hazardexonthenet.net
Incident investigations What does good look like? The BP approach Petrochemicals Shell’s PPC project and the shale revolution
Explosion science
Safety culture
Event review
UK-based organisations
2017 PSM survey
Hazardex 2018 Conference & Exhibition
May 2018
the journal for hazardous area environments
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contents may 2018 On March 15, a worker dragging his foot along a factory floor sparked an explosion at a Texas chemical plant that killed one and injured another two. Fears of further explosions and toxic chemical fumes prevented fire crews from battling the ensuing blaze and a large part of the Tri-Chem Industries plant in Cresson, about 80 kilometers southwest of Dallas, burned to the ground. With the plant still ablaze and a toxic haze hanging over the area, the Texas Commission on Environmental Quality, the state agency responsible for coordinating the cleanup, declined to produce a list of the plant’s on-site chemicals, telling a reporter to file a public information request. In recent years, Texas leaders have made it increasingly difficult for the public to find out about the chemicals manufactured and stored at such plants. After a fertiliser plant explosion in the city of West, Texas, killed 15 people in 2013, Greg Abbott, who was then attorney general and is now governor, ruled that state
14 17
agencies could withhold information about hazardous chemicals because of “ongoing terroristic activity.” This happened in Cresson as well as in Houston last August when Hurricane Harvey came to call and flooded the Arkema chemical plant, also covering a whole neighbourhood in poisonous fumes that local authorities refused to identify.
The Hazardex 2018 Event saw a strong conference programme focused on cybersecurity, with the Awards ceremony another highlight
So, the official message is: we can’t tell you what poisons you’re breathing right now as, if we did, the terrorists would win. But terrorists didn’t blow up an entire town - an unregulated fertiliser plant did.
25
After each of these incidents the number of people claiming their health has been wrecked by toxic fumes rises higher. It seems likely that, if this absurd situation continues, deregulation will cause more casualties across the country than terrorists ever will. …Alan Franck, Editor, Hazardex
Ethane from shale gas is transforming the US petrochemicals industry, with the Shell PPC project in the forefront of these developments
in this issue 5
29
News Extra
• US administration attributes cyber attacks to Russian state actors • Scientist claims Siberian craters could be caused by natural gas exploitation • European chlor-alkali industry safety improvement trend levels off • Large oil spill off Borneo coast ignites and kills at least five • US offshore regulator finds serious safety problems in Gulf of Mexico • UK-based explosion science organisations
15 Standards: The Role of IECEx ExTAG Decision Sheets
Incident investigations need a narrative, timeline and effective analysis, as well as a firm grasp of performance influencing factors
17 Hazardex 2018 Conference & Exhibition review 25 New Shell Pennsylvania Petrochemicals Complex takes advantage
34
of shale revolution
29 Better Investigations – the BP approach 34 The Petrotechnics 2017 Survey: Process Safety and Risk Management 37 Event previews A recent survey has produced some interesting insights into the state of operational risk and safety management
the journal for hazardous area environments
hazardexonthenet.net
Incident investigations What does good look like? The BP approach Petrochemicals Shell’s PPC project and the shale revolution
Explosion science
Safety culture
Event review
UK-based organisations
2017 PSM survey
Hazardex 2018 Conference & Exhibition
May 2018
40 Datafiles
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 Holly Reed holly.reed@imlgroup.co.uk
Design Graham Rich Design www.grahamrichdesign.co.uk
IML Group plc Blair House, High Street, Tonbridge, Kent TN9 1BQ, UK Tel: +44 1732 359990 Fax: +44 1732 770049 Email: events@imlgroup.co.uk ISSN 1476-7376
Register for weekly email newsletter & up-to-the-minute news at www.hazardexonthenet.net
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News Extra
5
Cyber attacks attributed to Russian state actors by US administration O
n March 15, the US administration accused Russia of of engineering a series of cyberattacks that targeted
and the Department of Homeland Security and the FBI first issued urgent warnings to utility companies in June. In the March 15
DHS and FBI characterize this activity as a multi-stage intrusion campaign by Russian government cyber actors who
American and European nuclear power plants and water and electric systems, and could have sabotaged or shut down
report, both agencies offered new details as the Trump administration imposed sanctions against Russian individuals
targeted small commercial facilities’ networks where they staged malware, conducted spear phishing, and gained
power plants at will. Observers saw the attacks as a signal by Moscow that it could disrupt the West’s critical facilities
and organisations it accused of election meddling and malicious cyberattacks.
remote access into energy sector networks. After obtaining access, the Russian government cyber actors
in the event of a conflict. According to a Department of Homeland
This was the first time the administration officially named Russia as the perpetrator of the assaults, according to the New
conducted network reconnaissance, moved laterally, and collected information pertaining to Industrial Control Systems
Security (DHS) report, Russian hackers made their way onto machines with access to critical control systems at power plants
York Times. And it marked the third time in recent months that the White House, departing from its usual reluctance
(ICS).
that were not identified. The hackers never went so far as to sabotage or shut down the computer systems that guide the operations of the plants.
to publicly reveal intelligence, blamed foreign government forces for attacks on infrastructure in the United States.
accessed workstations and servers on a corporate network that contained data output from control systems within energy generation facilities. The threat actors accessed files pertaining to ICS or supervisory control and data acquisition (SCADA) systems.
But new computer screenshots released by the DHS on March 15 made clear that Russian state hackers had the foothold they would have needed to manipulate or shut down power plants. The New York Times quoted Symantec security technology director Eric Chien saying there was now clear evidence the hackers were sitting on the machines, connected to industrial control infrastructure, that allowed them to effectively turn the power off or effect sabotage. American intelligence agencies were aware of the attacks for the past year and a half,
The Alert overview is as follows: Alert (TA18-074A) is a joint Technical Alert (TA) and is the result of analytic efforts between the DHS and FBI. This alert provides information on Russian government actions
In multiple instances, the threat actors
The threat actors targeted and copied
targeting US Government entities as well as organizations in the energy, nuclear, commercial facilities, water, aviation, and critical manufacturing sectors. It also contains indicators of compromise
profile and configuration information for accessing ICS systems on the network. DHS observed the threat actors copying Virtual Network Connection (VNC) profiles that contained configuration information
(IOCs) and technical details on the tactics, techniques, and procedures (TTPs) used by Russian government cyber actors on compromised victim networks. DHS and FBI produced this alert to educate network defenders to enhance their ability to identify and reduce exposure to malicious activity.
on accessing ICS systems. DHS was able to reconstruct screenshot fragments of a Human Machine Interface (HMI) that the threat actors accessed. For more information go to: www.us-cert.gov/ncas/alerts/TA18-074A
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News Extra
Yamal methane crater - Image: YamaloNenets regional government
thawing permafrost. But now, Russia’s leading authority on the phenomenon claims that many explosions may have been triggered by the largescale exploitation of natural gas in the region. Professor Vasily Bogoyavlensky of the
Scientist claims
Siberian craters could be caused by natural gas exploitation
7
in the region, some close to industrial infrastructure and human habitation. Some were underneath or next to pipelines that were being deformed by pressure from the swelling pingos. One large crater which exploded in the middle of the Mordy-Yakha River had only
Russian Oil and Gas Research Institute in Moscow told the Siberian Times he now suspected human activities were involved in the formation of the craters on the Yamal peninsula, some hundreds of metres wide. Leaks from gas wells
natural causes, said Bogoyavlensky, but it may not be typical. He also confirmed that some craters erupted repeatedly, rather than on a one-off basis.
could lead to unstable pockets of methane accumulating under frozen soil, he said.
monitor potential explosions close to gas pipelines or residential areas.
He called for more seismic stations to
Initially the gas caused the formation of pingos - ice mounds - in the tundra which
Gazprom has 11 gas fields and 15 oil, gas and condensate fields on the Yamal Peninsula and its adjacent offshore
explode when the gas builds up under a thick cap of ice, causing the craters. In an
areas. They consist of 16 trillion cubic meters (tcm) of explored and provisionally
nexplained craters in Siberia that first appeared in 2014 were
earlier report, he said that swelling pingos were a problem in the area because of their effect on pipelines and other infrastructure.
initially thought to be caused by natural underground methane eruptions in
evaluated gas reserves, and nearly 22 tcm of in-place and forecast gas reserves. Estimated condensate reserves are 230.7 million tonnes; estimated oil reserves are
He said satellite data showed 7,000 pingos
291.8 million tonnes.
U
8
News Extra
European chlor-alkali industry safety improvement trend levels off T
he latest figures from the Euro Chlor industry
current, chlorine, caustic, hydrogen (explosion), mercury hypochlorite,
association show a levelling off in the safety performance of the chlor-alkali industry in Europe. In 2016, Lost Time Injuries (LTIs) for member company personnel increased slightly from 1.9 to 2.0
sulphuric/hydrochloric acid and other reactants used in the electrolysis unit). In terms of number of incidents, the trend shows a 67% reduction
compared to 2015, whilst the LTI figure for contractor staff improved from 2.1 to 1.8. There had been a small worsening in the trend among chemical
between 2001 and 2016. The number of process incidents per million tonnes of chlorine produced now stands at 2.3. LTI trend 2001-2016 - Source: Euro Chlor In its report, Euro Chlor says
companies’ own employees in 2014 compared to 2013, but the situation
to the chlorine industry are accounted for, i.e. injuries directly related to electric
improved in 2015. Occupational safety is measured as lost time injuries per million working hours (LTI rate). Since 2011, only those accidents specific
that under the terms of its Safety Initiative, the association and its members are looking into options to improve the culture of incident sharing and learning from each other to further reduce the number of future incidents. This will include a closer focus on incidents and near misses.
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News Extra
Balikpapan Bay oil slick fires Image: Xinhua/Rex/Shutterstock
9
Large oil spill off Borneo coast ignites and kills at least five
O
n April 4, Indonesian oil company Pertamina said a break in one of its pipelines caused a 26km-long oil slick off the coast of Borneo, after denying
But the spill was still increasing in size on April 7. According to Kompas, a spokesman from the marine and coastal area data laboratory of the Fisheries and Maritime Affairs Ministry said
Pertamina suggested “an external heavy force” had caused the damage to the 20-yearold pipe. Balikpapan Bay sees heavy traffic, particularly of coal barges coming through
responsibility for four days. At least five fishermen died in Balikpapan Bay on March 31 when part of the slick ignited,
that the area polluted by the oil spill had widened to 20,000 hectares from 12,987 hectares.
from the Borneo hinterland.
and the total area covered by the oil spill had widened to 20,000 hectares by April 7. The city of Balikpapan on the east coast of
He said it was unclear what exactly was causing the spread - either the source of the leak had not been perfectly sealed
Borneo hosts the Pertamina Unit V Refinery. Initially, the refinery’s general manager said the company’s divers had not been able to find any
or the spill could be thinning and drifting away with
pipeline leaks, and that the spill had nothing to do with either the refinery or any of its pipelines.
the currents.
The police said a criminal prosecution may follow.
Pertamina says it Pertamina originally said that tests of the waters from the bay had determined that the substance was marine fuel oil, not the crude
has deployed four cleaner teams and 15 ships to
which is carried in its pipelines in the area.
clean up the bay.
The slick has devastated local fisheries and
Yudi Nugraha, Ka-
wildlife sanctuaries, with rare dugongs and river dolphins washed up dead and covered in oil.
limantan regional manager of social responsibility and communications at Pertamina said the company was using a variety of techniques and
Balikpapan city officials declared a state of emergency over the spill. According to the Jakarta Post, city officials warned residents to be extra careful when spending time at affected beaches, adding that they should not smoke near the area for fear of igniting the oil. The city has also distributed masks to protect local residents from the smell of fuel and 1,200 people have complained of nausea
equipment to clean the oil spill, from vacuum trucks, to oil booms and oil spill dispersant
and breathing problems after the incident.
(OSD).
www.hazardexonthenet.net
WORLD LEADING MANUFACTURERS OF HAZARDOUS AREA ATEX & IECEx CERTIFIED LIGHTING EQUIPMENT T: +44 (0)114 255 1051 E: info@wolfsafety.com
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10 News Extra
Explosion science organisations T
here are a number of organisations worldwide dedicated to furthering the
Each year, on average, two UKELG meetings are organised by a Committee of around 10 people drawn from industry,
following the research projects initiated in response to the Piper Alpha disaster.
understanding of explosion science: those below are two of the most prominent based in the UK. If you would like to bring any others to the attention of a wider audience, please send details to:
academia and regulators. Generally these are one-day events, held at scientific and research establishments and Universities all over the UK. Occasionally, longer meetings are held.
Its mission is to disseminate knowledge and best practice, and to develop guidance on the prevention and mitigation of fires and explosions and the protection of people and facilities from such hazards.
alan.franck@imlgroup.co.uk
To achieve open discussion of current research and development, the Group actively encourages the presentation of recent research and results, especially work-in-progress. The proceedings are not published to encourage informal
To this end, FABIG maintains contact with key industry experts and researchers to keep abreast of current technical challenges and ongoing research. Relevant technical information is disseminated to the membership via the quarterly Technical Meetings and Newsletters, and Technical Notes
The United Kingdom Explosion Liaison Group (UKELG) was established in 1982 by leading academics and industrial
contributions and discussion, but some presentations are placed on the UKELG
researchers in the field of explosion science. Today, 37 years later, interest in the subject is as keen as ever as scientists
website at the request or with agreement
and engineers wish to understand all aspects of explosions in order to improve the safety of industrial processes. In 2017, the 35th anniversary meeting was held over
There is no membership fee. UKELG is a registered charity. Any interested person is free to attend meetings, on payment of an appropriate small fee to cover
design issues.
three days at the DNV-GL Spadeadam test site in northern England. Presentations covered current knowledge on explosions
running costs. Students who require assistance with the registration fee and with travelling expenses can contact the
environment through the development and sharing of expert knowledge on hydrocarbon fires and explosions for the
from dusts to mists, from vapours to solids, interspersed by impressive demonstrations of the power of gas and TNT explosions.
Secretary. He may also be approached for financial assistance for those who are retired or otherwise financially unsupported
design of both offshore installations and onshore petrochemical plants.
Emphasis in the early days was on understanding gas explosions. The blast
by an affiliation. Attendance usually includes people from academia, industry, consultancies and the regulators. Details of
Whilst in the early days of FABIG, activities focused on fire and explosion issues on offshore installations, the scope
at Flixborough several years previously had shown that the mechanisms controlling vapour cloud deflagration and detonation were poorly understood. Over the years that
meetings are sent to a list of contacts by e-mail and are available from the UKELG website.
of activities has broadened to cover the design of both offshore installations and onshore petrochemical facilities, and to cover emerging topics such as
followed the scope of the meetings naturally broadened to include dust, mist and solid explosions, rapid phase transitions, BLEVEs and fireballs, ignition processes, and the response of structures to blast.
http://ukelg.ps.ic.ac.uk
design of floating production facilities, LNG, hydrogen, human factors, integrity management, and life extension.
of the authors.
and an important aspect of discussion covers root causes and lessons learnt.
www.hazardexonthenet.net
FABIG is committed to promoting the protection of life, property and the
Examples of technical topics covered by FABIG include: • Fire and explosion hazard management
Explosion modelling has always been a key component of the meetings. The field has advanced from empirical to computational fluid dynamics modelling as mechanistic insight and computing power have increased. However, accidents still occur
are produced to provide practising engineers with detailed guidance on challenging fire and explosion related
The Fire and Blast Information Group (FABIG) was created in March 1992 to continue the collation, appraisal and dissemination of knowledge on hydrocarbon fires and explosions for the design of offshore and onshore facilities
• Fire and explosion risk management • Fire loading and response • Explosion loading and response • Fire and explosion mitigation systems • Detailed fire and explosion design guidance http://www.fabig.com
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12 News Extra
US offshore regulator, under spotlight for r
finds serious safety problems in Gul I
n early March, the US Interior Department’s Bureau of Safety and
incidents” that occurred late last year on platforms and drilling rigs.
The focus of the regulatory review has been two safety rules that govern offshore drilling
Environmental Enforcement (BSEE) sent teams to the Gulf of Mexico to inspect giant cranes used in offshore
No one was killed or injured in those crane incidents, but lifting-related accidents
and the production of oil and gas. But the deregulatory push has also meant that progress has slowed, if not stopped, on
oil and gas operations that are a significant source of accidents. The inspections uncovered a number of
are the second-largest cause of offshore fatalities, outnumbered only by fires and explosions, agency records show. The
finalising other safety rules, including a 2015 proposal to enact new standards for offshore crane safety.
issues, some serious.
cranes are used to move workers and supplies from the Gulf up to the decks of the platforms.
More than 50 inspectors conducted surprise inspections on about 40 offshore platforms and drilling rigs, said Jason Mathews, the head of offshore safety management for the Gulf of Mexico at BSEE. The results were still being compiled, he said, but the inspectors found serious problems, including some that were potentially life threatening.
The Interior Department and its offshore safety bureau have been under a spotlight since the agency was ordered by President Trump to re-evaluate regulations enacted during the Obama administration. These were introduced in the aftermath of the Deepwater Horizon accident in 2010, which killed 11 offshore workers
Interior Secretary Ryan Zinke had discussed plans for the inspection push this month after the safety bureau issued an alert to offshore oil and gas operators in the Gulf. It warned about a series of
and created the largest marine oil spill in drilling history.
“potentially catastrophic crane and lifting
to the accident had been excessive.
www.hazardexonthenet.net
Many offshore oil and gas operators complained that the regulatory response
The New York Times reported on March 10 that several of the independent companies seeking a lightening of the regulatory burden had been cited for workplace safety violations in recent years at a rate much higher than the industry average. Interior Department records released to the NYT show the rate of lift-related offshore accidents last year increased by more than 4%, reaching the second-highest annual level in the past decade. On average, there was one incident for every 13.5 offshore platforms or drilling rigs, according to agency data. The crane inspections resulted in noncompliance notices for some offshore
News Extra 13
rule, estimating that oil companies would save $986 million in the coming decade. The
“We have no plans to alter two significant rules enacted following Deepwater Horizon,
proposal included many changes requested by the industry, such as loosening inspection requirements for blowout preventers and eliminating the need to shut down operations as lift boats approached.
the Drilling Safety Rule and the Safety and Environmental Management Systems Rule. The SEMS approach rightly moves operators toward a performance-based safety approach, allowing the government, industry and independent third parties to focus on improving safety outcomes.
There have also been allegations that the Trump administration’s appointment of Scott Angelle as BSEE Director could lead to conflicts of interest, given his close links to the oil and gas sector. Angelle rejected the criticism as unfounded, said his agency was committed to safe operations in the Gulf and that the regulatory changes would remove a burden on companies while maintaining standards.
rule changes,
lf of Mexico
But, according to the NYT, federal safety inspection records hint at the difficulties
weakening offshore safety or environmental rules. As a Louisiana native, and my state’s interim lieutenant governor at the time of the
many smaller operators have faced, and help explain why regulatory changes by the Trump administration are seen as so crucial to the
Deepwater Horizon tragedy, I fully understand the importance of worker safety and environmental protection.
industry’s survival in the shallower sections
“Our agency is working hard to fulfill Executive Orders, which require an extensive review of our regulations. Our common sense approach
The crane inspections are part of a broader effort to make safety inspections more focused
is to propose revisions that could potentially reduce burdens on operators without impacting safety and protections of the environment. Our changes will never reduce safety, and will in some cases improve safety.
Secretary Zinke announced this month that a risk-based program was formally in place, but the NYT says questions remain about the agency’s commitment to safety. Last month, a group of 19 Senate Democrats wrote to Zinke questioning why the agency had issued a stop-work order for a study by the National Academy of Sciences that was looking at ways to reduce offshore accidents. In late December, BSEE sent the White House a proposal to overhaul the Obama well-control
inspection protocol in 2018. Through these efforts, and many others, we are moving forward toward meeting the Administration’s goal of achieving energy dominance without sacrificing safety.”
In a January article in USA Today Angelle wrote: “Contrary to recent misleading news reports, the Department of the Interior is not
operators, which could result in fines, BSEE’s Mathews said.
on risks rather than routine scheduling, meaning inspectors concentrate on known hazards like gas leaks, or on companies that have a history of safety violations. The riskbased approach has been suggested to the Interior Department for several years by the Government Accountability Office.
“We are also strengthening our inspection program by implementing risk-based process that focus our efforts on potential safety problems. I am confident that we will be able to achieve the goal of integrating a risk-based
“Our agency enforces dozens of regulations, but we are currently seeking public input on changes to one: the Production Safety Systems Rule. Enacted in late 2016, this regulation is not related to the Deepwater Horizon incident. The changes we propose are common sense - reducing unnecessary notifications, clarifying when operators must provide documentation, and specifying that safety and pollution prevention equipment that meets required industry standards have achieved third-party verification. We propose to codify 17 updated standards so they bear the force of law as another sign of our commitment to safety. We are examining other rules, but have not reached the publiccomment phase.
of the Gulf. Approximately 240 platforms in the shallow waters of the Gulf, serving over 2,000 oil and gas wells as of last year, are listed by the Interior Department as “idle iron.” This means that they are severely damaged, not operating and no longer economically viable, and that they pose environmental and safety hazards. Most of these platforms are controlled by smaller operators. One abandoned well, formerly operated by a now-bankrupt company, has been leaking oil for 10 years and is considered to be the second worst source of US oil pollution after the Deepwater Horizon incident. The rule changes include proposals to ease the burden of set-aside payments by operators to pay for the decommissioning and removal of this “idle iron”. The Gulf generates 97% of offshore oil in the United States, about 18% of the country’s crude oil and $2.8 billion a year in royalty and lease payments to the federal government. In 2017, the Gulf produced a record 1.65 million barrels a day.
www.hazardexonthenet.net
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Standards 15
The Role of IECEx ExTAG Decision Sheets
Every two months, SGS Baseefa Technical Manager and IECEx Service Facility Certification Committee chairman Ron Sinclair MBE gives his perspective on the latest developments in the world of standards
I
n my previous article (Hazardex March 2018) I highlighted the role of
European Notified Bodies in providing common interpretations of procedures relating to ATEX certification by issuing ‘Clarification Sheets’. I also alluded to the IECEx having a similar system of issuing ‘Decision Sheets’.
known as an I-Sh, or Interpretation Sheet. After such a publication, IECEx may decide to delete the DS. I-Sh documents are automatically supplied with all future purchases of the standard. For those already owning the standard, the availability of I-Sh
concerned that some certificates appeared to allow combinations of terminals in increased safety junction boxes that would exceed the marked temperature class. This was because the necessary de-rating information for the individual terminals was not shown in the
documents can be checked on the IEC standards web site.
certificate.
The format of a DS usually follows the pattern of an introduction section, providing some background as to why the DS has been created, followed by a discrete Question and a related Answer. For example, DS 2017/01 was published in June last year, following a proposal from the convenor of one of the MTs, and the
As soon as more than between ten and fifteen terminals are included in a single enclosure, it is necessary to apply a de-rating to the individual terminals in order to control temperatures. This relates not only to the heat produced by the current passing through the terminals, but also the heat produced by the current in the enclosed wiring. In large boxes with many terminals, the rating of the
background information explains that there is not as much clarity as required relating to whether or not cable transit devices should
individual terminals may need to be reduced to less than 30% of the current rating marked on the terminal. This is not usually a problem, as such junction boxes are normally
The Decision Sheet (DS) can relate to the certification process, or it can relate to a common clarification of a requirement
be tested exactly like cable glands. Certainly the standards can be read that way, but some transit devices have appeared on the market
used for marshalling instrumentation wiring carrying less than 1 A, but the certificate can sometimes not make the de-rating clear.
in a standard. It cannot introduce new requirements or remove existing requirements covered by standards. That is a matter for
that would obviously fail such requirements. After significant background detail we read: QUESTION: Do all cable transit devices or
A lot more background information is provided, but the meat of the DS is:
the Maintenance Team (MT) for the particular standard, which works under the authority of IEC standards committee TC 31 and its
entry devices need to fulfil the requirements for cable glands according IEC 60079-0 Clause 16 and Annex A and any other additional requirements in the applicable
sub-committees.
Type of Protection standards? Draft DSs can be prepared by any member certification body (ExCB) or testing laboratory (ExTL) within the IECEx System, or can be proposed by the standards MT or the IECEx Secretariat. All draft DSs are subject to comment and vote by the members of IECEx ExTAG and, where deemed appropriate relating to the content, by the overall Management Committee of IECEx. There is also consultation with the relevant MT, if the
ANSWER: Yes, the requirements for cable glands have to be applied to all cable transit devices or entry devices, where the cable(s) are designated to connect different Ex Equipment enclosures or to lead into an Ex Equipment enclosure. All certificates issued by ExCBs for cable
QUESTION: In arrangements where there is a necessity to de-rate terminals (typically when an enclosure contains more than 10 to 15 terminals) is it necessary to indicate this de-rating in the information provided as part of the certificate? ANSWER: Yes. IEC 60079-0 contains the requirement in 6.1 b) that the equipment should comply with the normal industrial standards for the application, in addition to the specific Ex requirements of the IEC 60079 series. Such industrial standards would be presumed to include a requirement that the rating of the equipment is marked.
DS relates to clarification of a requirement in the standard.
transit devices will now follow this requirement. Meanwhile, the relevant MTs are looking at clarifying the texts in their next editions.
If the MT believes that the DS is of sufficient import, the MT can also issue an official
My colleagues at SGS Baseefa proposed the draft for DS 2017/004 which was published
For the full background information to these decisions, and to see all other published DSs, please go to www.iecex.com and follow the links to Publications, then ExTAG Decision
clarification in the standard itself, a document
in November last year. We had become
Sheets. All are free to download.
www.hazardexonthenet.net
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2018 Event Review 17
See the 2018 exhibition review video by clicking here
Hazardex 2018 Conference & Exhibition Many thanks to all attendees T
he Hazardex 2018 Conference & Exhibition for hazardous area
and the 2018 event benefited from a strong conference programme focused
and process safety specialists took place on February 28 and March 1 in Runcorn, Cheshire, and was judged
on cybersecurity, risk management, Industry 4.0, functional safety and practical challenges in hazardous environments. For
a success by attendees, even though difficult weather depressed overall visitor numbers compared to last year. Blizzards and high winds made access
reviews of the two conference streams by each chairman, go to pages 20 and 21.
to the event even more exciting than usual, and the organisers would like to thank all those exhibitors, speakers and delegates who braved the elements to attend.
The Conference & Exhibition aims to strengthen and expand the community that looks to the Hazardex website and journal for industry intelligence and information,
Although the main focus of the packed-two day event is the conference, the attached exhibition is also a vital element, and the 2018 event saw 36 hazardous area sector companies display their products and services to the assembled professional audience.
www.hazardexonthenet.net
18 2018 Event Review Exhibitors ran the gamut from process control electronics and software providers
The event offered exceptional opportunities for networking, with attendees from
The 2018 event also saw the Hazardex Awards ceremony, designed to recognise
to consultancy, certification and training companies, with a number providing niche technical solutions to the hazardous area industry. See the full list below.
government agencies, regulators and certification bodies meeting up with senior engineers and safety managers from the high hazard and process industries to share their experiences.
excellence in the hazardous area sector. A full list of winners and runners-up is provided on page 22 and 23.
These opportunities came to a climax at the drinks reception and Gala Dinner at the end of the first day, with after-dinner entertainment provided by the well-received stand-up Ian Irving.
and to all of our exhibitors.
A large majority of exhibitors expressed satisfaction with the quality of contacts they had made, to the extent that a majority indicated they intended to rebook stands in 2019.
We would like to express thanks to the event sponsor, CSA Group,
The organisers have announced the 2019 event will take place at the same venue on February 27 and 28.
The Conference & Exhibition aims to strengthen and expand the community that looks to the Hazardex website and journal for industry intelligence and information
Hazardex 2018 Exhibitors ABB
CCG UK
Getac
Newson Gale
Roxby
Anamet Europe
COGENT Skills
Hornbill Engineering
PEI Genesis
Sella Controls
ATEXOR Oy
CorDEX Instruments
Intertek
Peli Products
SGS Baseefa
Beka
CSA Group
Kan’to Instruments
Phoenix Contact
Tempa Pano
BSI (British Standards Institution)
Dekra Process Safety
Lewden Palazzoli
R Stahl
TVC training
Draeger
Moflash
RAS
Vega
C&P Engineering
Exloc
Moore Industries
Randall & Daniels
Services
FES Ex
Mutech
Rheintaco
www.hazardexonthenet.net
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Hazardous Areas
20 2018 Event Review
Hazardex 2018 – Main Conference Chairman’s Report O
nce again, I was only too happy to accept my invitation to chair
Since last year’s conference the HSE has embarked on an awareness raising campaign
Hazardex 2018 and brave the attendant blizzards and snow drifts, the ‘Beast from the East’. It was testament to the enthusiasm and resilience of our Hazardex speakers, several of whom had flown into the UK from abroad, that all succeeded in
to see where where industry is positioned with respect to cyber risks. Early indication is that a lack of both a formal CSMS and proper segregation between process control and IT systems will prove to be a conspicuous weakness across the sector. The HSE will
making the event.
shortly be publishing a consolidated report on the outcomes from the trial.
Hazardex 2018 Main Conference Stream Chairman Lee Allford, Energy Institute
I was especially looking forward to this year’s conference because the programme featured the topic of cyber security and more specifically the implications of cyber threats on
HSE is also currently in discussion about assuming the competent authority responsibilities under the Networks and
threats have the potential to give rise to common mode failures and to simultaneously
major accident safety. As part of my work for the Energy Institute I have seen a bewildering
Information Systems (NIS) directive when it comes into force in May 2018. If successful,
knock out several layers of protection. One speaker who shared lessons on accidents
amount of publicly available guidance on the subject from entities such as international bodies, national agencies, the insurance sector, trade and professional associations
the benefit for industry will be a common approach to inspecting both COMAH and NIS during a single site visit. NCSC is to produce guidance for the competent authority to use
specifically involving the storage and handling of fertilisers noted a pattern of catastrophes which have occurred since 1900 such as
and technology vendors, and the Hazardex presentations provided a welcome overview.
for NIS regulations. Whilst cybersecurity is a growing concern
Oppau, Texas City, Toulouse and West Texas. Advances in technology will help improve our understanding of accident impacts, particularly where the environment is concerned.
The conference kicked off with a joint keynote presentation with speakers from the HSE and National Cyber Security Centre (NCSC).
there is no doubt, as one speaker reminded the audience, that digitalisation changes everything. The opportunities afforded by
In summary the take home message from Hazardex 2018 is that there is no security
The HSE presentation was a follow up to the Hazardex 2017 keynote, when it presented on the highlights of its operational guidance on
greater integration and better connectivity are heralding Industry 4.0, the fourth industrial revolution, with the potential for making
without safety and no safety without security. It goes without saying that cyber security needs to be designed into a system from the
Cybersecurity for Industrial Automation and Control Systems (IACS) which was published in March 2017 and provides a model for a Cyber Security Management System (CSMS). The guidance, which is aimed at inspectors, acknowledges that current risk assessment
better use of big data and identifying patterns and correlations which had hitherto been unimaginable. There is no turning back from the march of technology but at the same time there are increasing risks and vulnerabilities.
outset and managed throughout the asset lifecycle. Amongst the key vulnerabilities are a lack of awareness and training among
methodologies are not effective when it comes to cyber threats. Instead the guidance outlines a simple approach for an operator to follow which then allows an inspector to deem what is reasonably practicable.
makes bad things happen faster!
Sarabjit Purewal, HSE Head of Operations
www.hazardexonthenet.net
As another speaker noted, progress just
Cyber threats aside, the conference heard papers on incident and risk management, including power outages, which like cyber
Ian Curtis, Process Safety Senior Consultant, Siemens
workers and a limited cyber security culture among vendors, suppliers and contractors. With the conference focus on the upsides and downsides of increased and accelerating use of technology it may be reassuring and disturbing in equal measure that the weakest link in the security and safety chain remains the human component.
Zsuzsanna Gyenes, Deputy Director, IChemE Safety Centre
2018 Event Review 21
Hazardex 2018 – Seminar Stream Chairman’s Report
Hazardex 2018 Conference Seminar Stream Chairman Ron Sinclair, Technical Manager, SGS Baseefa
In the afternoon, we saw how the ‘Industrial Internet of Things’ (IIoT) related to cyber
from a very small source. A standard, IEC 60079-28, has been available for some time
security. In the industrial environment, additional problems arise as information technology and operational technology converge. Experts in one do not necessarily have expertise in the other, but to ensure security it is important to understand how
but has not been universally applied, leaving the possibility they might be an ignition source.
each influences the other in the connected world.
compressed by a seal in a cable gland can shrink to a point where the cable is no longer held securely and the level of insulation is decreased to an unsafe level. We learned how to measure cold flow characteristics and what to do to remediate this situation.
Then we looked at ‘cold flow’ in cables, where over a period of time, a cable
had the privilege to chair the Seminar stream at the two day conference. While the majority of attendees were listening to the speakers in the main
Another interesting session involved a look at how one company was rationalising the differences of approach between conventional plant inspections, such as required by IEC 60079-17, and the
conference room, a good number opted to switch in and out to the seminar room, where more specialist
assessment of proof test intervals required by IEC 61508. More and more, the safety of a plant depends on an understanding
static electrical discharges, how they occur and the best ways to prevent static being a source of ignition. The guidance given in IEC
topics were under discussion.
of both these approaches and it is best to combine the assessments into one set of data for the plant.
60079-32-1 is a vital source of information, in addition to talking with companies that specialise in this field.
ensuring work is done well and safely. Empowering people to use their knowledge and skills is much more effective than laying
An important aspect of cyber security is the role of the system integrator. HSE Operational Guidance document OG 86,
And finally, we had an overview on the development of standards, and their role in managing risks in hazardous atmospheres.
down rigid procedures. Culture determines how people behave “when no one is looking”.
Cyber Security for Industrial Automation and Control Systems (IACS), which integrates well with IEC 62443-2-4, seems to be the
Ten sessions, some with ideas in common, and others on totally different subjects, but
Next, we had a free flowing discussion on the effects of mental health issues
most important part of the multipart standard on the same subject. System integrators are all well versed in the IEC 61508 or IEC
all providing food for thought in their own areas. I am sure those attending that were still with us for the final session may have
in the workplace as well as in the home environment. The stigma surrounding mental health is gradually being broken down. Employers are now able to recognise when
61511 SIS issues, but they also need to be up to speed on the security aspects. A presentation on LEDs was well-received
been having anxious glances out the window at the weather, but at Runcorn we actually saw the sun for short periods. Like me, a few travellers going directly east decided that
a mental health issue might also lead to safety issues affecting either the individual or their work colleagues, and take appropriate action to help that individual.
as, despite their popularity, they have brought a number of additional problems in the Ex field, not least because the optical radiation can come at very high intensity
staying the extra night was a safer option, but I am sure all those who attended the presentations in both venues felt it had been worthwhile.
Dr Kevin Fitzgerald, Risk Dept. Manager, Lloyds Register Energy
Matt Jakuc, Cybersecurity Technical Lead, CSA Group
I
Our first session focused on safety culture, which is as important as competence in
UKPIA Safety Director Jamie Walker
The penultimate session covered risks from
www.hazardexonthenet.net
22 2018 Event Review
Hazardex 2018 Awards for Excellence O
ver the last decade, the Hazardex Awards for Excellence programme has become a benchmark for those
Runner up: Ion Science - Cub Personal VOC Detector Runner up: Moore Industries - STZ
supplying products, services and systems within hazardous areas. The results of the 2018 programme were announced on the evening of February 28 at the Hazardex 2018 Event Gala Dinner at the Holiday Inn Hotel in
Functional Safety Dual-Input Smart HART Temperature Transmitter
Category 2 - Best User Application An application highlighting the benefits
Runcorn. Thanks to Awards evening sponsors Getac, RS Components and C&P Engineering Services.
of a product, system or service for use in hazardous areas
(Left) Josh Jones of Scotload, Contribution to Safety Award winner, presented by sponsor James Howarth of RS Components
Winner: SA Equip - SA POWERNET Mains Distribution Unit Exceptionally sturdy, stable, lightweight and portable, the SA POWERNET range features marine-grade steel and practically indestructible composite for decades of maintenance-free service in the most demanding of conditions.
Category 1 - Contribution to Safety A product, system or service which has made a significant contribution to safety in hazardous area environments
Centrica were looking to reduce costs and extend the life of the Rhyl Field, and SA
Winner: Scotload - Smartload Wireless Monitoring Technology
Equip were commissioned to assess the power supply on the Normally Unmanned Installation and provide cost-saving solutions.
Scotload’s ground-breaking SmartLoad wireless monitoring technology provides users with total system control and
ATEX certified products were required as the platform was still processing gas, however limited capacity on board led to the necessity
flexibility. SmartLoad uniquely incorporates intelligence and memory directly on the load cell itself, increasing functionality while
Louise Green of SA Equip, Best User Application Award winner, presented by sponsor Tristan Jones of C&P Engineering Services
enhancing the efficiency and safety of your lifting operations.
for portable power solutions. SA Equip products are lightweight and portable which enabled easy transportation of products around the deck using minimal manpower, reducing costs which was a requirement as they had limited resources
SmartLoad delivers a standard technology platform for use across a range of products. Requiring only one handset to connect links, shackles and other load cells, it reduces operational costs.
to spare. Centrica’s decision to buy the equipment was helped as the expenditure spread over the five-year period equalled a very low-cost of ownership, compared to the original intention of renting the equipment.
SmartLoad wireless technology is also now Zones 1 & 2 hazardous area approved.
Runner up: Ametek - XP2i Digital Test We have also recently achieved US and Canadian certification making us the only company with products certified to international, European and US and Canadian standards, providing total assurance to customers.
www.hazardexonthenet.net
Joanne Dean of Roxby collecting the Technical Innovation Award on behalf of winner ExHeat, presented by Mark Bannister of RS Components
Gauge with calibration reminder alert feature Runner up: CorDex - TOUGHPIX DIGITHERM ATEX and IECEx Digital and Thermal Camera
2018 Event Review 23 Category 3 - Technical Innovation An innovative product or system for use in hazardous area environments Winner: ExHeat - MFH Bulldog Portable Fan Heater The MFH Bulldog Portable Fan Heater is the world’s first truly portable hazardous area fan assisted heater. The Bulldog combines efficient design with simple functionality to provide a portable heating solution for use in hazardous environments where the atmosphere is classified as Zone 1 or 2 (IIA, IIB & H2). Certified to the new EN ISO 80079-36 and EN ISO 80079-37 standards for constructional safety, the Bulldog comes ready to ‘plug and play’ with the option of fitting a plug, or hard wiring to an isolator unit.
professionalism when dealing with enquiries
Exhibition, is for a product or service
and purchase orders from our company. Their level of customer service, attention to detail and speed of response really does afford us a competitive advantage.”
displaying particular excellence in the hazardous area sector over the previous 12 months
Supplier comment: “Exloc Instruments have been GM International’s sole distributor for the UK and Ireland now for six years. In that time they have represented us successfully and provided a responsive and efficient customer service to our growing UK customer base.” Runner up 1: FES/Roxby Runner up 2: Extronics
Category 5 - Event Delegate Award This award, with voting restricted to delegates at the 2018 Conference and
Winner: Moore Industries - STZ Functional Safety Dual-Input Smart HART Temperature Transmitter The newest member to the Moore Industries Associated Intrinsically-Safe (AIS) family of products is the SIL 2/3 capable STZ Functional Safety Dual Input Smart HART® DIN-style Temperature Transmitter with Associated IS sensor connections. The STZ is certified by exida to IEC61508 for systematic integrity up to SIL 3 and for single use in Safety Instrumented Systems (SIS) up to SIL 2. The STZ is designed and developed in strict compliance with IEC 61508 standards to provide the highest level of
The casing is moulded from a steel reinforced polymer which makes the Bulldog tough and durable. Using adjustable feet, the
system integrity and reliability.
heater can be angled to allow for flexibility in its positioning and, with its compact design, can be easily stored or transported.
STZ-DIN allows direct connection of sensors located in hazardous locations by including an embedded intrinsically-safe barrier in the front end of the STZ-DIN. The
Runner up: Mantracourt - X24 ATEX/ IECEX Wireless Telemetry Sensor System
STZ-DIN -AIS is an associated apparatus suitable for mounting in Non-Hazardous or Class I, Division 2/Zone 2 hazardous
Runner up: Getac - EX80 Fully Rugged 8-inch Tablet
locations with sensor input terminals connected to sensors or equipment in Class I, II, III, Division 1/Zone 0/1 hazardous
Category 4 - Customer Service A company or corporate division that has provided excellent customer service in the sector over the last two years
The intrinsically-safe -AIS option for the
(Left) Alison Fitzpatrick and Jenny Tither of Exloc Instruments, Customer Service Award winner, presented by sponsor Tal Hopkins of C&P Engineering Services
Winner: Exloc Instruments UK
associated apparatus includes the barrier in the receiving device. There is no need for the additional cost of the IS barrier, cabinet space, high integrity clean ground connection, separate power supply, or custom vendor backplanes.
Exloc Instruments is committed to excellence in customer service. We have a team of dedicated, experienced staff offering a professional, ethical and innovative service to our customers. We pride ourselves on being able to respond to customer needs in an empathetic and flexible way, and within
Hazardex 2018 Award sponsors were RS Components (Gold) and C&P Engineering (Silver). Check out their websites at: https://uk.rs-online.com/ web and http://www.cpengineering. co.uk
the time frame required by the customer. Customer comment: “Charter Tech should like to commend the team at Exloc Instruments for their diligence and
locations. Installation costs are reduced if an associated apparatus (STZ-DIN with -AIS option) is used, since the
(Left) Rob Stockham of Moore Industries, Event Delegate Award winner, presented by Hazardex Editor Alan Franck
For details of the 2019 Awards programme, contact us at events@imlgroup.co.uk
www.hazardexonthenet.net
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Petrochemicals 25
Artist’s impression of the completed PPC plant - Image: Shell
New Shell Pennsylvania Petrochemicals Complex
takes advantage of shale revolution I
n November 2017, Shell Chemicals officially started construction on its
This article, by Hazardex editor Alan Franck, looks at the scale of Shell’s
In addition, the company will build a 250-megawatt natural gas-fired power plant,
$6 billion Pennsylvania Petrochemicals Complex (PPC) ethane cracker plant in Potter Township, Pennsylvania, a project
project in Pennsylvania, and some of the likely consequences of the shale revolution on the petrochemicals
which will produce electricity and steam to run the cracker plant. About one-third of the electricity produced at the site will help supply
that will take several years to complete. Shell made it official in June last year when it announced a final investment
sector.
the local electrical grid.
The site preparation at Potter Township in
Finally, Shell will construct a 275-metre-long
decision on the plant. Since then, crews have been working around the clock to prepare the site for main construction.
Beaver County was a significant undertaking by Shell, which moved 5.5 million cubic metres of earth to transform the site, which
cooling tower, a co-generation tower, rail and truck loading facilities, a new water-treatment plant, an office building and a laboratory.
previously held a zinc smelter. These crackers—where ethane from shale gas is ‘cracked’ to form ethylene are transforming the US petrochemicals industry. Research company IHS estimates that the country’s ethylene capacity will expand by a massive 38% in the next few years, with new plants planned in Texas and Louisiana, as well as western Pennsylvania.
In addition, more than 4,200 steel pilings were installed for foundations across the property, while new bridges and rail lines were installed and state Route 18 was relocated in front of the plant. Now that the site is fully prepped for construction, the actual plant is ready to be built.
Traditionally, most plants made ethylene out of crude oil. But in the US, the chemical industry’s use of cheap ethane-rich natural gas from shale formations as a raw material has
The construction will include four large processing units that include one ethane cracker and three polyethylene units. The ethane cracker will be the most significant
climbed from 50% to 80% in recent years, according to IHS.
part of the plant with more than 200 major components and 95 miles of pipe.
The largest part of the facility will be the ethane cracker, comprising seven tail gas and natural gas fired ethane cracking furnaces featuring a rating of 60 million metric British thermal units (MmBtu) per hour of heat input each. Its furnaces are to be equipped with low NOx burners and will be controlled via selective catalytic reduction (SCR). One 1.5 million tonnes per year ethylene manufacturing line and two gas phase polyethylene manufacturing lines with an output capacity of 550,000t per year will also be part of the facility. In addition, one 500,000t per year slurry technology polyethylene manufacturing line will be installed.
www.hazardexonthenet.net
26 Petrochemicals The site will also feature four diesel-fired emergency generator engines and three dieselfired fire pumps. The petrochemical complex will feature facilities to facilitate the handling of polyethylene pellet blending, handling, storage and load-out processes. These facilities include one recovery oil storage tank, one spent caustic storage tank, two equalisation wastewater storage tanks, and one light gasoline storage tank. Two hexane storage tanks and two pyrolysis fuel oil storage tanks will also be built, along with a variety of miscellaneous storage tanks.
“Fence-line monitoring is used at other (Shell) facilities but was not included in our permit
The Potter Township plant will be at the centre of the Falcon Ethane Pipeline System, a 156 km pipeline network connecting three major ethane source points in Pennsylvania and Ohio. Shell Pipeline Company LP will build, own and operate the Falcon System.
Shell has also announced significant investment in environmental monitoring
due to the comprehensive internal monitoring Shell incorporated in the design,” Minnitte said. “In addition to the fence-line monitoring, Shell will have several hundred in situ gas and flame monitors along with a leak detection program
and control systems. It has signed an agreement with the Clean Air Council and the Environmental Integrity Project whose
monitoring over 70,000-plus components throughout the facility. This effort will utilize a combination of internal and external
Final right-of-way purchase efforts have been completed, permits have been submitted to state and federal agencies, and mainline
terms include the installation and operation of a fence-line monitoring program to ensure that any gases or contaminants remain at
resources.”
construction is scheduled for 2019.
The facility is expected to use shale gas from
The mostly 12-inch pipeline will secure
The company will also increase the frequency
the Marcellus and Utica basins to produce 1.6 million metric tons of polyethylene per year. That polyethylene will be used to make
ethane supply, building new and reliable infrastructure while keeping safety as the top priority, Shell says. The project will bring new
of monitoring the plant’s flares and ensure it meets or exceeds the requirements of the Clean Air Act by removing 98% of pollutants.
a wide array of products from food packaging to furniture to sports equipment, according to Shell.
jobs to the area, with up to 1,000 workers at peak of construction.
Joe Minnitte, a spokesman for Shell Chemicals, said the fence-line monitoring is in addition to other air pollution monitoring the company planned internally for the cracker plant.
At its peak, the project will require 6,000 construction workers, while 600 permanent
Potter Township is about 50 kilometres northwest of Pittsburgh. As a result of its close proximity to a reliable source of natural gas,
jobs will be created when the plant becomes operational early next decade.
Shell says the plant and its customers will benefit from shorter and more dependable
acceptable levels.
www.hazardexonthenet.net
All images - Shell
Petrochemicals 27
supply chains, compared to traditional sources of supply from the Gulf Coast. The location is
PTT was also offered sweeteners. Back in 2015, the company said JobsOhio, the private
also ideal because more than 70% of North American polyethylene customers are within a 1,100-kilometre radius of Pittsburgh.
economic development arm in the state, offered it an aggressive incentive package if it would build its cracker plant there, according to Columbus Business First. PTT said the proposal included tax credits for job creation, workforce training and infrastructure improvement grants, and local tax credits.
Other than Shell, Thailand-based PTT Global Chemical is also considering building an ethane cracker plant in the area, according to local sources, on the site of a now-demolished coal-fired power plant along the Ohio River in Belmont County, Ohio.
Because of the low cost of US ethane, the cost advantage of plastic made in the United States is significant, compared with Europe or Asia.
According to Construction Dive, these plants are big moneymakers. During a results forecast in
Other chemical makers that depend on natural
late 2017, Royal Dutch Shell said it expected the fully operational Potter Township plant to help add $3.5 billion to $4 billion of earnings each year to the company’s chemical division.
gas - such as fertiliser producers - are also building new plants. In the next five years, the industry expects to build or retrofit about a dozen facilities.
And according to National Public Radio, Pennsylvania gave Shell a 25-year, $1.65 billion tax credit to build its plant in the state. Officials
An industry-funded study from research company IHS estimates that the US chemical industry will make $129 billion in new
agreed to a 15-year tax amnesty and will give Shell a $2.10 tax credit for every gallon of ethane it purchases from state natural gas drillers.
investments nationwide as a direct result of shale gas - adding more than 50,000 permanent jobs to a workforce of around 800,000.
One of the conclusions of the International Energy Agency’s (IEA) latest five-year forecast, published in March 2018, is that the rise in the use of ethane and other shale-derived feedstocks will affect traditional refineries. World oil demand is expected to rise by 6.9 million barrels per day (bpd) by 2023, with a quarter of this growth coming from demand for petrochemical feedstocks ethane and naphtha. “Global economic growth is lifting more people into the middle class in developing countries and higher incomes mean sharply rising demand for consumer goods and services,” the IEA said. “A large group of chemicals derived from oil and natural gas are crucial to the manufacture of many products that satisfy this rising demand,” it added. Naphtha is made by oil refineries processing crude, but other petrochemical feedstocks - ethane or liquefied petroleum gas (LPG) are processed outside traditional oil refineries. “Ethane, liquefied petroleum gases and naphtha, pose a bigger threat to the refiners’ market share than electric vehicles and gas-powered transportation combined,” the IEA said, estimating refiners would see just 4.8 million bpd of the demand growth to 2023, missing out on 30% of it. The boom in US shale gas has dramatically expanded the availability of ethane, and a string of new projects are underway to process it. In total, the world is expected to add 1.4 million bpd in new petrochemical-producing steam crackers to 2023, the IEA said. Demand for ethane will expand at the fastest pace in the next five years, rising by 885,000 bpd, followed by naphtha with growth of 495,000 bpd and LPG with growth of 40,000 bpd, it forecast.
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Investigations 29
Better Investigations – getting value from investigation methods and process: What does good look like and does it really have to be complicated?
I
n this article, two very experienced ex-regulatory investigators working
availability of incidents or by the time and resource made available to investigate. This
Training is often more method- and software-focused and not well consolidated
for the BP group give a practical view of investigation as a process and an activity, rooted in a largely non-
makes gaining experience and expertise a challenge. Investigation methods vary widely too and are often adopted for perceived (but
by structured on-the-job training or other practical support. Human and organisational factors (HOF) are often not included
methodological approach.
then not fully realised) benefits. For example, a method may offer better and more detailed
effectively and are also very variably addressed in the methods themselves. Even the best methods are in the end
BP International Human Factors Advisor (Downstream) Simon Monnington and Independent Human Factors Consultant John Wilkinson here build on an earlier joint paper (Ref. 1) and update the ongoing case study, presented at the Hazardex 2017 Conference.
In practice, a single method may not be enough for all situations and so a toolbox approach is better
Investigation can be a very challenging activity for many people, whether they are leading or just occasional team members. Even after a good investigation, the actual impact of recommendations and their implementation can be disappointing.
root cause identification. But in practice this is made difficult for users by having multiple drop-down menus and poorly-explained choices. Methods may offer alleged improved validity and reliability, but again coupled with
Opportunity is anyway limited either by
poor usability.
very reliant on the investigators’ own HOF understanding and experience – so claims of HOF integration (and few methods offer this) are often unrealised in practice. Organisations may try to investigate lower level incidents and near-misses but there may be barriers, for example their internal incident classification system may only allow a site to deploy limited resource and capability to investigate. The resulting outcomes can then lack depth and rigour. Outcomes generally can just produce the usual suspects such as
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30 Investigations
more and longer procedures, and narrow
job competencies, and the competency
Traditional investigation methods are said to
re-training i.e. ‘fixing the last accident, not the next’. There is often a corresponding reluctance to improve design or take other measures higher up the hierarchy of control, or to tackle organisational factors such as resourcing, work planning and change issues.
management system. So the organisation may often fail, not just the individual.
Investigators can only find what they look for, and what they have the time, training, support
in practice, few – if any – actually do. There are a few standalone methods to consider
be linear. A Safety-2 stance is more forward looking, characterised by ‘chronic unease’ and a corresponding vigilance for system disturbances. So for investigation what does this mean? In essence it means making sure that as investigators we come to understand what made sense to those involved in the incident before things went wrong. In most
and ‘permission’ to look for. In this context the behaviours of real concern are those of the organisation, not of those closer to the sharp end.
HOF and human behaviour aspects, in addition to the normal investigation method. Be careful with methods that just offer lists
cases those involved did not see the incident coming so it follows that their view was different to what has subsequently been
or dropdown menus - does anyone really understand?
established by investigation.
Where methods are concerned, it’s vital to consider HOF. In a perfect world all methods would have these integrated appropriately but
Investigation depth can also be affected by contributions from others in the system.
Consider also the outputs – are they realistic
Whether error or violation was involved, they were not trying to cause an incident and did
Potential recommendations/actions may be challenged or played down during review and discussions. Lead investigators may feel
(not just SMART) and are they actually likely to be implemented? How clear are the recommendations and what happened to
not – with the information and experience they had - think it likely that one would occur. However, the few new Safety-2 investigation
under pressure not to push findings, especially if a senior manager does not really understand the issues concerned. This may be disguised
them?
methods are as yet not tried and tested. While there have been some case study reports, it is to date hard to see what the new methods are
by a “these recommendations are not SMART enough, too fuzzy” etc. response. It is also difficult if investigation findings reflect poorly
Investigation is the mirror image of hazard and risk analysis but we are looking backwards instead of forwards, i.e. in the rear-view mirror,
adding if judged by their outcomes.
on leadership by having a proper focus on the organisational contribution.
not through the windscreen. The human contribution must be properly considered and this includes recognising that most of the time people get things right, or at least
neutral terms such as ‘debriefing’ witnesses and others post-incident, rather than the more formal word ‘interviewing’ with all its implications. What you want to do is learn
make them work right. Often people (including you and me) are ‘working around’ difficult or sub-optimal conditions to get things done. In practice, we are often compensating for poor design or arrangements. When things go right all is well, when things go wrong then suddenly we are in the spotlight. And investigators have 20:20 hindsight (one of
first, then any proper accountability can follow if justified. But don’t start with this.
So what is needed? In a nutshell: an adequate narrative (the story), a reasonable timeline and effective analysis. Also proper consideration of what influenced performance on the day, the performance influencing factors (PIFs). These make human failures more or less likely on the day – if you have ever asked ‘Why this person, and why today?’ then the reasons lie in the PIFs. Usually people get things right and often they work around sub-optimal conditions. PIFs can be divided between the job, the person and the organisation, and often in practice will overlap across more than one, for example competence resides in the individual, the
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What is the process?
our well-known cognitive biases). The Safety-2 approach (Ref. 2) captures this kind of thinking, taking a systems’ stance to reflect the inherent complexity, messiness and non-linear state of the real world.
It will also help to consider using more
So what method to use? Keep it simple: does the method help you reliably establish a sufficient narrative, timeline and analysis? And does it encourage you to seek out corroboration and other support for key evidence to make sure hindsight bias is not distorting the investigation? Are other stories (explanations) considered? More than one story can explain a set of facts - so which is the right story and how does the method help you check this out?
Investigations 31
It’s vital that the method has good usability. Is it in fact used, and used consistently, and
Confirmation bias: our tendency to be selective in the evidence we look for, or that
They need training that goes beyond just the method(s) being used, for example,
is it really understood by the users? Are the method’s limitations and advantages known? And is there evidence that the method tail is wagging the dog? Check the outcomes to find out. Is there clear organisational support and understanding and is this expressed through effective training, resourcing and
we value on finding. So if we think a violation occurred, we won’t look hard for evidence of contributing errors at the individual or organisational level.
how is this applied to our workplace, our processes, my role, my investigation team and so on. They also need informed awareness of biases, of human and performance influencing factors including human behaviour, of method strengths and weaknesses. If the difference between errors
management support? Finally, is there sufficient HOF focus in the method – or allied approaches – and do investigators have sufficient (awareness of human and performance influencing factors? If they don’t, then the method can’t achieve this on its own.
contribution to an incident, and underestimate external factors, and to do the reverse for ourselves. For example, you were speeding – I was in a legitimate hurry to get to X on time, I’d done my risk assessment, the traffic was light, I had a lot on my mind, the signing was
and violations is not well understood then there is a big problem because the solutions to these two fundamental types of human behaviour are different.
poor, the light was poor etc. etc.
consider teams as well as individuals. Soft (non-technical) skills are important such as communicating effectively with others, and good interviewing skills are essential and require training.
Fundamental attribution error: our strong tendency to over-estimate an individual’s
Investigation is usually a team process, so
In practice, a single method may not be enough for all situations and so a toolbox approach is better. As a minimum, this means having a simple method for everyday and
There are others. Investigators need to be aware of these for themselves and for witnesses and other parties. They also
something more sophisticated for larger or more complex incidents. Starting with the simple method will soon tell you if you need
need to look for corroboration and different sources of evidence, and look for other stories that could explain the facts.
The BP approach
Training and competency
something else.
BP utilises a ‘logic tree’ method for analysis
Not everyone is a good fit for investigation –
of higher severity incidents and HFAT (Human Factor Analysis Tools) for human factors analysis. The logic tree - think of it as a type
These biases are part of what it is to be human. For investigation the most important ones are:
there should be some structured selection process (not just: ‘All supervisors will…’). Investigators need to be able to gain experience
of why / because analysis, similar to fault tree without the logic gates - is developed by the team using their choice of off-the-
Hindsight bias: the fact that we know what went wrong can let us view the pre-incident
and consolidate their training in a structured way. Where actual incidents are not available then substitutes such as cold case reviews
shelf software. It is a free-flowing method that involves early development prior to significant evidence collection allowing
picture very narrowly and without trying to understand why, for those involved, what was happening up until things went wrong made
and, even better, applying investigation skills prospectively through, for example, monitoring, audit and review, will find the factors that matter
hypothetical causes or contributory factors to be identified.
sense to them.
before something goes wrong.
The advantage of doing this is that the analysis tool can be used to frame lines of enquiry for investigation. The logic tree is then revisited and hypotheticals ruled in or ruled
Cognitive biases
Usually people get things right and often they work around sub-optimal conditions
www.hazardexonthenet.net
32 Investigations out. There follows a fresh round of hypothesis development and this cycle continues until
recommendations to help prevent recurrence.
draining the system. However, the incoming operator closed two drains and this was that
sufficient depth is realised. BP uses the logic tree to drive identification of lines to follow, and to capture and map causes and contributions. The completed tree then reflects all the causes identified and ruled in, ruled out or unverified. It therefore helps the investigator maintain a record of the breadth
So there is an ongoing program of HOF coaching during investigations, provision of training, discussions in investigator community forums and the deployment of HOF expertise as part of investigations which have a critical behavioural theme.
operator’s normal method for draining the system. The solution was released through the open third drain. It was found that the SOP in use was imprecise, for example ‘close all drains’, updated frequently and not written with sufficient operator involvement. In one of
and depth covered. The logic tree approach explicitly aims to address physical, human, management system and organisation / leadership factors. In addition, the method requires the
An example of this was on February 15 at a petrochemicals site where there was a release of 25m³ of an acetic acid solution during the process of filling the process plant after routine maintenance works. The temperature of the solution released was
investigator to look across the whole logic tree beyond the ‘linear’ cause and effect relationships. HOF are captured and analysed using LT linked to the BP human factors tool kit. For complex incidents, investigators are
67°C, marginally above flashpoint. The solution was released into the unit sewer system and captured at the waste water plant. Nobody was injured in the incident and the operation remained well within
provided with and trained in HFAT, developed by The Keil Centre. The completed LT then drives the development of findings and
the boundaries of the site’s environmental permit. Given the quantity of the release of the acetic acid solution, the incident was
The site took action in response to the incident, including: • Organisational structure – new unit operations leader roles created, allowing verification of task execution • SOP development and review tools and
recommendations.
classified as High Potential. At BP, this level of investigation involved the deployment of a Master Level investigation leader and
training rolled out • Updated policy on SOP development to reflect new tools and training
the utilisation of the logic tree incident investigation methodology.
• Enhanced self-verification processes implemented to check the area of operational rigour and line-ups before
The investigation identified that the outgoing operator opened three drains to drain the system - the operator’s normal method for
commissioning • Learnings from this incident applied into wider organisation
Experience so far The use of Logic Tree with HFAT, matched with a capable lead investigator, is driving breadth and depth in investigation. Findings tend to fall out of the approach more readily and this makes it easier to record
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the recent SOP updates, the unit leadership introduced the option to use the third drain in earlier steps of the SOP, allowing judgement of the operators. Unit leadership did not specify in writing in the SOP how to drain for the last steps of the SOP, nor did it specify expectations in another way, nor did it verify the task execution.
Investigations 33 The way forward The quality of HOF analysis and recommendations in an investigation report are primarily dependent upon the capability and performance of the investigation team. Remember, investigation teams are human too and as such subject to HOFs. Investigation methods, training and support from the organisation are all important factors in enabling an investigation team to do a good job. There are no perfect methods out there, and none that fully integrate human factors. So take a toolkit approach and have more than one method available, for example one simple, one for more complex cases, and possibly one for helping understand behaviours of concern. Make sure investigators have sufficient human factors’ awareness and understanding. Choice of methods should
working, interviewing, human factors / behaviour understanding (including key
References 1. Investigation – What Does Good Look Like
cognitive biases), and communication skills – needed to investigate well, as well as the need for structured practice and consolidation. Use cold cases or the same principles - for example the performance influencing factors – to apply prospectively
and Does It Really Have to Be Complicated? Simon Monnington and John Wilkinson. IChemE Hazards 26 Conference, Edinburgh, 2016. http://www.icheme.org/communities/ special-interest-groups/safety%20and%20 loss%20prevention/resources/hazards%20
as part of ongoing audit, monitoring and review before something goes wrong. Keep things neutral, for example use ‘debriefing’ rather than ‘interviewing’ and focus on the learning you want. If that includes proper accountability issues then you can move to
archive/hazards%2026.aspx?sc_trk=follow%20 hit,{0D792DA4-E5D3-4ADF-854C9478C33ADA27},wilkinson%20monnington
more formal approach. Either way, debriefing or interviews should be well structured.
humanfactors/topics/pifs.pdf
Look for corroboration and make good use of walking and talking through the incident and understanding the baseline against which to
be led by usability and simplicity – can those who are going to use them understand them, and will they be able to use them with
assess errors and non-compliance. Also, even if you have a coherent story that explains the facts you have established, make sure that
understanding. Method(s) should support and guide the team; the tail shouldn’t wag the dog. Check the (real, implemented) outcomes
there isn’t another (perhaps better) story that can do so.
to see if the method(s) are doing what you want or not.
Finally, make sure that relevant human behaviour in an incident is as rigorously approached as the technical and
Effective training requires more than just training on the investigation method. Don’t neglect the soft skills - such as team
engineering aspects. This will produce better investigations, recommendations and learning.
2. List of Performance Influencing Factors via HSE website: http://www.hse.gov.uk/
About the authors
John Wilkinson is currently an Independent Human Factors Consultant and an Associate at The Keil Centre, Edinburgh. He was Principal Human Factors Specialist Inspector and Human Factors Team Leader at the HSE from 1999-2011 and was lead HSE human factors investigator at Buncefield.
Simon Monnington is Human Factors Advisor, Downstream Safety and Operational Risk, at BP. He is a Chartered Ergonomics and Human Factors Specialist with a track record in incident investigation, safety optimisation and human factors in hazardous industries.
www.hazardexonthenet.net
34 Safety culture
The 2017 Survey: Process
Safety and Risk Management T
he 2017 edition of Petrotechnics’ process safety and risk management
(PSM) survey of senior leaders in the fields of process safety, asset integrity, and operational risk management in the hydrocarbon industry produced some interesting and occasionally startling insights into the state of operational risk and safety management.
The survey indicates important gaps in organisations’ ability to develop a single, shared view of the operational reality
evidence from the 2017 survey indicates that companies do not have readily accessible and carefully structured plans in place to achieve that goal. In fact, 61 per cent believe companies do not have well-defined safety performance measures, including leading and lagging safety indicators. What’s more, although reducing MAH risk is considered a major driver for improving
Safety culture, the real-world experience of risk, the various factors that affect
Indeed, achieving operational excellence
safety performance, 77 per cent believe that companies do not always maintain a sense of vulnerability about exposure to MAH risk.
and drive safety performance, and the role of systems and tools in enabling appropriate levels of safety and risk
was given as a main driver for improving safety performance for 61 per cent of survey participants. However, 59 per cent
Interestingly, only 31 per cent made a connection between improving safety
management were all discussed.
believe that process safety is not always fully incorporated within an organisation’s operational excellence strategy.
Simon Jones, head of professional services at Petrotechnics shares some of the survey results below.
A key component in operational excellence The connection between process safety and operational excellence is increasingly recognised. By operational excellence, we mean the pursuit of world-class performance that is delivered by enabling everyone within the organisation to consistently make the most effective operational decisions, taking into account a fully integrated picture of the risk, cost and productivity on operational reality.
www.hazardexonthenet.net
The top driver for improving safety performance was, not surprisingly, reducing operational and major accident hazard (MAH) risk – with 71 per cent of survey participants giving this as one of their drivers. However, despite the importance placed on reducing MAH risk, 57 per cent of the survey’s respondents said companies do not always have a defined roadmap in place for advancing safety performance. Although advancing safety performance and risk reduction is almost always a stated goal in company literature and annual reports,
performance and reducing operational costs.
Building a safety culture When asked to rate the factors with the greatest impact on PSM, organisational culture came top of the list – cited by 86 per cent of respondents. It was followed by maintenance and internal procedures (76 per cent each). However, 61 per cent also said that developing a safety culture was a challenge to delivering effective PSM – followed by 57 per cent who said leadership support was a challenge. Digging a little further into the role of leadership and culture, the survey showed that although corporate board members often say that safety is their highest
Safety culture 35
priority, that has not necessarily been well communicated or followed through. Among
operational risk as a whole. Once again, it is frontline operations that shoulder the
disconnect between process safety and frontline operations and the need for these
survey participants, only 36 per cent say that corporate or board priorities are a driver for improving safety performance.
responsibility.
two functions to be better understood.
Together this information suggests that process safety and frontline operations must be better connected, and the relationship between the two better understood.
They also add evidence to the inherent contradictions between safety culture and safety ambitions previously noted. This is confirmed by 70 per cent of respondents
Operators need to ensure that everyone across the business understands and manages risk against the same criteria — and has a practical understanding of how their decisions directly or indirectly influence the risk picture.
who acknowledge that there are gaps between the intent of process safety planning and what actually happens on the plant or asset.
The majority of respondents (65 per cent) also felt that the C-suite has little to no understanding of the health of process safety barriers and their importance. That said, the majority (51 per cent) also felt that the C-suite is responsible for understanding where there is risk, but not for measuring and evaluating its impact – or for managing and mitigating its impact. Perhaps more telling are the responsibilities attributed to frontline staff and functional heads respectively. The majority believe frontline staff – including shift supervisors, operations
Recognising the potential sources of risk, and how they can accumulate, is a key challenge that requires a “common currency” approach to managing the disparate sources of data. In this way they can construct leading indicators
This gets to the heart of the PSM challenge. There is a well-established body of mature engineering science around process safety that defines how to design and operate plants to keep assets and people secure, to keep process fluids in pipes, and to stop loss of primary containment escalating into a major accident. However despite the specifications arising from this body of knowledge, once the facility is built and
supervisors, or maintenance supervisors – are responsible for understanding, measuring, evaluating, managing and mitigating
that provide actionable insights.
operational risk. The overwhelming majority also believe that maintenance managers have responsibility for almost every aspect of
Under the anonymity of the survey, participants gave voice to comments rarely heard in public. Some of the most telling
operated, the in-built safety barriers start to degrade over time.
operational risk management – greater than both frontline safety supervisors and senior safety managers.
observations came when participants were asked why incidents and accidents still happen. For example:
This was acknowledged by 70 per cent of respondents, who believe or have observed that there is a measurable change in the
Connecting the enterprise
The role of planners and schedulers is also noteworthy. The majority of respondents
“Process safety is specialised knowledge, not typically understood by operations and maintenance, leading to implementation
level of risk exposure on the plant between planned PSM hazard review periods. As already noted, 61 per cent confirmed that
again believe these roles need to understand the risk levels on a given plant or facility and plan/schedule work accordingly.
gaps.” “Production takes priority over safety, which often leads to shortcuts and
companies do not always have well-defined leading and lagging safety indicators. These two facts represent a challenge for operators
However, with their vast list of equipment to maintain and resources to allocate, they are lacking the insight that this particular three dimensional game of chess needs.
safety incidents, despite corporate safety policies.” “Corporate lip service to PSM policies that are not backed up with effective and efficient planned preventative maintenance.”
– risk levels change between reviews and few indicators leading indicators are in place to try and get a handle on how risk is changing.
Equally significant is functional leadership and awareness of the health of safety barriers, which in the view of survey participants is much lower than their awareness of
These are by no means the only reasons given, but they are an indication of a
On top of this, perhaps out in the open for the first time, is an acknowledgement that only six per cent of respondents believe their companies are fully up-to-date with scheduled safety-critical maintenance.
www.hazardexonthenet.net
36 Safety culture Better information, better decisions
performance standards or expectations
combination of regulations and technology
The survey observed gaps between operational intent and operational reality and between policy and implementation. As one senior leader put it, “Risks are not fully understood.”
• 56 per cent do not have effective real-time solutions for monitoring and managing impaired process safety barriers • 74 per cent do not employ effective solutions for monitoring and managing the combined risk arising from operational activities, impaired health of process safety
have made their industry safer. The goal now is to build on that, and deploy the systems that enable organisations to bring PSM into the fold of operational excellence.
For example, 45 per cent said that communicating process safety principles to the frontline was a challenge to delivering effective PSM and 66 per cent believe that operations personnel do not always understand the aspects of their jobs that are
barriers and other management system deficiencies • Finally, 90 per cent believe that risk awareness and safety would be improved if the workforce and management had access to real-time process safety risk
The Petrotechnics PSM survey was conducted online between June 14 and July 27, 2017. More than 200 individuals took part, of whom 50 per cent have worked in process safety, asset integrity and operational risk for more than 15
most critical in managing process safety risk. To close these gaps, everyone within an organisation needs to be armed with the right information at the right time and in the right format so they can make better, more informed decisions.
indicators on the plant – a significant increase from 73 per cent in 2016 This challenge facing operators was neatly summed up by one of our respondents: “It’s important that we understand hazards on a real-time basis and that the continual state of barriers is maintained as designed
There is no shortage of information: only
to reduce incidents.”
11 per cent suggest that lack of data is a challenge for delivering effective PSM.
A single, shared view
Nor is there a shortage of IT systems: just 11 per cent see shortage of IT support as a challenge.
The survey indicates important gaps in organisations’ ability to develop a single, shared view of the operational reality. This critical information should be accessible to
What is needed is the ability to bring together meaningful OT data with intuitive real-time IT. The survey showed that although some
everyone from board-room to frontline and is essential to reducing exposure to MAH risk.
progress has been made on this front, there is still some way to go. For example: • 34 per cent of companies do not have
The good news is that process safety, operational risk and asset integrity professionals understand the complex
effective, real-time solutions for monitoring and managing operational activities • 54 per cent do not have effective, real-time
nature of the challenges they face, and the organisational, cultural and technological hurdles to overcome. They also appreciate
solutions for monitoring and managing deviations from management system
that tools and systems are there to provide the real-time safety analysis and summaries – and then publish that information to all who need it. Eighty per cent believe that a
Methodology and participants
years. Two thirds of respondents have management responsibilities at the corporate level, with the remaining third having single-site or regional responsibilities. Survey participants work in the oil and gas sector (44 per cent), chemicals (41 per cent) and other manufacturing or utility companies (15 per cent). About the author
Simon Jones is Head of Professional Services at Petrotechnics and has more than 20 years’ experience in the chemical, oil and gas industries. Currently, he leads the company’s global oil and gas consulting practice in operational management, safe systems of work and operational risk management. Simon is particularly interested in the potential of technology to transform the oil and gas industry by enhancing asset integrity and improving operational performance. Simon’s background is in process safety – he holds an engineering Master’s degree in process safety and loss prevention from Sheffield University in the UK and is actively involved in the Center for Chemical Process Safety’s (CCPS) European Regional network.
www.hazardexonthenet.net
Events 37
Safety 30 - Piper Alpha Legacy: Securing a Safer Future Date: 5 to 6 June 2018 Location: Aberdeen, UK It is 30 years since the world looked on in horror as the terrible events of Piper Alpha unfolded. Learnings taken from that tragedy have ensured health and safety offshore is entirely different now. How the legacy of Piper has shaped current operations and how we continue to create an even safer future is the focus of this conference – organised by Oil & Gas UK in association with the International Regulators’
Forum. Together we will turn the spotlight on health and safety plant, process and people in the past, present and future. Lord Cullen - who chaired the public inquiry into Piper Alpha - will remind conference of the need to build on safety lessons drawn from investigations of Piper and other major accidents for our industry and its people
‘digital’ generation of workers. We will also explore the importance of learning lessons as well as transferring experience from one generation to the next.
today and tomorrow.
These topics and others will be brought to life in plenary and workshop sessions by key industry and regulatory figures from around the world as well as experts from other industries.
Specifically, we will consider how the business environment affects health and safety; the impact of increased efficiency and lower costs, new operators, technological advances and engaging a
http://safety30.co.uk/about-safety-30
ACHEMA – World Forum and Leading Show for the Process Industries Date: 11 to 15 June 2018 Location: Frankfurt / Main, Germany More than 2,700 exhibitors from around the globe will be showcasing their innovations for the chemical, pharmaceutical and food industries from laboratory to largescale plant through to the packaging line. And there is no lack of topics: the energy turnaround, novel antibiotics, water treatment and innovative materials, to name but a few, as well as chemistry and process engineering solutions for practically all sectors.
Given the immense interest of exhibitors, the organisers anticipate a corresponding rush of visitors, which exceeded 167,000 for the last event in 2015. Pharmaceutical technology and automation are expected to be particularly popular,
for applications spanning vehicles to power stations, impact this sector worldwide”, explains Dr. Thomas Scheuring, CEO of DECHEMA Ausstellungs-GmbH. “That makes
but there should also be keen interest for ‘classical’ ACHEMA exhibition groups, such as pumps, process engineering and the
the event far more than just a trade venue – ACHEMA is where global trends are launched.” Besides business transactions at the fair,
laboratory sectors.
discussions at the stands and in the lecture halls are the heart and soul of ACHEMA.
“Many challenges, be they energy efficiency, shorter product cycles or novel materials
http://www.achema.de/en/home.htm
Hazards Australasia 2018 Date: 26 to 27 April 2018
pressure when maintaining operations.
Location: Perth, Australia Process Safety is at the heart of what we do and IChemE is pleased to announce that in June 2018, the globally recognised process safety conference, Hazards Australasia will return to Perth and be held for the fourth time. Since the inaugural Hazards Australasia in 2013, commodity pricing is still under great pressure in the global markets, and this means businesses continue to face
We are still seeing companies reduce employee numbers and strive to increase production at the same time. This has resulted in a need for those remaining and the businesses to be more resilient. We need to think about how we will not just maintain the status quo, but build resilience in our operations, including reviewing capabilities and responsibilities to ensure we can adequately respond to changing demands.
knowledge and competence, engineering and design, systems and procedures, assurance, human factors and culture are fundamental to managing process safety. You will see these topics reflected across all themes of the conference. www.icheme.org/events/conferences/
IChemE recognises that leadership across
hazards-australasia-2018
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38 Product Datafiles SIL 3 Capable SSX and SST Functional Safety Isolators from Moore Industries Provide Reliable Isolation for Analog and HART® Signals
Connecting you to Global Markets
Moore Industries’ SSX and SST Safety Isolators and Splitters provide reliable isolation and effectively pass valuable HART® data in Safety Instrumented Systems (SIS) and process control settings. Part of Moore Industries’ FS Functional Safety Series, the exida certified SIL 3 capable SSX and SST were designed and built to strict IEC 61508:2010 standards for use in safety-related applications. They protect safety systems by isolating an SIS from basic process control or monitoring systems so that disconnections or other failures don’t impact the safety system.
CSA Group is a global organization dedicated to safety, social good and sustainability. We provide testing, inspection and certification services for products in industrial and hazardous locations. We realise our customers need access to global markets and they need it quickly. As such, we’ve evolved our processes to respond even better to the pressures our customers face, while offering the marks needed to access markets around the world. Our large team of certification engineers are focused on completing projects within agreed-to timelines and we consistently start and finish projects with some of the best lead-times within the industry.
Learn More: http://www.miinet.com/InterfaceSolutionDownloadCenter/ Products.aspx?product=245
T: +44 (0) 1244 670900 E: ukinfo@csagroup.org
W: www.csagroup.org
Leading the Customer Service Experience in the Certification Industry
ATEX Certified Humidity/Moisture and Temperature Sensors
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.
ROTRONIC Intrinsically Safe sensors and measurement transmitters with analogue outputs are suitable for use wherever there is a risk of explosion due to dust or gas in the environment. HygroFlex5-EX transmitters and probes from ROTRONIC conform to the latest international ATEX standards. The transmitter is Intrinsically Safe (secondary side) , there are two channel outputs, the housing is heavy duty. Interchangeable probes are available for all applications, including those at pressure and low dew point.
T: +44 (0) 1244 670 900 E: ukinfo@csagroup.org W: www.csagroupuk.org
Technical datasheet available Tel: 01293 571000 Email: instruments@rotronic.co.uk Web: www.rotronic.co.uk
New control panel with built-in SD interface
Han® M23 Power connector from Harting
The Schmersal Group is extending its range of control panels with the new BDF 200-SD model. This product variant now has a built-in SD interface. The BDF 200-SD is also fitted with an EMERGENCY STOP function with electronic OSSD outputs and can be fitted with up to three operational command and alarm devices, such as illuminated push-buttons, illuminated alarms, selector switches and key switches. Using the built-in SD interface, the non-safe diagnostic signals from the command and alarm devices can be transferred via an SD gateway to the controller. In the safety circuit, different electronic safety switchgear devices, such as sensors and interlocks, can easily be connected in series using the BDF 200-SD.
The Han® M23 Power from HARTING is a new hybrid industrial connector that combines the capability to transmit both power and signals with a high degree of environmental protection. The new connector extends the Han® M23 series by allowing the industrial lifelines of signal and power to be fully supplied from a single device. The field of application includes drive technology as well as any areas with increased demands on vibration safety and protection against dust and water as well as other external mechanical influences. Built-in shielding also offers additional protection against electromagnetic interference. The robust housing of the Han® M23 Power meets IP protection classes 67 and 69K in the closed position, making it particularly suitable for harsh industrial environments.
For more information: www.schmersal.com
T: 01604 827500 E: enquiries@harting.com W: www.harting.com
AR-050: Artidor’s new Zone 1 air conditioner With the introduction of the AR-050 Zone 1 air conditioner, Artidor provides an answer to a wide range of demands in the market for explosion-safe products. The AR-050 is designed with the harsh marine, offshore and coastal conditions of tropical countries in mind: they are corrosion resistant, durable and suitable for ambient temperatures up to 55 °C. By integrating an additional heat exchanger and water pump, the units can be delivered as a water chiller for process cooling purposes. The optional 4-way valve upgrades the air conditioner or water chiller to an actual heat pump, also capable of heating. The controls of the air conditioner are all housed in a maintenance-free flameproof housing. The unit can be operated by means of the switches and push buttons on
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the outside of this housing. A 3.8” graphical colour display gives feedback to the operator on the actual temperatures, the status of the system and provides troubleshooting information. The electrical connections can easily be made in the stainless steel, increased safe housing. There is no need for special, and often hard to install, Ex d cable glands. The AR-050 air conditioners and water chillers are available in capacity levels from 5 kW in steps up to 15 kW. They are explosion-safe according ATEX and IECEx, product category II 2G, group IIB and temperature class T4. The units are CE marked. Contact: Mr. Marc Moolenaar (director) E-mail: sales@artidor.com Phone: +31 (0)40 7873911
Buyers Guide 39
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 Phones Tablets
www.pepperl-fuchs.co.uk Cable Glands
Tel.: 0161 6336431
Explosion Proof Cranes
sales@gb.pepperl-fuchs.com
Training
Consultancy
10% OFF all CompEX Courses • Foundation • EX01 to EX04 • EX01 to EX04 Refresher
• Dust EX05 to EX06 • Mechanical EX11
Quote Code: HAZ10
+44 (0) 1642 770310
www.tte.co.uk/accredited
Training
Control Panels
Heaters
J.B. Systems Ltd
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 Your Total Solutions Provider Specialists in design and custom build of a wide range of Hazardous Area Equipment
Registered OEM for Technor Marechal 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
Square shaped beam LED floodlights collection
PURE LIGHT
Thanks to the “square shaped beam” optics, the explosion-protected floodlight SLED series of Cortem Group ensures a uniform illumination over large spaces, both indoors and outdoors. Characterized by high light output with a white light and a colour rendering index greater than 70, they are able to replace the sodium vapour or metal halide floodlights, ensuring the quality of the light, energy saving and visual comfort.
II 2GD Ex de IIB+H2 method of protection for environments with the presence of hydrogen High luminous efficiency Energy saving Optimization of plant engineering and maintenance costs Cool White LED, color temperature 6.500 K Long Term Performance SLED-600 30.800 lm
cortemgroup.com
SLED-400 20.750 lm
SLED-250 13.050 lm
Zone of installation 1, 2, 21, 22 | ATEX/IECEx/TR CU certificates Class temperature T5 (100°C) T6 (85°C) | Degree of protection IP66 Power supply 100-277 Vac ±10% and 120-277 Vac ±10%