved impellers can be used. These fans must have IP55 environmental protection against dust and liquid ingress due to the particles and vapour in the atmosphere. The correct level of moisture in the woodchip is crucial to ensure the biomass
If using an industrial fan in a heavy application, the fan selector must ensure that there is enough pressure generated by the fan to achieve the desired result. For example in wood chip applications, we must consider how much there is and how thick it may be. With the correct pressure, in this example, the woodchip can be dried effectively to pass on to the end user.
Renewables 23 Type of Install
airflow closely can also help achieve cost
When selecting the fan, it is important to
savings on energy consumption.
closely at new technology, and given their importance within the biomass generation
Temperature
process, the latest generation of industrial fans will have a key role to play.
recognise the type of installation. Is the industrial fan to be installed directly into the equipment to produce or extract air? Using the example of a wood chip burner, an industrial fan may be attached to the machine to pump air and therefore increase
If using heat exchangers, the temperature will be too hot for certain industrial fans and high temperatures are common in biomass applications. Therefore the selected fan must
the temperature.
be suitable for the application.
Maintenance Programme
Volume of Air
Typical life expectancy of biofuel projects might be around 20 years making an effective maintenance programme essential.
The right selection of air volume helps with the heat transfer in biomass applications. Too much and the heat cannot be felt, too
It is important to know how often to check and maintain industrial fan components to keep the equipment running optimally.
little and there would be too much heat. Not only will the desired effect not be achieved but energy could be wasted in the process.
Control
Biomass technology is safe, clean, reliable and sustainable, and with the right
Fan control is important because circumstances change. In the instance of woodchip boilers, the fire could be blown out if airflow is too strong, and it would not do the job if is not strong enough. Controlling
equipment, a company can save up to 70% on heating and 50% on fuel costs. With savings such as these, it is no surprise that companies in the sector are looking
About the author
Andrew Ward is a Sales Engineer at Axair Fans
www.hazardexonthenet.net
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Standards 25
IEC 60079-19: What is it and what does it mean to me? D
r. Martin Killeen of the AEMT (Association of Electrical and Mechanical Trades) outlines the
IEC 60079 is a series of explosive atmosphere standards that covers a wide array of considerations for component usage
standard removed the exclusion of mining and introduced all explosive atmospheres - including dusts. It also introduced new
requirements of the international Repair, Overhaul and Reclamation of Hazardous Area Equipment standard IEC 60079-19,
in hazardous areas, as well as defining different hazardous area classifications. An important section of the series specifically
requirements for competency of persons, and when it comes to liability in the event of an explosion, those last requirements serve
and highlights how it impacts on both the service provider and the end user.
covers equipment repair, overhaul, reclamation and modification. This is distinct from the maintenance of equipment, other
to define responsibility.
Over the years we have all seen in the news the disastrous consequences of explosions in hazardous area installations. From Piper Alpha to Buncefield to
than when repair and overhaul cannot be separated from maintenance.
overhaul and repair services, and signing them off, along with those companies who are offering the services, should also be aware that IEC 60079-19 was significantly
Deepwater Horizon, the collateral damage and loss of life represent a cost that simply cannot be counted.
the early 20th Century after a serious coal mining accident, with FLP (Ex d) or flameproof motors being the first examples of Ex rated components. In 1984, AEMT and BEAMA jointly produced a code of practice for the repair of Ex rated equipment, and in 1993 this was first adopted as a British standard and published as BS EN 60079
Certainly such disasters bring into sharp focus the requirement to specify compliant products for hazardous area installations, covered by international standard commissioners such as IECEx, and legislative frameworks such as the European ATEX directive. But what are the implications for the repair, overhaul and reclamation of equipment used in explosive atmospheres?
Ex rated equipment was first defined in
Part 19. The standard was internationalised in 2004 and published as IEC 60079-19, with additional requirements during overhaul and repair of Ex equipment. Further, the updated
Those parties charged with buying-in
updated again in 2011, with a subsequent amendment in 2015, with the inclusion of specific Group I requirements and the inclusion of offshore requirements.
General principles IEC 60079-19 lays down the general principles of repair, overhaul, reclamation, alteration and modification that are common to all explosion-protected equipment, with additional clauses to provide instructions relevant to specific types of protection. Assuming that repairs and overhauls are carried out using good engineering
www.hazardexonthenet.net
26 Standards
practices, then the finished equipment
Where equipment is to be modified rather
temporary repair should be brought up to
is considered as being conformant to the original standard the manufacturer’s specification. Where this specification data
than repaired, then either alterations need to be specifically permitted in the certificate documentation, or, if that documentation is
full repair standards as soon as possible.
is not available, then equipment can be described simply as having been repaired in conformance to IEC 60079-19 and meeting the relevant standard the equipment was
not available, then the proposed alteration needs to be confirmed by the manufacturer, in writing, to be permitted by the certificate.
A key section of the standard details additional requirements for the repair and overhaul of equipment that is Ex d rated. The standard focuses on requirements
designed to meet. Of course, steps taken to obtain the original specification data should be documented. All repair or overhaul work carried out must be fully documented, and job reports submitted to the user. Repair facility records should be maintained to provide a complete audit trail of the work carried out and all of the steps taken, including measurements such as flame path or radial gap compliance. Equipment returned to the end user should be clearly labelled as having been repaired or overhauled, with the relevant manufacturing standards it meets, and the repairer identified. Where reclamation is being carried out, this should be performed by competent personnel. Ultimate responsibility falls under the repair facility, even if reclamation work is out-sourced to a third party. It should be noted that not all procedures are applicable to all types of protection, and IEC 60079-19 gives detailed instructions on what can and cannot be reclaimed.
www.hazardexonthenet.net
Ex rated equipment was first defined in the early 20th Century after a serious coal mining accident, with FLP (Ex d) or flameproof motors being the first examples of Ex rated components
Additional requirements
for enclosures, cable and conduit entries, terminations, insulation, internal connections and windings (including repair of rotating machine rotors). Detailed instructions are also given on a number of testing processes for windings after any repair, which should be completed as far as is reasonably practicable. There is also a host of additional requirements for the likes of flameproof brakes, other auxiliary devices, lighttransmitting parts, encapsulated parts,
If a modification means that the equipment can no longer be confirmed as meeting the original certified specification, then the user needs to be notified in writing, with a report stating that the equipment cannot be used in an explosive atmosphere without additional assessment.
batteries, lamps, lampholders, ballasts and breathing devices.
Temporary repairs to achieve continued short-term operation of equipment can only be carried out if it can be demonstrated that explosion-protection capabilities are maintained or if other appropriate explosion-
glands, terminations, soldered connections, fuses, relays, shunt diode safety barriers, PCBs, optocouplers, electrical components, batteries, internal wiring, transformers, encapsulated components, and non-
protection measures are taken. Any
electrical parts.
A further section within the standard goes on to detail additional requirements for the repair and overhaul of equipment rated as intrinsically safe (IS). This focuses on equipment such as enclosures, cable
Standards 27
Not all of these parts are able to be repaired, and should simply be replaced. Where equipment is repaired or overhauled, the work should be followed by testing of the dielectric strength of the insulation between the intrinsically safe circuit and the metallic enclosure.
(increased safety), type ‘n’, Group III ‘t’ (Dust), and type ‘pd’ (pressurised).
Responsible persons A very important section of IEC 60079-19 to be aware of is Annex B, which defines the knowledge, skills and competencies of ‘responsible persons’ and ‘operatives’.
the surveillance of the responsible person. Other operatives involved in the overhaul and repair processes do not need to be independently assessed as competent to IEC 60079-19 although they need to be aware of the requirements of the standard. The service facility of course has a
No attempt at reclamation should be made on components on which intrinsic safety depends, and any modification of equipment needs to be considered as modification to the complete system from that shown in the IS documentation, and a reassessment
Responsible persons are those who are responsible for the processes involved in the overhaul, repair and reclamation of the types of explosion protected equipment as defined within the standard. These responsible persons should confine their involvement to
responsibility to demonstrate compliance with the requirements of IEC 60079-19, but importantly there is also an onus on the user to ascertain that the service facility can indeed demonstrate compliance. In the event of any problem with repaired,
should be carried out by a qualified third party – not the company which made the modification.
overhaul, repair and reclamation, and should not be involved in modification without expert guidance.
overhauled or modified equipment, investigation bodies will look for evidence of due diligence from both parties.
Another clause within the standard details requirements for the repair and overhaul of
Any repair facility must appoint a ‘responsible person’ with the required
pressurised equipment. While it is preferable to obtain new parts from the manufacturer,
competencies within the management organisation, to accept responsibility and
We can see then, that the requirements of IEC 60079-19 are extremely stringent, and measures that were once guidelines and a recommended code of practice
in principle damaged parts such as enclosures can be repaired or replaced. Detailed instructions are provided as to what can and cannot be done with the likes
authority for ensuring that the overhauled/ repaired equipment complies with the certification status agreed with the user. That person must have a working knowledge
of enclosures, cable and conduit entries, terminations, insulation, internal connections and windings, along with instructions for
of the appropriate explosion protection standards and an understanding of this standard. This requirement means that it is
testing after the repair. While Ex d, pressurised and intrinsically
the responsible person who takes the final decision that Ex Equipment is in compliance and can be returned to the customer.
safe equipment will probably represent the bulk of the most safety-critical repair and overhaul work in hazardous areas, the scope
Operatives, as defined in the standard, who will be working on equipment and
of IEC 60079-19 is more comprehensive, offering detailed instructions for the likes of equipment with protection type ‘e’
who may be taking decisions that would have an impact on the certification status of the Ex equipment, need to work under
are now highly prescribed legislation. However, in areas with potentially explosive atmospheres, the stakes are high and the potential for the next Buncefield or the next Piper Alpha is never far from our minds. About the author
Martin Killeen joined the AEMT in September 2016 after retiring as the Head of Technology at Loughborough College. He started his career with an apprenticeship at Brush Electrical Machines, before becoming their senior design engineer for traction and Turbo Alternators. He has been involved with the AEMT Hazardous Area Courses since 1996 and trained a large number of engineers and technicians involved with Hazardous Area Equipment Repair.
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ATEX
Process safety 29
Sharing lessons in process
safety across the European Union T
he UK chemical and downstream
Major Accident Hazards (COMAH) Strategic
How good is industry at exchanging knowledge?
oil sectors experience of learning from safety related events has been shaped by the recommendations
Forum Managing Risk: The hazards that can destroy your business aims to make the principles of good safety leadership
following the Buncefield explosions and fires in 2005. These have largely been driven by the Process Safety Leadership Groups (PSLG) Principles
more accessible. Search for “COMAH Strategic Forum Managing Risk” for more information.
including where those people are working on many different sites across several different countries. Learning lessons from incidents, near misses and communicating
of Process Safety Leadership which recommend that: “Sharing best practice across industry sectors,
However, should we stop within our local borders? With new technologies, social media and cloud based sharing platforms
good practice about how to tackle common problems is clearly advantageous, and can be achieved relatively easily without the
and learning and implementing lessons from relevant incidents in other organisations, are important to
we have access to a wealth of knowledge and tools that can help us to further improve our performance in process safety.
legislative barriers that may impede external sharing.
maintain the currency of corporate knowledge and competence”
Businesses are generally good at sharing information amongst their own people,
The nuclear industry is an exemplar of how information within one sector can be shared more widely on an
The Process Safety Forum established in the UK to share knowledge and best practice between different industry sectors
international basis, in this instance through the World Association of Nuclear Operators (WANO). Other sectors, such as the chemical
is one example of how this is achieved, and was the subject of an article for the July edition of HazardEx.
and downstream oil industries in the UK, have become better at sharing externally because of their commitment to implement the PSLG principles. There are also many international bodies and publications that share information on incidents, such as the Centre for
All businesses that have the potential to cause a major accident are now being encouraged through various cross industry-regulator groups to look at leadership in process safety and determine what more they can do, including sharing and learning. A recent UK publication by the Control of
Chemical Process Safety (CCPS).
Industry engagement in sharing
However, the more widely we try to communicate the more difficult it becomes to stimulate and maintain engagement and commitment.
www.hazardexonthenet.net
30 Process safety A model for greater communication The Tank Storage Association (TSA) is actively engaged with its member companies to promote the adoption of the PSLG principles, and to share and learn from incidents, near misses and good practice. It actively promotes this within the bulk liquid storage sector in the UK through its leading role in key groups such as the Process Safety Forum, COMAH Strategic Forum and Chemical and Downstream Oil Industries Forum.
FETSA member countries
The TSA works with its European counterparts through the Federation of
gain access to a wide range of process safety knowledge and experience – as well as influence process safety regulation under Seveso III as part of the traditional lobbying and advocacy role. With regard process safety, the aim of greater collaboration is to:
European Tank Storage Associations (FETSA). Traditionally this relationship has been in place to ensure collaboration in lobbying activities and provide advocacy to the European Commission (EC) on relevant Directives, for
• become more open in sharing information on recent incidents and near misses, where this is permitted under individual member governance and agreed with the originator. • actively share information on good practice
to process safety amongst participating organisations. For FETSA, this already exists as a network to collaborate on lobbying and advocacy for relevant EC topics.
example the Integrated Pollution Prevention and Control Reference Document on Best Available Techniques on Emissions from
and new and emerging guidance and standards. • use the networks within FETSA to ask
To facilitate the exchange of information a cloud based SharePoint has been established where guidance, safety alerts, performance
Storage (known as the Storage BREF). Although limited to European countries, FETSA provides an existing forum of likeminded trade associations with links to a wide network of bulk liquid storage operators. Countries within the European Union (EU) also share many common legislative instruments derived from European Directives, including Seveso III (implemented in the UK as COMAH). With common legislation and challenges, FETSA provides the ideal platform for members from participating countries to
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relevant technical questions originated from the trade association members to assist them in clarifying any issues they may have. • use the networks within FETSA to understand the approach taken by the regulator on relevant topics providing the sector with a Europe wide overview. • use collective experience to greater influence responses to consultations on relevant safety-related directives or standards originating from the European Union. • investigate the development of common process safety performance indicators which can be collated and anonymised through the FETSA secretariat. The data
may then be used as a reference point for individual member countries.
Implementing the model The model described above is a simple one – it facilitates the sharing of information relevant
data and other relevant publications can be posted. Having a central repository is an important facility as it allows FETSA members to screen information before onward transmission to their member companies – ensuring only relevant information is distributed further. As the SharePoint becomes more populated it should also provide a useful library of process safety information. From a UK perspective, the TSA shares information it receives from: • the Process Safety Forum – Safety Alerts and Learning Briefs
Process safety 31
• the COMAH Strategic Forum – Seveso III policy approaches and strategic topics
Stimulating participation
Conclusion
In the UK, the stimulus for establishing closer
Many different sectors will have the networks
• the Chemical and Downstream Oil Industries Forum – Guidance on process safety, environmental and occupational health and safety topics • the Process Safety Management Competence Board – Process safety
collaboration and sharing of knowledge and good practice was Buncefield. This brought about a fundamental change in the relationship between industry and regulator, and highlighted the benefits that could be gained by working together to
in place to collaborate with their European (or worldwide) peers on legislation and standards. These same networks can be adapted to share knowledge on process safety. Virtual networks can be formed and participants encouraged to contribute and ask questions
training initiatives • TSA initiatives – member safety alerts (where agreed with the originator), quarterly and annual safety statistics
identify common issues and the solutions to mitigate them. We are still working on these relationships in 2017, fine-tuning and improving.
- sharing of information requires a cultural change, a commitment from all involved to think about what may be useful and to take a genuine interest in what is put forward by others
Information received from European partners
When considering collaboration at a
will be reviewed for onward dissemination through TSA member companies or where relevant the wider major hazards sector through the PSF.
European level there is perhaps not the same drive and determination. Regulators do behave differently and interpret safety and environmental directives in different ways. Cultural, business and legal influences may also impact on what can be shared, and there
The TSA and FETSA are very much at the start of this process. There is a great deal of effort required to maintain interest and to encourage people to contribute, but there is an acceptance that ensuring safe and profitable operations is our main priority.
access to many terminal operating companies which can bring a wealth of knowledge to any
will be language barriers in some instances.
Exchanging the knowledge that we have is a valuable tool in helping to achieve this.
technical questions raised, for example: • What is your regulator’s approach to bund capacity? • Are terminals operating in your region
There should be no expectation of an instant and seamless solution. What is critical as that the right information is shared with the right people – key pieces of information that can be
The most immediate benefit to participants is
obliged to investigate the contamination of sediment at the point of the wastewaterdischarge? • What level of risk assessment do you carry out for ignition risk from radio frequencies?
About the author
demonstrated to have had a positive impact will drive forward changes in attitude and highlight the importance sharing. For the TSA and FETSA, process safety is an agenda item at quarterly meetings
Having a large evidence base from responses to questions raised can benefit an operator in determining an appropriate course of action
with participating trade associations to maintain visibility of the process. Any topic or document posted on the SharePoint that
or assisting in dialogue between the terminal, its trade association and regulator.
warrants further discussion and action will also be discussed at these meetings.
Peter Davidson is Executive Director of the Tank Storage Association and sits on the Executive Committee of the Federation of European Tank Storage Associations (FETSA).
Sharing and learning – UK perspective
The Tank Storage Association (TSA) represents the interests of twenty-twomember companies engaged in the storage of bulk liquids. Collectively members operate over 280 terminals and distribution hubs in the UK and have over 8 million cubic metres of storage capacity. More than 60% of the products stored and distributed are refined petroleum, however members also store many other substances including a wide variety of chemicals, molasses, fats & oils, ethanol and glycerine.
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AWARD NOMINATIONS NOW OPEN
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 programme will be announced shortly, the committee 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 – for any queries about the conference.
www.hazardexonthenet.net
Cybersecurity 33
Cybersecurity - The lessons from history I
n order to better protect Industrial Control Systems from cyber attacks, companies should take heed from
The legend has it that one of the main gates to the city had been left open by an outbound raiding force. This open gate was quickly
however, is truly isolated from the outside world, just as no city is ever truly isolated by a moat; there needs to be a way in to allow for
the wise words of successful military tacticians and the lessons learned from some of the greatest failures in military defence, says Tim Ricketts, Director of
discovered by a small group of Ottoman forces, who realised that they could get inside and raise their banner. The raising of the banner caused panic among the defending
updates and to access equipment remotely, and this will always leave the possibility for mistakes to be made.
M.A.C. Solutions. In 2016, NATO officially recognised
forces, who retreated and lost vital ground within the City walls. The ensuing Ottoman forces eventually overwhelmed the city’s
Regular maintenance tasks, such as removing outdated pieces of equipment, could also be likened to our story. Think of
cyberspace as a warfare domain – an important change that has led many Cyber Security companies to liken their strategies
internal defences and, as history tells, for the Byzantine and the Roman Empire in the East – the battle was lost.
it like this: you have your very own Wall of Constantinople in the form of your firewall, and you have gates through that wall in the
for preparation and defence to Sun Tzu’s philosophies shared in “The Art of War”. While it is important to take heed from the wise
With the history lecture now out of the way, it is important to pick out the key points
form of ports. When an engineer removes that piece of equipment, but doesn’t close the port, then you now have an open gate –
presented in this story and take these as golden nuggets: • Your organisation’s defences may be
one that has turned into an exploitable attack vector. So it is imperative to have software that can detect these open ports, quickly allowing engineers to close these gates to your operational network.
This article looks at a historical defence failure that mirrors that of many security breaches in the cyber realm, where a persistent threat will take full advantage of an opportunistic weakness in the defender’s wall. This historical event took place in Istanbul (then
strong, but will always need entry points. • Ensure that access to entry points is well reviewed, logged and audited. • Plan for the worst; be as proactive in your internal defences as your external ones. • “These lessons learnt are great,” you may be thinking. “But how do they apply to my Industrial Control System?”
known as Constantinople) in the year 1453, fought by the defending Roman Byzantine rulers and the advancing Ottoman Empire. The Roman rulers erected a series of defence structures that featured large, high walls and
Let’s start with the first one: you may not have a wall – but you do have a moat, in the form of an air gap. This keeps your operational network seemingly safe from the
and unauthorised access to systems. Detection of these breaches could help to close gaps or even prevent major incidents, but if you notice that there is an entry point that is infrequently used or is now surplus
secured entrances, spanning the city and protecting it from conquest.
outside world, with the ‘jump’ being too great for your conventional attack. No network,
to requirements, then you should consider its removal. The most useful products on
words of a successful military tactician and philosopher, it is paramount that we look to history for some of the greatest failures in defence so that you may learn from these too.
You will almost certainly understand where your entry points are, but you should also be aware of the times, manner and reasons in which people access them. An early warning sign to a breach on your network is sporadic
www.hazardexonthenet.net
34 Cybersecurity the market learn about your usual network traffic, making it easy to spot traffic that is
recuperate from the worst possible outcome, often meaning that your disaster recovery will
unusual for your network, such as traffic that occurs during off-peak hours, unusually large packets or unexpected protocols.
be mature and developed enough to restore services as quickly as possible. Frequently monitoring the state of your network devices allows you to develop customised, efficient and profoundly effective plans that evolve along with your organisation’s scale.
Planning for the worst is not the same as admitting defeat, but rather being prepared to
About the author
Tim Ricketts is Chairman of M.A.C. Solutions (UK) Ltd, the UK partner for CyberX. He has over 35 years of experience in the automation and process industries, and has a wide understanding of technologies within industrial networking, process alarm management, change control management and industrial cyber security.
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36 Event preview
ADIPEC confirms expanded programme for
world’s largest oil and gas technical conference submissions for presentations at this year’s edition, a 10 per cent increase from last year, and for the second consecutive year setting a record for the number of submitted abstracts in the oil and gas industry.
O
“The key to growth for oil and gas companies will be to find new ideas, and to share
Technical abstracts came from 622 organisations located in 70 countries.
Exhibition and Conference (ADIPEC), hosted by ADNOC, have confirmed the event’s technical conference, already
information in the pursuit of best practice,” said Ali Al Rawahi, Reservoir Manager Studies (BUH/SE Asset), at the Abu Dhabi
Underlining ADIPEC’s expanding international reach, 59 per cent of submissions were from outside the Middle East. The ADIPEC
the world’s largest for oil and gas professionals, will see a significant increase in scope for 2017 to include the
Company for Onshore Petroleum Operations Ltd. (ADCO), and ADIPEC 2017 Technical Conference Chairman.
2017 technical committee, comprised of 164 industry leading experts, selected 809 highquality abstracts.
downstream industry for the first time, as well as more sessions for specialised areas including offshore and marine
“ADIPEC is clearly established as the leading platform for knowledge exchange in oil
Conference sessions include exploration and production geoscience; production
and gas. What the conference offers has never been more important than it is today. Resource owners are getting better prices for their product, but nobody can rely on further rises to ensure their business. The focus will continue to be on improving efficiency and reducing cost, which can only be achieved through sharing experience between companies and across borders.”
facilities technologies; field development; operational excellence; drilling and completion technology; health, safety and environment; projects engineering and management; gas technology; unconventional resources; improved and enhanced oil recovery; people and talent; and petroleum advanced analytics.
rganisers of the annual Abu Dhabi International Petroleum
exploration and production. ADIPEC will be held at Abu Dhabi National Exhibition Centre from 13 to 16 November 2017. With around 900 speakers scheduled for more than 200 sessions, the conference will bring together the industry’s most respected experts, global leaders and top decision makers, with around 10,000 delegates attending over the course of the event’s four days. The expanded technical programme will encompass all layers of the industry, including upstream and midstream sessions organised by the Society of Petroleum Engineers (SPE), while dmg events, Global Energy, will oversee a new programme of downstream sessions. Organisers say the change reflects the accelerating search for efficiency and integration in a challenging market.
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The expansion to include the downstream sector reflects one of the emerging industry trends in oil and gas, as upstream and midstream companies are increasingly looking towards integration, collaboration and diversification across refining and petrochemicals, processing, and endproduct sales to boost overall profitability. The ADIPEC Technical Conference programme received 3,060 abstract
The 2017 edition of the ADIPEC Conference programme will feature two ministerial sessions, four global business leader sessions and four downstream global business leader sessions, eight panel sessions, three offshore plenary panels, nine C-suite dialogue sessions, three industry breakfasts and three topical luncheons. ADIPEC organisers have confirmed the involvement of 13 CEOs for the Global Business Leader panels and are in talks with many more across the global industry.
Event preview 37
A further nine CEOs have been confirmed for the Downstream Global Business Leader
Baker Hughes, a GE company.
programme.
Offering a regional perspective on oil and gas investment will be Mansour Al Mulla, Chief Financial Officer, Petroleum and Petrochemicals, Mubadala Investment Company, while Brian Gilvary, Group Chief Financial Officer at BP, will offer an
The confirmed CEO speakers include Bob Dudley, Group Chief Executive at UKheadquartered multinational, BP; Datuk Zulkiflee W. Ariffin, President and Group CEO of Malaysian national oil company, Petroliam Nasional Berhad (Petronas); Patrick Pouyanné, Chairman and CEO of France’s Total; Vagit Alekperov, President, Member of the Board of Directors, and Chairman of the Management Committee, at Russia’s
international view.
Lukoil; Musabbeh Al Kaabi, CEO, Petroleum and Petrochemicals, Mubadala Investment Company; Mario Mehren, Chairman of the Board of Executive Directors, Wintershall; Toshiaki Kitamura, President and CEO at Japan’s INPEX Corporation; and Claudio
business success, with discussion of the most pressing topics facing the sector today. There will also be a highly focused session on energy finance, investment, consolidation and diversification.
Descalzi, CEO at Italian multinational, Eni.
A full-day Women in Energy programme will focus specifically on the opportunities
“At ADIPEC we create one meeting place, in one city, for one global industry, and the conference programme represents that approach,” said Christopher Hudson, President – dmg events, Global Energy, which organises ADIPEC. “It is a complete platform for a complex global industry, where we create value for every layer of the most
Their individual perspectives include experience at some of the world’s largest vertically integrated oil and gas companies, including
for and achievements of women working in the oil and gas industry. The co-located Security in Energy conference returns for a
vertically integrated oil and gas business. With CEO-level support from the industry’s most influential corporations, ADIPEC is
two of the industry ‘supermajors’, operating across a diverse range of international markets, both in terms of exploration and production, and in terms of sales.
second year, recognising the increasingly
essential for sharing knowledge, driving innovation, and generating business.”
They will be joined by the heads of three of the biggest international suppliers of oilfield services: David Dickson, President and Chief Executive Officer at McDermott; Mark McCollum, CEO at Weatherford, and Lorenzo Simonelli, President and CEO at
With ADIPEC 2017 to be held under the theme ‘Forging Ties, Driving Growth’, the four Global Business Leader panels will focus on strategies that can deliver continuing
A full-day Women in Energy programme will focus specifically on the opportunities for and achievements of women working in the oil and gas industry
critical importance of cyber and infrastructure security within oil and gas operations.
Held under the patronage of His Highness Sheikh Khalifa Bin Zayed Al Nahyan, President of the UAE, hosted by the Abu Dhabi National Oil Company (ADNOC), and organised by the Global Energy division of dmg events, ADIPEC is one of the world’s leading oil and gas events, and the largest in Africa and the Middle East.
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@P E R F T E C
Antweep 2017
In the regions hazardexonthenet.net Protecting Plant, Process & Personnel
20 complimentary delegate places available to first who apply
We are pleased to announce the next Hazardex in the Regions event will take place in Antwerp, Belgium on November 29th 2017 and will be co-located with PEFTEC, the event for petroleum refining & environmental monitoring technologies.
The underlying philosophy of Hazardex in the Regions is to bring the latest safety-related intelligence to process plant and hazardous area specialists at a venue near their workplace, reducing travel time and expense. The conference will be supported by an exhibition of products and services relevant to those working in hazardous environments, and offers free access to PEFTEC conferences, seminars & the wider exhibition.
Following on from the success of the decade long series, this is another opportunity for all those interested in process plant safety in Belgium and the surrounding countries to participate in one of our hazardous operationsfocused one-day conference & exhibitions.
These events will be useful for engineers, safety managers, directors with corporate liability and other members of the hazardous area community from all the process and high hazard industries, including oil & gas, petrochemicals, fine chemicals, pharmaceuticals, mining, manufacturing and the food & beverage sector, amongst others.
If you are interested in presenting a paper, exhibiting or attending the event, please contact:
russell.goater@imlgroup.co.uk or phone + 44(0) 1732 359990 www.hazardexonthenet.net
@instmc
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87 Gower Street London WC1E 6AF +44 (0)20 7387 4949 conferences@instmc.org Reg. Charity: 269815
Event preview 39
5th Annual Gas Asia Summit & Exhibition (GAS) 2017 Date: 25 to 27 October 2017 Location: Singapore Gas Asia Summit & Exhibition (GAS) returns in its 5th edition to the Marina Bay Sands in Singapore from 25 to 27 October 2017 as part of the Singapore International Energy Week (SIEW). GAS is the legacy event to the Gastech
Conference & Exhibition – the world’s largest event for the natural gas & LNG industry and also encompasses the Asia Pacific Small & Mid-Scale LNG (APAC LNG) Forum. This multi-stream event gathers a global spectrum of VIPs, C-level executives, business leaders, technical experts and industry practitioners. It is a crucial
business platform for the natural gas and LNG industry in Asia to discuss regional developments, discover innovative solutions and build profitable business relations. http://gasasiasummit.com
OPITO Safety and Competence Conference 2017 Date: 08 November 2017 Location: Kuala Lumpur, Malaysia OSCC 2017 – New Generation, New Thinking - held on November 8th 2017 at The Royale Chulan, 5 Jalan Conlay, Kuala
OSCC 2017 will present the opportunity to explore what the industry offers the next generation in terms of current support, how the learning and education experience is changing and the role technology will play in this process.
pace with the next generation will also be considered by a range of industry experts. OPITO, the industry’s partner in safety and
Keynote presenters will highlight the ways in which young people can be encouraged to embark on a career in oil and gas and discuss the issues around attraction and
competence, will play a vital role shaping the ways in which the future workforce learns. During the conference, we will
Lumpur. With new technologies and ways of working developing all the time, the expectations of the younger generation are changing. It is vital that the oil and gas industry evolves with these changes and adapts its learning processes to meet the needs and demands of the future workforce.
retention. The importance of working with millennials to ensure that the oil and gas industry future is buoyant and how training and safety standards can evolve to keep
consider what needs to be done to meet the needs and aspirations of the next generation whilst maintaining standards. www.opito.com/oscc-conference
Offshore Decommissioning Conference 2017 Date: 27 to 29 November 2017 Location: St. Andrews, UK
November and will incorporate a gala dinner on the evening of 28 November.
The 2017 conference, run jointly by Decom North Sea and Oil & Gas UK, will take place from 27 – 29 November at the Fairmont Hotel, St Andrews. The conference will build upon previous sell-out events and will encompass numerous keynote and break-out sessions all focused on the latest
The key objective of the conference is to bring a wide spectrum of oil and gas companies into one room; small supply
decommissioning updates, trends and case studies. The main conference will follow a welcome drinks reception on the evening of 27
Attending this annual event allows you to: *Update your knowledge and learn from
chain companies, contractors and many of the large operators. Previous conferences have shown attendees to be actively involved and willing to contribute and discuss the challenges and opportunities associated with offshore oil and gas
industry leaders and key stakeholders *Take part in an excellent business development and networking opportunity,engaging with 350+ industry professionals
decommissioning in an open and engaging atmosphere.
http://offshoredecommissioningconference. co.uk
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NEW FOR 2017
A Report on the World Market for Hazardous Area Equipment HazardEx has worked with IHS Markit to provide this new edition of a report on equipment for use in hazardous environment.
JOHN MORSE AT IHS MARKIT T +44 1933 408 077 E John.Morse@ihsmarkit.com
RUSSELL GOATER AT HAZARDEX T +44 1732 359 990 E Russell.goater@IMLgroup.co.uk
technology.ihs.com
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‒ World market revenues and shipments with detailed analysis of selected products ‒ Data from 2016 to 2021 ‒ Many market segmentations including: by region, country and industry ‒ Estimated market shares of leading suppliers
Product Datafiles 41 Leading the Customer Service Experience in the Certification Industry
ATEX Certified Humidity/ Moisture & Temperature Sensors
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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.
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Schmersal presents AUX power version of AZM and efficient safety solutions at Motek Visit Schmersal at Motek in Stuttgart, Germany, from 9 to 12/10/2017: Hall 7, Stand 7103 The Schmersal Group exhibits innovating safety systems for complete plants and complex machinery at this year’s Motek. These solutions meet essential requirements of Industry 4.0 concepts and can be adapted easily to varying applications. They enable preventive maintenance, increase productivity and efficiency and at the same time ensure a high safety level. Compliant to ISO-14119: New AUX Power Version of AZM 300-AS The new AUX variant of the AZM 300 AS, a solenoid interlock with integrated ASi-Safety-at-Work interface, achieves the highest safety level PL e with the safe twochannel release function. Therefore, it is worldwide the first AS-I solenoid interlock which meets all user requirements of the ISO 14119 standard
Schmersal safety installation systems The new Schmersal Safety Installation Systems support users in their use of series connection of different safety switching devices such as safety sensors and solenoid interlocks within larger safety functions and enable simple, failsafe and cost-optimized wiring solutions. With the new installation systems PDM and PFB, larger systems can be constructed thanks to the cascading capability. Wire cross sections of up to 1.5mm² reduce voltage drops in the supply cables. The internal autoreset fuses for each safety interlock saves the mandated individual fuse when the wire cross section is reduced. For more information: www.schmersal.com
F-Series: For safe and hazardous areas The F-series product range offers you an extensive selection of Indicators, Controllers and Monitoring Systems for liquid and gas flow applications, as well as for Level, Pressure and Temperature Measurement in safe and hazardous areas. The F-Series are available with intrinsically safe approvals according ATEX, IECEx, FM and CSA C-US for gas and dust applications. Robust enclosures The most visible feature of the Fluidwell F-Series is the one of a kind enclosure. These robust enclosures are available in GRP or durable aluminium. The GRP is a sturdy, light-weight and budget friendly enclosure. Even more rugged is the durable aluminum enclosure with various entry threads. In fact, the F-Series is so rugged, even a truck can stand on it! The 3 extremely rugged push buttons, won’t wear out on harsh treatment or environmental conditions. The F-Series withstands extreme weather conditions as rain, snow, sun, salty atmospheres or temperatures as low as -40°C or as high as 80°C, which is -40°F to 178°F.
Easy to operate The intuitive and user-friendly menu structure, saves significant time and cost in installation and programming. Fluidwell users all around the world appreciate the clearly indicated, alphanumerical descriptions. Those familiar with a Fluidwell product, can therefore also program and install all F-Series without a manual or hiring technical experts: Know one, know them all! Video: www.fluidwell.com/hazardex-f-series or contact us at sales@fluidwell.com
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42 Buyers Guide
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The MPC-2070 7-inch panel computers with Intel Atom processor E3800 series deliver a reliable and durable platform for use in industrial environments. With two software selectable RS-232/422/485 serial ports and two gigabit Ethernet LAN ports, the computers support a wide variety of serial interfaces as well as high-speed IT communications, all with native network redundancy. They offer -40 to 70°C temperature range, and come with a fanless, streamlined enclosure designed for highly efficient heat dissipation, making this one of the most reliable industrial platforms available for harsh, hot, outdoor environments like oil and gas fields, or drilling platforms. They also feature a 1000-nit LCD panel offering a sunlightreadable, projected-capacitive, glove-friendly, multi-touch screen. https://www.moxa.com/product/MPC-2070.htm
To advertise in the Product Datafiles or Buyers Guide contact Kathryn Startin on +44 (0)1732 359990 or kathryn.startin@imlgroup.co.uk
AWARD NOMINATIONS NOW OPEN
Sponsorship & exhibition stands now on sale Contact the HazardEx sales team on +44 (0)1732 359990 or events@imlgroup.co.uk
Square shaped beam LED floodlights collection
PURE LIGHT
Thanks to the “square shaped beam” optics, the explosion-protected floodlight SLED series of Cortem Group ensures a uniform illumination over large spaces, both indoors and outdoors. Characterized by high light output with a white light and a colour rendering index greater than 70, they are able to replace the sodium vapour or metal halide floodlights, ensuring the quality of the light, energy saving and visual comfort.
II 2GD Ex de IIB+H2 method of protection for environments with the presence of hydrogen High luminous efficiency Energy saving Optimization of plant engineering and maintenance costs Cool White LED, color temperature 6.500 K Long Term Performance SLED-600 30.800 lm
cortemgroup.com
SLED-400 20.750 lm
SLED-250 13.050 lm
Zone of installation 1, 2, 21, 22 | ATEX/IECEx/TR CU certificates Class temperature T5 (100°C) T6 (85°C) | Degree of protection IP66 Power supply 100-277 Vac ±10% and 120-277 Vac ±10%