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Legislation & Regulation Explaining the Radio Equipment Directive Controls & Instrumentation Advanced diagnostics and overfill prevention
Functional Safety Designing FS into the system
Controls & Instrumentation Rugged HMIs
Functional Safety The release timeline of IEC61511
March 2018
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contents march 2018 The UK Labour Party’s 2017 manifesto called for the renationalisation of the country’s energy, water, rail and mail sectors. This has proved popular with the electorate, with recent polls showing majority support for these proposals, despite the lack of details in the manifesto or from senior party figures on where the money to fund the acquisitions and subsequent investment would come from. In January, the Centre for Policy Studies think tank concluded that taking the public utilities into public ownership would add £176bn to the national debt. Another think tank, the Social Market Foundation (SMF), forecasts the cost of nationalising water industry alone at £90 billion, equivalent to 10% of all current Whitehall spending and more than twice the NHS wage bill for 2015/16.
14 21
The SMF calculated that in the medium term, spending on water infrastructure would be equivalent to more than 13% of the entire Government capital spending budget. Quite apart from the affordability of these proposals, those who remember or who have studied recent British history point to another fundamental problem - the lack of evidence that the state would do a better job than private companies.
The right functional safety product and management systems can deliver long-term security and a lower life-time cost
27
In a recent speech, Oxford economist and former head of the Office of Fair Trading Sir John Vickers said neither public nor private control was innately superior for businesses where consumers can’t shop around - such as control of water pipes. Independent regulation can deal with many problems, he said, but added: “Memories can be short. The previous era, the nationalised era, was not exactly glorious in terms of efficiency, customer service and investment in these sectors.” …Alan Franck, Editor, Hazardex
Advanced diagnostics level sensors can improve plant safety by reducing the number of dangerous undetected (DU) failures
in this issue 5
33
News Extra
• Maritime piracy and armed robbery reaches 22-year low - report • South African mine fatalities increase in 2017 after decade of improvement • Former US coal company CEO, jailed for deadly mine explosion, to run for Senate seat • Texas town devastated in 2013 fertiliser plant explosion to receive $10 million damages • Three cleared of negligence in Canada railway disaster • A decade after fatal Georgia sugar plant blast, US dust explosion standards remain elusive • Iranian oil tanker disaster in East China Sea claims lives of 32 crew, threatens widespread pollution
17 Standards: The European Notified Bodies Group Meeting Many human machine interfaces (HMIs) or operator panels on the market are claimed to be “rugged”, but how is this term defined?
19 Demystifying the release timeline of IEC61511 21 Why it pays to focus on functional safety management
39
27 Advanced diagnostics and overfill prevention 33 Rugged HMI - What does this really mean? 39 Machinery safety and the Radio Equipment Directive 44 Datafiles
The EU’s new Radio Equipment Directive will require suppliers of radio-enabled machinery to make significant adaptations
46 Events
the journal for hazardous area environments
hazardexonthenet.net
Legislation & Regulation Explaining the Radio Equipment Directive Controls & Instrumentation Advanced diagnostics and overfill prevention
Functional Safety Designing FS into the system
Controls & Instrumentation Rugged HMIs
Functional Safety The release timeline of IEC61511
March 2018
47 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
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News Extra
5
Maritime piracy and armed robbery reaches 22-year low - report A
total of 180 incidents of piracy and
“Although the number of attacks was down
In the Philippines, however, the number
armed robbery against ships were reported to the International Chamber of Commerce’s (ICC) International
in 2017 in comparison with 2016, the Gulf of Guinea and the waters around Nigeria remain a threat to seafarers. The Nigerian authorities
of reported incidents has more than doubled, from 10 in 2016 to 22 in 2017. According to the report, the majority of
Maritime Bureau (IMB) in 2017, according to the latest IMB report. This is the lowest annual number of
have intervened in a number of incidents helping to prevent incidents from escalating,” said Pottengal Mukundan, the IMB Director.
these incidents were low-level attacks on anchored vessels, mainly at the ports of Manila and Batangas. Vessels underway off
Nine incidents were recorded off Somalia in 2017, up from two in 2016. In November, a container ship was attacked by armed pirates
the Southern Philippines were boarded and crew kidnapped in the first quarter of 2017. However, alerts broadcast by the IMB’s Piracy Reporting Centre (PRC), on behalf of
incidents since 1995, when 188 reports were received. In 2017, 136 vessels were boarded, while there were 22 attempted attacks, 16 vessels fired upon and six vessels hijacked. In 15 separate incidents, 91 crewmembers were taken hostage and 75 were kidnapped from their vessels in 13 other incidents. Three crewmembers were killed in 2017 and six injured. In 2016, a total of 191 incidents were reported, with 150 vessels boarded and 151 crewmembers taken hostage. Beyond the global figures, the report underlined several takeaways from the past year.
approximately 280 nautical miles east of Mogadishu. The pirates, unable to board the vessel due to the ship’s evasive manoeuvring fired two RPG rockets, both of which missed, before retreating.
the Philippine authorities, have since helped to avoid further successful attacks.
Six Somali pirates were subsequently detained by the European Union Naval Force, transferred to the Seychelles and charged with “committing an act of piracy” where they face up to 30 years’ imprisonment, if convicted.
UK-based tanker owner and operator Union Maritime confirmed one of its vessels, MT Barrett, had been the subject of a pirate attack. The vessel was last reported to be at anchor off Benin on January 9 when contact was lost. On January 18, Union Maritime confirmed the MT Barratt and its crew were safe.
“This dramatic incident, alongside our 2017 figures, demonstrates that Somali pirates retain the capability and intent to launch attacks against merchant vessels hundreds of miles from their coastline,” said Mr Mukundan.
In the first months of 2018, at least two vessels were hijacked in the Gulf of Guinea.
In 2017, there were 36 reported incidents in the Gulf of Guinea off West Africa and 10 incidents of kidnapping involving 65 crew
Indonesia recorded 43 incidents in 2017, down from 49 in 2016. The IMB report
Several weeks later, Anglo-Eastern of Hong Kong said it had lost contact with its vessel Marine Express on February 2, also off Benin. Four days later the company announced the crew of 22 had been
members in or around Nigerian waters. Globally, 16 vessels reported being fired upon – including seven in the Gulf of Guinea.
notes that Indonesian Marine Police patrols continue to be effective in the country’s 10 designated safe anchorages.
released, but there was no news of its cargo of gasoline, estimated to be worth US$8 million.
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News Extra
South African mine fatalities increase in 2017
after decade of improvement
F
or the first time in a decade, the South African mining sector has
reported an increase in occupational deaths. Data from the Chamber of Mines of South Africa industry association showed 81 fatalities from January to November 2017, compared with 73 in 2016, the lowest on record.
7
Miners are having to go deeper and further in ageing shafts to access new seams in a
implement the systems failed to do so.”
country that has been mined commercially for over a century. While injuries from falling rocks are decreasing, accidents related to seismic activity and rock-bursts - where rock under pressure explodes - are on the rise, Chamber spokeswoman Charmane Russell said.
But Peter Bailey, chairman for health and safety at the National Union of Mineworkers, the biggest miners union, said: “Companies are maximising profits while violating safety procedures.”
The increase in deaths in 2017 “is particularly disappointing given the improvements we have seen over the past two decades,” Russell said in an email to Bloomberg. Anglo American Platinum CEO Chris Griffith, who heads the Chamber’s CEO Zero Harm Forum, said the industry, government and labour needs to “accelerate initiatives that could improve this unacceptable performance”.
Mine fatalities have compounded problems with an already restive workforce and low productivity levels. Sibanye Gold Ltd. and AngloGold Ashanti Ltd. have both objected to the Department of Mineral Resources temporarily halting operations after accidents, while the regulator argues the companies are not following the law. The two companies report among the highest losttime incident and fatality rates for precious metals miners, Bloomberg Intelligence analysis shows.
Most miners killed last year worked in gold
Thomas van den Berg, head of safety
Nevertheless, the long term South African mine safety trend is positive, and is now not
and platinum mines, the world’s deepest and most dangerous. They accounted for 57 of 73 deaths in 2016, according to the
and technology at Harmony Gold, said: “Many accidents are caused not because the systems implemented failed or were
too far from countries such as the US and Canada for fatality rates per hour worked. The 2017 figure can be compared to the
Chamber.
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8
News Extra
boost his Senate campaign. Being jailed during the Obama administration was probably a “badge of honour”, Blankenship told CBNC in an interview. The former Massey Energy CEO said he did not believe his sentence would hurt his Republican bid to become one of the state’s two senators.
Former US coal company CEO, jailed for deadly mine explosion,
to run for Senate seat
Once dubbed West Virginia’s “king of coal” for his working-class background and tough approach to business, Blankenship helped build Massey into Appalachia’s largest coal producer, with more than 7,000 employees and more than 40 mines.
ormer Massey Energy CEO Don Blankenship, sentenced in 2016 to one year in prison on a conviction stemming from the deadliest US mine explosion
federal mine safety standards at Massey’s Upper Big Branch Mine in southern West Virginia where 29 workers died in a 2010 explosion. In September 2017, the US
An investigation by the US Government’s Mine Safety and Health Administration (MSHA) concluded that the disaster was caused by a lengthy period of safety violations by Massey and that the company’s management prioritised
in four decades, has announced he will launch a campaign to wrest the West
Supreme Court rejected his appeal against the conviction.
coal production and profits ahead of safety protections for miners.
He is aligning himself with President Donald Trump, and is banking on the significant
Blankenship maintains his innocence, saying natural gas and not methane and excess coal
support in West Virginia for the President to
dust caused the explosion.
F
Virginia US senate seat currently held by moderate Democrat Joe Manchin His sentence was for conspiring to violate
News Extra
Aftermath of West Fertilizer plant explosion - Image: CSB
9
Texas town devastated in 2013 fertiliser plant explosion
to receive $10 million to settle damages claims
T
he city of West, Texas, where a fertiliser plant exploded killing 15 people, has settled its claims with manufacturers and distributors of the product that exploded. The town’s
led to questions over the state’s ability to oversee the storage of ammonium nitrate, the risks facing rural fire departments and their communities from stored chemicals, and more generally the effectiveness of federal
grants. Under the terms of the agreement, CF Industries will pay $6.4 million, El Dorado Chemical $3.9 million and Adair Grain $143,000.
lawsuit accused the companies of negligence in selling highly explosive
chemical safety regulations.
Adair Grain, which owned West Fertilizer, only had a $1 million insurance policy. The total
ammonium nitrate to West Fertilizer, owners of the plant. The companies denied responsibility but settled before
The US Chemical Safety Board (CSB) said in a report that the city, state and various federal agencies all could have taken steps that
cost of the damage from the explosion has been estimated at more than $100 million.
the case went for trial on January 16.
would have made the disaster less likely.
The blast the night of April 17, 2013, killed
In 2015, the Texas Legislature passed a
West Mayor Tommy Muska told KCEN-TV he was very satisfied with the settlement, but that it had been a long time coming.
15, injured more than 160, destroyed or damaged more than 150 buildings and caused extensive damage to local infrastructure.
law regulating storage and inspection of ammonium nitrate and granting authority to the Texas Commission on Environmental Quality and local fire marshals to effect and
The city was required as a municipality to disclose the terms of the settlement, while private damages claims have been largely
enforce such regulation.
confidential.
The companies will pay the city $10.44 million to compensate the city for damages not covered by insurance or governmental
In 2016, government investigators determined the fire that triggered the blast was deliberately set.
Ten volunteer firefighters who responded when they received reports of a small fire at the plant, two men helping them and three nearby residents were killed. The incident
Level switches
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10 News Extra
The Lac-Megantic inferno - Image: TSB
Three cleared of negligence in Canada railway disaster
O
n January 19, a Canadian court cleared three railway workers
causing an inferno which destroyed 40 buildings and killed many of the people inside.
oversight for the crash, pointing to the huge increase in shipments of oil by rail, from 500 in
of criminal negligence in one of the country’s worst train disasters, which killed 47 people in the eastern Quebec town of Lac-Megantic in 2013. Former
The blasts devastated a large area of LacMegantic and forced some 2,000 residents to flee their homes.
In the aftermath of the disaster, authorities announced tougher rail safety rules, including
Montreal, Maine & Atlantic (MM&A) train conductor Thomas Harding, operations manager Jean Demaitre and railway
Harding, the conductor, admitted that he only applied seven handbrakes and did not
the phasing out or retrofitting of substandard tanker cars used to transport flammable liquids.
traffic controller Richard Labrie faced 47 counts of criminal negligence - one for each death..
fully test them before leaving the train. The prosecution argued that more handbrakes would have stopped the train from moving
Harding is still facing other charges relating to his role in the disaster.
After a trial lasting almost four months, the jury took nine days to reach the not guilty verdict.
and that he, and Demaitre and Labrie, were each criminally negligent in their own way for failing to ensure the train was safe.
Meanwhile, on January 23, the federal government committed to building a railway
The three accused could have faced life in prison if convicted. The disaster involved a train carrying 7.7 million litres of shale oil in 72 tanker cars from North Dakota to the Maritimes, which had been parked overnight in the village of Nantes, south of Quebec City. The conductor, the only operator on the train, left it unattended as he went to his sleeping quarters. In the night, a fire broke out in the main locomotive and firefighters extinguished the flames and turned off the engine, which cut the air brakes. With insufficient brake power and on an incline, the 10,000 tonne train started moving downhill, gathering speed until 11 km later it reached a curve in the track in Lac-Megantic where it derailed. Several of the tanker cars exploded,
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2009 to 160,000 in 2013.
bypass for Lac-Megantic. The defence argued the conductor had followed MM&A policy in applying the brakes, and any failings were the company’s. Transportation Safety Board of Canada (TSB) investigators blamed poor safety standards at MM&A, saying the company had a “weak safety culture”. After the crash, the US-headquartered company declared bankruptcy. Charges against the company are still pending. In a 191-page report they listed other contributory factors including improper brake tests, a highly flammable cargo in substandard tanker cars and a curve in the tracks at the bottom of a slope. But the report also blamed a lack of regulatory
In a statement, Transport Minister Marc Garneau said the federal government would provide a “substantial amount” to build the bypass, and was in discussions with the Quebec provincial government on the project. Specifics will be announced before the anniversary of the explosion in July, he said. Quebec’s environmental review board, BAPE, put forward five bypass options in a report released last July. The one most favoured by Lac-Megantic residents would reroute the train tracks to the north of the town. Initial estimates show a bypass would add 11 or 12 kilometres of track and would cost about $130 million, although those figures still need to be refined.
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News Extra 13 Aftermath of Imperial Sugar plant explosion - Image: Wikimedia
ground to a halt, and OSHA has moved it over to its list of “long-term actions.” Industry observers say major impediments faced by OSHA include the large potential cost of the rule’s introduction, an antiregulatory political climate and an increasingly drawn-out rulemaking process.
A decade after fatal Georgia sugar plant explosion, US dust explosion safety standards remain elusive
I
In 2013, the Chemical Safety Board took the rare step of rebuking OSHA for not implementing national safety standards on combustible dust, citing the Imperial Sugar explosion and more than 200 other fires and explosions around the country. Even Imperial Sugar CEO John C. Sheptor joined the chorus of critics, saying that although his company and others had taken the dust control message to heart, “Where I am most displeased is that we still do not
n February 2008, a series of dust explosions at the Imperial Sugar
The dust explosion on February 7, 2008, was caused by an accumulation of sugar dust
Company plant at Port Wentworth, Georgia, killed 14 people and injured
on surfaces within the Port Wentworth plant, killing 14 and injuring a further 36, some
have a standard from Washington.”
dozens more. After the incident, Congress passed a bill requiring the Occupational Safety and Health
seriously. OSHA accused Imperial Sugar of 221 safety
The Trump Administration finally killed the proposed rule last July, citing resource constraints and other OSHA priorities.
Administration (OSHA) to set standards on combustible dust, but, ten years on, no such standards have been introduced
violations. The investigations determined that the company had been warned about dangerous sugar dust inside the Georgia
The agency now offers only guidance on the issue, highlighting the dangers and the practices and controls that can reduce
and, every year, dust explosions continue to claim lives across the country.
plant as recently as 2002, and that prior warnings had been issued since as early as the 1960s.
the potential for an explosion.
After the Georgia incident, there was widespread pressure on OSHA to introduce a national standard on combustible dust and in 2009, the agency proposed a new rule. But the proposed introductory process soon
press for new safety standards, may also be on the way out. This past November, the agency was informed that the White
In 2010, Imperial paid more than $6 million in fines relating to safety violations at the Georgia refinery and its plant at Gramercy, Louisiana. It originally faced investigations by OSHA, the US Chemical Safety Board (CSB) and the Bureau of Alcohol Tobacco and Firearms.
The Chemical Safety Board, which has irritated the administration by continuing to
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14 News Extra
The tanker engulfed in flames on January 13 - Image: China Transport Ministry
Iranian oil tanker disaster in East China Sea claims lives of 32 crew, threatens widespread pollution
A
n Iranian tanker carrying ultra-
search the vessel and brought back two
all the Sanchi’s crew were killed in the first
light crude oil to South Korea has sunk in the East China Sea, more than a week after its collision with a
bodies, along with the ship’s black box, the transport ministry said. The workers, wearing protective apparel and oxygen
hour of the incident due to gas releases and explosions.
cargo ship 160 nautical miles east of Shanghai, China’s Ministry of Transport said on January 14. Shanghai Marine Search and Rescue Centre confirmed that the oil tanker Sanchi sank about 150 nautical miles from its initial collision point with the Panamax dry bulk carrier CF Crystal
tanks, spent under 30 minutes on board due to the high temperatures, fumes and thick smoke.
The 164,154-dwt Sanchi was a 2008-built, Panama-flagged vessel owned and operated by the National Iranian Tanker Co., and the 75,725-dwt CF Crystal is a Hong Kong-flagged vessel which was carrying soya beans from the US West Coast to South Korea.
Three crewmen have been found dead, and the other 29 are missing, presumed dead. China’s Ministry of Transport said in a statement that after a series of massive explosions, including one where flames rose almost a kilometre into the sky, the Sanchi sank around 12pm on January 14. While the tanker was still afloat on the morning of January 13, four Chinese salvage workers went on board to
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The two dead crewmen were found in a lifeboat, bringing the total number of crew members recovered to three. The body of another was found in the sea soon after rescue vessels first arrived on the scene. The black box data recorder is designed to withstand extreme shock, impact, pressure and heat, and could reveal more information about the incident. The Iranian tanker, carrying around 136,000 tonnes of South Pars condensate, first caught fire on January 6 after the collision. The Iranian rescue team said information from the CF Crystal’s crew suggested that
CF Crystal’s bow was damaged and the entire crew rescued. On January 8 the bulker was escorted by a rescue vessel into Zhoushan, south of Shanghai, where it is currently moored. Chinese officials said that “there was no precedent for this accident,” noting not only that conditions were worse than anything they had trained for, but also that it was the first time a tanker carrying this particular type of cargo had exploded.
News Extra 15
Search and rescue efforts were hampered by bad weather and high seas, extreme
heavier and would persist far longer in the marine environment than the condensate.
conditions created by explosions and fire, the toxic chemicals involved and the remote location of the accident, which necessitated a 20-hour roundtrip to replenish equipment to fight the fires.
China’s State Oceanic Administration said a week later that three separate oil slicks from the sunken vessel had a total surface area of 332 sq. km.
The collision occurred east of Shanghai,
An article in Nature on January 24 pointed
but high winds pushed the ship away from China and into Japan’s exclusive economic zone (EEZ) where it sank eight days later.
to the unique nature of the oil spill.
Initially, the massive fire and fumes would have killed plankton, birds, marine mammals and fish that were caught in the vicinity when the tanker ignited. After the fire, the impact of the incident becomes harder to discern because the exact chemical composition of the condensate is not known and the amount burned off or evaporated can also only be guessed at.
The Japan Times said the incident was the
Large scale spills in the past — such as the Deepwater Horizon disaster in the Gulf of Mexico in 2010 or the Exxon Valdez tanker incident in Alaska in 1989
largest release of condensate ever. If most of the cargo has not burned up in the fire, the accident would have produced an oil spill larger than that created by the Exxon Valdez disaster in 1989.
— involved heavier crude oil. The Sanchi carried more than 136,000 tonnes of natural gas condensate, a lighter, more volatile petroleum product which has never before been released at sea in large quantities.
already under intense pressure.
By January 22, the leak from the sunken vessel has split into four separate slicks
Unlike heavy crude, most of whose constituent elements accumulate in slicks on
mammals, including three species of whale. Pollution from existing maritime traffic, runoff
that covered about 101 square kilometres in total, and affected an area up to 200 nautical miles long. Experts said the
the water’s surface or sink to the ocean floor, condensates burn off, evaporate or dissolve into the water, where some of its chemical
from industries on shore and overfishing have already placed 60 of 194 marine species there at risk of extinction, according
ship was leaking its own fuel, which was
components can linger for weeks or months.
to some estimates.
What particularly alarms marine biologists is that the event took place in an area important for wildlife and fisheries that is
The Japan Times said the affected parts of the East China Sea were an important spawning ground for fish and crab, as well as a migratory pathway for marine
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Standards 17
The European Notified Bodies Group Meeting
Every two months, Ron Sinclair MBE gives his perspective on the latest developments in the world of standards
O
nce a year, most of the European Notified Bodies for
Among many other topics, this year, we
the European-only standard EN 50381.
looked at how to handle the transition between the different editions of ISO 9001, which must happen later this year. The specific QA standard for Ex Equipment is unlikely to be available until possibly early 2019, so there is a gap to be filled. The agreed policy is that Notified Bodies
Normally the older standard would be retired in favour of the later document (there are 13 years between their dates of issue), but, in this case, there is a requirement to keep the older document as it is referenced in some national legislation relating to activities in the North Sea. We
will use the ISO/IEC version of 80079-34, which should be published by the relevant date, without waiting for the EN version. Further, as a fall-back, if there is a delay
cannot have two standards with different requirements both claiming to be state of the art, so this is a problem for further resolution.
in publication of the ISO/IEC version, we will use the FDIS draft document, which will be available early this year. The FDIS is
The two most recent standards available from IEC, 60079-0 and 60079-15, were
the ATEX Directive (ExNB) meet in Brussels. This group is sponsored by the European Commission and its function is to sort out
available to purchase from IEC and can act as a “pre-purchase” for the final version of the standard.
published in 2014. There has been a delay in putting the EN versions forward, as the Cenelec rules have changed about the presentation of Annex ZZ. This may not
details of procedure and technical interpretations for the operation of the ATEX Directive, in much the same
Related to QA aspects, there is a reminder that all manufacturers have a responsibility for checking that their ATEX
seem a big deal to most of the people who use the standards, but it is meaning a lot of extra work for the CLC-TC31
way as IECEx ExTAG discusses and issues Decision Sheets related to the IECEx Scheme. Because many of the
Type Examination Certificates still reflect the “State of the Art” as outlined in the current harmonised standard, and the QA
secretariat. The strong advice is to use the IEC text until the EN versions are available. The table of differences between
certification bodies are members of both systems, there is an attempt to maintain a commonality of approach,
assessor will be checking that there is a specific procedure in place to ensure this is done.
these new standards and the previous editions is available as a free download from the IEC web site (select “preview”),
where possible. As IECEx is a self-governing system, it can have its own system of sanctions where bodies transgress (fortunately a very infrequent occurrence). In Europe, ExNB does not have quite the same teeth, because the ATEX Directive is effectively the law in each country, but its views are taken into account by the Commission when it advises national governments on proceedings that should be taken. It is the national governments that are responsible for notifying their respective conformity assessment bodies to the Commission, hence the term “Notified Body”. The Commissions ATEX web page gives access to the “NANDO” list of Notified Bodies.
If a new IEC or ISO edition is published ahead of the EN version, it is good general advice to work to that edition, but the various Notified Bodies are in a position to give detailed advice. Normally the EN version follows quickly after the international version, with official “harmonisation” taking place a few months later. A harmonised standard is recognised as covering relevant Essential Health and Safety requirements of the directive, so conformity with the standard is the normal method of demonstrating conformity with the directive. However, we have a current problem for ventilated rooms, as the new standard IEC 60079-13 overlaps the scope of
so manufacturers can start preparing for the changes, even if they wait for the EN version before buying the document.
About the author SGS Baseefa Technical Manager Ron Sinclair MBE is chairman of BSI Committee EXL/31, responsible for the UK input to both European and International standards for Electrical Equipment for use in potentially explosive atmospheres. He is also chairman of Cenelec TC31, represents electrical standardisation interests on the European Commission’s ATEX Standing Committee and chairs the IECEx Service Facility Certification Committee.
www.hazardexonthenet.net
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Functional Safety 19
Demystifying the release timeline of the 2nd edition of IEC61511 I
EC61511 is the Functional Safety standard for Safety Instrumented
- Safety instrumented systems for the process industry sector - Part 0: Functional
Systems for the Process Industry. The first edition was released in 2003 and withdrawn in 2016 with the release of Edition 2.0. Unfortunately, the long overdue release in 2016 did not go as smoothly as the IEC (International Electrotechnical Commission) might have hoped for. Below is a summary of the different parts being released, including the latest addition of the technical report zero (0) released in January 2018.
• IEC61511-1:2016, (Part 1: Framework, definitions, system, hardware and
safety for the process industry and IEC 61511). The technical report provides an overview of the other three parts of the IEC61511 The technical report was released on 23-012018.
Part 3 remains the informative part of the standard and was released on 21-072017. • IEC61511-1:2016/COR1:2016,
application programming requirements). Part 1 outlines the requirements for compliance from clause 5 through 19. Project planning, management, documentation, and
(Corrigendum 1 – Functional Safety – Safety instrumented systems for the process industry sector – Part 1: Framework, definitions, system,
requirements for competence, as well as the technical requirements for achieving safety throughout the safety lifecycle, are all
hardware and application programming requirements). The official Part 1 released in February 2017 contained some
defined. Part 1 remains the normative part of the standard and was released on 24-02-
errors, e.g. the minimum Hardware Fault Tolerance (HFT) table 6 in relation to mode of operations for SIL 2 is corrected for
2016. • IEC61511-2:2016, (Part 2: Guidelines for the application of IEC 61511-1: 2016). Part
low demand mode versus high demand or continuous mode, SIL 4 performance range limits, etc.
2 provides guidance on how to read and understand the clauses of Part 1. Part 2 remains the informative part of the standard and was released on 28-072017. • IEC61511-3:2016, (Part 3: Guidance for the determination of the required safety integrity levels) Part 3 gives general guidance for risk and safety integrity levels.
The corrigendum was released on 15-092016. • IEC61511-1:2016/AMD1:2017, (Amendment 1 - Functional Safety – Safety instrumented systems for the process industry sector – Part 1: Framework, definitions, system, hardware and application programming requirements). Besides the corrigendum, Amendment
*Annex A covers the ALARP principle (As Low As Reasonably Practicable) *Annex B through I covers both quantitative and qualitative approaches to SIL selection using event tree analysis,
1 replaces some terms, definitions and abbreviations that affect SIS requirements, design and engineering, and application programming. Amendment 1 was released on 16-08-2017.
safety layer matrix method, risk graph, LOPA (Layer Of Protection Analysis) and risk matrix *Annex J is new in Ed. 2.0, handling multiple safety systems describing systemic dependencies
• IEC61511-1:2016+AMD1:2017 CSV. A consolidated version consisting of the second edition (2016) and amendment 1 (2017) in one document was also released on 16-08-2017. • IEC TR 61511-0:2018, (Functional safety
In summary, IEC61511:2016 continues, with two fundamental concepts to its application - the safety lifecycle and safety integrity levels (SILs) - to express how well the system is expected to perform. The emphasis in the 2016 edition is clearly on functional safety management in order to minimise human failures with new measurements, monitoring and assessments definitions. Furthermore, security risk assessments shall be carried out, including cyber security as part of the hazard and risk analysis phase of the IEC61511 life cycle.
About the author
Tino Vande Capelle is a Senior FS Expert and Trainer for Safety Instrumented Systems (SIS) and his company is an accepted course provider for the TÜV Rheinland Functional Safety Program, on which he has trained over 2,000 people worldwide. He was educated in Belgium where he gained qualifications in Automation & Critical Control Systems and his 30-year career has involved roles in the LNG, Petrochemical, Refining and Petroleum Industries.
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Functional safety 21
Why it pays to focus on functional safety management
Q
uite apart from any moral
considerations, skimping on lifecycle safety requirements can be an expensive mistake, say John Walkington of ABB. The right functional safety product and management systems focus can deliver long-term security
Spending money and resources on equipment and Functional Safety Management
All this additional safety assurance will
When it comes to specialised instrumentation, control equipment and operations and maintenance for functional safety and security
invariably have an impact on the cost of the SIS overall. However, the adage to remember here is that ‘good safety is good business’ and a little more spend on FS assurance during specification, selection, design and change
applications, it’s true to say that as in most things in life, ‘you get what you pay for’.
management pays dividends during the many years of operation.
With companies facing considerable pressure to cut costs in every possible area, many find themselves subject to tightening budgets, even in areas as critical as functional safety. Moreover, as the safety and cyber security standards currently accepted as good practice are not actually legal requirements
Making sure an instrumented safety system (SIS) doesn’t fail when you need it demands a combination of good quality equipment that has been extensively tested and analysed which can then be integrated using a competency and management system
The second point is that safety is a niche application linked to a facility’s ‘licence to operate’ requirements. For example, an offshore platform might easily have over a thousand control loops distributed around the facility but fewer than 150
in many countries, there is an obvious temptation to be sparing on safety and security system implementation, as well as the follow-on operational inspection, testing and repair regimes. But operational decisions
with a demonstrable systematic capability (SC). It may also mean that to achieve a defined level of safety integrity and safety functionality, the devices used in the SIS need to possess a level of redundancy and a
dedicated safety functions. This more specialised market for safety equipment and safety lifecycle management simply doesn’t benefit from the same economies of scale as the mass-market
that skimp on functional safety management requirements (FSM) are very unlikely to prove a cost-effective strategy in the long run.
self-diagnostic capability far outstripping that required for non-critical systems.
in standard controls.
and a lower life-time cost.
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22 Functional safety Lifetime savings Managing functional safety and security is an
be used as the basis for designing and engineering the safety system solution.
increasingly complex challenge and involves specifying safety and security requirements and ensuring that they are successfully transposed into design and engineering solutions by your supply chain partners.
This consists of the input sensors, the logic solver and the final elements, including the functional safety management system used to successfully integrate the various SIFs into a compliant SIS.
Assurance and savings
The introduction of Edition 2 of the IEC
Rather than looking for the cheapest
Additional verification, independent assessment and extra paperwork may not
61508:2010 functional safety standard gives a higher priority to defining a suitable, dedicated safety requirements specification (SRS) for each project. It introduces a formal stage between the conclusion of the hazard analysis stage of a project and specifying
option, it’s important to look for an SIS with instruments, safety and security management systems and supporting services offering the optimum combination of functionality, reliability, security and cost-effectiveness over their design and
sound like a cheap option, but there are several ways in which opting for higher integrity and demonstrable systematic capability can both save money during initial project execution and in the longer term, and most importantly, for providing the necessary
particular SIS requirements leading into the design and engineering phase. The same focus on requirements specification can also be found within the sector standard IEC 61511:2016 Edition 2 and the associated links to SIS security risk assessment in
operational lifetimes.
systems assurance for protecting the asset.
As a general rule, it is almost always better to design risk out of a process before installing specialised systems to control it. This will often reduce the required safety
The first is that the safety requirements are implemented and the design efficiently delivered without the need to ‘design by assumption’. If an FSM is not in place at the
conjunction with compliance to Standard IEC 62443.
integrity level (SIL) and therefore the cost of the safety systems needed to deliver it.
outset of the project, this lack of ‘process’ invariably brings with it significant additional
Ultimately, the SRS is intended to bring together all the information necessary to
The other key factor to be considered is the systematic capability of the SIS. This
issues such as extended clarifications from within the supply chain, extensive TQ requests seen as normal operation,
make sure that any SIS required provides the right level of performance and risk reduction without being overly complex or expensive.
relates to factors such as the methodology, techniques, measures and procedures used in both the manufacturing of the
If safety systems are over-specified, they are likely to cost more upfront, and because of the extra complexity, require more operational management and maintenance
safety devices used and the integration of those devices to form the entire safety system during the design, engineering, operations and maintenance lifecycle
once commissioned.
phases. Many integrators purport to offer a safety standards compliant FSM process, however it is important to question whether they are truly robust in technical depth, have independent certification from a recognised source such as TÜV and whether their
Over-specification pushes up the Opex running costs over the lifetime of the plant. By contrast, the consequences of underspecification can be much more serious as the safety system may well be inadequate and unable to provide the correct level of risk reduction, i.e. one with the potential to result in a failure on demand and/or cyber security breach.
in-house competencies are evident in their in-country location regarding systems assurance.
Confusion can often arise when it comes to designing a safety system as it’s not as simple as just applying a blanket SIL to
The other thing to look out for is the quality of documentation available from the equipment supplier and systems integrator, for example: • Are their instruments certified by
cover an entire process. Instead, operators must first determine the requirements for individual safety instrumented functions (SIF) within a process that are necessary to protect against a specific hazardous event.
independent testing bodies? • Have they got a sufficiently strong functional safety management and competency assurance system in place that can demonstrate the
Once safety functionality and safety integrity are identified, they can then
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necessary systematic capability claims for the safety devices / integrated solution?
• Are the device manuals and certificates / project documentation suitable for the specific safety related application and who has independently verified the solution provided is fit for purpose?
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24 Functional safety unexpected design changes, delays in planning / milestones not completed,
interval can be extended significantly if equipment can demonstrate a higher HFT
SIS designed, engineered and installed in accordance with the safety and
document / revision control and approval issues, and so on, all of which impact on project management and ultimately cost.
(Hardware Fault Tolerance) and a lower frequency of dangerous undetected failures. This will deliver lower operating costs for any user having chosen the correct safety devices and implemented the necessary practicalities for maintenance & testing requirements during the design stage.
security standards has the supporting documentation in place to rapidly ‘impact assess’ for management of change implications. Such a robust process will allow for efficient FS assessment, modifications and upgrades to take place without the need to undertake
The difference is likely to be especially significant in industries such as Offshore, Refining and Petrochemicals, where gaining access to the operational safety systems can be difficult and expensive.
extensive system gap assessments and documentation site surveys to try and re-establish the SIS baseline. Even more so, it provides the necessary traceability and confidence that changes to the SIS are being managed correctly to ensure it
The subsequent area where significant savings can be made is in the area of operational change management and maintaining systematic capability. An
will continue to operate on demand.
Following a defined safety lifecycle approach means the project execution phase is optimised in terms of the impact to cost and schedule. Issues that could affect functional safety and systematic capability are identified and addressed early during FS Audits and Assessments so that the installed and commissioned SIS meets the necessary safety requirements. Next the safety systems do not need testing as often to check that they are still working properly. The required proof test
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The fourth area where savings can be made is related to demonstrable compliance
Functional safety 25
with good practice safety standards for insurance underwriting purposes. Systems that are not-easily demonstrated to comply
of financial penalties, but also the impact that an accident or incident can have on a company’s share price and reputation.
with industry good practice standards may also require extensive systems ‘reengineering’ of key documentation before insurers will agree to provide cover. In some cases, it may well be that the ‘licence to operate’ is not agreed or is suspended with
Add to this the imperative to protect personnel and be a good neighbour to the surrounding community and the case for excellence in safety systems including the necessary management focus and spend on functional safety is compelling –
the regulatory authorities and the facility is not allowed to start-up / operate until such safety assurances can be demonstrated, thereby introducing extensive start up delays and loss of production / plant availability costs to the business.
whatever the state of the economy.
However, ultimately it is the prevention of accidents that still offers the biggest potential financial savings, not just in terms
About the author
So, in your organisation, when it comes to specifying safety systems and applying industry good practice requirements, don’t be tempted to ignore the cost of functional safety. The benefits for actively seeking implementation far outweigh the significant business risk to simply ignore it.
John Walkington is Managing Consultant, Functional Safety, within the ABB UK Oil, Gas & Chemicals Technology Group and manages the activities of the ABB safety lead competency centre (SLCC). He has some 36 years’ experience within the Process Industries, having worked previously for companies such as ICI Agrochemicals, Refining and Petrochemicals and BASF Polymers & Plastics where he held a series of posts in process plant operation & maintenance, technical engineering and project management. He is a Fellow of the Institution of Mechanical Engineers, a Member of the Institution of Measurement and Control and is a TUV Rheinland certificated FS Expert.
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Controls and instrumentation 27
Greater emphasis on reducing dangerous undetected failures helps to improve plant safety
T
here is a growing opinion that dangerous undetected (DU) failure rates are more relevant than safe
applications such as overfill prevention. Highprofile incidents such as the Buncefield fire in 2005 have shown that failing to prevent
failure fraction as a basis for selecting a safety-critical level instrument. Tim Hill, Technical Director at Emerson Automation Solutions, explains how the advanced diagnostics capability of the latest vibrating fork level switches enables them to help improve plant safety by reducing the number of DU failures.
overspills in vessels containing hazardous, flammable or even explosive materials can have devastating consequences for assets, the environment and personnel. It is therefore essential for operators to implement robust Overfill Prevention Systems (OPS) using the most reliable level sensors to minimise risk, meet environmental regulations and improve safety.
To ensure that industrial processes operate safely and efficiently, it is essential that they are equipped with instruments providing accurate and reliable measurements. Within
Safety instrumented systems and safety integrity level
refineries and petrochemical plants, for example, level monitoring and measurement devices play a critical role in safety
Worrying about tank overfills is logical because there are hundreds of tank spills An illustration of how vibrating fork technology can be used on a tank, with an overfill switch
of hazardous materials every day (United States Environmental Protection Agency, 2014). However, a properly designed and
www.hazardexonthenet.net
28 Controls and instrumentation
implemented OPS helps to reduce their frequency and severity. Safety instrumented systems (SIS) such as OPS are required
would be wrong, for example, to say that a device is ‘SIL 3-rated’. It should instead be stated that the device is ‘suitable for use in
categorised in one of four ways: safe undetected (SU), safe detected (SD), dangerous detected (DD), and dangerous
to meet safety performance targets, and safety integrity level (SIL) is a quantifiable way to establish this. The international SIS standard IEC 61511 defines SIL as the
a SIL 3-rated safety instrumented function’. In other words, the SIL rating applies to the entire loop and not its individual components.
undetected (DU).
degree of necessary risk reduction for a certain safety function to be implemented by a SIS, to achieve or maintain a safe state for a process, with respect to a specific hazardous event. A function is furthermore defined as a set of instruments
There are two ways to determine the level of SIL system in which a device is suitable for use. The first is FMEDA (Failures Modes, Effects and Diagnostic Analysis) – a systematic analysis technique to determine the device’s failure rates, failure modes and
affect the safety function of the system. Dangerous failures, meanwhile, pose a significant safety risk and can potentially have catastrophic consequences. If a safety-critical instrument fails but the failure is detected and reported via the device’s
intended to detect an imminent accident, decide to take an action and carry out actions as appropriate.
diagnostic capabilities. The second method is known as Proven in Use, which uses historical data field to determine whether there are systematic design faults in the device.
Safe failure fraction and dangerous undetected failures
diagnostic coverage, this enables the system to be brought to a safe state and is classified as DD. Even if a device has a large fraction of dangerous failures, so long as enough of these can be detected and safe action taken, it is still considered a safe device. However, if such a failure occurs without being detected and reported, this can create a critical state and
is determined to be SIL 1, SIL 2, SIL 3 or SIL 4 - the higher the SIL, the higher the requirements to achieve a tolerable risk and SIS must be designed using equipment that meets the necessary SIL.
The analyses and data used to determine a SIL rating also helps to establish a product’s safe failure fraction (SFF), which is a percentage of its safe failures compared to its total failures. To calculate
is therefore categorised as DU. The formula for calculating a device’s SFF is the sum of its SD, SU and DD, divided by the sum of its SD, SU, DD and DU. This can be displayed as follows (where λ = total failure
It is important to note that field devices alone are not attributed a SIL rating. It
a device’s SFF, it is first necessary to understand that when random hardware failures occur within SIS, they can be
rate per hour): λ SU + λ SD + λ DD λ SU + λ SD + λ DU + λ DD
There are many procedures available for the actual determination of a function’s SIL, but their common goal is to establish the probability of harm occurring and the severity of that harm. Each safety function
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30 Controls and instrumentation Recent enhancements in SIS product design have enabled manufacturers
Vibrating fork level switches
to improve their devices’ SFF figures. However, because DU is merely one component of SFF, it is possible to achieve an improved SFF figure by reducing the SD, SU and DD elements of the equation, rather than DU. Consequently, there could be a scenario where two different devices
a logic solver and a final control element in the form of actuated valve technology. Within such systems, vibrating fork level switches are often the technology of choice for providing reliable point level detection. The operating principle of vibrating fork
technologies - such as float switches, ultrasonic gap switches and capacitance switches - for safety-critical applications such as overfill prevention. A lack of moving parts that can wear or stick makes them less prone to failure and means that they require virtually no maintenance.
have the same SFF figure and SIL rating, but one of them has a much lower DU figure than the other, and is therefore less likely to fail in a dangerous way. Until now, many users have relied on SFF figure and SIL rating as their basis for comparing the
level switches is that of a tuning fork. The switch, comprising a fork with two tines, is oscillated by an internal piezo-electric crystal. The switch is mounted on the side or top of a vessel so that the tines protrude into it. When in air, the tines vibrate at their
Their sensing is virtually unaffected by flow, turbulence, bubbles, foam, vibration, solids content, and coating. Their installation is straightforward and there is no need for them to be calibrated, which therefore makes them less prone to human error
reliability of safety-critical level instruments offered by different suppliers. However, there is a growing opinion within safety circles that users ought to look deeper than SFF and SIL, and that DU should be regarded as the more relevant figure,
natural frequency, which is continuously monitored by a detector circuit. When liquid covers the tines, the frequency of oscillation drops and this is detected by the switch electronics, which in turn changes the output state of the switch to operate an
during commissioning.
because the most important factor is the likelihood of a device failing in a dangerous
alarm, pump or valve. This makes vibrating fork level switches a reliable technology for
capability enables these devices’ electronic and mechanical health to be monitored
way and the system not knowing of the failure.
use in low and high-level alarm applications and overfill prevention.
continuously, with the result that the number of DUs possible is significantly reduced.
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OPS typically consist of a level sensing device,
There are several reasons why vibrating fork level switches are preferred to other
Latest technology The reduction of DUs was a specific aim within the design of the latest vibrating fork switch technology. Advanced diagnostics
Controls and instrumentation 31
It is important to note that field devices alone are not attributed a SIL rating
monitoring the current and voltage drawn over the device’s lifetime. Any
About the author
unusual behaviour which may indicate an emerging issue, such as internal corrosion, can be detected.
Conclusion Plant managers fear DU failures in safety-critical level instruments, as they
These devices have diagnostics that can detect external damage to the forks, internal damage to the sensor, corrosion and over-temperature. Frequency analysis functionality enables emerging conditions such as media build-up
can lead to a critical state in a SIS, with potentially catastrophic consequences. The calculation of a device’s SFF is used as a means of establishing its suitability for use in an SIS, and end users have traditionally relied on SFF
which unchecked could lead to fork blockage, or excessive corrosion to be detected over time, enabling preventative maintenance to be carried out before functionality and / or reliability is affected. These devices may also have a new
as a basis for selecting instruments. However, opinion is now shifting to the DU figure having more relevance than the SFF in determining product safety. Consequently, the latest vibrating fork level switches have been designed with
diagnostic tool known as power advisory functionality, which enables operators
advanced diagnostics capability, to reduce the number of DU failures and
to identify any potential problems with internal components and circuitry by
increase plant safety.
Tim Hill (FIMechE) is Engineering Manager - Level Products at Rosemount Measurement, part of Emerson Process Management. He was formerly a project manager at the UK Atomic Energy Authority and before that worked in senior engineering positions for several UK-based companies.
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ZONE 0 HEADLIGHT
It has a TFT display indicating the resistance measurement and is capable of measuring both wrist straps and footwear.
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IDB Systems Limited is registered in England and Wales under 7324859 and the registered office is 10 Mostyn street, Llandudno, LL30, Conwy, North Wales © IDB Systems 2011-2017
SPECIFICATIONS & FEATURES
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For those that work in hazardous environments, finding tools that are fit for the job can be an unenviable task, and torches are no different. The Unilite ATEX range has been built to
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Control box dimensions: L200 x W175 x H120mm
It has a TFT display indicating the resistance measurement and is capable of measuring both wrist straps and footwear.
Maintenance:
IDB Systems Limited is registered in England and Wales under 7324859 and the registered office is 10 Mostyn street, Llandudno, LL30, Conwy, North Wales © IDB Systems 2011-2017
T • 00[44] 1527 584 344 E • sales@unilite.co.uk
www.unilite.co.uk
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within a conductive regime.
both wrist straps and footwear. meet individual customer MOD preferences.
JSP482 for operation within a conductive regime.
It has a TFT display indicating the resistance measurement and is capable of measuring both wrist straps and footwear.
IDB Systems Limited is registered in England and Wales
under 7324859 and the office is IDB Systems Limited isregistered registered in England and Wales 10 Mostyn street, Llandudno, LL30, Conwy, North Wales © IDB Systems 2011-2017 under 7324859 and the registered office is is registered in England and Wales IDB Systems 10 Mostyn street, Llandudno, LL30, Limited Conwy, North Wales © IDB Systems 2011-2017
under 7324859 and the registered office is 10 Mostyn street, Llandudno, LL30, Conwy, North Wales © IDB Systems 2011-2017
Controls and instrumentation 33
Rugged HMI - What does this really mean? T
here are a variety of human machine interfaces (HMIs) or operator panels on the market that claim to be “rugged”, but many different ratings, standards and laws may be cited to justify the use of this term. This article by Jeff Hayes of Beijer Electronics aims to define ruggedness in HMIs and clarify some of the associated issues.
Some industries require most electronics and computing equipment to meet certain rugged characteristics
Rugged implies something tough and durable;
• Operate properly for extended periods of time
strongly built and designed to operate in harsh conditions. Truly rugged HMIs are tested and certified to operate in wet, dusty, hot, cold, high vibration, and hazardous environments.
in the environments they are deployed into • Not be the source of any safety related incident
The purpose of rugged ratings, standards and regulations is to ensure that the equipment will:
In industry, what might be considered rugged to some, may not be to others. The national and international ratings vary and include different aspects, depending on specific operating conditions and country.
Need for rugged Equipment that may work well in a clean, climate-controlled environment may fail in a dirty, outdoor environment. Engineers must specify the components, equipment and computer based on the environments they need to operate in. HMIs are included in this specification process. An HMI is a touch panel display that is integrated into a machine or computer system that communicates the operator’s desire to manage and control the machine. All HMIs are designed and manufactured based on the environments they will be deployed into. Consider the following classes of HMIs in order of ruggedness:
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34 Controls and instrumentation
Standard HMls • Used for light duty, indoor factory or plant operations. • Designed for indoor environments; e.g., dry and moderate (O·50° C) operating temperatures. • The most widely deployed HMls throughout the world. • Require basic certifications for emissions. susceptibility, safety, conformity such as CE marking.
Rugged HMI
Extremely rugged HMI
• Engineered to withstand challenging and abusive environments.
• Designed for environments where flammable gases or vapors are expected.
• Does nol require supplemental heating or cooling.
• Often require additional heating and cooling equipment for proper operation.
• Most often deployed in highvibration, extreme temperatures, direct sun and/or wash-down environments. • Often require:
• IP 66. NEMA·4. UL 5OE Type 4 outdoor ratings (or hlgher) • NEC/CC Class I Divisionon 2 • ATEX Zone 2 • IECEx Zone 2 certifications • ABS. DNV. GL and/or LR certificatlon for marine/maritime deployments.
• Expensive and limited to certain industries and environments requiring extreme protection. • Often require: • UL Class I Division 1 • ATEX Zone O/Zone 1 • IECEx Zone 0/Zone 1 certifications.
Vibration For HMIs, the mechanical vibration of the machinery and equipment it is installed on can cause fatigue, resonant frequencies, and problems with seals. Standard HMIs undergo none or minimal vibration testing. Rugged HMI panels should be tested with various methods which may include swept-sine and random testing (acceleration or power spectral density testing).
Shock Shock occurs when an HMI is mechanically dropped, hit or struck. Depending on the scope of the shock, an HMI’s display can
As with all electronics, moisture is a critical
be broken; the touch panel partially or completely rendered inoperable; electronics broken or loosened; or the integrity of the sealing compromised. Rugged HMIs are designed to withstand reasonable shock given the targeted operating environments.
be designed for the extremes, but also be tested and certified to the appropriate level.
factor for HMIs. A small amount of moisture, rain or snow can ruin electrical components,
Sunlight
The following areas are key in the design and testing of rugged HMIs.
shortening the life of the device or making it fail entirely. Rugged HMIs are therefore tested and certified to withstand the ingress of water.
In outdoor applications, the viewability of a standard HMI displays will be difficult if not impossible in direct sunlight. Rugged HMI
Temperature
Dust and particles
The most common issue and qualifier are
Dust causes harm and reliability issues
backlights are sufficiently bright to enable the HMI to be read in these conditions. A standard HMI has a screen brightness of 300-
extended operating and storage temperature ranges. Over half the applications that call for a rugged HMI demand a solution capable of performing while exposed to extreme
for electronics and impacts performance, reliability and longevity of the HMI. Certain food processing plants (candy, spice, sugar), coal plants and paper plants can produce
500 cd/m²; a rugged HMI display that will be deployed in direct sun environments requires a backlight of 1,000 cd/m² or greater. Direct sunlight on an HMI introduces additional heat
heat and/or extreme cold temperatures. In the oil fields of the Middle East and the mines of South America, the temperatures regularly reach 50°C and higher. In Canada
dust in concentrations that under certain conditions can become explosive. The HMI must not be the source of a spark that could ignite the powdered material.
and damaging effects of ultraviolet (UV) rays. This is an important reason rugged HMIs are designed to operate in the 60°C to 70°C range and include a special UV coating.
The selection process is streamlined by understanding where a product will be used. The harsher the deployment environment, the more rugged the components and technology must be. The HMI must not only
and Russia, operations may be exposed to extended periods at -30°C.
Moisture, rain and snow
Power source issues Outdoor environments often have volatile power sources which can be dangerous to electronic devices. Load dumps, reverse polarity and spikes can cause electrical havoc for standard HMIs. Rugged HMIs are designed to operate with unreliable or inconsistent power conditions.
Electromagnetic compatibility HMIs must be immune from a certain level of electromagnetic interference (EMI) to operate properly. They also must not emit electromagnetic disturbance that will impact the operation of nearby electrical equipment. Rugged HMIs will withstand a higher electrostatic discharge (ESD) and tolerate higher radiation emissions.
www.hazardexonthenet.net
PROTECTING
your critical shutdown valves Valvescan Type VSD ‘smart’ valve controller allows plant operators to capture valve stroke performance data. It monitors and logs every valve operation as well as allowing partial stroke testing (PST), full stroke testing (FST) and solenoid testing to be performed, enabling a detailed performance and condition history to be built. Standard Features include: ● Simple and cost effective installation using conventional Ex d solenoid valves – ‘zero’ air consumption. ● Simple to calibrate, operate, and test. ● Does not degrade the SIL rating of the safety function (SIF) to which it is attached. ● Does not violate the Process Safety Time Constraints of the ESD valve. ● Easily retrofitted to existing ESD valves. ● Suitable for pneumatic or hydraulic systems. ● ATEX / IECEx II 2 G / Ex d (ia) IIC T4/T6.
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pressure sensors KELLER (UK) Ltd. Little Keep Gate, Barrack Road, Dorchester, DT1 1AH UK and Ireland: T. 0845 643 2855 F. 0845 643 2866 E-Mail: sales@keller-pressure.co.uk Web: www.keller-pressure.co.uk www.keller-druck.com
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Controls and instrumentation 37 The world of rugged Some industries require most electronics
product range meets the rugged testing and certification requirements. Rugged HMIs will
The process of designing, engineering, testing and certifying rugged HMIs is a core
and computing equipment to meet certain rugged characteristics. Rugged HMIs are often deployed outdoors, in direct sun, in hazardous and explosive situations, as well as dusty, wet, and/or corrosive settings. Also in extremely harsh applications, for example on board icebreakers, a rugged HMI can be
take the abuse that standard HMIs cannot, while still functioning reliably and efficiently. While there are some indoor environments that demand rugged HMIs (dusty, high vibration, wet), it is the outdoor environment that dictates the need for unique features not found in off-the-shelf standard HMIs.
competency. Those companies that build rugged HMIs understand the industries and environments the HMIs will be deployed into. They want their products to be ruggedly reliable and operational for years. “Test early, test often” is not just an adage, it is fundamental to the culture of those
used on deck and reliably solve visualisation tasks in snow and arctic cold. The most common industries that require rugged HMIs include: • Oil and gas (drilling, refining, processing, distribution)
Certifications are extremely important for most rugged-type applications. In the industrial manufacturing segment, certifications specify and dictate electrical, mechanical, emissions, environmental, safety
• • • • • •
Water and wastewater Paper and pulp Chemical Maritime and off-shore Mining Agriculture (storage, processing, refining)
manufacturers. About the author
requirements and conditions for acceptable installation and usage. Typically, certifications are specific to industries, individual countries and/or established global standards where the products will be installed and operated.
• Textiles • Transportation
Conclusion
• Power generation and distribution (coal, biomass, hydro, wind, solar)
A rugged HMI must be rugged to the core – designed, tested and certified to operate in the most difficult and hazardous
Manufacturers that produce rugged HMIs are aware of the special requirements demanded by these industries. They will ensure that their
environments. These HMIs must be tested and certified against some of the world’s most rigid standards.
Rugged is more than tough or durable.
Jeff Hayes is a product manager at Beijer Electronics in Salt Lake City, Utah. He was previously Latin American Regional Sales Manager and Business Development Manager at the company, and was an adjunct professor teaching business skills at the University of Phoenix from 2006 to 2011.
www.hazardexonthenet.net
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Legislation and regulation 39
Machinery safety and the Radio Equipment Directive T
he introduction of the European Union’s new Radio Equipment Directive, which is applicable to all electrical and electronic devices that
modules (M2M), and products and machines (P2M). As increasingly complex and convergent technologies are introduced and we head towards Industry 4.0-based
telecommunications technology. However, now millions of devices are inter-connected, including those used in manufacturing plants. Consequently, the wireless world is having
intentionally emit and receive radio waves at frequencies below 3000 GHz, will require some significant adaptations as to how radio-enabled machinery is manufactured and supplied.
production methods, so the machinery safety compliance process can appear ever more intricate and unpredictable.
a significant impact on the manufacturing supply chain, as radio equipment covers an ever growing variety of products, driven by the growth of mobile devices and wearable applications, which increase our levels of connectivity.
In this article, Paul Taylor of TÜV SÜD looks at the ramifications of the Directive’s introduction, and the specific obligations necessary throughout the supply chain.
Industry 4.0 is a system of collaborative computational, mechanical and electrical elements which communicate in real time, enabling smart factories to digitise processes that improve both efficiency and quality,
While the connected world of Industry 4.0’s smart factories adds a new dimension of
Manufacturing plant and processes are becoming ever more connected, and
while reducing manufacturing costs. Often referred to as the ‘fourth industrial revolution’, Industry 4.0 includes cyber-physical systems, the Internet of Things (IoT) and cloud computing.
complexity in terms of machinery safety challenges, even before we reach this golden goal, machines being used today are increasingly incorporating components which rely on the radio spectrum to operate.
the digital transformation of production equipment and production lines will impact the communication between machine
In the past, the use of the RF spectrum was mainly in the domain of PCs and
For example, systems for the wireless connection of safety devices, such as E-stops; or in the operation of metal detectors.
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40 Legislation and regulation Now, the entire machinery supply chain (manufacturers, importers and integrators of
• Radio equipment assembled or modified by and used by radio amateurs.
connection between a radio system and a device which, when considered separately,
radio equipment) has the European Union’s new Radio Equipment Directive 2014/53/ EU (RED) to deal with. This replaced the old Radio and Telecommunications Terminal Equipment Directive (R&TTE) in June 2017, and changes between the two frameworks is proving to have a significant impact on the
The introduction of the RED means if machinery manufacturers want to carry on selling within the EU and European Free Trade Association countries, they must test and if required re-certify to the RED, otherwise they can no longer be placed on the market.
is subject to the scope of one or more other directives, such as the Machinery Directive. Now all of these devices must also meet the general requirements of RED, possibly along with the requirements of the original appropriate directives. This is because the individual components of combined equipment
manufacturing industry. This is because the RED’s wide ranging changes are requiring some significant adaptations to how radio-enabled machinery is manufactured and supplied. It is therefore crucial to fully understand these regulatory differences in
A significant change is that radio broadcast receivers are no longer excluded from the scope of the directive. Previously such products were required to comply with the EMC and Low Voltage Directives as they were
were previously considered separately, but now the final product as a whole comes under the RED. This means that additional measures may now need to be taken, which were not previously required for the complete device.
specifically excluded from the old R&TTE Directive. Consequently, many manufacturers are finding achieving compliance to be a significant challenge as they have never before been required to undertake RF testing.
Supply chain responsibilities
importer, distributor, authorised representative). The Directive is applicable to all electrical and
Also, combined equipment is now additionally within the scope of RED. Combined
manufacturer’s contact details, in a language which can be easily understood within the
electronic devices that intentionally emit and receive radio waves at frequencies below 3000 GHz. This is also the first time that equipment
equipment is where there is a physical
Member State in which it is being sold.
order to avoid time and cost overruns. The RED’s new requirements are intended to clearly spell out the responsibilities and obligations for every economic operator involved in the supply chain (manufacturer,
operating below 9 kHz requires radio testing as the RED scope is for products operating below 3000 GHz, whereas the R&TTE scope started at 9 kHz. The following definition explains what products are subject to the RED: “Radio equipment – an electrical or electronic product which intentionally emits and/or receives radio waves for the purpose of radio communication and/or radiodetermination, or an electrical or electronic product which must be completed with an accessory (such as an antenna) so as to intentionally emit and/or receive radio waves for the purpose of radio communication and/or radiodetermination.” The RED does exclude: • Radio equipment exclusively used for activities concerning public security, such as defence and state security. • Marine equipment that falls within the scope of Council Directive 96/98/EC. • Airborne products, parts and appliances falling within the scope of Article 3 of Regulation (EC) No 216/2008. • Custom-built evaluation kits designed for professionals to be used solely at R&D facilities.
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To enable full traceability, every economic operator within the supply chain must identify who has supplied them and to whom they have supplied radio equipment. The product must also be accompanied by instructions, and the
AUTOMATION CONTROL & TECHNOLOGY Specialists in design and custom build of a wide range of Hazardous Area Equipment
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42 Legislation and regulation Under the RED, importers also have new responsibilities as, when appropriate, they must now carry out sample testing, investigate and maintain a register of complaints and product recalls, as well as keep distributors informed of this monitoring process. For up to ten years after the equipment has been placed on the market, surveillance authorities have a right to request a copy of the Declaration of Conformity (DoC), and it is the importer’s responsibility to ensure that this is available. There are also two new options for the Declaration of Conformity (DoC): 1. Include a copy of the full DoC covering all applicable Directives with each piece of radio equipment. 2. Include a simplified DoC, which must include the exact website address where the full version can be obtained.
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where radio equipment is re-badged and supplied under their own name or trade mark.
Risk assessment It is an employer’s responsibility to ensure that all machinery meets the requirements of the Machinery Directive and Provision and Use of Work Equipment Regulations (PUWER), of which risk assessments are an essential ingredient. Therefore, if a machine has a substantial change made, a full CE marking and assessment process must be completed before it can be returned to service. Any configuration change in the production line may require re-certification of the whole facility. The RED conformity assessment process also requires that a risk analysis and assessment is undertaken. This should be instigated at the start of the conformity assessment process, and not at the end,
The RED has also changed who is responsible for re-branded equipment within the supply
as many manufacturers may be more used to doing. While manufacturers have
chain. For the first time, importers and distributors take on the responsibilities, which were once those of the original manufacturer,
experienced approvals managers, they may not have the skill set to deal with this new requirement. Also, many manufacturers are
Legislation and regulation 43
struggling to fully understand these changes, as there is no explicit description of the risk
• The potential harm • The likely severity of harm - the
This includes responsibility for product traceability, risk analysis and assessment,
assessment process within the RED - it is instead referenced in the EU’s New Legislative Framework.
foreseeable level of harm to the subject and probability must be assessed to determine the level of risk • Risk reduction/mitigation – demonstrate how the individual risks are controlled. • Controlled Risk Evaluation - once risks have been reduced, re-evaluate the
sample testing, and a register of complaints and product recalls.
The RED technical documentation must therefore include an adequate risk analysis and assessment. This is a fundamental part of the technical file as it is required to demonstrate compliance with the essential requirements. To demonstrate compliance, the aim is to reduce the risk as far as practicably
risk level. For the first time a manufacturer must also undertake a safety assessment that takes into account the reasonably foreseeable use, not just the intended use as outlined in
possible. An adequate risk analysis and assessment should therefore cover: • Product Definition - identify radio and non-radio functions and features, together with labelling information and instructions for use. Associated accessories or
the equipment’s instructions.
components should also be identified. • Risk Identification – identify the hazards
to increase our levels of connectivity. The RED also introduces a range of new
and subjects at risk. • How the hazard may harm the subjects at risk
responsibilities for the entire supply chain, including manufacturers, importers and integrators of radio-enabled machinery.
These new wide ranging changes are requiring some significant adaptations to how radio-enabled machinery is manufactured and supplied. It is therefore vital that the entire supply chain understands and complies with their specific obligations. About the author
With the world going wireless, radio equipment covers an ever growing variety of products, driven by the growth of mobile devices and wearable applications aiming
Paul Taylor is General Manager for Machinery Safety at TÜV SÜD Product Service, the global product testing and certification organisation. He has more than a decade of hands-on experience in the field of machinery safety, across a range of industry sectors. His areas of expertise include risk assessment, EMC testing, CE marking, functional safety, PUWER inspections, training and project management. At TÜV SÜD Product Service, he is responsible for a team of engineers who have extensive experience in electrical and mechanical machinery inspection, offering specialist health & safety advice to enable clients to reach their compliance goals.
www.hazardexonthenet.net
44 Product Datafiles
Flexible Conduit Specification Guide for Hazardous Areas from Flexicon Responding to the demand to safely protect power and data cabling in today’s interconnected world, Flexicon has launched its most extensive flexible conduit Products and Solutions Guide for Hazardous Areas. Says Tim Creedon, Sales & Marketing Director for Flexicon: “It has never been more important to get cable protection specification right to ensure on-going operation throughout a system’s life and protect people, property and processes. Hazardous Areas, by their nature, present many risks and depending on the application the hazards faced can vary enormously. The risk of explosion due to operating environments, flammable liquids, gases or dust, hazards such as ingress of water, corrosion, exposure to chemicals, impact, crushing, fire, UV light, vandalism can all impact safety and operational efficiency.” “Our new specification guide features 16 different cable protection solutions for use in Hazardous Areas. The guide makes it easy to correctly specify a system of both conduit and gland or fitting to match the nature and magnitude of the hazards faced.”
The 46-page guide highlights many of the potential hazards faced by cabling, using simple icons. It is focussed on product solutions for hazardous areas and features Flexicon’s range of Flameproof Barrier Glands with the latest IECEx, ATEX and CU-TR certification. It also features conduits for Hygienic applications and Flexicon’s new Stainless Steel annular corrugated conduit systems, FSS and FSSBRD. Tel: 01675 466900. Email: sales@flexicon.uk.com. Web: www.flexicon.uk.com
Leading the Customer Service Experience in the Certification Industry
Double Under Voltage Monitoring Relay for Hazardous Environments
Providing exceptional customer service is a key aspect of the work we do at CSA Group. Over the last 18 months CSA Group has made significant improvements to the way we provide our service to our customers. Our customers have scored us 90% in overall customer satisfaction, with 4 out of 5 clients saying they would recommend CSA Group to a colleague. Interested in learning how we do it? Please contact us to arrange a no obligation project planning meeting.
Carlo Gavazzi launches the DUB72 double under voltage relay for Class 1 Division 2 applications according to ANSI/ISA12.12.1 Norm for potentially explosive environments. The user can set two independent dials, one for each of the 2 thresholds, measuring the level of its power supply. One of the thresholds, the one associated with output 1, can be used as a pre-alarm signal; the other is associated with a high-power 20A-rated relay which can be used to drive the load directly and features a low-profile DIN housing suitable for installation into electric distribution panels as well as industrial cabinets.
T: +44 (0) 1244 670 900 E: ukinfo@csagroup.org W: www.csagroupuk.org
For more information regarding Carlo Gavazzi and its range of products, please visit the website: www.carlogavazzi.co.uk
ecom and Pepperl+Fuchs announce the new explosion-proof tablet - the Tab-Ex® 02
ecom, a Pepperl+Fuchs brand and market leader for mobile computing and communication in hazardous areas, introduces the successor to the world’s first tablet series Tab-Ex 01 for use in Zone 1/DIV1 - the explosion-proof Tab-Ex 02. This new generation of tablets was, like Tab-Ex, developed in close cooperation with Samsung Electronics. It is was especially designed for use in harsh and hazardous environment and will be available as a rugged, a Zone 2, and as a Zone 1 (autumn 2018) device matching all application requirements. www.ecom-ex.com/products/mobile-computing/tablets-android/tab-ex-02-dz2/ or: www.ecom-ex.com
Explosion Proof ATEX Zone 2 iPhone 8 (Plus) Atexxo Manufacturing BV is offering the Apple iPhone 8 (plus) suitable for use in hazardous locations. The explosion proof iPhones are originally manufactured by Apple, and then converted and certified according to the ATEX directives by Atexxo Manufacturing B.V. This makes the phones suited for safe use in gas /vapour zone 2 hazardous locations. Compliance with ATEX / EX regulations is achieved by modification of the casing together with the intrinsically safe electrical circuit, which makes the phones suitable for safe use in hazardous locations. All features of the original product are preserved. Even the fingerprint scanner can be used safely in hazardous locations. The ATEX iPhone 8 comes with a black case finish and is available as iphone 8 and iphone 8 models, both 64Gb and 256Gb versions.
www.hazardexonthenet.net
Beside safe use as a cell phone for telecommunicating, both versions are excellent for use as an intrinsically safe camera. Features: -Explosion safety level: II 3G ; Ex ic IIC T4 Gc -Charger 220-240VAC -Charger 50/60Hz Applications: Hazardous material storage, petro chemical plants and oil and gas extraction sites. Atexxo Manufacturing B.V. of The Netherlands is a market leader in the field of user friendly and easy to install explosion proof equipment. For more information or custom solutions please contact our sales department or visit our website: www.atexxo.com
started on the right path and can be best described as a door opener to the subject of hazardous area static control.
1 DisplayPort, dual storage, and a Mini PCIe socket for Wi-Fi and 3G/4G LTE. Moxa’s Proactive Monitoring and Smart Recovery software tools enable predictive maintenance.
For more information please contact Newson Gale. www.newson-gale.co.uk
Tel: +49 89 3700 399 – 0 Product Europe@moxa.com www.moxa.com
Asecos Q range – proven solutions Pressure technological fire resistance of minutes for hazardous 90 environments Labtex’s Asecos Type 90 storage cabinets Elfab recognise the importance of eliminating and preventing safety hazards provide extremely safe, regulationhence striving to manufacture and develop solutions to make the selection compliant storage of hazardous materials in and fitting of safety critical products a simple one. Elfab make every effort to laboratories and other work spaces. Each enhance the installation process of its products and with its latest successful cabinet variant is furnace tested in accordance with EN 14470-1 and proven to developments, these are the first of many installation improvements to be give fire resistance of 90 minutes. Extremely robust in construction for maximum announced by Elfab supporting their training packages which are dedicated to torsional rigidity and with tamper proof lock and indicators built in, every process safety improvements. ASECOS cabinet has GS approval and CE conformity. In addition the Q range Being leaders in offering safety critical protection for personnel and is offered in range of scratch-resistant paint colours and with extensive interior hazardous work environments, Elfab offer exclusive maintenance and equipment options Warranty cover is available up to 10 years. installation devices. Firstly, its maintenance tool, “Test-Tel™” is designed to Tel:+44 (0)1484 check rupture disc600200 status and ensure correct disc installation, saving long-term Please contact Greg Smith at greg@labtex.co.uk investment and downtime. Secondly, installation methods are also crucial when
Datafiles
45
ATEX Certified Humidity/Moisture & Temperature Sensors ROTRONIC Intrinsically Safe sensors and measurement it comes to correct installation. transmitters with analogue outputs are suitable for use “System Loc+” is another low-cost wherever there is a risk of explosion due to dust or gas in tool offered by Elfab improving the environment. safety and ease of installation by HygroFlex5-EX transmitters and probes from ROTRONIC preventing the rupture disc holder conform to the latest international ATEX standards. The transmitter from been installed incorrectly, eliminating risk factors. is Intrinsically Safe (secondary side) , there are two channel outputs, As process safety and risk reduction are increasing concerns to date, Elfab the housing is heavy duty. Interchangeable probes are available for has developed a range of training packages consisting of “Lunch and Learn” all applications, including those at pressure and low dew point. workshops in order to train maintenance staff, fitters and engineers. Each training programme canavailable be tailored dependent on the essential process safety Technical datasheet improvements that areEmail: required. Tel: 01293 571000 instruments@rotronic.co.uk Web: www.rotronic.co.uk Contact Elfab today for a quote via sales@elfab.com
Asecos Q rangeyou – proven fire Markets Connecting to Global resistance of 90 minutes CSA Group is a global organization dedicated to
Factair Factair is a specialist manufacturer of compressed and breathing-air packages. Established in 1976 and accredited to ISO9001:2008, the company has a range of ATEX Zone 1 and 2 packages available in both portable and fixed installation formats. For specific site or project requirements Factair also offers custom designed packages. With extensive experience in the oil and gas industry, Factair supplies compressor packages in containerised and DNV 2.7-1 frames. Factair’s breathing-air packages feature integrated fail safe emergency reserve and alarm systems, together with CO and CO2 suppression systems. Also available from Factair is a range of ATEX rated long duration breathing-air cylinder cascade packages, anti-static BA hoses and filtration systems. Tel: +44 (0)1473 746408 www.factair.co.uk enquiries@factair.co.uk
safety, social good and sustainability. We provide Labtex’s Asecos Type 90 storage cabinets testing, inspection and certification services for provide extremely safe, regulationproducts in industrial and hazardous locations. compliant storage of hazardous materials in We realise our customers need access laboratories and other work spaces. Each to global markets and they need it quickly. cabinet variant is furnace tested in accordance with EN 14470-1 and proven to As such, we’ve evolved our processes to respond even better to the pressures give fire resistance of 90 minutes. Extremely robust in construction for maximum our customers face, while offering the marks needed to access markets around torsional rigidity and with tamper proof lock and indicators built in, every the world. ASECOS cabinet has GS approval and CE conformity. In addition the Q range Our large team of certification engineers are focused on completing projects is offered in range of scratch-resistant paint colours and with extensive interior within agreed-to timelines and we consistently start and finish projects with some of equipment options Warranty cover is available up to 10 years. the best lead-times within the industry. Tel:+44 (0)1484 600200 T: +44 (0) 1244 670900 E: ukinfo@csagroup.org W: www.csagroup.org Please contact Greg Smith at greg@labtex.co.uk
Schmersal group founds subsidiary in Japan To improve its coverage of the Japanese market, the Schmersal Group has founded an independent subsidiary in Japan. Tetsuya Horimoto has been named managing director of the new Schmersal Japan KK. He takes over from Dr Tekashi Kabe, who entered his well-earned retirement at the end of 2017 after many successful years as 4236 - HEX Jan17 Edn.indd 33 of the previous Schmersal sales office in Japan. the manager Tetsuya Horimoto is an electronic engineer with many years of management experience at leading international companies in the automation sector. He is also a TUV-certified Functional Safety Engineer. “By founding a subsidiary in Tokyo, Schmersal will extend its range of safety technical components and systems for the Japanese market. At the same time, we will increasingly be able to offer our customers our comprehensive services from our tec.nicum division on a local basis,” explains Tetsuya Horimoto. The aim is to expand the Schmersal site in Japan in terms of both space and personnel. In future, a separate warehouse should allow faster deliveries to the
www.hazardexonthenet.net customers. Additional qualified engineers will soon ensure better customer support. “The majority of our customers in Japan come from the mechanical engineering sector, the steel industry, 20/12/2016 11:24 the automotive industry and lift construction. Japanese mechanical engineering companies in particular export the majority of their products. It is these customers in particular that we can support with the sound knowledge of our tec.nicum experts about the different international and European legal directives and standards on machine and occupational safety, and the relevant safety solutions.” The newly founded Schmersal Japan KK is based at the same location in Tokyo as the previous Schmersal Japan Branch Office, the contact details will remain the same: Tel: +81-3-3247-0519
Rotork orders for new refinery include SIL certified IQ3 valve actuators for critical safety systems Now under construction, Iraq’s State Company of Oil Projects’ (SCOP) Karbala Refinery will have a refining capacity of 140,000 barrels of crude oil per day (bpd), and production will meet the latest international standards. Rotork orders for the Karbala Refinery include large quantities of IQ3 non-intrusive intelligent electric valve actuators, designed specifically for automated flow control systems in hazardous environments. With their diagnostic and asset management abilities, the IQ3 actuators will facilitate the reliable, efficient and safe operation of the refinery. Comprehensive operational data including valve torque profiles stored in actuator dataloggers can be downloaded and analysed to enable predictive maintenance and optimise plant performance. or critical areas, actuator duties will include the provision of a Safety Integrity Level 2 (SIL2) Emergency Shutdown (ESD) function. Recognised around the world, the SIL system identifies the requirements for a Safety Instrumented System (SIS). These actuators are equipped with the Rotork SIL safety module, which monitors the standard IQ3 control board and provides diagnostic coverage and redundant control in order to perform the desired safety function. A safety function status relay provides remote indication of the actuator availability and the redundant safety function operation, with the same status duplicated locally on the actuator display. Contact us on Telephone : 01225 733200 Email : information@rotork.com Web : www.rotork.com
www.hazardexonthenet.net
46 Events
Behavioral Safety & Culture: Barriers & Success Stories Date: 18 to 20 April 2018 Location: Berlin, Germany This conference will enable you to: • Discuss what is the way forward in Health & Safety? What does it take for a paradigm change and do we need one? • Explore behavioral based safety? Comparing different practical approaches to using behavioral insights • Discuss what are the practical barriers in implementing a BBS Programme?
• Document the practical positive impact of a BBS programme on safety • Explore how to influence, manage & measure organisational culture • Assess your current organisational culture and how it impacts safety • Learn from cultural change programmes in road safety that try to introduce a new safety behavior • Benchmark safety leadership approaches Develop an organisational culture where safety is not paid only lip service, and
where insights from psychology are well used to understand behaviour and nurture a safe environment. Website: http://www.meassets.com/HTMLEmail/ BehavioralSafety2018Agenda.pdf
2018 Spring Meeting and 14th Global Congress on Process Safety Date: 22 to 26 April 2018 Location: Orlando, FLA, USA The AIChE Spring Meeting is the year’s key technical conference for practicing chemical engineers. A wide range of subjects relevant to the current needs of industry is covered. Plus, the Global Congress on Process Safety covers the critical needs of process safety practitioners more broadly and deeply than any other conference. The 2018 AIChE Spring Meeting features the following topical conferences: • 4th Big Data Analytics • 6th International Conference on Upstream
Engineering and Flow Assurance • 18th Topical Conference on Gas Utilisation • 21st Topical Conference on Refinery Processing • Distillation Symposium • Innovative and Smart Manufacturing
14th Global Congress on Process Safety in Orlando, FL as an event sponsor or exhibitor. Showcase your brand as you
• The 30th Ethylene Producers’ Conference • Sustainable Engineering • Process Intensification
support the profession. Put your offering in front of decision makers and potential buyers.
• Emerging Technologies in Clean Energy • Ways to Participate If chemical engineers and process safety are your target markets, then join AIChE at the 2018 AIChE Spring Meeting and
Website: http://www.aiche.org/ conferences/aiche-spring-meetingand-global-congress-on-processsafety/2018
Cyber Security: State of the market and expert overview Date: 24 to 26 April 2018 Location: London, UK
remain unknown, what is clear is that successfully implementing cyber defence remains a critical, unsolved issue for
The number of cyber attacks is on the rise and Industrial Control Systems must be secured, in order for global organisations to avoid suffering real, physical damage.
industry.
On Friday 20th October 2017, the FBI and Department for Homeland Security released a report stating major nuclear,
the discussion around cyber security for industrial control systems; demonstrating not only how to secure your facility against the threat of today, but will, uniquely, also explain how to defend against the threat of tomorrow through cultural change and human engagement.
energy and critical manufacturing industries had been successfully compromised by cyber attacks. While the full implications of these attacks
www.hazardexonthenet.net
As the leading event of its kind in Europe, the ICS Cyber Security conference 2018 (24th - 26th April, London) will continue
Ahead of the ICS Cyber Security conference, more than 350 experts from all around the world have answered our recent survey and shared their views on the nature of the cyber threat, implementing solutions and in what time frame and their thoughts on the throughlife support offered by the industry. Web site: http://www.icscybersecurity. iqpc.co.uk
Buyers Guide 47
For a complete range of hazardous area solutions Intrinsic Safety Isolators • Zener Barriers • Zone 1&2 Remote I/O • Fieldbus Exe Enclosures • Exd Control Panels • Ex Lighting • Purge Solutions • Zone 1 & 2 HMI’s PC’s
www.pepperl-fuchs.co.uk Cable Glands
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Control Panels
Heaters
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To advertise in the Product Datafiles or Buyers Guide
EExd & EExe enclosures Custom built panels, terminal boxes & control stations
contact Kathryn Startin
Tel: 01296 489967 Fax: 01296 393515 Email: sales@jbsystems.co.uk Website: www.jbsystems.co.uk Control Panels
HMI
AUTOMATION CONTROL & TECHNOLOGY Specialists in design and custom build of a wide range of Hazardous Area Equipment
Southampton SO40 9AH +44 (0) 2380 665544 enquiries@trant.co.uk trant.co.uk
on +44 (0)1732 359990 or kathryn.startin@imlgroup.co.uk