February 2019
the journal for hazardous area environments
hazardexonthenet.net
Nuclear Small Modular Reactors Regulation DSEAR documentation best practice
Staff demographics
Kashagan field
Surveillance technology
How wearable technology can help
The challenges of personnel location
Hazardous environment security
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contents february 2019 This month’s Hazardex includes the third edition of our PPTex supplement, which is aimed at extending our coverage into Personnel Protection Technologies, equipment incorporating electronic and technological systems that the user can wear, hold or use to minimise hazards at work. Every month brings news of innovative products, services and systems in this ever-expanding sector, with the best likely to have a significant positive effect on personnel safety and production efficiency in the manufacturing, process and high hazard industries.
14 21
The response to our first two supplements has been enthusiastic and we are expanding the reach in this edition to include surveillance technologies that impact directly on workforce location and security, whether incorporating wearable technology or not. The supplement contains a good range of articles covering different sections of the smart PPE world, but we want more. If you have any product news, new technology intelligence, op-eds, feature articles or case studies relating to the PPT sector that you would like to share, please send them in to me for inclusion in future editions.
Connected safety technology can help bridge the gap between generations in the workplace and improve safety for all
27
…Alan Franck, Editor, Hazardex
in this issue 5 News Extra & Standards
• Czech coal mine gas explosion kills 13 • Australian newspaper casts doubt on safety of offshore electrical equipment • State agency orders closure of 14 BP wells in Alaska following December leak • Trump pro-fossil fuel policies fail to stem decline of US coal sector • California utility to file for bankruptcy protection • Mexican offensive against fuel theft causes widespread gas station shortages • Hitachi shelves UK nuclear plans • Pennsylvania proposes tightening up emissions from oil & gas production sites • Four killed in Paris bakery explosion
Personnel location in the particularly hostile work environment of the Kashagan oilfield requires a range of technologies
31
17 PPTex Supplement 3 18 Comment - Harnessing Industry 4.0 technology to improve staff safety 39 19 PPTex products & trends
Artificial intelligence and machine learning for object recognition and video analysis can be useful in ensuring employee safety
44 21 Connected workers: bridging the gap between millennials and the ageing workforce 50 24 Surveillance technology in hazardous environments: a look at the future 54 27 Case study - The challenges of personnel location in the Kashagan Field
36
31 Ensuring PPE compliance through the use of artificial intelligence 34 Enhancing staff safety in site evacuation scenarios through management technology 36 Small Modular Reactors and the future of nuclear power
The emergence of small modular nuclear reactors offers a number of benefits, not least that of safer and flexible power generation
40 Best practice for DSEAR documentation 44 Combustible dust explosions: are you at risk? February 2019
the journal for hazardous area environments
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 £147; EU £215.25; Airmail £315 and single copy price is £23.10 plus P&P.
hazardexonthenet.net
Nuclear Small Modular Reactors Regulation DSEAR documentation best practice
Staff demographics
Kashagan field
Surveillance technology
How wearable technology can help
The challenges of personnel location
Hazardous environment security
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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 Email: events@imlgroup.co.uk ISSN 1476-7376
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News Extra
5
The CSM mine near Karvina, Czech Republic - Shutterstock
Czech coal mine gas explosion kills 13 A
gas explosion killed 12 Poles and one Czech at an eastern Czech coal mine on December 20, according to mine operator OKD. The state-run
Other mineworkers were evacuated to the surface soon after the incident with 10 reported injured, one critically.
mine and the miners’ trade union.
company said that a methane blast more than 800 metres underground hit a gallery in the CSM coal mine
The accident is the worst mining disaster in the Czech Republic since 1990, when 30 miners died in a fire at a mine near Karvina in
of the two worst-affected survivors had improved slightly. One of these has deep burns across half of his body and remains
near the town of Karvina. OKD said that attempts to rescue eight miners originally reported as unaccounted
the same region, according to a list compiled by CTK news agency.
n a critical condition.
for had had to be abandoned due to conditions in the shaft..
The Polish victims were miners employed via the ALPEX company, OKD said. Polish President Andrzej Duda declared a day of
“Rescue squads were immediately called in after the explosion. As we dug into the damaged section we gradually found many
national mourning on December 23.
wounded, as well as one dead miner, and kept going. Unfortunately, we have reached a point where it was impossible to move forward, because there was a fire raging and zero visibility,” OKD managing director Boleslav Kowalczyk said.
sensors deployed in the mine had not detected anything unusual prior to the blast.
In a report on December 24, the Czech news agency CTK said that the condition
The mine was closed until December 27,
Kowalczyk said a network of methane
OKD spokesman Ivo Celechovský said that the concentration of methane gas must have been 4.5 times above the safety limit, but was unwilling to speculate on the causes.
after which production restarted in the northern section of the mine, according to Čelechovský. The company spokesman said the state of emergency had been lifted at the mine. “The 29th seam area was enclosed by explosion-proof barriers and has been inerted with nitrogen. Over the next few weeks, only control measurements of the concentration of gases will be undertaken there,” Čelechovský said
While there were still men deeper in the tunnels, air concentrations were deemed incompatible with life and the head of disaster management decided to seal off four sections of the mine to starve the fire of air. Rescue teams would then recover the victims when conditions allowed,
“In parallel with the rescue operations, a special commission is analysing the exact causes of the tragedy, so we will have to wait for their results.” The commission includes regional and police
These control measurements have confirmed that methane concentrations were still high in the section seven days later. By then, four bodies had been taken to the surface and the remaining nine will remain in the mine until their recovery is
Kowalczyk said.
representatives, as well as those from the
deemed safe.
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6
News Extra
Ichthys Venturer FPSO - Image: Inpex
Australian newspaper casts doubt on safety of electrical equipment on Ichthys offshore field production facilities
I
n an exclusive report on January 10, the Perth-based West Australian newspaper said it has seen documents
On January 13, the newspaper quoted an Inpex spokesman who said the company believed the audit reports quoted
The Ichthys project is expected to operate for 40 years, producing 8.9 million tonnes of LNG, 1.6 million tonnes of LPG and
that call into question the safety of electrical equipment in hazardous areas on the Ichthys Explorer semi-
were early drafts. He said many of the comments reported were inaccurate or no longer valid and others had been taken
100,000 barrels of condensate a year.
submersible platform and Ichthys Venturer oil production vessel now producing gas and condensate from the Ichthys field off the Kimberley coast.
out of context.
Australian gave details of problems at the Bladin Point LNG facility.
The newspaper said it had obtained audits of the facilities that reveal more than half the electrical equipment in hazardous areas did not pass independent safety checks.
In a report on 2 November 2018, the West
A spokeswoman for Kentech said they provided a snapshot at a set point in time.
This part of the project is mired in
She also said the comments reported were from early drafts and did not reflect the final reports.
multibillion-dollar contractual disputes between operator Inpex, chief contractor JKC and many subcontractors. US
A spokesman from Australian offshore regulator NOPSEMA said it had inspected
engineering group KBR, a JKC joint venture member with Japan’s JGC and Chiyoda, revealed the full extent of the problems in
Ichthys operator Inpex commissioned international engineering company Kentech to audit the vessels last year.
electrical equipment in hazardous areas on both facilities before gas flowed. Subsequently, the West Australian said
a filing to the US Securities and Exchange Commission.
According to the West Australian, the oil vessel audit said the electrical equipment
NOPSEMA had requested the Kentech reports from Inpex and would review them.
KBR chief financial officer Mark Sopp told analysts that it had claims of about $US950 million against Inpex for changes to the
“introduced an unsatisfactory level of risk that is outside the tolerable levels acceptable at other comparable major hazard facilities”. The platform audit said the work planned to fix the problems “do not, in their current form reduce the risk of a major accident event from the ignition of flammable gases by electrical equipment to as low as reasonably practical”.
The A$63 billion Ichthys project draws gas from beneath the seabed 450km north of Broome, Western Australia, and partially processes it before sending it via pipeline some 820km to Bladin Point, near Darwin.
project, equivalent to a $US3.2 billion total claim from the joint venture. An arbitration ruling that Inpex was liable for subcontractors’ costs from delays resulted in KBR receiving $US330 million of its claims.
Tokyo-based Inpex owns 66.2% of
An Inpex spokesman said safety was its number one value and it had a continuing, rigorous program to maintain the integrity of
Ichthys, French oil major Total 26%, and the remainder of the equity sits with five Japanese and one Taiwanese energy utility. First Gas was achieved on 30 July 2018 and the first condensate cargo was loaded on 1 October 2018, followed by
Construction disputes over large and complex LNG projects are not uncommon and the ones at Ichthys follow disputes impacting Chevron’s $US54 billion Gorgon LNG project in Western Australia, and Santos’ $US18.5 billion GLNG project in
its electrical equipment.
the first LNG cargo on 22 October 2018.
Queensland.
www.hazardexonthenet.net
News Extra
7
investigating the December leak and is holding a hearing to address the incident next month. A more severe incident happened in 2017 at a different BP well with a similar design. BP linked the earlier accident to thawing permafrost deep below the surface, which put uneven stress on the well. Eventually it rose several feet out of the ground, colliding with the top of the well house and causing the uncontrolled leak. Following the 2017 incident, the commission
State agency orders closure of 14 BP wells in Alaska following December leak
A
ccording to local media, the
Alaska Oil and Gas Conservation Commission has ordered BP to plug and abandon 14 wells which were identified as being at risk after a major incident in 2017. BP discovered one of its wells was
ordered oil companies across Alaska’s North Slope to review thousands of wells. BP reported 14 more at-risk wells, which were later shut in — meaning the wells were no longer operational but could potentially be used to produce oil again.
leaking gas and a small amount of oil on December 7. The company estimates two gallons of oil were spilled in the
BP confirmed the well that began leaking last
well house.
The Commission is now requiring that these
The Commission is in the process of
wells all be plugged and abandoned to ensure they do not leak in future.
month was one of the 14 at-risk wells.
8
News Extra
Trump pro-fossil fuel policies fail to stem decline of US coal sector A
new update from the US Energy
According to CleanTechnica, another 23.1
Since taking office in January 2017, the Trump
Information Administration (EIA) released on January 10 shows that despite President Trump’s 2016 pledge
GW of coal plant retirements have already been announced or received regulatory approval for 2019 to 2024, marking 71.9
administration has announced its intention to leave the 2015 Paris Agreement on climate change and is relaxing Obama-era rules on
to revive the US coal industry, since then prospects for coal have considerably worsened. At the same time, the EIA is
GW of coal retired or scheduled to be retired between 2014 and 2024.
emissions from power plants as it seeks to boost domestic production of oil, gas and coal.
forecasting big increases in renewables and gas generating capacity.
Analysis by Reuters shows that total coal generating capacity will have fallen from above 310 GW in 2010 to around 210 GW in 2025.
The administration also tried to slow the retirement of coal and nuclear plants through
The 4.5 GW figure in 2019 compares with 13.7 GW of coal capacity retired in 2018.
a directive in 2017 from Energy Secretary Rick Perry to subsidise ageing plants because they make the electric grid more resilient.
For 2019, EIA forecasts up 10.9 gigawatts (GW) in new wind capacity and 4.3 GW of utility scale solar in the United States. Under a separate report, the office also notes that another 3.9 GW of small-scale solar capacity are on the way this year. New natural gas capacity, mainly from the new generation of high efficiency combinedcycle plants, is expected to provide 7.5 GW of new capacity. The EIA forecasts no new coal power plant capacity additions in 2019. Meanwhile, the agency expects a number of coal power plants to be retired in 2019, mainly at the end of the year. One especially significant coal power plant retirement is the 1970s-era Navajo Generating Station in Arizona. Efforts to keep that power plant afloat have fallen flat. Its 2.4 GW of capacity will account for almost half of the 4.5 GW in total coal retirements expected in 2019.
www.hazardexonthenet.net
This means that more US coal-fired power plants were shut in President Donald Trump’s first two years than were retired in the whole of Barack Obama’s first term, despite Trump’s efforts to prop up the industry to keep a campaign promise to coal-mining states. Cheap natural gas and the rising use of renewable power like solar and wind have kept electricity prices relatively low for years, making it uneconomic for generators to keep investing in older coal and nuclear plants. Other than the coal plant retirements, generators said they also planned to shut around 1.5 GW of nuclear capacity in 2019. Trump has tried to roll back rules on climate change and the environment adopted during the Obama administration to fulfill pledges to voters in states such as West Virginia and Wyoming.
This was rejected by the US Federal Energy Regulatory Commission (FERC), led by former Chairman Kevin McIntyre. Reuters said this plan could resurface now that Trump has a chance to replace McIntyre, who died on January 2. US emissions of carbon dioxide, the main greenhouse gas, spiked in 2018 after falling for the previous three years. After 5,144 million tonnes in 2017, the lowest since 1992, the EIA projected the country’s energy-related carbon emissions would total 5,299 million tonnes in 2018. The rise has been fuelled by cold weather spurring gas demand for heating and the booming economy encouraging travel and freight movements, particularly in the aviation and road transport sectors.
News Extra
9
The president said last month that Mexico’s armed forces would take part in security at Pemex installations around the country, including its refinery in Salamanca. Pemex said it is aiming to boost distribution in the affected states by up to 20% transporting fuel by tanker trucks and trains, according to Reuters. A May 2017 study commissioned by the national energy regulator found that thieves, between 2009 and 2016, had tapped pipelines roughly every 1.4 kms along Pemex’s approximately 14,000 km pipeline network.
Mexican Government offensive against fuel theft
causes widespread gas station shortages
A
n offensive by Mexico’s new
crime could also weigh on the economy if
On January 10, President Obrador said the federal government’s anti-fuel theft strategy was yielding impressive results, albeit with the unintended consequence of generating widespread gasoline shortages.
government against fuel theft at one of the country’s main refineries has led to a lack of fuel at gas stations in
shortages drag on. Violent criminal gangs have for years used
Before the plan was implemented, he said, enough fuel to fill 787 tanker trucks
several central states, according to a Reuters report. The news agency said the shortages followed the closure of a pipeline from the Salamanca refinery in
fuel theft as a way to supplement their income, bleeding money from state coffers and driving bloodshed as they fight rivals and extort oil workers.
was stolen daily. Now that figure has been reduced to 177 tankers a day, he said, estimating that the strategy had already generated savings of 2.5 billion pesos
the central state of Guanajuato as the state-owned oil company Pemex started using more tankers to transport fuel.
President Andres Manuel Lopez Obrador, who took office in December, confirmed that
But other sources claimed the government’s
Theft by gangs and oil industry workers from Mexico’s state-controlled refineries is a major
less fuel was being sent through pipelines. He has vowed to tackle theft at Pemex, or Petroleos Mexicanos, which estimates that
anti-theft strategy was less effective than claimed. Mexican Daily News, quoting the newspaper Milenio, said the fuel thieves
drain on government resources, the report said, but the measures taken to tackle the
fuel worth more than 146 billion pesos ($7.40 billion) has been stolen since 2016 alone.
were now piercing the pipelines at night to avoid police and military patrols.
(around US $130 million).
US food processing group ADM reports explosions at two separate plants over two days
A
rcher Daniels Midland Co. (ADM) reported explosions at two separate plants on January 4-5, one
Jackie Anderson told local media. Reports said an explosion occurred after fire crews arrived.
of which resulted in the death of a firefighter and a critical injury to another. A fire at an ADM grain facility in Clinton, Iowa, on January 5 led to an explosion that resulted in the
The other incident occurred on January 4 at an ADM corn processing plant in Decatur, Illinois, according to the Decatur Herald & Review.
death of 33-year-old Lt. Eric Hosette. Workers on site observed smouldering material in a silo storage bin within the loading facility at about 5:45 a.m. and called firefighters, ADM spokesperson
Company spokesman Jackie Anderson told the newspaper that no injuries were reported, and company officials are investigating the cause of the blast and assessing damage.
Ms. Anderson said the explosion occurred in the corn plant’s conveyor belt system. The incidents come a little more than a month after an explosion was reported at the ADM Milling Co.’s flour mill in Calgary. No injuries were reported in that incident. Last November, emergency personnel were called to the Decatur facility for a dust explosion and fire in a grain elevator, Powder & Bulk Solids reported. No injuries were logged during that incident.
www.hazardexonthenet.net
10 News Extra Artist’s impression of completed Wylfa plant - Image: Horizon NP
development of the Wylfa Newydd project, as well as work related to Oldbury, until a solution can be found. In the meantime we will take steps to reduce our presence but keep the option to resume development in future.” Hitachi said the decision would cost it an estimated 300bn yen (£2.1bn) in expenses, plus another 300bn yen in extraordinary losses. UK Prime Minister Theresa May said she had discussed the Wylfa plans during a meeting with Japanese Prime Minister
Japanese engineering group shelves UK nuclear plans H
itachi has scrapped plans to build
Tokyo. The group has already invested
Shinzo Abe, but that in the end it was a commercial decision for the company. She said: “The Government has been in discussion with them for some time, has been providing support. We do want to see new nuclear as part of our energy mix in the future.
a nuclear power station in Wales, becoming the second firm in two months to abandon a major nuclear
£2bn in the scheme.
project. The £16bn Wylfa plant on Anglesey in north Wales was meant to be the next in a line of a series of new
2,900 MW, was forecast to bring in £5.7bn and up to 10,000 jobs to the Welsh economy. Welsh Secretary Alun Cairns
a reasonable level for the consumer.”
nuclear plants behind Hinkley Point C but the Japanese conglomerate failed to reach an agreement with the UK
described the scheme as the “biggest infrastructure project in Wales for a generation”.
government’s energy policy and hopes of attracting major foreign investments post-Brexit. With the planned closure of
The 300 people employed by Hitachi’s UK subsidiary overseeing the project, Horizon
many existing nuclear and conventional power plants over the next 10 years, the government has a huge hole to fill in the
The project, for two reactors producing
government on financing for the project. Wales Online said the Japanese group
“We also have to make sure that the cost of any energy that is provided by nuclear is at
The decision is a serious blow to the
is understood to have had fundamental disagreements with the UK government over the price paid for electricity produced at the plant, which was to be set significantly lower than that paid to EDF Energy from the new Hinkley Point C nuclear power station being built in Somerset.
Nuclear Power, will lose their jobs, as well as around a thousand more in the supply chain
The UK government had been willing to
Duncan Hawthorne, CEO of Horizon said:
Toshiba pulled the plug on its proposed new Moorside plant in Cumbria last November, leaving EDF Energy as the only definite player in new nuclear for the UK market. Negotiations continue between EDF and government over the construction of another new plant at Sizewell in Suffolk.
take a public stake in the project of at least £5bn to help the project, in a reversal of a decades-long policy of not investing directly in nuclear power.
“We have been in close discussions with the UK Government, in cooperation with the Government of Japan, on the financing and associated commercial arrangements for our project for some years now.
A Chinese consortium is also proposing a new plant at Bradwell in Essex, but this project is increasingly controversial given doubts about that country’s involvement in
It was also willing to discuss a guaranteed price for electricity higher than offshore windfarms, but lower than Hinkley Point C. Hitachi cited rising construction costs as the direct reason for the Wylfa project’s suspension following a board meeting in
www.hazardexonthenet.net
Horizon was also overseeing preparatory work on a site for a second nuclear plant at Oldbury in Gloucestershire.
late 2020s and early 2030s.
UK and European infrastructure projects. “I am very sorry to say that despite the best efforts of everyone involved we’ve not been able to reach an agreement to the satisfaction of all concerned. “As a result we will be suspending the
Horizon’s Duncan Hawthorne said the Anglesey site remained “the best site for nuclear development in the UK” and that the company would “keep the option to resume development in future”.
News Extra 11
California utility to file for bankruptcy protection P
acific Gas and Electric Corporation (PG&E) has said it plans to file for
resulting from the recent wildfires.” It went on to say that a Chapter 11 reorganisation was the only viable option for meeting these goals.
On February 13, PG&E’s chief executive, Geisha Williams, resigned. Its debt has already
Governor Gavin Newsom, a Democrat, told reporters his team was discussing the
bankruptcy protection due to the huge costs it faces from last year’s wildfires. In a statement issued on January 14, PG&E said it planned to file for Chapter 11 protection from creditors on or about January 29. Liabilities for the wildfires
been downgraded to junk status, a rating that indicates investors have little faith their money will be paid back.
possibility of helping PG&E stay solvent, but no decisions had been made. The state, Newsom said, is determined to keep services running to its customers.
could exceed $30 billion, according to the utility.
unprecedented Northern California wildfires of 2017 and 2018 have had a profound impact on our customers and their communities.
to the ignition of more than a dozen wildfires in the past two years, and is a suspected cause of the deadliest fire in state history, which swept through the town of Paradise in
- almost 40% of the population of the state, warned it could face “significant liability” beyond its insured amount if its equipment was found to have caused the fires which
“PG&E faces extensive litigation and significant potential liabilities resulting from these wildfires.
November, killing 86 people and destroying 90% of homes and businesses there.
devastated huge areas of the state. The utility, which has 20,000 employees, has
“It is clear that a solution is needed that enables the continued safe delivery of natural gas and electric service to our customers
to allow PG&E to pass along the costs associated with victim lawsuits and other fire losses to ratepayers, as they did last year for
assured its customers it expects to continue supplying power “without disruption”.
and supports the orderly, fair and expeditious resolution of PG&E’s potential liabilities
a series of deadly northern California blazes in 2017.
The 150-year-old company said: “We recognise that the devastating and
PG&E, which serves 15 million Californians
The legislature and the governor could decide
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The utility’s power equipment has been linked
12 News Extra industry sources, part of which the Trump administration is considering rolling back.
rules are finalised, and pointed to DEP’s own data showing a reduction in a number of pollutants across the state.
Pennsylvania proposes tightening up VOC emissions from hydrocarbon production sites
The rules would apply to storage tanks, pneumatic controllers and pumps, and certain kinds of compressors at natural gas processing plants, other midstream facilities and well sites, according to documents prepared for a meeting with the Air Quality Technical Advisory Committee (AQTAC).
But data from 2015 shows methane emissions and VOCs from unconventional gas well sites and midstream facilities in Pennsylvania actually increased.
O
DEP said that despite an US Environmental Protection Agency (EPA) proposal to withdraw some VOC guidelines, the state plans to
If the proposals were to become reality, they would come after DEP implemented more robust permitting requirements for new unconventional gas wells and some midstream facilities that were aimed at
Protection (DEP) unveiled draft regulations aimed at curbing smogforming emissions from existing oil and natural gas production and midstream
move forward with the regulations for existing sources. Earlier this year, the DEP submitted comments to the EPA opposing the withdrawal.
better controlling methane emissions and other pollution sources, such as VOCs and nitrogen oxides. The steps are part of Governor Tom Wolf’s broader plan to reduce
operations. Operators would also be required to conduct more stringent leak monitoring and repair quarterly at well sites, gathering and boosting stations,
Producer cartel the Marcellus Shale Coalition (MSC) said while its members are concerned about the price tag of any new requirements,
n December 13 the Pennsylvania Department of Environmental
and processing plants.
industry emissions. The proposed rules were supported by environmental groups. Pennsylvania produced 5.4 trillion cubic feet
The proposals are similar to Obama-
more pressing questions loom about DEP’s legal authority to advance the rules, given the federal government’s stance.
(Tcf) of gas in 2017 and is on track to finish 2018 having produced 6 Tcf, second only to Texas in nationwide production. Ohio
era guidelines for the industry issued in 2016 for limiting emissions of volatile organic compounds (VOC) from older
The MSC said it would be prudent for DEP to delay any regulatory proposals until federal
regulators last month also announced plans for more industry air emissions regulations based in part on the Obama-era rules.
Taking hazardous areas seriously Manage your explosive atmosphere with our latest products, providing you with reassurance and peace of mind.
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Hazardous Areas
News Extra 13
A gas leak had been reported in the building and firefighters had arrived to deal with it when the explosion occurred. In an interview with the newspaper Le Parisien, prominent local politician Alexandre Vesperini said the blast was a direct result of the poor condition of the Paris gas supply
Four killed in Paris bakery explosion
A
powerful explosion at a bakery in the Rue de Trevise in the 9th
said no hypothesis was being ruled out.
network. He said the network, built at the beginning of the twentieth century, was in a state of advanced dilapidation and that what had happened in the Rue de Trevise could hap-
arondissement in Paris killed four and injured dozens more on January 12. Two firefighters and a Spanish tourist died, as well as a women in a flat above the
A fire service spokesman said 40 firefighters were clearing the debris by hand due to the dangerous conditions.
pen anywhere in the city.
bakery. Around 55 people were injured, nine of them seriously, including several foreign tourists.
Twelve buildings were closed after the blast, with officials saying the safety of each would be assessed before they could be reoccupied. Some 50 people who lived in adjacent
pipeline network was renewed or replaced every year, 50 million euros were spent annually on maintenance and the system was constantly monitored to ensure optimal
The blast gutted the lower part of the building which housed a bakery and a restaurant, and also overturned cars, leaving glass and
flats were put up in temporary accommodation.
security.
rubble strewn across the street. Initial reports stated that the explosion was caused by a gas leak, but the public prosecutor’s office
The owner of the bakery told RTL that the business only used electricity, but that gas could have seeped in from the flat next door.
This was rebutted by Paris gas distributor GRDF, which said 40km of the 1,944km
GRDF said it was “too early to identify the
Protect your people, plant and processes
cause” of the explosion, which it called the largest and most serious in more than a decade.
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CompEx Modules are available for electrical & mechanical craftspersons/operatives/technicians, professional application design engineers and responsible persons/duty holders.
For more details go to www.compex.org.uk CompEx Certification Body - JTLimited, Part of the JTL Group Email: info@compex.org.uk
Equipment Asset Registers, Site Inspection and Defect Management is an integral part of the Responsible Person's duties, CompEx Ex14 provides guidance to understand and manage these key responsibilities.
New worker on site? Always ask to see their CompEx® certificate
CompEx is a registered trademark of JTLimited, the CompEx Certification Body www.compex.org.uk * JTLimited, the CompEx Certification Body is accredited to ISO/IEC 17024:2012 General Requirements of Certification Bodies providing certification of persons
Photographs courtesy of Dow Corning, BP, Statoil, Total and JTLimited.
Digitalisation is king Digitalisation is king! Standards 15
to the business. But why am I giving you the independent verifier as a “person o basicBut information if, like organisation, with the to thesuch business. why am I giving youmost of the the independent verifier as a “person or appropriate com suchreadership, basic information likefamiliar most of the organisation, with the appropriate competency youif,are with the hazardous in the applied protection methodology,
Brexit and the future
readership, you are familiar with the hazardous area business?
in the applied protection methodology, responsible for the verification of desig responsible for the verification of design calculations, assessment and testing w calculations, assessment and testing who I mention these to ahighlight issue aredistinct separate and distinct by managem I mention these facts to facts highlight big issue a bigare separate and by management for manufacturers of explosion and other resources including financia for manufacturers of explosion protected protected and other resources including financial, from products and systems: they could come into the person or organisation responsible for products and systems: they could come into the person or organisation responsible serious conflictconflict with their customers. associated with the design, serious with their customers. all the activitiesall the activities associated with the de area business?
manufacture or sales of the equipment.” manufacture sales of the equipmen a lot of money and time, without any I could continue with this listorbut these On the one hand, end users will not accept a improvement in safety. Money and time examples must suffice. I should also On the onethey hand, users will not accept situation in which canend establish modern For EPLa(equipment protection level) “a”, the which European industry would be far add how much I have appreciated situation in which they can establish modern For EPL (equipment protection level) “a digitalised processes and procedures in the evaluation of the equipment has to be done better spending facing up to international collaborating with my many British safe digitalised areas of theirprocesses process plants, cannot by verifiers, for EPL “b” by andbut procedures in three the independent evaluation of the equipment has to be competition. colleagues in the standardisation and applysafe the same technologies in hazardous two, and for EPL “c”, one independent verifier areas of their process plants, but cannot by three independent verifiers, for EPL conformity assessment community, and areas because of a lack of applicable modern is enough. theand same technologies in hazardous andcontinuing for EPL “c”, I amapply also sad angry as a European I look forwardtwo, to this long one into independen products due to restrictions set by the safety citizen whobecause is convinced that the UK is the future at is IEC and IECEx. areas of a lack of applicable modern enough. standards. On the other hand, manufacturers The first two years after the introduction of Every two months, IECEx Chairman a very important part of Europe and the products due to restrictions set by the safety are obliged to fulfill these safety standards, this new procedure were quite a surprise. No Prof. Dr. Thorsten Arnhold provides European Union and should stay inside. I recently discovered another interesting Every two months, IECEx Chairman Prof. an update on developments within whichstandards. are defined On by the IECEx CB asked for first a scope and the introductio thedocuments other hand, manufacturers The twoextension years after Every two months, IECExan Chairman But I am still hoping that there will be a fact. In 1912 the first international Dr. Thorsten Arnhold provides update his organisation mentioned above. as a result, no certificates were published. are obliged this new procedure onDr. developments within his organisation Prof. Thorsten Arnhold provides positive outcome.to fulfill these safety standards, conference on explosion protectionwere in quite a surpr During the last year, however, the situation has and the world of standards. an update on developments within which are defined by the documents mining took place IECExinCB asked for a scope extension Pittsburgh, USA, t the present time, there are few This has been a major concern for IECEx. changed significantly. Now we have more than his organisation Nor should we forget the important with experts present from Belgium, result, certificates conferences or technical trade Threementioned years ago, atabove. its annual Management 10 Ex CBs andas ExaTLs with ano respective scopewere publish o write an article about the contribution the British have had on the Germany, France, Austria and the USA. last year, however, the situa shows that do not have the Industrial Committee Meeting in The Hague, the extension and aDuring numberthe of applications. current status of international development of safety methods and Internet of Things (IIOT) as the main organisation launched a new procedure to t the present time, there are few This has been a major concern for IECEx. changed significantly. Now we have m certification of products and services technologies for hazardous areas. The Two years before the First World War focus. One of theor most important adoptThree the new IEC 60079-33 standard. This A look in the IECEx online conferences technical trade years ago, at its annual Management 10 Ex CBsdatabase and Exshows TLs with a respectiv for use in hazardous areas without very first explosion protected equipment began, in which millions of young people consequences of this trend are the covers the protection method “s” for “special”, that already more than 20 certificates based shows that do Brexit not have thebeIndustrial Meeting The Hague, the killed each other, extension a the number mentioning would a serious wasCommittee invented in 1815 by SirinHumphry expertsand from same of application drastically shrinking value chains and which was introduced to permit the quick on IEC 60079-33 have been published, and I oversight in these times. Davy, a famous scientist and colleague of countries exchanged knowledge on how Internet of Things assector, the main organisation launchednew a new procedure innovation cycles(IIOT) in every and adoption of new technologies, materials amto confident that many others will follow. Sir Henry Cavendish at the Royal Society to save the lives of miners. focus. One ofinthe important adopt the newa IEC 60079-33 standard. This A look in the IECEx online database sh especially the most process industries. etc. This implements practice which has At the moment, manufacturers and in London. Davy and his assistant George beencovers field-proven in the ATEX area For IECEx, thisthat development recognition consequences of this trend are the the protection method “s” for “special”, already ismore than 20 certificates their clients in the European Union Stevenson developed the Davy lamp, an Human history is full of such strange In process facility safe areas, the speed since 2003. that its focus on this area has been useful drastically shrinking value which was introduced permit the quick on IEC 60079-33 have for been published (still including the UK) arechains very and oil lamp with a special safety to mesh which stories. of adaptation to this trend is restricted the industry and high levels of safety will be innovation cycles every sector, adoption technologies, am confident that many others will follo confused aboutin the future validityand saved the livesof ofnew thousands of miners new materials by the innovation of the suppliers and the Under the ATEX directive, the fulfillment of maintained. of ATEXincertificates issued by UK overetc. the This following decades. a practice which has So I am convinced that the work carried especially the process industries. implements financial and technical capabilities of the the general requirements of appendix II with Notified Bodies. Despite the fact out by international organisations such as beenhealth field-proven the ATEX area For IECEx, this development is recogn operators. the basic and safetyinrequirements is The executive group is preparing a promotion that all big UK Notified Bodies are in He also discovered the effects of laughing IEC and IECEx is vital, not just for more harmonised standards are just conference during 31 spring session In process facility safe areas, the speed obligatory, sinceand 2003. thatthe itsTC focus on this areainhas been us very close communication with their gas on human beings, something we efficient business and safe workplaces, Many process sector companies have to one way to do this. Split Croatia on 23 April 2018, to be held by of adaptation to this trend restricted thefreedom industry and high levels of safety w European customers andis are trying might all benefit from when considering for also for the and improved handle hazardous substances, with potentially IECEx in conjunction with the UN, UNECE and by the innovation of the suppliers and the Under the ATEX directive, the fulfillment of maintained. hard to provide acceptable solutions, the strange developments of our times! welfare of people everywhere. severe consequences for the life and health of To enable the IECEx Certification Bodies the Croatian Standards Institute. The focus there and is still uncertainty and nobody financial technical capabilities of the the general requirements of appendix II the employees in their plants. and Test Labs to issue Test Reports and of with this conference will be on industry and knows what difficulties will have to But back to explosion protection In 2019, we will continue with the operators. the basic health safety the requirements The executive group is preparing a pro Certificates based on IECand 60079-33, usersisof Ex equipment, and, as with all IECEx be faced in the coming months and another huge contribution was the successful development of our The equipment intended for use in these areas IECEx Operational Document OD 233 was International Conferences, attendance is obligatory, and harmonised standards are just conference during thefree TC 31 spring se years. development of a new and very important international certification system has to fulfill certain safety requirements in order developed and published, and the second of charge (See: www.iecex.com/meeting-andMany process sector companies have to one way to do this. Split Croatia on 23 April protection method following a disastrous together with our friends from the UK. 2018, to be h to avoid the ignition of potentially explosive edition has been available since February events/iecex). handle potentially explosion at a pit in Wales in 1913 IECEx in conjunction with the UN, UNE As hazardous the chairmansubstances, of the IECEx with system, atmospheres. These requirements are defined 2017. The central and critical element of both I could take a relaxed view of the which led to the death of 439 miners. In May we come together inStandards different severe consequences for the IEC life 60079 and health To enable IECEx Certification Bodies thewill Croatian in the international standards and of the standard andthe the OD is the so-called In addition, IECEx be holding a series ofInstitute. The f situation and propose that our UK The subsequent investigation identified working groups and in the executive the employees and Testverifier’. Labs to issue Test Reports and this conference will be on industry a IEC 80079. in their plants. ‘independent working group of meetings in Weimar, Germany, friends open their markets directly for an electric spark in the mine signalling group in Singapore, and in September in June where feedback application of and, as with al Certificates based on IEC 60079-33, the users of from Ex equipment, products with IECEx certificates, as system as the cause of the accident, we will have our annual Management Interesting, you might say, if you are paragraph 3.4, the standard defines Ex “s” process will also beConferences, discussed. The equipment intended usedone in new these areasUnder IECEx Operational Document OD 233this was International attendance their Australian relativesfor have following which British scientists Committee meeting in Dubai. At this has to developed and published, the second of charge as (See: www.iecex.com/meeti forfulfill manycertain years. safety requirements in order developed the concept of intrinsicand safety, meeting my successor chairman of today one of the most widespread IECEx will be elected, and at the end of www.hazardexonthenet.net to avoid the ignition of potentially explosive edition has been available since February events/iecex). But as a representative of a German methods of explosion protection 2019 my second term will be over. Until atmospheres. These requirements are defined 2017. The central and critical element of both manufacturer I am sad and angry about worldwide. then there is a certain way to go, and a in the international standards IEC 60079 and the standard and the OD is the so-called In addition, IECEx will be holding a ser this situation. It will cost the industry few more columns in Hazardex to write!
A T
A
IEC 80079.
‘independent verifier’.
Interesting, you might say, if you are new
Under paragraph 3.4, the standard defines
working group meetings in Weimar, Ge in June where feedback from applicati www.hazardexonthenet.net this Ex “s” process will also be discuss
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The 2019 Hazardex International Conference and Exhibition will take place at the Holiday Inn Hotel in Runcorn, Cheshire, UK, on February 27th & 28th.
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The two-day event includes workshops, a networking dinner and awards ceremony World classTemperature conferenceprocess speakers include: PERFORMANCE values
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The connected worker Comment: Harnessing Industry 4.0 technology to improve staff safety Connected workers: Bridging the gap between millennials and the ageing workforce Surveillance technology in hazardous environments: a look at the future Case study: The challenges of personnel location in the Kashagan field Ensuring PPE compliance through the use of artificial intelligence Enhancing staff safety in site evacuation scenarios via management technology
18 PPTex - Comment Advances in Internet of Things (IoT) technology allows plant managers to understand more about the safety of staff. Workers and employers can use these emerging technologies to better monitor their health while managing risks in their environment.
The connected worker
at a safe speed around humans and will stop if a worker gets too close.
Bringing it all together Cloud-based software allows manufacturers to integrate all safety technologies into one platform that can be easily managed and optimised.
Personal protective equipment (PPE) can connect with factory systems via the Industrial
Honeywell, for example, has developed the
Internet of Things (IIoT) to automate safety management. For example, wearable sensors can detect abnormal worker behaviour, such as entry into a restricted area, and
connected worker concept to develop its safety software. The platform incorporates headsets that deliver automated voice instructions so that workers can keep their hands free. It also has
alert management and the employee of the potential dangers.
asset management functionalities to ensure that all safety-centred PPE is functioning correctly.
The Daqri Smart Helmet (see next page)
Manufacturers can input a range of information
uses augmented reality to improve safety and efficiency in industrial applications. The helmet is fitted with cameras and sensors to collect real-time information about the
into Honeywell’s Safety Suite software to consolidate safety management, such as recordings from IoT enabled PPE, results of inspections and safety or training records.
worker’s environment, such as valve readings, temperature and any possible hazards. The wearer can also display safety guidelines or
Manufacturers then have a comprehensive view of safety and compliance across the facility, which helps them understand the actions they
instructions on the helmet’s screen to improve accuracy when carrying out maintenance and reduce avoidable mistakes.
must take to improve safety.
ccording to the International Labour Organisation, 151 workers have a work-related accident every 15 seconds.
As well as monitoring the environment, sensors in PPE can measure the wearer’s blood pressure, heart rate and breathing
technology advances to improve productivity, manufacturers can harness technologies such as digital PPE, robots and cloud-based safety
Manufacturers should place greater emphasis on the health and safety of their staff to reduce this figure and can invest in
rate to directly monitor their health. This is important for engineers that work in confined spaces, from a semiconductor plant to the
software to keep staff safe.
automation to help. Here Jonathan Wilkins, director of industrial automation parts supplier EU Automation, explores some
wing of a Boeing 747.
technologies that can improve the safety of workers as Industry 4.0 becomes reality.
Of the non-fatal injury reports that HSE received in 2016/2017, 22% were caused by lifting and handling objects, many of which
Manufacturers must do more to prevent avoidable injuries caused by falls, overexertion or operating heavy machinery. These injuries
can now thankfully be delegated to robots. Robots are suited to tasks that require repetitive, physical actions because they can
can negatively impact the health and well-being of staff as well as slow productivity and increase operating costs.
work for 24 hours a day without tiring and can lift heavier objects than humans, without injury being a concern.
Harnessing Industry 4.0 technology to improve staff safety A
About the author
Delegate to robots
A new standard for health and safety at work,
As employees and robots work more closely
ISO 45001, was published in 2018 to help business owners reduce the risk of workplace injuries. This standard provides a framework to assess and reduce risks while improving employee well-being, allowing manufacturers to proactively improve occupational health and safety performance.
together, manufacturers must find robots that do not require cages or light curtains. Collaborative robots (cobots) are designed with human safety in mind because they have no sharp corners, exposed motors or pinch points. Cobots also have sensitive force monitoring devices to ensure the robot moves
www.hazardexonthenet.net
Plant managers must do more to reduce non-fatal injuries in their facility. As IoT
Jonathan Wilkins is the marketing director of industrial automation components supplier EU Automation and is a prolific writer on Industry 4.0 in the industrial automation sector. A professional brand advocate and commercial marketing strategist, Jon has been part of the EU Automation team since its beginnings in 2009.
PPTex products 19
Daqri Smart Glasses
This had a 4D head-up display, high-definition camera, 2D target recognition and tracking
Users also have access to productivity apps via the company’s Worksense content
and object/colour recognition.
platform. These apps enable working handsfree while viewing real-time information.
A programme within the camera called Intellitrack could capture and display information about the user’s environment and the location of the wearer could be identified without relying on GPS, Bluetooth or WiFi. Daqri’s latest AR offering builds on the experience gained from the Smart Helmet. Smart Glasses (left) are portable and lightweight wearables for workers. The device comes with a tethered computer with generation Intel Core m7 processor. The AR device features 6DoF tracking and Los Angeles-based Daqri first came to prominence with the augmented reality (AR) Smart Helmet (top), specially designed for sharing information in industrial situations.
an intuitive hands-free user interface. Users may adapt the DAQRI Smart Glasses with prescription lenses.
The AR glasses feature positional tracking for precise and reliable interactions with the surrounding environment and users may store up to 64GB of content internally. They also connect via Bluetooth or Wi-Fi and have sensors such as a wide-angle tracking camera, a depth-sensing camera, and an HD colour camera for taking photos and videos. Daqri partnered with contract manufacturer Flex to build the device and is collaborating with Dell on supply chain applications. Daqri has also partnered with enterprise software offerings from Oracle, IBM, Autodesk, Siemens, Emerson, and others. https://daqri.com/products/smart-glasses
Intellinium collision avoidance system driver and worker at risk to notify both about the possibility of an imminent collision.
• As well as collision-avoidance, it also has man-down and panic button functionality • Is always worn by both drivers and workers
The smart device is attached to safety shoes or boots and a beacon located in the driver’s cabin will detect the presence of a worker
and is not an extra device • Batteries have a life of several days between charging
nearby and give a powerful foot vibration signal to both driver and pedestrian.
• Can fit any static or dynamic site The solution will be ready for pilot testing by
The system is designed to ensure a proper detection bubble to lower false positives. Workers walking besides vehicles will not French wearable technology specialist Intellinium is developing a site collision avoidance system worn by both drivers
get notifications while workers in front and/or behind the vehicle will get an immediate signal.
and pedestrians. The basic idea is to use vibration-enabled equipment worn by both
Benefits of the system include: • Immunity to external noise
Reactec ATEX HAVmeter The Reactec Analytics Platform is a mobile tracking and management solution, which
Intrinsically Safe apparatus for potentially explosive
includes the ATEX HAVmeter, to better protect employees from Hand Arm Vibration exposure.
atmospheres to comply with European ATEX and International IECEx directives required for potentially hazardous and explosive environments.
The ATEX HAVmeter is designed and manufactured to the requirements for
APRR, the French autoroute operator, in April 2019 and is planned for mass production in September 2019. https://intellinium.io/avoid-collisionbetween-vehicles-and-workers
The Reactec Analytics Platform monitors in real-time, worker exposure using the HSE points system. It also provides practical and useful information to help implement and measure the most effective actions to support HSE guidelines. www.reactec.com
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According to the HSE over 12,000 people die every year in the UK, from lung diseases related to hazardous dust in the workplace – nearly seven times the number killed in road traffic accidents. Preventing this starts with highly accurate, real-time, full-spectrum, continuous monitoring of these killer particulates. Take action now and let’s start the fight back. Find out more at Trolex.com
from
Proper dust monitoring
PPTex - Workforce safety 21
Connected workers: bridging the gap between millennials and the ageing workforce T
he shifting demographic makeup
more likely to operate in higher-risk sectors
at home. What used to be purely physical
of the global workforce is posing unprecedented challenges when it comes to catering for workers’ safety
and perform more physically demanding tasks than older workers[4]. As a result, young workers are up to 50% more likely
devices – such as hard hats and gas detectors – can now be part of the Internet of Things (IoT).
requirements, from the millennial generation’s digital needs[1] to the health concerns of increasing numbers of older workers[2]. Gene Vena, vice president of engineering and chief technology officer for Honeywell Industrial Safety discusses how connected safety technology can help bridge the gap between generations and improve
to suffer workplace injuries than their older counterparts[5] and are also vulnerable to the development of occupational illnesses later in life[6].
safety for all. A key challenge for the safety industry is to develop technology that keeps workers across all age groups safer and
broadband and smartphones being the norm they expect instant access to information[7] and three-of-four believe that access to technology makes them more productive at work[8].
more productive while catering to their diverse needs. At the millennial end of the spectrum, there are specific health and safety concerns to consider. Young workers are overrepresented in temporary and more precarious jobs that often lack appropriate supervision or training[3]. They are also
The safety industry is addressing such multifaceted challenges by developing smarter and more connected personal protective equipment (PPE) that offers workers the same level of interactivity and ease-of-use as the technology they use
Millennials also have specific expectations that set them apart from the rest of the workforce, especially when it comes to technology. Having grown up with
For a start, RFID and Bluetooth-enabled PPE and gas detectors now connect to smartphones to become smart, edge devices able to collect and transmit data. They can help address the younger workers’ lack of training and experience, enabling them to take advantage of the technology they’re most familiar with. For example, a worker can interrogate their equipment with a smartphone and receive immediate, ondemand training on its use through tutorial videos and checklists. The transformation of safety hardware into smart equipment is also automating many manual safety compliance activities. For example, gates equipped with RFID or Bluetooth identifiers can immediately detect whether a worker has appropriate training to access a hazardous area and is wearing the
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22 PPTex - Workforce safety right equipment to perform a certain task, sending them – and the safety manager – an
Like their younger colleagues, older workers have specific health and safety concerns
comes in.
alert on their smartphones.
that need to be taken into account. They are, for example, more likely to be affected by chronic health problems and take longer to recover from injuries[9]. The latest connected safety equipment can
For example, the latest portable gas detectors, combined with software and cloud technology, enable safety managers to immediately access, on a smartphone, tablet or PC, critical data such as toxic gas readings, man-down alerts and the worker’s
in the long term. In many industries, the focus has historically been on detecting major, potentially fatal gas leaks, but rising public awareness of occupational lung disease has broadened the attention to potentially dangerous lower-level exposures.
help address some of these challenges, but it may prove ineffective without the buy-in of the older workers, many of whom were brought up before the digital revolution. It is vital that employers educate and support them so that they fully understand the
location. PPE integrating wearable biometric monitors can also measure personal vital statistics to warn of biomedical dangers such as abnormal body temperature and blood pressure. Armed with this intelligent health and safety data, the safety manager
Bluetooth-enabled portable gas detectors combined with software and cloud technology now enable safety managers to receive and analyse data on a worker’s
benefits of using the new technology in their working life. Although younger workers are generally
can immediately alert a worker operating in a confined space to step out of a dangerous situation or send immediate rescue if a mandown alert is received.
exposure to toxic gas in real time and over time, making it possible to monitor their health from the outset and take proactive measures to help prevent occupational
more vulnerable to on-the-job injuries, occupational deaths are more likely to occur among older workers, with those between 60 and 64 years old having a fatal injury rate
The ability to monitor and protect older workers’ health and wellbeing over time further supports the case for connected
diseases later in life.
almost double that of younger workers[10]. A lot of these fatalities may be due to lack of appropriate preventative measures and
technology. For example, the integration of miniaturised motion sensors and portable wireless transmitters in PPE can
effective rescue procedures, which is where connected, data-driven safety equipment
help address one of the most common work-related conditions: musculoskeletal
Honeywell’s experience with customers suggests that this connected approach to safety can help foster younger workers’ uptake of PPE and also protect their health
The ageing workforce: making a case for connected technology
www.hazardexonthenet.net
PPTex - Workforce safety 23
disorders (MSDs)[11]. Intelligent harnesses and smart footwear enable safety managers
safety industry is moving from a policy-based approach to an information-driven approach
to continuously monitor a worker’s posture, enabling them to tackle MSDs proactively.
to reduce workplace risk, which will lead to a safer and healthier workforce regardless of age.
To encourage the older generation’s uptake of connected safety technology, it is also crucial to develop interfaces that are as
References 1. The so-called millennials are expected
simple and intuitive with easy-to-use appbased, touch-screen environments. Voice recognition technology is now taking this trend even further, with display screen equipment turning into a pure visualisation tool that doesn’t require any manual input.
to make up 50% of the global working population by 2020: https://www. pwc.com/m1/en/services/consulting/ documents/millennials-at-work.pdf 2. Workers aged 55–64 are due to account for 30% of the workforce in many
The safety industry is at a turning point. Safety equipment that, historically, has too often been regarded as ‘a necessary evil’, is
European countries by 2030: https:// healthy-workplaces.eu/en/what-issue 3. https://oshwiki.eu/wiki/Young_workers 4. https://oshwiki.eu/wiki/Mainstreaming_
now starting to be perceived as an enabler of safety, health and productivity that is meaningful to workers across generations. By using retrofitted wireless data transfer
OSH_into_education 5. https://oshwiki.eu/wiki/Young_workers 6. https://osha.europa.eu/en/themes/ young-workers
technology, like Near Field Communication (NFC), everything from eyewear to hardhats can become connected, while further
7. https://www.pwc.com/m1/en/services/ consulting/documents/millennials-atwork.pdf
innovations in wearable sensors make it possible to monitor any parameter that could affect a workers’ health. Ultimately, the
8. https://www.pwc.com/m1/en/services/ consulting/documents/millennials-atwork.pdf
About the author
Gene Vena is Vice president of engineering and chief technology officer at Honeywell Industrial Safety. Responsible for leading the global technology and engineering team, Gene directs all R&D activities to drive innovation and deliver connected safety solutions that meet the industry’s evolving requirements. He has over 25 years of experience in new product development, engineering and business management.
www.hazardexonthenet.net
24 PPTex - Security and surveillance
Surveillance technology in hazardous environments: a look at the future W
hile the majority of industries
intelligence (AI), machine learning, connectivity
Rise of connected devices. IoT has been
keep safety and security as a core function of an operations department, there are a number of organisations,
and Internet of Things (IoT), advanced cybersecurity measures, and video-centric analytics in a number of markets. Each one
a major trend for the past few years. This trend continues and is expanding to include environments that must meet stringent
such as those in oil and gas exploration and production, critical infrastructure and manufacturing, where these two
of these relies heavily on video at its core. For hazardous environments, the protection of video capture equipment and the implementation of
regulatory standards, as cybersecurity efforts are bolstered and sensors are integrated into a network. The collection and analysis
pillars are of prime importance. This article by Simon Reed of Oncam looks at developing trends in security and
robust camera functionality can bring increased insight into the state of a site.
of the data will give rise to a plethora of applications such as intelligent management of facilities, an increased ability to detect
surveillance and the critical role of video in hazardous environments.
Machine learning and AI-enabled devices. Software manufacturers are looking toward machine learning and AI to help propel
anomalies and ultimately perform predictive maintenance. Organisations can benefit by having additional intelligence for situational
Technology being developed to meet the needs of these sectors is centred on the balance between providing innovation with functionality and security in an effort to protect companies and organisations. While these environments can often become the target of threats, such as vandalism, theft and even terrorist attacks, a measured response that
advanced analytics in an effort to deliver more situational awareness to operators and an increased ability to proactively assess threats. While video and data analytic capabilities have been around for quite some time, in the past they were rudimentary in comparison with software that uses AI and machine learning to make existing applications such
awareness, emergency management as well as opportunities to provide advanced asset performance management. .
incorporates emerging technology solutions to implement a comprehensive security plan can protect employees, assets and the surrounding communities. At the centre of this innovation are a number
as facial recognition much more accurate and to create new ways to detect anomalies in an environment. In addition, AI/machine learning will increasingly be used to make sense of the large amounts of data that are being generated by intelligent sensors and by
goes without saying that as devices are increasingly connected along a network, the risk of breaches also goes up, which is why there has been a shift over the last few years towards strengthening the cybersecurity of networked devices. All network connected
of technology buzzwords, including artificial
analysing the growing amount of video.
devices such as DVRs/NVRs, servers,
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Increased focus on cybersecurity. Cyberattacks have become, and will continue to be, a major threat to businesses, making this one of the most important trends. It
PPTex - Security and surveillance 25
video cameras, access controllers, intrusion alarms and smart sensors, are vulnerable,
ATEX, IEC and IECEx certified enclosures for explosive locations where combustible fuel
platforms that drive not only security efforts but also provide business optimisation tools to
leading manufacturers to build additional cybersecurity into their products. What’s also emerging is that integrators and end users are starting to factor in cybersecurity as one of the major buying criteria for physical security hardware and software.
and materials are in close proximity. Combined with additional ratings such as IP69K/IK10, these enclosures are rated for resistance to high-pressure water jets, dust and vandalism, taking the surveillance of critical infrastructure to the next level.
meet process safety.
Increasing use of video in new markets and applications. Video is the cornerstone of security, providing both real-time and forensic coverage for emerging threats and incidents. The use of video will continue
Another consideration to make when exploring the options around video surveillance for hazardous environments is whether the solution is an open platform. Open platforms can deliver the kind of flexibility and scalability
open areas and providing full situational awareness in these locations. Panoramic coverage in 360 degrees offers security operators and facility managers the ability to see an expansive area with no blind spots, and also allows operators to zoom into
to grow for traditional applications in new markets, as well as for use in newer applications that are not necessarily security related. In some industries such as oil and
organisations often require to use existing systems and continue to implement new ones as needs change. Incorporating solutions that allow for the flexibility to scale,
areas of interest without losing the ability to simultaneously record video in real-time and playback. A single 360-degree camera can also replace between four and five traditional
gas, there is a trend towards extending video coverage to monitor operations in extremely harsh and hazardous environments, so surveillance manufacturers will have to
as well as the means by which to achieve business intelligence and increase situational awareness, can aid security officials in establishing a comprehensive security plan
cameras, resulting in a more expansive, costeffective solution for critical infrastructure and hazardous areas sites.
develop appropriately certified equipment to meet this demand. Manufacturing facilities such as food processing plants are also
that maximizes investment. Open-platform solutions also bring forth
Whether it’s to defend against organised crime, discover vulnerabilities in the supply chain, provide evidence of incidents, keep
increasing their use of video for training and HSE compliance purposes to prevent incidents such as food recalls
integrations between disparate systems, incorporating not only video data capture, but also the ability to collect information from third-party systems, including access
strict HSE requirements or ensure compliance, panoramic surveillance delivers a robust, highly reliable and cost-effective monitoring and safety tool for hazardous environments.
Robust video surveillance in hazardous environments One method by which the protection of
control, industrial control protocols, motion detection sensors, leak detection sensors, thermography, license plate recognition and
these facilities can be achieved is through the implementation of robust video surveillance. It is critical for organisations to select security
other robust analytics features. The ability to combine data from these sources allows security leaders to achieve true situational
cameras with the correct housing for each application. Video solutions that combine both exceptional video quality and protective
awareness that will take security and safety to new levels in this ever-changing landscape.
enclosures are making the safekeeping of these critical sites possible and include the strategic placement of panoramic surveillance
Real-time video surveillance solutions have become the standard for facilities that are considered hazardous, as well as their related
cameras. IP cameras are now available with
assets. Today, these organisations seek out
Additionally, specialised 360-degree surveillance technology has emerged as a major element in a comprehensive security plan, delivering wide angle views of large,
About the author
Simon Reed currently serves as Vice President of Sales, EMEA and Asia, for Oncam, where he leads the implementation of the company’s strategic vision to expand market share, propel new deployments of the company’s award-winning technology, and boost strategic alliances. He formerly held senior sales and project management positions at Samsung Techwin and Wachter Inc.
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PPTex - Personnel location 27
Kashagan D-island
Case study: The challenges of personnel location in the Kashagan Field T
he Kashagan Field is a very
at some of the challenges of personnel
temperatures regularly soar up to around
large offshore oilfield located in Kazakhstan’s sector of the North Caspian Sea. The region is
location in this particularly hostile work environment and explains the solution arrived at to provide effective coverage
40°C. Equipment installed on the top of the pipe racks could experience the full force of this heat, taking temperatures closer to
environmentally interesting and important as it is home to several species of sturgeon, the Caspian seal
and mitigate risks on the site.
80°C unless some shading from the direct sunlight is provided.
and reed beds visited by many species of migratory birds. The Caspian is a land locked sea, divided into three regions; the Northern, Middle and Southern.
The region in which D-island is situated experiences a wide temperature variation from around -35°C in the winter to +40°C in the summer. At these temperatures, the low salinity of the sea means it regularly freezes over, and so the site is shielded by barriers in the sea which help to protect the island from the pressure of the expanding ice in the winter.
The North Caspian region is very shallow, only about 3-4 m deep above the Kashagan Field, so a platform was constructed here on barges mounted on concrete pillars. The largest of the manmade islands built to extract the oil and gas is D-island, which is approximately 120,000 m2. Dr. Charlotte Richardson of S3 ID looks
Environmental Challenges
Personnel Safety Additionally, the oil in the Kashagan Field contains a high proportion of gas and a very high H2S content of around 19%. This is very unkind to metals; steel, brass, and other materials therefore need protecting from this corrosive gas. It also is highly toxic and so presents a danger to the workers on site.
The wide temperature range makes the environment very challenging for engineered equipment. Cold weather can be very cruel to battery technology used in wearable equipment. At the opposite
To help to manage this risk, D-island has been divided into zones; breathing apparatus must be carried in the yellow zones and worn in the red zones. To be
end of the scale, in the summer months,
allowed to access these areas, personnel
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28
PPTex - Personnel location
Only authorised workers are allowed in the restricted zones
visibility for the last location of each worker, which, during an emergency allows the emergency response teams to focus their search more effectively and efficiently in the right areas. There are also significant quantities of pipe racks on site, which can be challenging for the various radio technologies due to propagation and reflection, known as multipath errors. The pipe racks and walkways can be on several levels and there is a requirement to know which level a person is on to inform rescue attempts, so groups of sensors were also installed on stairwells. The UWB technology includes several techniques to introduce resilience to multipath errors.
Position of D-island in Caspian Sea
are required to complete stringent training. It is key to ensure that only authorised
Because the size and scale of the site is similar to an onshore site, a longer-range
The temperature on D-island can drop to -35°C which can cause problems for
workers are in the restricted zones and a system was needed to oversee this.
S3 ID designed an ATS (Automated Tracking System) to suit the requirements of D-Island
tracking technology needed to be used. Ultra-Wide Band (UWB) technology was chosen due to its responsiveness and ability to provide location information to a high precision; UWB uses pulses of radio waves with a central frequency of 6-8 GHz to locate
technology. To overcome the challenges of the extreme cold, the ATEX certified sensors all contain heaters to enable the equipment to operate in this environment. PTC (Positive Temperature Coefficient) heaters were used to supply heat rapidly at very low
and to also mitigate further risks for the site.
tags precisely. This technology provides
temperatures and to self limit.
ATS Solution
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PPTex - Personnel location 29 Site size Another challenge presented by D-island is the sheer size of the site and the number of personnel on site at any one time. It is necessary for the safety and efficiency of the facility to locate personnel in real time, so over 600 sensors were installed and over 1,000 tags issued. Typically, to improve
Visibility and interaction with long range location technologies One challenge with long range location systems is that when a person with a tag is far from the sensing device, there can be little feedback that they have been registered. On an offshore rig with a short-
location accuracy, sensors are installed in pairs, however as the site is so large, buses are sometimes used to transport personnel. Bus stop zones, each equipped with four sensors due to the larger area, were installed to track personnel entering or alighting from
range system, this interaction would typically be provided by a display as a person musters, or traffic lights on bridge tracking systems. To provide the peace of mind that the system is functioning correctly, tag checking stations were installed at the exit
vehicles.
points of the Living Quarters. In addition to showing the person’s ID details, the battery health status of the tag is also displayed so that batteries can be changed before leaving
The UWB technology also provides the ability to geo-fence areas and can indicate which zone a person with a tag is in, whether they have permission to be there, and access control technology is linked with this system, providing an additional barrier
the safe area if required.
for restricted areas.
via a calibrated detector and displays the information on a portable device so that people on the ground can see that they had
Due to the geography and climate of
site so that, should an incident occur, all personnel can be located as quickly and efficiently as possible. Additionally, it allows the operators to check that workers are on site when expected and ensure that only authorised personnel are working in restricted areas. This ATS was specifically designed to work in the extreme temperature range and harsh environment of the North Caspian Sea and can be adapted and engineered for use in most locations around the world. About the author
Similarly, the technology allows the sampling of the RSSI of the tags during a muster
D-island, evacuation vessels need to be ice breaking and flat-bottomed. There are also temporary refuges at strategic points on site where personnel can seek shelter from the
mustered.
elements, or refill air supplies. It is important to know whether someone has entered or left these refuges and evacuation vessels,
environment of D-island in the Kashagan Field have been overcome by the design and creation of this bespoke long-range
so all vessels, refuges and helipads are monitored by the ATS.
Automated Tracking System. The system aims to provide responsive location information to operators and personnel on
Conclusion The challenges posed by the unique Dr. Charlotte Richardson is the Product Development Manager at S3 ID Ltd and has been with the company since 2009. S3 ID specialises in personnel location systems for hazardous areas in the onshore and offshore oil, gas and energy industries. Prior to working with S3 ID, Charlotte had various engineering roles and also worked as a lecturer teaching Mechanical Engineering. Charlotte holds an M.Eng (Hons) in Mechanical Engineering and French and a Ph.D. from the University of Sheffield and also has a P.G.C.E./P.C.E.T. from the University of Huddersfield.
Temperatures reach -35 oC in winter and +40 oC in summer
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PPTex - Artificial intelligence 31
Ensuring PPE compliance through the use of artificial intelligence
T
he safety of employees in the workplace is integral to any business, and with tighter government legislation, workers are better protected by the law than ever before. Nevertheless, workplace accidents still pose a serious threat to businesses’ financial viability.
According to our survey, we found on average 27 injuries lead to days off work for each business
This threat is particularly acute in industries that operate in potentially hazardous environments where Personal Protective Equipment (PPE) for employees is often a necessity. Companies may well have extensive rules and regulations governing the use of such equipment, but it can be difficult to enforce correct usage. No matter how many times you run through safety drills or training talks, some workers will always forget basic precautions, including their PPE. This article from Cortexica Vision Systems looks at how the latest technology can help. Working with health and safety professionals, the application of artificial intelligence and machine learning for object recognition and video analysis can be very useful in ensuring employee safety.
With a background of a £14.9 billion per year overall cost of work-related injury and 31.2 million days lost due to non-fatal accidents and ill health (source: hse.gov.uk), we undertook some research, surveying 100 board-level and C-suite professionals who are directly responsible for the health and safety of workers within construction, manufacturing and high hazard industries.
Setting the scene: What are the challenges facing businesses that need to stay compliant in terms of personal protective equipment (PPE)? Our survey shows that traditionally, the key challenges businesses have faced with regards to PPE have been: • 43 % - Meeting legal obligations of PPE • 38 % - Employee non-compliance
• 36 % - Educating the workforce in the correct use of PPE • 36 % - Monitoring correct use of PPE From this we can see that compliance and the correct use of PPE is a serious issue among the workforce. As new tech solutions make their way on to the market to address these issues, do health and safety professionals predict these challenges will continue in the future, or are they expecting a new set of difficulties?
Future challenges involving PPE According to respondents, employee compliance will continue to be a big concern moving forward, with over a third (35%) believing that their main focus in the next 1 to 5 years will need to be the continued monitoring of their growing workforce. Increasing standards and stricter legislation involving PPE is the greatest worry to respondents (51%), as they try to minimise their liability for workplace incidents. After all, if those responsible for implementing PPE are unaware of the latest legislation, it could cost the company significants amounts in injury claims and insurance.
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32 PPTex - Artificial intelligence Solutions to the challenges
heart-rate and body temperature.
as well as heavy lifting and handling. Those responsible for the health and safety of their
Away from specific technological solutions, respondents indicated that the development of new PPE materials (30%), and safer workplace equipment (27%) will help by making the general working environment safer and increase PPE effectiveness at a basic level.
workers should be aware that these areas in particular are where companies can do better to prevent injuries and save the business money.
How many injuries are preventable? According to our survey, we found on average 27 injuries lead to days off work for each business interviewed, of which 29% (that’s
According to our survey we found: • 84% of businesses lost money from injuries due to PPE non-compliance in the last year • 30% of businesses lost more than £250,000 through improper use of PPE in the last year
almost 8 injuries per business) could have been prevented through the proper use of PPE.
• 5% of businesses lost over £1m through improper use of PPE in the last year
With the speed of technological progress, there are now an array of industry-ready automated solutions that are available to address PPE-related concerns. The most popular solution, at 35%, comes in the form of AI video-monitoring which can identify PPE non-compliance in real time. These kinds of systems can provide a single answer to a lot of PPE challenges in one go; whether these be issues with employee non-compliance, workforce monitoring or legal obligations. The other favoured solution to prevent workplace injuries, at 32%, is wearable technology (think Fitbit, but for high-risk environments) that can monitor vitals including
Most of these accidents are a result of human error when dealing with industrial machinery,
How much money does PPE failure cost?
Systems can focus on monitoring employee PPE while keeping workers anonymous
AI video monitoring can identify PPE non-compliance in real time
www.hazardexonthenet.net
PPTex - Artificial intelligence 33 The damage from PPE failure
reach far wider than the direct costs. The hidden, indirect damage caused from PPE failure and
is being worn, not faces or behaviour. Systems using artificial intelligence and machine
* Where is the money being lost?
resulting workplace injuries is also considerable.
The biggest financial hit businesses take following a workplace injury is compensation pay-outs to injured employees, with 30% of businesses surveyed stating that they lose the greatest amount of money via the courts. Not
For instance: • 71 % say it makes it more difficult to recruit the right people • 69 % say they lose new business
learning for object recognition and video analysis can offer levels of sophistication that overcome barriers to implementation.
forgetting the vast amounts spent on legal representation in these situations, 29% of respondents said legal fees were just as much, or more than the pay-outs themselves.
* The hidden costs of workplace accidents Workplace injuries have consequences that
opportunities • 80 % say they lose productivity
Winning the PPE race For businesses at risk of dealing with the fallout of workplace injuries and PPE noncompliance, video-monitoring systems which take the human error out of PPE monitoring can be the way forward. But how can businesses progress towards this goal?
Key barriers to the implementation of automated systems
The future of AI in PPE Despite these concerns, respondents were nevertheless optimistic about the benefits current AI systems could bring to tackle the challenges previously highlighted with PPE. Some 81% agreed that these systems would increase the speed and accuracy of identifying potential dangers, and 77% said they would encourage businesses to invest in real-time, video-monitoring technology. When looking to the future of their own businesses, nearly two thirds (64%) believed that their company would specifically benefit from AI PPE video-monitoring and would be actively looking to invest in an automated
The key issue preventing large-scale adoption of new products seems to be lack of awareness of available solutions. According to
system of this nature within the next 1-5 years.
our feedback, health and safety professionals are most concerned about the following when adopting new AI solutions: • 74 % - Investment of time and money
they’re on long shifts and have to monitor hundreds of employees at the same time. Products like AI-based PPE compliance monitoring systems, which can monitor
• 65 % - Employees finding continuous monitoring intrusive • 65 % - Cyber-crime and hacking
any number of people continuously and constantly, never get tired or bored and are more accurate at spotting issues.
• 63 % - Malfunctioning AI Although the talk of AI technology may seem
Additionally, the time that AI can save collecting and analysing data allows Site and Safety Managers to focus on new strategic
complicated to those who are unfamiliar with it, the truth is that products such as PPE compliance monitoring systems have often
and innovative ways to improve safety for everyone in the workplace, instead of constantly checking in on employees.
been designed specifically to make life easy for both decision-makers and employees alike. The Cortexica solution, for example, focuses on monitoring employee PPE while keeping workers anonymous. It focuses purely on what
Humans make mistakes – particularly if
In industries where employees are putting themselves in harm’s way, simple errors can lead to serious consequences. This is why Health and Safety is a sector that is ripe for disruption and technological evolution.
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34 PPTex - Personnel location
Ensuring staff safety in site evacuation scenarios through management technology W
hen it comes to keeping staff on
site safe at all times there are particular environments, such as ATEX sites, that clearly have higher risks of fires and other hazards. All businesses have a duty of care to their employees and as such, must ensure that their safety procedures are of the utmost quality. Fire drills and evacuation run-throughs are an obligation that every business must fulfil, and they play a vital role in staff safety. Adequate systems must be in place, and employers must make sure that employees are aware of the appropriate procedures down to the tiniest detail, especially in hazardous environments.
a genuine incident. But one of the most
Simple, affordable technology now exists to ensure that when an incident happens, no-one is left behind
critical areas where drills fall down is the gathering of data showing who is present on that day, and the process of trying to ascertain if there is anyone unaccounted for. It is imperative for this step to be completed as quickly as possible to make sure that those who may be in real danger are identified.
sighs at the prospect of having to evacuate the building or site, and stand outside for a prolonged period of time to be counted. Dan Harding of Sign-In App says that the latest technology can be harnessed to streamline this process and improve site safety, as well as ensuring all staff
Some sites may be so small that who is present on a particular day might be recalled fairly easily, but in an emergency is this a system that can be relied upon? The memory of colleagues may stretch far enough to cover regular employees, but what about visitors, maintenance staff and contractors?
Nevertheless evacuation drills, which have been a part of everyone’s lives since their school years, are considered a nuisance by many. Drills have a habit of disrupting the work day at inconvenient times, and are often met
can be accounted in the event of a genuine incident.
Evacuation drills should be concise and efficient, undertaken as though there is a
Moreover, as team sizes grow, this becomes even more of a challenge and the potential of missing someone is significantly increased, as well as the time it takes to confirm everyone has
with complacency and begrudging
real emergency, to fully prepare in case of
evacuated the site safely.
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Outdated procedures
PPTex - Personnel location 35
The traditional paper and pen sign-in book is an outdated method - not everyone can
To ensure these records are accurate and the system is efficient, staff information can
Conclusion
be trusted to accurately sign in or out when entering and leaving a site. In an emergency situation, who will remember to collect the physical book? And how confident can you be that its contents are accurate?
be pre-inputted into the app, so upon arrival they need only click their name and enter their unique code to sign in, or use their individual QR code to scan and sign in or out in seconds. Staff need no longer spend precious minutes laboriously writing down
companies must move forward and embrace technology that will ensure that in the event of a fire or other emergency effective steps are in place to account for everyone on site.
Also, the impact of GDPR is still fresh and businesses are continuing to take this legislation into account. A physical sign-in book will likely not be compliant, however. Names, car registrations, job titles, email addresses – readily available to anyone
their details, and visitors and contractors do not need to queue at reception to get a printed badge. This can instead be done from a stand-alone device, requiring zero accompanying personnel - ideal in larger site environments where either receptions
Simple, affordable systems now exist to ensure that when an incident happens, no-one is left behind.
passing - pose a significant security and compliance risk.
are redundant or receptionists are busy with other duties.
An effective solution
Reachability
Staff management apps may be an effective replacement for the sign-in book. An accessible management app can provide a clear, single view of all personnel located
A cloud-based device that updates in realtime allows staff and visitor management to be accessible from anywhere on site. Standalone devices can be installed at key
on site. By logging into an online portal through any mobile or internet-connected device, those with the right authority can
entrances or exits, and at key communal areas to ensure that those on site are never overlooked. Similarly, the online portal
view the entire list of people registered as in the building or on site, including visitors and contractors. This solution is particularly useful for fire marshals, who need quick
can be accessed from any device with an internet connection, so those working with laptops or mobile phones have that option as well. Clearly much more scalable and
access to these details without the risk and danger of collecting physical records from a site.
efficient, this form of solution can effectively cover a large or complicated site with many entrance and exit points.
If safety is to be considered paramount,
About the author
Dan Harding founded All Things Code, the creators of Sign In App, in 2013 after working at Director level in the IT industry for a number of years. With a keen passion for technology enhancements within business, he is focused on creating and producing software that improves the workplace and employee engagement, to leverage enhanced productivity, safety and continuity.
www.hazardexonthenet.net
36 Nuclear
Fibre-optical penetration for reactor
Small Modular Reactors and the future of n T
homas Fink, General Manager of the
concerns in regards to pollution and overall
produced, additional modular reactor units
Nuclear Safety Division at SCHOTT Electronic Packaging, looks at the emergence of modular reactors and the
environmental impact. The combination of these factors has led to the rapid development and deployment of modular
can be added to a site incrementally should a capacity increase be required.
intriguing benefits they present for safe, flexible power generation. High-quality component development and integration
nuclear reactors.
Examples of potential applications include remote sites in the far reaches of the world, such as maritime shipping locations and
as well as ambitious development projects in China are pushing the way forward for a new generation of nuclear power that could prove to be a lowcarbon emissions answer for the future According to the World Nuclear Association, there has been a ‘revival of interest in small
of nuclear reactors that provide economic affordability and flexible power generation. A common type of modular reactor found today is the small modular reactor (SMR), defined by the International Atomic Energy Agency (IAEA) as a unit of 300 MWe or less. Modular reactors and SMRs are suitable for a wide range of users and applications and
and simpler units for generating electricity from nuclear power.’ The physical footprints of traditional, large nuclear power plants – coupled with substantial construction and operation costs – have presented challenges to the energy generation sector, while fossil
use high-quality components that deliver enhanced safety performance. Most modular reactors and SMRs are amply-equipped to replace the power generation capabilities of “traditional” power plants, such as coal-fired units. Thanks to their efficient designs and
Small Modular Reactors offer substantial benefits
fuel-based energy sources pose significant
the ability for components to be factory
designs are efficient and cost-effective
www.hazardexonthenet.net
Modular reactors are a new-generation breed
military installations, where a single SMR could power an entire community. More recent development projects, particularly in China, are slated to bring larger modular reactors to the forefront as a commercialscale power generation option to meet growing energy demands.
SMRs are an attractive option for power generation in a wide variety of instances, particularly in remote or unusual environments. Factory-made
Nuclear 37
power source to assist the existing power grid, among others. Their modular design allows additional units to be added as and when required. For example, if a small town was to rely on one SMR for its energy supply and that town was to grow as the area develops, additional units can easily be added to the existing infrastructure to meet these demands. SMRs also have the potential to be used in both civil and military settings. A small reactor could be fitted to power a submarine or surface vessel, giving it an almost infinite range. In order to deliver high-output power generation in a small package, SMRs must operate at a higher temperature than typical nuclear reactors. To create
Modular reactor projects and advanced components deliver intrigue for the future While small modular reactors offer much promise for efficient and flexible nuclear
the highest possible level of safety, engineers have taken steps to address any points of concern in the SMR operating environment. An example of this comes
power generation, new projects in China are aiming to ambitiously use modular technology on an even larger scale as they look towards a low-carbon emissions future.
through bolstering the strength and durability of the electrical penetration assemblies (EPAs) that supply power and
A natural progression can be seen in the work of the ongoing partnership
data transmission into the reactor’s first loop. Rather than using polymer-sealed assemblies that cannot withstand high temperatures, SMR engineers have made
between Chinergy Co., Ltd, and Jiamusi Electric Machine Co., Ltd. The companies cooperated to develop and construct the Shidaowan twin high temperature reactor
glass-to-metal sealed EPAs a standard in SMRs. Glass-sealed assemblies can withstand temperatures of several
(HTR) in the Shandong province of China. The reactor is slated to be connected to the power grid and go online this year.
as they enable offsite manufacturing in a
hundred degrees Celsius without issue and handle extreme pressure levels. This makes them ideal for supporting reliable
The current Shidaowan HTR, as with all hightemperature gas-cooled reactors, fell under
controlled environment. SMR production is faster than that of larger scale reactors and due to their compact size, they are
day-to-day SMR operation while also providing maximum protection to maintain infrastructure integrity and mitigate any
the classification of being a small modular reactor because of its power generation capability of less than 300MWe: the twin
easier to place on site. Factory production capability also means high quality control measures can be implemented that were
potential severe accident scenario. In addition to bolstering safety, glass-
reactors at Shidaowan will power a single steam turbine capable of producing 210 MWe. However, the benchmark has already
not previously possible with largely on-site based construction methods. In financial metrics, the quick construction track and small modules create the opportunity for a fast recuperation on initial investments in SMRs. The application flexibility provided by SMRs
sealed EPAs offer a factor of simplicity that is well-aligned with the overall benefits of SMR construction and usage. Advanced EPAs on the market today use strong connectors that can join 140 electric compactors together in a single step. It is simply plugged in, securely locked, and then ready for operation. Supplying
been set higher. Chinergy and Jiamusi Electric Machine are working towards a new undertaking known as the HTR-PM600 project. Here, the modular reactor is getting added muscle and will emerge as an intriguing option for large-scale commercial power generation. A total of six identical modules will be coupled to a single steam
is exceptional. They can be used in areas where conventional nuclear power plants cannot typically be constructed, such as remote locations lacking the network infrastructure for a large plant, sites without access to bodies of water for cooling, and
individual wires to a junction box can take hours of strenuous work. By choosing a connector-based plug and play option, the process can be completely streamlined to prevent any slowdowns or missteps stemming from an otherwise complicated
turbine.
areas requiring a small supplementary
installation.
HTR-PM600 unit is ongoing and has a list
nuclear power
While the HTR-PM600 project is in the early stages, Chinergy has begun preliminary development work at a site in Wan’an, Fujian province. Location selection for a second
www.hazardexonthenet.net
38 Nuclear Most modular reactors and SMRs are amplyequipped to replace the power generation capabilities of “traditional” power plants, such as coal-fired units.
of potential sites that includes Sanmen
from southern Germany for both projects, the
as they worked in close collaboration with
in Zhejiang, Xiapu in Fujian, and Bai’an in
successful integration of glass-to-metal sealed
the teams at Chinergy and Jiamusi Electric
Guangdong. The first units are planned to be built in pairs for a total output of 1200MWe and completion is currently scheduled for 2022-2023.
EPAs in the Shidaowan project paved the way for planned repeated integration in the HTRPM600 units.
Machine. The result was the achievement of a tailored solution that meets the unique installation requirements and can withstand the high temperature, high pressure environment of
As with all modular reactors, the Shidaowan twin-reactor HTR facility and HTR-PM600 units differ from regular reactors because their components are manufactured or replicated in-plant for fast replacement and greater longterm cost-efficiency. SCHOTT provided design recommendations and technical consultation
the HTR’s primary loop.
A common thread between the projects is the use of glass-to-metal sealed electrical penetration assemblies in the primary loop of the modular reactor infrastructure for information and control signal transmission. Supplied by glass specialist SCHOTT AG
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The incorporation of glass-to-metal sealed EPAs in the primary loop of these new HTR units is a promising step forward for shaping the future of next generation nuclear power. Glass-sealed EPAs already represent a superior
Nuclear 39
solution for “traditional” nuclear power plants, as they maintain uncompromised seal integrity for
About the author
a qualified lifetime of 60 years. In comparison, polymer-based seals are organic and age naturally, resulting in degradation and the need for multiple replacements over the lifetime of the reactor. This presents both a cost burden and potential safety risk. In HTR applications, glasssealed EPAs are the only viable feedthrough option for the primary loop as polymer cannot withstand the high temperature and pressure of the working environment.
Future Outlook As advancements continue to be made in modular reactors across a wide range of applications, the combination of unique and innovative assembly and operation of SMRs along with the superior safety and performance of glass-to-metal sealed EPAs represents a viable option for the advancement of nuclear power in the years to come. With carbon emissions mitigation becoming a topic of greater importance with each passing day, utilities and governments cannot afford to brush aside nuclear power as an energy option of the past. The nuclear industry worldwide will be watching as advanced modular reactor projects in China to take significant steps towards delivering commercial-scale power generation with modern nuclear technology.
Thomas Fink is General Manager, Nuclear Safety Division of SCHOTT. He is a recognised authority for glass-tometal sealing technology, especially with respect to its use in nuclear applications, and has written a number of published works about nuclear safety and learnings from the Fukushima accident. His paper “Post-Fukushima Technology Enhancements to Improve Safety Margins” has been presented at expert conferences internationally, including events hosted by the American Nuclear Society and the China Nuclear Energy Association. He also is an Advisory Board Member of the Ohio State University Nuclear Engineering Program in the United States.
Connector solutions for reactor
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40 Legislation & Regulation
Best practice for good DSEAR documentation T
he Dangerous Substances and
not specify exactly how this Risk Assessment
assessment can be followed in the process
Explosive Atmospheres Regulations (DSEAR) 2002 are concerned with protection of personnel against risks
should be conducted or recorded, but does provide much useful guidance.
of developing DSEAR risk assessments. The ACOP also states that DSEAR risk assessments should not be carried out in
from fire, explosion and similar events arising from dangerous substances used or present in the workplace.
Some key points include: * That the risk assessment must record the nature of the hazard;
isolation from those required under other legislation, such as the Management of Health and Safety at Work Regulations,
The Regulations have been in force for a decade and a half, and yet many operating companies are still unsure
* Who might be harmed, and how; * The measures that are currently in place to address the risk;
and that other risk assessments conducted by operating companies, such as fire risk assessments, functional safety studies etc.,
whether they are fully meeting the requirements for compliance.
* Any additional measures that could be taken; and * Actions arising from the assessment of
may cover many of the requirements of DSEAR.
To help navigate this potential minefield, Peter Hodgson of ABB takes a look at the key requirements of DSEAR, outlines how compliance can be achieved and demonstrated, and crucially explains how to maintain an up to date set of documentation. A key requirement of DSEAR is the need for a Risk Assessment. This must provide evidence that the employer is aware of all the risks associated with the dangerous substances used on site, and has applied sufficient measures to eliminate the risks or reduce them as far as practicable. The Approved Code of Practice (ACOP) for DSEAR does
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the risk. The HSE’s extensive guidance on risk
Assessing the risk A good starting point is to examine the existing process safety risk assessments
Legislation & Regulation 41
that are already in place for a site, as it
by removing dangerous substances
subjected to hazard studies will already
may well be the case that many of the requirements of DSEAR have already been addressed. Many operators of high hazard
altogether (though this may not be possible where they are required for the process), or by the application of inherent
have evidence that this hierarchy of control has been applied, and the hazards will be recorded together with their safeguards.
processes have a suite of risk assessments in place (e.g. HAZOPs, HAZIDs) which will have considered the risks associated with
safety principles. Where risks cannot be eliminated, they should be reduced as far as possible. This may be achieved
However, these hazard studies often focus on the major hazards present within a process, and may not encompass
dangerous substances, and DSEAR does not intend to re-invent the wheel. Provided that a recognised process safety risk assessment
by substituting dangerous substances for others with less volatile properties, by using process containment to limit
all the risks associated with dangerous substances. It is therefore advisable when conducting a DSEAR risk assessment to
methodology has been followed, and the risk assessment satisfactorily addresses the requirements of DSEAR, then it can be
the potential for flammable atmospheres to form, or use of ventilation to disperse flammable concentrations of gas or
ensure that every potential hazard has been considered, regardless of scale.
incorporated into a DSEAR risk assessment.
vapour, for example.
Many large companies will have their own risk assessment procedures and formats, with risk matrices for categorising hazardous events. These can be used for ranking risks and targeting those that require further action to bring them into the
Control of ignition sources should next be addressed. Every effort must be made to avoid the ignition of flammable atmospheres by correct selection, installation, operation, inspection and maintenance of equipment in hazardous
For example, a hazard study may have identified the potential for a major incident, involving an internal explosion in a process vessel, handling flammable materials, with extremely serious consequences and many safety functions and safeguards in place as a result. However, it may not have considered the risks associated with
tolerable, as low as reasonably practicable (ALARP) region. At all times, the hierarchy of control should be followed: Eliminate; Reduce; Control; and finally, Mitigate.
areas. In addition, controlling the generation and accumulation of static electricity and the methods of work processes that are carried out in those locations is also crucial.
material handling. Charging powders into a vessel via the manway presents a risk to the operator carrying out the activity, either due to the flammable powder or if the vessel contents are flammable. The consequences can range from a flash
Many processes which have been
fire to an explosion that kills the operator.
It is always preferable to eliminate risks wherever possible. This can be achieved
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42 Legislation & Regulation Consequently, it is important to examine all processes involving dangerous substances.
materials under the Management of Health and Safety at Work Regulations, then
hazard process, or one that is frequently reconfigured, a shorter interval between
An analysis of the process steps can identify all points at which there is the potential for a flammable atmosphere to form, and
their current procedures and safeguards associated with these materials can be incorporated into the DSEAR risk
reviews would be appropriate.
potentially be ignited. All the hazards can then be identified and the safeguards designated. This is the purpose of carrying out a DSEAR
assessment.
Area classification
be reviewed whenever significant changes occur. It is therefore important to ensure that your Management of Change (MoC)
risk assessment, after all – to ensure that personnel are protected from the hazards associated with the processes involving dangerous substances.
Only when a DSEAR risk assessment has been carried out and the hierarchy of control has been applied should Area Classification be focussed on. This is because Area Classification is aimed at ensuring control of ignition sources; it identifies the areas
process includes prompts to identify whether the proposed change affects the risks associated with dangerous substances, and if so, that the DSEAR risk assessment and Area Classification are reviewed accordingly. It may be necessary to review
covered compressed gases, substances corrosive to metal, and the upper flashpoint for materials being classified as flammable has been raised from 55°C to 60°C, due to
where a residual risk of forming a flammable atmosphere exists, after everything has been done to reduce the risks as far as practicable.
the MoC process and the competencies of those authorised to handle such reviews, in order to ensure this requirement can be demonstrably fulfilled. The ACOP also states
the Classification, Labelling and Packaging Regulations. This means that a DSEAR risk assessment must cover the use of compressed gas cylinders and also diesel.
DSEAR regards the Area Classification of a process as an integral part of the risk assessment documentation, and dictates that the DSEAR documentation must be
that the DSEAR risk assessment should be reviewed whenever there is reason to suspect it may be invalid. This may be the case if a site has an incident involving
The advice regarding these substances is that the fundamental risk associated with these materials has not changed. Provided
reviewed at regular intervals. The frequency of review is not defined in the Regulations, but it is advised that it should depend
dangerous substances. Even a near miss should prompt a review to ensure that the risks were correctly identified, with nothing
a diligent operating company was already addressing the risks associated with these
on the nature of the risk, and the likely degree of change. Therefore, for a high
overlooked, and consider whether additional safeguards need to be introduced.
Importantly, since 2015 DSEAR has also
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Also, the DSEAR documentation should
Legislation & Regulation 43 Conclusion In conclusion, compliance with the regulations requires a DSEAR risk assessment to be carried out, including compressed gases and substances corrosive to metal, and all DSEAR documentation to be regularly reviewed and updated. Applying the hierarchy of control, ensuring risk assessments meet the key requirements of DSEAR, and defining a sensible interval for reviews enables compliance to be demonstrated and maintained.
Frequency and periodic review
Regulation 10 of COMAH requires that
Since there is no defined frequency for the regularity of reviews, it is important to define an interval that is frequent enough to
safety reports are fully reviewed every five years; the Offshore Installations (Safety Case) Regulations also require a five yearly review. The British Standard 60079
demonstrate a commitment to maintaining compliance with the regulations. Good practice would be to identify an interval that is manageable for the process without being
Explosive atmospheres Part 14: Electrical installations inspection and maintenance’ specifies that fixed equipment inspection intervals should not exceed three years
so frequent that adhering to the programme is impractical, or that the review becomes rushed and ineffective; whilst also ensuring
without the basis for the extension being documented. With this in mind an interval of three years can be seen as good practice
that it is not infrequent. If we consider the frequency at which other process safety documentation is
and consistent with the requirements of other relevant standards. If a longer interval was justified then no more than five years would be advisable, based on typical
required to be reviewed, that can help to influence the definition of a suitable interval.
requirements for major process safety related documentation.
About the author
Peter Hodgson is a Safety Consultant with ABB. He has over 10 years of experience in the ATEX and DSEAR field, including Hazardous Area Classification, DSEAR Compliance, and Mechanical Equipment Risk Assessment, in many industries including oil & gas, chemicals, paints and coatings, material handling, pharmaceuticals and offshore.
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44 Dust
Combustible dust explosions: are you at risk? T
hink about combustible dust
mixing, sifting or screening dry materials. The
• Food (e.g., candy, sugar, spice, starch,
explosions and coal dust, grain storage and flour mills will immediately spring to mind because they make primetime news. However, any
build-up of dried residue from the processing of wet materials can also generate dust. Levels of dust in the workplace continues to increase from such daily activity, which is
flour, feed) • Grain elevators, bins and silos • Fertiliser • Tobacco
workplace that generates dust is potentially at risk to dust explosions, says Tim Turney of Casella.
why employers need to stay vigilant to the amounts of dust in the workplace in order to protect workers from hazardous incidents
• Plastics • Woodworking facilities • Furniture
and the potential detrimental consequences.
• Paper • Tyre and rubber manufacturing • Textiles
Dust is created when materials are transported, handled, processed, polished,
Industries potentially at risk include:
ground and shaped. Dust can also form from abrasive blasting, cutting, crushing,
• Agriculture • Chemicals
• Pharmaceuticals • Metal powder processing or storage (especially magnesium and aluminium) Employers are reminded of the importance to efficiently monitor dust levels from the severity of combustible dust explosions over the last few years. In 2014, a fatal combustible dust blast in a Chinese processing facility left 75 people dead and 185 severely injured. The blast is one of many that has affected China recently with an incident in 2012 in the city of Wenzhou killing another 13. On top of the
Factory dust and fume extractor
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explosive risk, there is the additional risk to health at much lower levels of exposure. In the United Kingdom during 2015-2016, 13,000 deaths were reported as a result of past exposures at work, primarily to chemicals and dust.
Dust 45
With such risks to employee safety and health, what can employers do to reduce the risk of a combustible dust explosion? The Dangerous Substances and Explosive Atmospheres Regulations 2002 set out the minimum requirements for improving health and safety protection within potentially explosive atmospheres through the safe handling and use of dangerous substances. In accordance with the regulations, it is the employers responsibility to protect employees from these risks to their safety in the workplace. Employers need to identify where explosive atmosphere conditions occur and to assess the risk and record what actions are being taken to prevent an explosion and fire. So, what are the conditions that employers need to assess to prevent a combustible dust explosion? A dust explosion can only occur when the following five factors are present:
Such a system can provide concentration
combustible dust hazards. Material Safety
• Fuel, in the form of dust particles • Dispersion of the fuel in the form of a dust cloud
using a gravimetric filter but also a time history profile, which could help identify the source of the problem.
Data Sheets (MSDS) are also ineffective in communicating to employers and workers the hazards of combustible dust explosions
• Oxygen in the form of air • Confinement of the dust cloud in the form of a container (e.g. a dust collector) • A source of ignition
Fixed, AC powered solutions could also be used on a continuous basis for high-risk areas. These have the advantage that the
and ways to prevent them. This is all the more reason for all employees to have a basic awareness of the hazards of dust explosions and the best way to mitigate those risks.
There are a number of ways Dispersion can occur, such as a dry filter being pulse cleaned
data can be made available remotely using a web-based interface. These systems provide real-time alerts via text message or an email
or from an initial (primary) explosion in processing equipment, causing a blast wave that disturbs accumulated dust that, if ignited,
should limits be exceeded. Reports can easily be automated and sent to multiple users, which allows an early intervention to avoid a
causes a secondary explosion. The latter is often far more destructive than a primary explosion due to the increased quantity of
potential problem.
dispersed dust.
atmospheres that may require instrumentation to be intrinsically safe or require a hot-work permit and, action thresholds should always
Should monitoring dust concentration also be part of the mitigation? Undertaking a walk-through survey using a hand-held, real-time sampler would give instantaneous indication of concentration. It could also be used to check the effectiveness of control measures such as local exhaust ventilation e.g. pre and post filter. Industrial hygienists may already be undertaking personal monitoring for toxic or sensitizing dusts and the same air-sampling pump could be used in combination with a real-time sampler when housed in a robust, portable case, on an unattended, short-term basis.
Dust extraction unit at Biomass plant
About the author
Great care should be taken in hazardous
be set at a fraction of the Lower Explosion Limit (LEL) for the dust in question. However, if there is any doubt whatsoever, ensure that you speak to the relevant site manager or supervisor that have responsibility for risk assessment and permitting and who can advise accordingly. Dust explosions continue to be a persistent problem for many industries resulting in loss of life, injuries and destruction of property. Even those individuals most highly trained, including government enforcement officials, insurance underwriters and company safety professionals often lack awareness of
Tim Turney is Technical Product Manager at Casella and graduated as an engineer from Queen Mary and Westfield in London. Since starting at Casella in 1998, Tim has been involved in the acoustics and air sampling industry, specialising in measurement and instrumentation technologies.
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46 Data File/Buyers Guide Control Panels
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