hazardexonthenet.net
Functional safety Why SIL is the best thing that has happened to process safety
Inspections Ensuring your Ex Inspections are carried out correctly
Food & beverage
Fossil fuels
Security
Dust explosion hazards in the food industry
Germany to phase out coal-fired power by 2038
The need to review physical security in hazardous areas
March 2019
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contents march 2019 A recent report by Eurofound, the European labour and working conditions organisation, concludes that meeting the Paris Agreement targets on emissions reduction would be positive for the EU, with investment in renewables and energy efficiency helping to boost economic growth and employment. Hitting the 20C target set out in the Paris Agreement would result in 1.1% additional growth between now and 2030 across EU member states, plus a 0.5% increase in employment, compared to a business-as-usual scenario. Boosted by higher spending on renewables and energy efficiency, alongside lower spending on fossil fuels, the report projects a 1.7% investment boost over the period, as well as a 0.7% rise in consumption across the EU by 2030. On a national level, Spain and Germany should enjoy marked increases in jobs as a result of economic restructuring as energy systems and infrastructure adapt. Some countries could suffer, however, because of their larger than average dependence on fossil fuels. Due to its large coal mining sector, for example,
14 19
Poland could suffer a decrease in employment under the modelled scenario. On page 11 we look at the German government’s decision to finally close down its coal-fired power stations by 2038 - a long way off, but a momentous change given the traditional reliance of that country on electricity from black and brown coal.
SIL-rated instruments can offer maximum protection against unsafe events escalating into dangerous failures
Also interesting is how electricity consumption has declined in some countries as more efficient equipment and appliances are introduced, and industry adapts to new economic realities. This seems to be the case in the UK, where power plant output has fallen by 16% since 2005 and demand has closely followed (see page 12). Although there is still a long way to go, some European countries have made huge strides in decarbonising their energy sectors over the last few years and could well reap both economic and employment dividends. …Alan Franck, Editor, Hazardex
23
Foodstuffs such as grain, sugar, sweeteners, starch and powdered flavours can explode violently in the form of a dust cloud
in this issue
28
5 News Extra & Standards
• Mexican pipeline explosion fatalities reach 127 • More than 320 dead and missing after Brazil iron mine dam failure • US sues Lockheed, others for alleged corruption over clean-up of nuclear site • Thirteen miners killed at Chinese-owned gold mine in Ghana • Germany agrees to phase out coal-generated electricity by 2038 • UK power stations see electricity output fall to lowest level since 1994 • At least 14 dead after two gas tankers catch fire off Crimea • Fourth explosion in three months at US grain processor injures three • ExxonMobil settles with Cal/OSHA over 2015 Torrance incident
All too often, someone with little or no experience can be found employed as an expert inspector or even leading a team of inspectors
17 Standards: The European ATEX Notified Body meeting in Brussels 19 Why SIL is the best thing that has happened to process safety –
31
and why it needs to go further
23 Dust explosion hazards in the food industry 28 How can you be sure your Ex Inspections are carried out correctly? 31 The need to review physical security in hazardous areas
The consequences of lapses in physical security can be traumatic for the personnel involved and expensive for their companies
34 Events
the journal for hazardous area environments
hazardexonthenet.net
Functional safety Why SIL is the best thing that has happened to process safety
Inspections Ensuring your Ex Inspections are carried out correctly
Food & beverage
Fossil fuels
Security
Dust explosion hazards in the food industry
Germany to phase out coal-fired power by 2038
The need to review physical security in hazardous areas
March 2019
35 Datafiles Hazardex is a controlled circulation journal published monthly. Completed print or online registration forms will be considered for free supply of printed issues, web site access and online services. Annual subscription for non-qualifying readers is: UK £147; EU £215.25; Airmail £315 and single copy price is £23.10 plus P&P.
Hazardex content is the property of the publishers or relevant content providers. The publishers and sponsors of this magazine are not responsible for the results of any actions or omissions taken on the basis of information in this publication. In particular, no liability can be accepted in respect of any claim based on or in relation to material provided for inclusion.
Editor Alan Franck alan.franck@imlgroup.co.uk
Group Publisher Russell Goater russell.goater@imlgroup.co.uk
Sales Executive Kathryn Startin kathryn.startin@imlgroup.co.uk
Circulation subscriptions@imlgroup.co.uk Tel: +44 (0)1732 359990
Production and Events Holly Reed holly.reed@imlgroup.co.uk
Design Graham Rich Design www.grahamrichdesign.co.uk
IML Group plc Blair House, High Street, Tonbridge, Kent TN9 1BQ, UK Tel: +44 1732 359990 Email: events@imlgroup.co.uk ISSN 1476-7376
Register for weekly email newsletter & up-to-the-minute news at www.hazardexonthenet.net
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18.01.19 13:17
News Extra
5
report by the state oil company, a figure that is far higher than previously thought. Pemex data and federal intelligence reports show that fuel theft and the financial damage it causes have both risen year over year in the three-year period. In 2016, fuel thieves known as huachicoleros, stole an average of 26,000 barrels of fuel a day, costing the company 30.8 billion pesos (US $1.6 billion at today’s exchange rate). The thieves sold the fuel for an average of 10 pesos a litre, generating profits of 15 billion pesos (US $790 million). In 2017, daily fuel theft rose to 43,000 barrels, costing Pemex 50.1 billion pesos (US $2.6 billion). The price of fuel on the black market increased to 12 pesos a litre and criminal gangs’ profits doubled to an estimated 30 billion pesos (US $1.6 billion).
Death toll in Mexican pipeline explosion reaches 127 O
Last year, fuel theft spiked to an average of 58,200 barrels a day, reducing Pemex’s revenue by 66.3 billion pesos (US $3.5 billion). The price of stolen petroleum increased to 15 pesos a litre, and thieves’ earnings soared to an estimated 50.6 billion
n February 5, Hidalgo state authorities said the death toll from the January 18 explosion and fire at
particularly vulnerable pipelines have been closed down, with filling stations supplied by tanker truck from refineries. This has caused
pesos (US $2.7 billion).
an illegally tapped oil pipeline near the town of Tlahuelilpan, north of Mexico City, had reached 127. They said only
a shortage of fuel across many central states.
suffered 14,894 illegal taps in 2018 alone.
20 of those hospitalised remained alive out of 81 admitted after the disaster and that apart from a small number who had
The explosion, on a pipeline linking a refinery in Tuxpan on the Caribbean coast with the central Mexican town of Tula, was one of the
that dozens of bodies from the January 18 disaster remained unidentified because the high temperatures involved had degraded
been discharged, some 75% had died in hospital.
worst in recent history.
According to Pemex, company pipelines
Hidalgo authorities said in early February
Another pipeline burst into flames in the
the victims’ DNA. Specialist forensic teams will attempt to recover DNA from the victims’ teeth, which is thought to have had a better
Video footage of the incident showed hundreds of local residents gathered in a field as a geyser of gasoline spouted high into the air from the illegal tap, followed by an explosion and a huge fireball rising up into the night sky, with screaming people running from the flames. Local media said residents ignored soldiers’ warnings to steer
neighbouring state of Queretaro because of another illegal tap on the same day, but Pemex said the fire near the city of San Juan del Rio was in an unpopulated area and there was no risk to the local population.
chance of surviving the fireball in a readable form. According to the Hidalgo Attorney General’s Office, 53 sets of human remains are still unidentified and the process of identification could take many months.
There have been many previous explosions due to fuel theft in Mexico. In 2010, a
Alejandro Gertz Manero, general prosecutor of Mexico, said that a “preliminary belief” of
clear of the site.
pipeline blew up in the state of Puebla, leaving 28 people dead and scores injured.
The government of President Andres Manuel Lopez Obrador has made tackling fuel theft a top priority. The armed forces have been deployed to protect pipelines of the
The effect of this petroleum theft is much worse than previous estimates. This cost Pemex 147.2 billion pesos (US $7.7 billion)
investigators was that static electricity from the clothing of people around the pipeline may have caused the blast. He noted a large number of people were around the pipeline, some of whom were wearing clothes made with synthetic fibres that could “generate
state-controlled oil company Pemex and
between 2016 and 2018, according to a
electric reactions.”
www.hazardexonthenet.net
6
Mine tailings lake - Shutterstock
News Extra
More than 320 dead and missing after Brazil iron mine dam failure O
n January 25, a tailings dam attached to an iron ore mine owned by Brazilian mining company Vale SA failed, unleashing a deadly mudslide that by February 5 had a confirmed death toll of 120. Some 200 others are still missing and most of these are presumed dead, officials said. The company is the world’s biggest producer of iron ore and nickel. The collapsed dam at Vale’s Corrego do Feijao mine in Minas Gerais province buried mining facilities and nearby homes in the town of Brumadinho, as well as infrastructure downriver from the dam. A second dam at the mining complex thought to be at risk after the first dam’s collapse was later declared safe by Brazilian authorities. Some 192 people were rescued alive in the first hours after the dam break and Vale initially said 305 employees, contractors and residents were missing. A sea of muddy sludge buried the site’s cafeteria where hundreds of workers were eating lunch, before engulfing nearby houses, vehicles and roads. Conditions facing rescue teams were difficult
www.hazardexonthenet.net
Vale Chief Executive Officer Fabio Schvartsman said in a television interview the disaster happened even after the company followed experts’ safety recommendations
The cause of the dam burst remained unclear. Recent inspections did not indicate any problems, according to the German firm that conducted the inspection. Avimar de Melo Barcelos, the mayor of Brumadinho, said Vale was “careless and incompetent,” and blamed the mining company for the tragedy and the state of Minas Gerais for poor oversight. Vale Chief Executive Officer Fabio
with the mud up to 15m deep in places and rescuers had to use helicopters and earthmoving machinery. “After 48 hours of work, the chance of finding [someone] alive is very low,” Col Eduardo Angelo, who led the search operation, told relatives of the missing. “But we’re working with the possibility that we’ll find people alive,” he added.
Schvartsman said in a television interview the disaster happened even after the company followed experts’ safety recommendations. “I’m not a mining technician. I followed the technicians’ advice and you see what happened. It didn’t work,” Schvartsman said. “We are 100% within all the standards, and that didn’t do it.”
After announcing the latest number of
The CEO promised “to go above and beyond any national or international
confirmed dead, state civil defence agency spokesman Flavio Godinho told reporters he expected the death toll to continue rising.
standards. ... We will create a cushion of safety far superior to what we have today to guarantee this never happens again.”
News Extra
Vale’s board of directors suspended its planned shareholder dividends, share buybacks and executive bonuses in light of the disaster, according to a securities filing on January 27. The board also created independent committees to investigate the causes of the dam burst and to monitor relief efforts. Five people have been arrested, Brazilian prosecutors said on January 31. Three were Vale officials, whose responsibilities included dealing with environmental impact licences. Vale said it was co-operating with prosecutors.
Vale’s board of directors suspended its planned shareholder dividends, share buybacks and executive bonuses in light of the disaster, according to a securities filing on January 27
7
were checked after the 2015 disaster and periodic reviews carried out. He insisted instruments used to measure dam pressure had not detected any problems. A state official told Reuters that all evidence suggested the dam burst was caused by liquefaction - a process by which a solid material such as sand loses strength and stiffness and turns to liquid. Lliquefaction was the cause of the Mariana dam collapse three years ago. Both structures are upstream dams, mostly built
operations at the Corrego do Feijao mining complex. On January 27, courts nearly doubled to 11 billion reais ($3 billion) the amount of Vale assets frozen in anticipation
with dried mining waste or tailings, a mixture of sand and clay-like mud.
Mariana iron ore mine belonging to Samarco Mineracao SA, a Vale joint venture with BHP Group, less than 100 km to the east. The resulting torrent of toxic mud
of damages and fines.
authorities now face the difficulty of dealing with the 12 million cubic metres of toxic mud that was released.
killed 19 people, buried a small village and contaminated a major river in Brazil’s worst environmental disaster on record.
had failed to apply more stringent regulation to the hundreds of tailings dams around the country.
Brazilian news outlets are also asking about the other 790 mining dams nationwide, with some industry observers denouncing
The Brazilian government ordered Vale to halt
Schvartsman said all of Vale’s tailings dams
insufficient and inadequate safety inspections at many of these sites.
In 2015, a tailings dam collapsed at the
Federal prosecutor Jose Adercio Sampaio told Reuters that state and federal authorities
As hopes of finding anyone alive dwindle, the
8
News Extra
At the time, MSA was owned by Lockheed Martin Integrated Technology LLC, Jacobs Engineering Group Inc., and Centerra Group. It awarded the subcontract to Lockheed’s technology group without competition, according to the Justice Department. MSA, now owned by Leidos and Centerra Group, holds a 10-year contract valued at $3.2 billion to provide site-wide services at the Hanford nuclear reservation. Services include security, fire protection, utilities and information technology.
US Government sues Lockheed, others for alleged corruption over clean-up of nuclear site
The Justice Department is accusing MSA of using half-truths, omissions, kickbacks and outright lies before its purchase by Leidos to get the Department of Energy to consent to a $232 million subcontract to a company with which it had ownership ties. Lockheed Martin Corp. was a principal owner of MSA in 2010, when it awarded a subcontract for information technology services at Hanford to Lockheed Martin Services Inc. The lawsuit alleges that from 2010 to
T
he United States Department of Justice has announced it is sueing
Lockheed Martin Corp, Lockheed Martin Services Inc, and Mission Support Alliance LLC, as well as a Lockheed executive, for alleged false claims and bribes on a multi-billion dollar contract to clean up the Hanford nuclear site in Washington state. The Hanford site, located 200 miles from Seattle, produced more than 67 metric tonnes of plutonium for the US defence programme between 1944 and 1987. It is considered to be the most contaminated nuclear site in the USA and the Department of Energy is working on a $110 billion project to clean up 56 million gallons of chemical and nuclear waste stored in as many as 177 underground tanks there. The complaint alleges Lockheed paid more than $1 million to Mission Support Alliance (MSA) executives in order to win a $232 million subcontract for providing
www.hazardexonthenet.net
A Lockheed Martin spokeswoman denied the allegations, saying the company “rejects the suggestion that the corporation or its executives engaged in any wrongdoing”
management and technology support at the Hanford site from 2010 through the middle of 2016 at inflated rates. The case also involves former MSA President Frank Armijo
2015 the defendants misrepresented billing rates charged to DOE, the effort estimated to be needed to complete work and the anticipated additional profit for the subcontractor. “Defendants’ fraud allowed them to obtain grossly inflated and improper additional profit on the subcontract,” the Justice Department said in a news release. In some cases DOE was billed by both Mission Support Alliance and Lockheed Martin Services for the same work, the lawsuit said. The profit paid for Lockheed Martin Services Inc. work was in addition to money Lockheed Martin Corp. was already earning on the same work through its partial ownership of MSA, according to the Justice Department.
A Lockheed Martin spokeswoman denied the allegations, saying the company “rejects the suggestion that the corporation or its executives engaged in any wrongdoing. Lockheed Martin will defend this matter vigorously.”
DOE repeatedly made clear that the subcontractor, Lockheed Martin Services Inc., could not earn profit on top of what its owner was already being paid through Mission Support Alliance, the lawsuit said.
News Extra
Armijo, and Rich Olsen, the MSA chief financial officer, also worked on behalf of Lockheed Martin Corp. and misused their positions at Hanford to help Lockheed Martin Corp. obtain grossly inflated pricing, the Justice Department alleged. Olsen paid $124,440 in August to resolve his liability and agreed to cooperate in the federal investigation. He denied any wrongdoing in agreeing to the civil settlement.
The proposed new Hanford spending plan includes $730 million for the vitrification plant, including $60 million to continue work at the High Level Waste Facility
Mission Support Alliance said that ethical
than proposed for the next fiscal year by
business conduct is one of its hallmarks and that it is committed to integrity and compliance throughout all levels of the company.
the Trump administration.
9
The focus at the vitrification plant has been on preparing to treat low activity radioactive waste no later than a courtordered deadline of 2023. The money included for the facility to treat high level radioactive waste would help prepare the plant to meet a court-ordered deadline that it be fully operating by 2036. The 586-square mile Hanford site is administered by the Department of Energy, Environmental Protection Agency and the state of Washington.
The Senate’s final spending bill for next year puts the Hanford nuclear reservation
The waste tanks at Hanford are reportedly leaking toxic and radioactive vapours and chemicals that have been linked to cancer, brain damage,
This comes at a time when President Donald Trump’s administration is attempting to reduce the costs of
budget at $2.4 billion, some of which will go towards a planned vitrification plant, which will encase the site’s nuclear waste in glass.
and lung damage. There were at least 61 workers exposed to those deadly vapours in 2016, the last year for which figures are available. Hundreds of
cleaning up the site. This has been countered by the Senate, which proposed a Hanford clean-up budget $15 million
The proposed new Hanford spending plan includes $730 million for the vitrification
workers were forced to take cover after a tunnel over a train containing nuclear waste collapsed in May 2017, and
higher than the current fiscal year’s spending level, and $342 million more
plant, including $60 million to continue work at the High Level Waste Facility.
there have been other safety incidents since.
10 News Extra The head of the local Ghana Small-Scale Miners Association, Robert Tampoare, vowed to stop Shaanxi Mining Company Ltd “from killing our people”. Recent deaths at the mine include: • October 2018: A cleaner died after being hit by a machine inside a mining pit.
Thirteen miners killed at Chineseowned gold mine in Ghana
T
• April 2017: Seven illegal miners died after being trapped by smoke. • January 2016: An employee of the company died after he was buried under a pile of ore. • April 2015: Two miners died and eight were critically injured from fumes from explosives. • April 2014: Two miners died from poisonous fumes and one was severely injured. • October 2014: Three miners lost their lives when a pit collapsed on them.
he Ghana Mineral Commission has directed Shaanxi Mining Ghana Limited to suspend all operations at its
the small-scale miners nearby, local media said.
Gbane mine site with immediate effect following the death of 13 small-scale miners in a blast on the site. Several other miners have reportedly been
Antwi-Boasiako, said in a statement copied to Joy News, “Management of Shaanxi Mining Company Limited is directed to suspend all mining operations at Gbane with immediate
• May 2013: Three illegal small-scale miners perished in a tunnel following an explosion.
injured. Reports indicate that the incident occurred while company workers set off blasting explosives on the site.
effect until further notice pending investigations into the tragic incident that occurred today.”
responsibility for the latest incident. Company Public Relations Officer Maxwell Wooma said the individuals concerned were not Shaanxi
The Chinese-owned mine at Gbane has faced years of protests because of its safety record.
staff and they had been illegally mining near the company’s operational facilities.
The resultant smoke clouds and fumes killed
The CEO of the Minerals Commission, Addae
But Shaanxi Mining Ghana Ltd denied
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News Extra 11 German lignite mine - Shutterstock
Rolf Martin Schmitz, RWE’s chief executive, warned the plan would have serious consequences for the company’s lignite (brown coal) operations and unions in the energy sector have agitated against an early phase-out of coal. The commission said that gas would become Germany’s backup power of choice, rather than coal, which would make it more similar to the UK energy system. Much of this gas will come from Russia via the controversial NordStream pipelines.
Germany agrees to phase out coal-generated electricity by 2038
This move comes as part of German government plans to increase the share of renewables in electricity generation from 40% today to 65% in 2030.
ermany has agreed to end its reliance on polluting coal-fired power stations
will decide if the deadline can be brought forward to 2035.
Figures from the Frauenhofer Institute showed that in 2018 for the first time, renewables beat coal, with 40% and
by 2038, in a long-awaited decision that will have major ramifications for Europe’s attempts to meet its Paris climate change
One of the most difficult issues has been the cost of compensating energy firms
38% of the share of electricity generated respectively. Renewables included wind, solar, biomass and hydro plants. Other
targets. The country is the last major bastion of coal-burning in north-western Europe and the dirtiest of fossil fuels still provides almost 40% of Germany’s power.
for shutting coal plants before the end of their lifetime. About €40bn will be awarded under the commission’s plans, while the industry had hoped for €60bn.
than renewables and coal, nuclear provided 13% and gas 7% of electricity in 2018. All German nuclear plants are due to be closed by 2022.
In comparison, only 5% of the UK’s power is generated from coal, and this
RWE, which runs many of the country’s coal plants, said the 2038 date was
By this year, clean power capacity added as many as 111 gigawatts, more than
fuel source will be phased out entirely by 2025 in that country.
far too early for a complete closedown of coal-fired generation and it hoped the 2032 review would be a chance to
double the 45 gigawatts invested in coal plants.
The German coal exit commission has members across industry, politicians and NGOs, and has been working for nine
extend the final end date. In a statement, the utility said the proposals: “would have far-reaching consequences for the
Germany plans to shut its last coal mine in November, with fuel for its approximately 120 coal-fired power plants imported from
months to decide on a final exit date. The commission agreed that a review in 2032
German energy sector and in particular for RWE.”
the US, Russia and Colombia, according to Bloomberg.
G
French 2018 power output sees strongest growth in decade
F
rench electricity generation saw its biggest increase in ten years, up 3.7% at 549 terawatt-hours (TWh) compared 2017. This was due to a surge in power output from nuclear
year-on-year in 2018, RTE said in its yearly report.
and renewables sources, French grid operator RTE said on February 6.
sharp fall in power generation from coal, gas and oil-fired generators, down 26.8% in 2018 compared with the previous year.
The increased output from nuclear and renewables enabled France cut is carbon emissions from power generation by 28%
The strong availability in nuclear and renewables, and a mild winter, also led to a
RTE said renewable wind, and solar power in France rose 15.3% and 11.3% respectively in
2018 thanks to favourable weather conditions and a rise in installed renewables capacity, which added 2,400 megawatts during the year, the equivalent of two nuclear reactors. It said power consumption was stable for the sixth year in a row at 474 TWh, in line with its forecast. It helped to keep France as the top, net electricity exporter in Europe with 86.3 TWh exported, while 26 TWh was imported during the year.
www.hazardexonthenet.net
12 News Extra 8 million more people living in the UK. Analysts said the figures were a sign of
electricity generation as more power is sourced from renewables and less from coal. The
increasingly efficient use of energy and the country’s changing economy.
carbon intensity from electricity generation was down 6.8% last year and has more than halved since 2013.
The UK website Carbon Brief, which analysed government and industry data, found that 335 terawatt-hours (TWh) were generated by power plants last year, down by about 1% on the year before. Since 2005 the level has fallen by 16% – or the equivalent of two and a half Hinkley Point C nuclear power stations.
UK power stations see electricity output fall to lowest since 1994
T
he output of British power stations fell in 2018 to levels last seen in 1994,
while renewables achieved a record share of the UK electricity supply. The reduced need for power came despite there being
The analysis by Carbon Brief found that renewable sources including biomass, hydro, solar and wind power supplied a record 33% of electricity in 2018, up from 29% last year. Renewables were just 6.7% of the mix in 2009.
The website said a combination of more
Meanwhile coal-driven output was down 25% despite warnings of a coal comeback driven
efficient appliances, energy-saving lightbulbs and LEDs, as well as better fridges and more efficient pumps in the retail and industry sector, had cut demand significantly. Changes in the
by high gas prices. Nuclear power also had a weak year, with generation down 8%, mainly due to ageing reactors being taken offline for safety checks. Gas remained the top source of
country’s economy away from energy-intensive manufacturing was also partially responsible.
electricity supplies, but fell 4%.
While generation fell almost every year between
Carbon Brief said of the renewables total, wind accounted for 17%, solar 4% and biomass
2008 and 2014, it remained stable between 2015 and 2017, before resuming its downward trajectory in 2018.
11%. Other sources estimated that in 2018 nuclear power supplied 19%, coal 5% and gas 39% of total generation. The remainder
Separate data from the National Grid showed that 2018 was the greenest year to date for
was provided by hydro and other sources, and imports through interconnectors from the continent.
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News Extra 13 likely had drowned, they added. One vessel was transferring fuel to the other when an explosion and fire on the first reportedly set the second on fire. They were named as the Kandy, with a crew of 17 from Turkey and India, and Maestro, with 14 sailors aboard. Rescuers abandoned
At least 14 dead after two gas tankers catch fire off Crimea
attempts to douse the flames, and the vessels were left to burn out. Most of the sailors on both vessels jumped overboard after the explosion, with 14 initially rescued. The remaining crew remembers are missing.
The names of the two vessels both appear on a US treasury list as possible targets for sanctions over petroleum shipments to Syria. The US tightened sanctions against Syria back in 2011 in response to what it said was President Bashar al-Assad’s “continued atrocities” committed against the Syrian people. The Kerch Strait is a focus of tension between Russia and Ukraine. In November, Russian border guards seized
Authorities said that no signal was received from either of the two captains during or after the incident. Those rescued were taken ashore to the Russian-occupied Crimean city of
three Ukrainian naval vessels near the narrow channel, which links the Black Sea with the Sea of Azov.
Kerch, and there were no reports on whether or how badly any of these were injured. The crew members were in neutral waters in
A court in Russia has extended by three months the detention of 24 Ukrainian sailors captured in the incident. They are accused of illegally crossing into Russian territory.
thought to have died in fires on two Tanzanian-flagged gas tankers in the Black Sea near the Kerch Strait, Russian
the Black Sea when the incident occurred, authorities said. Russian news service TASS reported rescuers saying the two Tanzanian-
Ukraine condemned the Russian move, denying that its ships had violated the
authorities said on January 21. Rescuers reportedly witnessed a further three people struggling in the water who most
registered ships were ‘illegally anchored’. A criminal investigation has been launched into the deaths.
navigation laws in the area. The strait lies off Ukraine’s Crimea peninsula, which Russia annexed in 2014.
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14 News Extra Workers on site observed smouldering material in a silo storage bin within the loading facility and called firefighters, ADM spokesperson Jackie Anderson told local media. Reports said an explosion occurred after fire crews arrived. The other incident occurred on January 4 at
Fourth explosion in three months at US grain processor injures three
A
n explosion and fire on January 31
an ADM corn processing plant in Decatur, Illinois, according to the Decatur Herald & Review. Anderson told the newspaper that no injuries were reported, and company officials are investigating the cause of the blast and assessing damage. The explosion occurred in the corn plant’s conveyor belt system.
This follows three other incidents at different ADM
The incidents come a little more than a
at the Archer Daniels Midland (ADM) soybean processing plant in Lincoln, Nebraska, resulted in the hospitalisation of three workers with non-life threatening
plants in November 2018 and January 2019.
month after an explosion was reported at the ADM Milling Co.’s flour mill in Calgary. No injuries were reported in that incident.
injuries, fire officials told local media. The cause of the latest explosion and blaze is under investigation. No estimates
which resulted in the death of a firefighter and critical injury to another. A fire at an ADM grain facility in Clinton, Iowa, on January 5 led to an
Last November, emergency personnel were called to the Decatur facility for a dust explosion and fire in a grain elevator, Powder
on damages to the Lincoln facility were available.
explosion that resulted in the death of 33-yearold Lt. Eric Hosette.
& Bulk Solids reported. No injuries were logged during that incident.
ADM reported explosions at two separate plants over the weekend of January 4-5, one of
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News Extra 15
ExxonMobil settles with Cal/OSHA over 2015 Torrance incident E
xxonMobil has agreed to pay $566,600 in a settlement with California’s Division of Occupational
refinery to New Jersey-based PBF Energy later in 2015, which spent over $800 million on refinery upgrades and employee training
debris from the precipitator more than 100 feet to within five feet of a tank filled with thousands of gallons of modified hydrofluo-
Safety and Health for eight safety and workplace violations levied in the wake of the February 2015 fire and explosion
to rectify some of the problem areas identified by federal and state bodies.
ric acid. If breached, the tank could have released a toxic cloud with the potential to kill and maim many in the neighbourhood.
that tore through the Torrance refinery in south-west Los Angeles. Cal/OSHA has been negotiating with the group for
The February 2015 explosion and fire at the Torrance refinery destroyed part of the site, rocked the area with the force of a 1.7
Regulators in 2016 approved Exxon’s request to restart the Torrance refinery, which
four years over the violation charges and fines.
magnitude earthquake, released flammable hydrocarbons, injured several workers and caused substantial property damage.
was largely shut down after the explosion. This caused a spike in fuel prices across the state, given that it normally supplies
As part of the settlement announced last week, according to the Daily Breeze, all willful violations among the original 24 cita-
The blast came in a fluid catalytic cracking unit after exhaust particulates unevenly
tions initially announced were either reduced to the next level, serious, or withdrawn, although the total fine remained unchanged. The settlement figure is the maximum possible under US federal legislation governing OSHA operations.
accumulated on expander turbine blades. The imbalance caused the turbine to shut down. Flammable fuels in a main column then flowed into a reactor, regenerator and electrostatic precipitator, where they ignited.
ExxonMobil announced the sale of the
The explosion catapulted a 40-ton piece of
20% of the gasoline used in Southern California and 10% statewide. In May 2017, the US Department of Justice filed a lawsuit against ExxonMobil seeking answers to questions raised by the US Chemical Safety Board (CSB) in its final report into the 2015 explosion. The CSB report said Exxon had failed to respond adequately to a number of its requests for information.
16 News Extra Work is still suspended at the other four drill sites in the oil field, awaiting approval from the regulatory authority to restart. Leak testing still needs to be done on the other drill centres. Husky said in a news release that adverse weather guidelines were updated and risk assessments and safety reviews were completed before restarting work at the drill centre.
Husky restarts limited production from White Rose oilfield off Newfoundland
I
The November leak from the flowline happened while crews were preparing to restart production after operations were
n late January, the CanadaNewfoundland Offshore Petroleum Board approved Husky Oil’s request to restart production at the White Rose
separate flowline from the one where the leak originated. That will remain closed until the company can retrieve the broken connector, plug the flowline and flush it with water. This
suspended the previous day due to high winds and rough seas.
oilfield off Canada’s Atlantic coast. Operations have been suspended since a November 16 oil spill of an estimated 250,000 litres caused by a faulty
requires a two-day weather window which might not happen for weeks.
after the petroleum board found Husky violated operations protocols during a near miss with an iceberg in 2017. In that incident, the vessel did not properly disconnect lines
flowline connector to the SeaRose FPSO, stationed about 350 kilometres off the coast.
happen during daylight hours, as a condition of the regulator’s approval. Other conditions will require aerial and vessel surveillance,
used to bring oil onboard as the iceberg approached.
The approval is for one drill centre that uses a
operational and wildlife observers on board and monitoring of Husky’s onshore activities.
The offshore board’s investigation into the November incident is still ongoing.
In the meantime, key operations are to
The SeaRose was shut down earlier in 2018
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Standards 17
Brussels in February Body is doing it. So it mainly discusses processes for certification, but it can discuss interpretations of the directive and put recommendations to the European Commission.
For manufacturers whose quality system is fully compliant with ISO 9001:2015, the transition should not cause many problems. An interesting discussion concerned the
In our case, this will then be discussed in the EU ATEX Working Group, with a
LED light source now almost always present in a smartphone. Assuming that the rest of the phone can be made compliant with
view to producing text that can go in the next edition of the ATEX Guidelines document (available from the ATEX section of the Commission web site). If the subject concerns an interpretation
an appropriate hazardous area standard; should the LED be considered as part of the camera function, or should it be considered as a portable light source, as the impact test requirements are different. There were
from the European ATEX Notified Body meeting in Brussels, held, as usual, in the first week in February.
of a standard, this will be referred directly to the Maintenance Team or committee responsible for that standard.
contrary views in the meeting, including discussing the possibility of disabling the “torch” function of the smartphone. As the
For the UK Notified Bodies present, there was still the question “Would this be our last meeting, or would there be a
The meeting discussed issues related to the problem of dealing with QA assessments
relevant standard maintenance team (IEC TC31 WG22) is meeting on 29 March, it was decided to take no action, other than
sensible Brexit deal?” All the UK bodies have produced their own “Plan B” in case of “No Deal”, so that they can
during the period when ISO 9001:2015 has compulsory application, but before the new EN ISO/IEC 80079-34 is published, later
waiting for a decision from the standard committee.
continue to service their customers, but the lack of certainty does not help.
this year, and becomes harmonised.
As chair of Cenelec TC 31, I was challenged to give an explanation of the delay in publication of the EN version of
Every two months, SGS Baseefa Technical Manager and IECEx Service Facility Certification Committee chairman Ron Sinclair MBE gives his perspective on the latest developments in the world of standards
A
s I am writing this, I am just back
It was agreed that it is not appropriate to What was very heartening was the resolution taken by the meeting that, whatever the nature of Brexit, all UK bodies would be welcome to attend next year, even if only as observers. As it happens, even if the UK crashes out, the same individuals are likely to be attending on behalf of their EU body, as well as being an observer on behalf of their UK body. In my case, I was also
use the current harmonised standard EN ISO/IEC 80079-34:2011, as it contains mandatory references to clauses in ISO 9001:2008 which has now been formally withdrawn.
representing SGS Fimko Oy in Finland, and that allowed the meeting to re-elect me as vice chairman. Martin Thedens (PTB) was reelected as chair and Thierry Houeix (Inneris) as the other vice chair. Although not in the
as the reference document. The Notified Body group is satisfied that there are no requirements within ISO/IEC 8007934:2018 that conflict with the requirements of the harmonised standard EN 80079-
constitution, it works well having the chair and vice chairs from different countries.
34:2011.
The role of each Notified Body Group in Europe (for each of the directives) is to work out ways of ensuring that things are done in similar ways, whichever Notified
As a harmonised standard cannot be used, the next available standard is ISO/ IEC 80079-34:2018, which should be used
Additionally, the Annex ZB of EN ISO/ IEC 80079-34:2011 should be applied, as the equivalent text is not in ISO/IEC 80079-34:2018, but will be published in the new edition of EN ISO/IEC 80079-34.
IEC 60079-15:2017. The IEC version has been available for well over a year, but the European version has not yet appeared. There is a combination of reasons for the delay, but I am pleased to be able to confirm an expected publication date during March.
About the author SGS Baseefa Technical Manager Ron Sinclair MBE is chairman of BSI Committee EXL/31, responsible for the UK input to both European and International standards for Electrical Equipment for use in potentially explosive atmospheres. He is also chairman of Cenelec TC31, represents electrical standardisation interests on the European Commission’s ATEX Standing Committee and chairs the IECEx Service Facility Certification Committee.
www.hazardexonthenet.net
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Functional safety 19
Why SIL is the best thing that has happened to process safety – and why it needs to go further
A
s the front line in any industrial
process, instrumentation has a key role to play in helping to minimise the risk of accidents
What are the main changes in process safety since you started your career?
When dealing with SIL, it is important
Having worked in this industry for many
to understand that the SIL rating relates not to the instrument itself but rather the process it is being used in. Individual safety
caused by abnormal or unsafe operating conditions. By continuously monitoring critical parameters,
years, I can confidently say that the introduction of Safety Integrity Levels, or SIL, in 1998 has been the most significant
instrumented functions (SIF) and safety instrumented systems (SIS) within a process can obtain SIL ratings but instruments can
instruments can help to warn operators of potentially dangerous conditions and ensure that processes are safely shut down before a catastrophic failure occurs.
change in process safety.
only be perceived as being compatible with a particular SIL-rated application.
For this reason, it is necessary to select instruments that can offer maximum protection against unsafe events escalating into dangerous failures. One way to do this is to select SIL-rated instruments.
Up until 1998, there was a growing need for improvements in health and safety to prevent dangerous process failures and reduce the risk of hazardous events. SIL, as defined by IEC 61508, was introduced to rate the efficiency of a safety system within a process and its probability of failure on demand (PFD), when dealing with dangerous
The whole idea behind SIL is redundancy and the ability to mitigate risk if a measuring instrument of some kind fails in place. Having either a back-up function or spare instrument in case the primary device fails makes perfect sense and provides an added safeguard against process failure.
In this Q&A, David Bowers, Product
fluids and chemicals. SIL ratings range from SIL 1 up to SIL 4, with the lower number indicating the lower chance of system failure.
Even then, it is not a case of ‘job done’. If these instruments are not checked, recalibrated and maintained, then all
Manager Pressure and Process Flow at ABB, explains more about SIL and its impact on process safety.
As the numbers increase so does the cost of maintaining the safety of a complex system and the risk of process failure that could lead
safety measures go out of the window, highlighting the vital contribution that a thorough maintenance regime can make
to injury and even death.
to process safety.
www.hazardexonthenet.net
20 Functional safety How recognised is SIL in industry? The most surprising element of SIL is the fact that so few people are aware of it. Even after events at Buncefield in 2005, many companies do not appreciate the relevance of applying the SIL approach to their own operations when it comes to measurement. Throughout most industrial sectors we have instruments measuring water quality, steam distribution in power plants and custody transfer but there are no legal requirements to have redundant or failin-place instruments installed. A good example is chemical dosing in potable water treatment applications. Many of these chemicals can be harmful to human health if administered incorrectly. Although doses of these chemicals are monitored extremely closely, the instruments making the measurements are not often monitored to ensure they haven’t failed in place. In addition to helping safeguard against human injury or loss of life, having instruments with back-up protection in place can also help to protect against the loss of vital process data. The loss of data due to an instrument failing with no redundancy measure in place can cause a company enormous financial damage, especially where processes are subject to traceability requirements. Both can harm a brand’s reputation, not to mention incurring huge revenue losses due to delays or heavy fines for breaching legislation.
www.hazardexonthenet.net
Taking all this into consideration, why wouldn’t you want to know if your
widespread adoption of SIL, namely cost, skill and knowledge gaps, and the burden of
instruments aren’t working correctly?
responsibility.
What factors do you think have acted as a barrier to the adoption of the SIL approach across industry?
As with most businesses, expenditure
In my opinion, there are three key factors that have presented a barrier to the
instruments, the initial outlay may be hard to justify but these costs pale into insignificance
is closely monitored and if there are opportunities to cut spending they are usually taken. When it comes to SIL-rated
Functional safety 21
over the entire instrument lifecycle. While there are SIL rated continuous measurement
The other main barrier concerns the burden of responsibility. With huge implications if
Ideally, if we could get to a point where SIL became standard, no other alternatives
instruments, point measurement devices, which are only called into action when needed, can help to extend the total lifespan significantly and reduce lifetime cost. To ensure these instruments will function properly when called upon, it is advisable that
a life-threatening incident occurs, including potentially large fines and prosecution of responsible individuals, plus the lengthy training process, it is not surprising so few people put themselves forward for this type of work.
would exist. With larger awareness and take up, these standards would become the norm, which would ultimately drive down cost when implementing safety systems in the future, helping to greatly enhance the overall management of safety
they are frequently checked, with additional maintenance and recalibration if necessary.
What more could be done to improve understanding/ awareness?
throughout industry.
Unfortunately, this occasional use can also support the idea that SIL instruments are an unnecessary expense. When you consider
Most concerning is the use of SIL-rated instruments is still not a more common legal requirement. There needs to be
though the £750 million fine Total had to pay after the Buncefield disaster, SIL approved instruments might not seem so expensive after all.
more support from Government in the first instance, but this looks unlikely since not much has happened in terms of promoting SIL and its importance even after
SIL skill and knowledge gaps have also proved to be a major barrier. SIL is a complex topic and cannot be learned
Buncefield. Expanding SIL requirements to measurement instruments across all industries would be a positive step. Although most sectors aren’t as dangerous
overnight. Training courses are time consuming and costly, which means there are very few experts with the required knowledge
as the petrochemical industry, there is no reason why stricter safety measures should not be applied across the board as a matter
to implement and approve SIL-approved safety systems. Businesses can also be wary of training employees to be SIL accredited, well-aware of the high premium that SIL-
of best practice.
accredited status offers, as well as the risk of losing out to companies willing to pay more for the employee’s services.
The greatest achievement would be for SIL-rated instruments to be used more frequently and become commonplace.
How would you like to see things develop over the next five years?
About the author
David Bowers is the Process Flow and Pressure product manager for ABB Measurement and Analytics division, joining the company over four years ago. He has nearly 30 years’ experience in the industry and is a member of the Institute of Measurement and Control.
www.hazardexonthenet.net
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13/02/20
Food & beverage 23
Dust Explosion Hazards in the Food Industry N
early all foodstuffs and ingredients
to be present within processing buildings,
ranging from fine to coarse, the fines play
including grain, sugar, artificial sweeteners, starch, and powdered flavours will burn with difficulty as a
explosible dust clouds are regularly formed inside the material handling/processing equipment, i.e. silos, bin filling/emptying,
a prominent part in the ignition and the explosion propagation. As dust settles, larger particles drop out of suspension, leaving the
powder layer, but they can explode violently when ignited in the form of a dust cloud.
pneumatic conveying or dust collectors. In addition, dust layers in buildings, if roused for example by a ‘primary’ explosion inside a vessel, can form combustible concentrations throughout the entire building. These so called ‘secondary’ dust explosions are often the most devastating.
finest particles to form the dust cloud. The presence of dusts should be acknowledged in a process stream, regardless of the starting particle size of the material. For example, friable materials (granular sugar) will create very fine dust in transfer operations by means of attrition.
The dust cloud density is quite important and it would need to resemble a dense fog before ignition could occur. Although such
The particle size of the dust is another important property which influences the explosibility of the dust cloud. The finer the particles, the greater the surface area per unit mass and thus the more explosible a given dust is likely to be. When the cloud
Moisture content will also affect the explosion risk. A dry dust contains less than 10% moisture and the dryer it becomes the higher the ignition sensitivity and explosion violence. Therefore dry dusts, of small particle size will be more easily ignited and produce more
concentrations are not normally expected
is composed of a series of particle sizes,
violent explosions.
This paper from Dekra Process Safety outlines the many factors that affect the explosion violence or the sensitivity to ignition of a dust cloud such as particle size, cloud density or moisture content.
www.hazardexonthenet.net
24 Food & beverage However, it must be noted that moisture contents in the range of 12 – 18%, as found naturally in many agricultural products, are not enough to render the dust nonflammable. Care must also be taken concerning material that has been present in process equipment for a long period of time, e.g. due to poor cleaning programs, and
In order to determine the sensitivity of a dust cloud to ignition, appropriate laboratory tests should be performed
which has now dried out. Please also be aware that with the introduction of chemicals such as artificial sweeteners, and powdered vitamins into the food industry in recent years, the explosion
in 2008, resulting in 14 fatalities, multiple injuries and major facility destruction.
Conditions required for dust explosions to occur
Most commonly identified ignition sources in dust handling/processing plants include welding, mechanical sparks, hot bearings, hot surfaces, open flames, burning embers, self-heating, electrostatic discharges, and electrical sparks. In order to determine the sensitivity of a dust cloud to ignition, appropriate laboratory tests should be performed.
Assessment of dust explosion hazards in your facility A systematic approach to dust cloud
properties of products may now be totally different, with potential for increased sensitivity to ignition and greater explosion violence.
A number of conditions must exist simultaneously for a dust explosion to occur: • The dust must be combustible (combustible, flammable, and explosible all
explosion hazards involves: • Identifying areas where combustible dust clouds could occur under normal and abnormal conditions;
Dust explosions in the food industry are nothing new, and the oldest recorded dust explosion occurred in Mr. Giacomelli’s Bakery
have the same meaning); • The dust must be dispersed (forming a dust cloud in air); • The dust concentration must be within
• Preventing the formation of explosible dust clouds • Determination of ignition sensitivity and explosion severity characteristics
in Turin on December 14, 1785. As facilities increased in size, equipment became more mechanised and sophisticated, the
the explosible range (above the Minimum Explosive Concentration, MEC); • The dust must have a particle size
through appropriate laboratory tests on representative dust samples; • Identifying potential ignition sources that
consequence of incidents also increased, such as the grain elevator explosion in April 1981 that killed 9, injured 30 and caused US$30 million damage. And one of the most
distribution capable of propagating flame; • The atmosphere in which the dust cloud is present must be capable of supporting combustion e.g. contain enough oxygen;
could exist under normal and abnormal conditions; • Taking measures to eliminate/control ignition sources; and
catastrophic dust explosions in recent years occurred at a sugar refinery in the USA,
• Any ignition source must have sufficient energy to initiate combustion.
• Taking measures to protect against the consequences of dust cloud explosions.
www.hazardexonthenet.net
Food & beverage 25 Laboratory testing assess explosion characteristics of dust clouds In order to assess the potential for an explosion and to select the most appropriate Basis of Safety for any operation, the explosion characteristics of the dust(s) handled in the processes should be
Likelihood of an explosion (Ignition Sensitivity) and consequences of an explosion (Explosion Violence) usually define the dust explosion risk
determined. The explosion characteristics normally fall within one of two groups, “likelihood of an explosion (Ignition Sensitivity)” and “consequences of an explosion (Explosion
replaced with a hot coil to provide more energy. If this is still negative, a 20-Litre sphere test using a 2 kJ chemical igniter would be used (an acceptable alternative to the 20-Litre sphere, normally in the case of
Violence)”. Taken together these two groups define the dust explosion risk of a material.
limited material, is the GG vertical furnace).
Laboratory testing to determine “ignition sensitivity”
make the processes fall under the ATEX or DSEAR regulations. This test answers the question “Can this dust explode?”
Processes handling powders which propagate flame during any one of these tests, would
cloud at its optimum ignitable concentration. The test is used primarily to assess the susceptibility of dust clouds to ignition by electrostatic discharges (sparks). Minimum Ignition Temperature of a Dust Cloud – MIT (EN 50281-2-1) This test determines the lowest temperature capable of igniting a dust dispersed in the form of a cloud. The MIT is an important factor in evaluating the ignition sensitivity of dusts to such ignition sources as heated environments, hot surfaces (electric motors), and friction sparks. Minimum Ignition Temperature of a Dust Layer – LIT (EN 50281-2-1) This test determines the lowest temperature
Combustible Dust and Combustible
capable of igniting a dust layer of standard thickness (5 mm). The LIT is used in evaluating the ignition sensitivity of powders to ignition by hot surfaces (electric motors).
Flyings Determination (BS EN ISO/IEC 80079-20-2) This test determines whether a dust cloud
Self-Heating - (JA Abbott (ed.) “Prevention of Fires and Explosions in Dryers”, Institute of
will explode when exposed to a sufficiently energetic ignition source. The first part involves using a vertical tube with a constant arc ignition source to see if the dust is
Chemical Engineers, 1990) / BS EN 15188
Minimum Ignition Energy - MIE (BS EN
Ignition of bulk powders can occur by a process of self-heating when the temperature
capable of supporting combustion and propagating flame. Should the test show no flame propagation, the constant arc is
ISO/IEC 80079-20-2) The MIE test determines the lowest electric energy that is capable of igniting a dust
of the powder is raised to a level at which the heat liberated by the exothermic oxidation or decomposition reaction is sufficient to exceed
MIE test in action
www.hazardexonthenet.net
26 Food & beverage the heat losses and to produce a “runaway” increase in temperature. The minimum onset temperature for selfignition of a powder depends mainly on the nature of the powder, its volume, vessel dimensions and the way it is heated. If these variables are predictable, a reliable
These data can be used for the purpose of designing dust explosion protection
Approach to process safety testing
measures such as explosion relief venting, suppression, and containment.
Table 2 specifies the type of data that might be required to assess dust explosion hazards associated with some common unit operations in the food industry and to define a Basis of Safety. Note that this should only be used as a guide and specific data
The basis of safety for dust cloud explosion hazards Safety from dust cloud explosions includes
assessment of the onset temperature for self-ignition and also the induction time to self-ignition can be made by appropriate small-scale laboratory tests: > Bulk Powder Test: Simulates bulk powder in IBCs, bags, bottom of dryers, hoppers
taking measures to avoid an explosion (explosion prevention) or designing facilities and equipment so that in the event of an explosion people and processes are protected (explosion protection). The selection of explosion prevention and/or
requirements for a particular unit operation may be different.
> Aerated Powder Test: Simulates fluid bed drying > Powder Layer Test: Simulates powder deposits on dryer walls/surfaces and tray
protection measures is based on: • Defining where flammable atmospheres occur • The available flammability data
one of the following measures is ensured: • An explosible dust cloud is never allowed to form • The atmosphere is sufficiently depleted of
drying > Basket Test: Simulates large-scale storage or transport conditions
• The nature of the processes and operations • The level of personnel knowledge regarding the consequences of a dust
oxidant that it cannot support combustion • All ignition sources capable of igniting the dust cloud are removed, or • People and facilities are protected against
Minimum Explosive Concentration MEC (EN 14034-3) MEC test determines the lowest
explosion and adherence to the preventive measures (employee training and culture) • Environmental effects of a dust explosion
concentration of a dust cloud in air that can give rise to flame propagation upon ignition. This test answers the question “What is the minimum concentration of a dust cloud to
• Business interruption resulting from a dust explosion Table 1 lists Explosion Characteristics of
Avoiding formation of explosive dusts clouds should always be the primary objective. This might be through inherent safety or other means such as good dust extraction,
sustain combustion”.
some dusts that are commonly used in the food industry.
handling techniques, equipment containment and maintenance, and housekeeping.
Explosion prevention and protection measures The risk of an explosion is minimised when
the consequences of an explosion by suitable “protection measures”.
Limiting Oxygen Concentration LOC (EN 14034-4) LOC test determines the minimum concentration of oxygen (displaced by an inert gas such as nitrogen or carbon dioxide) capable of supporting combustion. An atmosphere having an oxygen concentration below the LOC is not capable of supporting a dust cloud explosion.
Laboratory tests to determine the “explosion violence” Maximum Explosion Pressure (Pmax), Maximum Rate of Pressure Rise, Dust Constant (Kst Value) (EN 14034-1 & 2) The Maximum Explosion Pressure and Maximum Rate of Pressure Rise values are determined by using a 1m3 or more commonly a 20-Litre Sphere test apparatus. The maximum explosion pressure and maximum rate of pressure rise are measured and the latter is used to calculate the Dust Constant (Kst) value of the dust cloud.
www.hazardexonthenet.net
1. Explosion Screening is only conducted if the combustibility of the powder/dust (as being present in the process/facility) is not yet established. If the material is found to be non-combustible, other tests in the table may not be required. 2. LOC is determined if the Basis of Safety is inert gas blanketing. 3. LIT and MIT are also required for determining the maximum allowable surface temperature for electrical and non-electrical equipment used in hazardous (zoned) areas.
Food & beverage 27
Note that since ignition sources are difficult to completely prevent, particularly for
Secondary dust explosions are especially common in industries where traditionally
Safeguard reliability
ignition sensitive materials, a robust basis of safety often requires these measures to be combined e.g. ignition source avoidance combined with explosion protection. Explosion protection on its own does not usually constitute an adequate basis of
little concern exists for the presence of dust outside the process equipment due to the material not being toxic and not being particularly expensive. Unfortunately, the food industry falls squarely into this category. After all we use sugar and flour at home all
since June 2003 to reduce the likelihood of dust explosions occurring. The ATEX1 workplace directive and DSEAR2, in the UK, are designed to show awareness of dust explosion hazards and to minimise the potential risk to employees. All safeguards
safety. Other prevention measures must also be used to ensure explosion protection systems have minimum demand on them. Even if protection systems work as intended, you have had an explosion and this is not a good outcome.
the time, how can it be dangerous? Under the right conditions these very familiar materials can be killers. Housekeeping activities must strive to minimise the presence of dust outside
intended to prevent dust explosions must be recognised, understood and maintained. Operators should be aware that signs of overheating, excessive vibration, or noise indicating mechanical malfunction or misalignment need prompt attention
equipment. Of key importance is evaluation of dust release points and exhaust ventilation needs. It is much easier to replace a gasket, refit a manway, or install local dust extract
before a small smouldering clump of dust leads to a serious explosion. Likewise protective safeguards such as explosion relief vents must be appropriately designed
of safety, if those who operate it do not understand the hazards involved, and the precautions designed to control them.
systems, etc., than to spend time cleaning up the dust that has escaped. Other common practices are explosion venting, inside a building. The flame and pressure
and maintained with clear, safe passages of discharge. Maintenance programmes for equipment should be in place and a routine inspection and testing programme should
A majority of the most serious dust explosions over the years have not been caused by the primary explosion inside the
waves from such a release can cause unimaginable damage to people and plant let alone the increased risk of a secondary
be created for safety critical explosion protections.
plant, but from a secondary explosion within the building, as mentioned earlier. A small initial event causes pressure and shock waves to propagate into the workplace,
explosion occurring.
References
and dust deposits around the workroom are shaken into a cloud, which subsequently ignites. When this happens in a series of
companies should strive to create a suitable culture in the organisation for example that does not tolerate dust layers outside
connected rooms, the result can be fatalities and horrific building collapse.
equipment.
Secondary explosions and good housekeeping A well designed plant is no guarantee
In the EU, legislation is has been in place
1. ATEX 153, EU Directive 1999/92/EC
To avoid these conditions occurring, training and competency are key. In addition,
2. DSEAR, Dangerous Substances and Explosive Atmospheres Regulations
www.hazardexonthenet.net
28 Inspections
How can you be sure your Ex Inspections are carried out correctly? C
ompanies cannot afford to take chances with explosion safety.
may require many different specialist skills covering the technical knowledge for the
inspections covered by this standard.
More than ever industry is seeing enforcement and claims for noncompliant inspections, with entire teams being replaced on sites for not being
range of protection techniques available for equipment explicitly designed for use in explosive atmospheres. The inspection team leader or responsible person will need the
The RP/TPEF is responsible for the maintenance and inspection documentation. Known as ‘the verification dossier’, it shall include as a minimum the following:
competent. Personnel competence schemes only
management skills to be able to manage the team and to conduct, analyse and thus action the results of an inspection.
a) Zone classification of areas and, and if included, the equipment protection level (EPL) required for each location.
partially address the requirements for undertaking Ex Inspections. They do not determine if the team has the correct
Accredited Inspection companies (for example to ISO/IEC 17020 ‘Inspection Body’)
b) Gas and Dust equipment group (IIA, IIB or IIC and/or IIIA, IIIB or IIIC), temperature class requirements and maximum surface
level of experience, technical support, impartiality and suitable recording and analysis methods backed by appropriate
have to be able to demonstrate not just a level of training and assessment for team members, but they should also have suitable
temperature as required. c) Equipment characteristics e.g. temperature ratings, type of protection, IP rating,
accreditation.
experience, specialist skills and levels of supervision and data recording analysis.
corrosion resistance, vibration resistance etc. d) Sufficient records to enable the explosion
In this article, Paul Hague of ExVeritas takes a look at the requirements for inspection teams and the individuals who lead them.
The ‘Technical Person with Executive Function’ and ‘Responsible Person’ IEC 60079-17 defines the Technical Person with Executive Function (TPEF) as having adequate knowledge in the field of explosion protection. They should be familiar with the installation and local conditions, and
protected equipment to be maintained in accordance with its type of protection for example, the list and location of equipment, spares, certificates, technical information. e) Copy of the initial and periodic inspection records and details of any repairs or maintenance.
requirements of the inspection team and management. All too often, someone with little or no experience can be found employed as an expert inspector or may even be leading a team of inspectors.
have overall responsibility and control of the inspection activities associated with electrical equipment within hazardous areas. Although from the standard this role is assigned to the ‘continuous supervision’ type of inspection, it is clear that it also applies to the role of
In order to retain and review the required information, an ‘Ex register’ is required. This will normally be some form of electronic database that records all Ex equipment whether in the hazardous area or performing
Competent inspection team members
the Responsible Person (RP) and all types of
some form of safety function outside of the
The history The Ex Industry has come to rely on the individual competence of Ex inspectors on a project rather than the collective competence
www.hazardexonthenet.net
Inspections 29
hazardous area, e.g. associated apparatus (Ex i barriers) and overload tripping devices used on some increased safety motors, etc. It should also include protective systems, e.g. mitigation devices, and non-electrical equipment that is certified or risk assessed.
The Inspection Team The RP/TPEF shall ensure that an inspection team is in place to undertake the inspections. This team should have the breadth of knowledge available to encompass the range of the Ex protection techniques or concepts covered by the installation. To get an inspector with the correct knowledge and skill set is not easy, as they are not readily available. Specialist companies that provide this service to industry must invest in their staff ensuring that the inspection team members have the range of skills, knowledge and experience necessary to undertake the inspection activity in a meaningful and safe manner. Most training and/or assessments schemes aimed at the practitioner level can never really cover every aspect of information required for inspection, therefore without experience and additional knowledge this may not be sufficient to cover every aspect required of the ‘inspection team’. It is therefore clear that competent ‘inspectors’ need on-going mentoring and study additional to the level offered by the various assessment schemes. The inspection team shall be able to gather the evidence during the inspection activity and then the RP/TPEF should be able to use this information to derive meaningful decisions in accordance with their documented inspection and maintenance strategy. Sources of evidence could include: • Risk assessment studies; • Specifications; • Equipment certificates and manuals; • Maintenance procedures; • • • •
Maintenance records; Test and inspection records; Competence records of the installer; Compliance against safety management system procedures; • Field observations.
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30 Inspections Competence for Ex Inspection Bodies over the individual competence requirements Specialist companies that provide these inspections services should, like the RP/ TPEF and inspection team members, have a proven level of competency. It is not just about getting the right people in place to control or undertake the inspections, it is important to ensure that policies, procedures and methodology are in place to meet the benchmark level expected by industry. To assist with this process a range of
Summary It is not enough just to conduct Ex Inspections – there must be policies, strategies and programmes in place that identify a clear and concise route, not only for the inspection, but also for any corrective actions identified, including on-going maintenance.
manage all of the requirements discussed in this article, companies should look for UKAS accreditation, which is Government recognised accreditation. In certain industries, such as high risk or public sector sites, using UKAS accredited suppliers for critical services
The RP/TPEF must be able to demonstrate that any strategy and programmes are effective and that they maintain (or ideally reduce) the level of risk which has been deemed acceptable for the people, environment and assets. The RP/TPEF
will be standard practice. For smaller sites or sites with a lower risk, this option should also be considered, as who can afford to get explosion safety wrong?
International and National documents are available. 1) ISO/IEC 17020 Conformity assessmentRequirements for the operation of various
therefore has a key role in the explosion safety of a site or facility/plant.
bodies performing inspections. 2) UKAS RG101: Accreditation for the inspection of electrical equipment and installations in potentially explosive
safety roles must be verified and attributed, at intervals not exceeding five years, on the basis of sufficient evidence that the person is competent across the specified range of
atmospheres. 3) HSE: COMAH Competent Authority. Inspection of Electrical, Control and
activities and has the relevant knowledge and understanding underpinning the competency.
Instrumentation Systems at COMAH Establishments (Operational Delivery Guide) 4) Energy Institute Publication - Guidelines for managing inspection of Ex electrical
To assist with competency assessment, CompEx have developed the CompEx module EX14 - Responsible Person Module. This aims to assist responsible persons in meeting their
equipment ignition risk in support of IEC 60079-17
legal obligations including maintaining an Ex asset and inspection register and implementing a practical approach to the inspection and
Accreditation to standards such as ISO/IEC 17020 should be considered a minimum.
www.hazardexonthenet.net
To assist with selecting a competent Ex Inspection Body to undertake and
About the author
The competency of people in these key
maintenance of equipment in explosive atmospheres using IEC 60079 Parts 14 & 17.
Paul Hague is the Site Operations Manager at ExVeritas. Having started his professional career at ICI Runcorn, Paul has over 25 years’ experience working in potentially explosive atmospheres including DSEAR/ATEX compliance, hazardous area classification, installation and inspection. Paul’s experience includes oil and gas, heavy and speciality chemicals, pharmaceuticals and the food industry.
Plant security 31
The need to review physical security in hazardous areas T
he latest New Year has brought with it
reports from around the world of civil unrest, terrorist insurgency and cyberattacks. In this article, Doug Woodbridge of SecurEx looks at how the high hazard industries, which are particularly vulnerable, can best protect their critical infrastructure, physical assets and personnel from outside threats. In the high hazard industries the implications of any attack can be profound. Against this backdrop, I decided out of curiosity to investigate for myself the scale of these dangers in order to put some empirical value on the need for ever more vigilance, physical security and intruder detection in the hazardous Ex world.
reported, including those that have been
Locks in this grade should also ideally be to be designed to meet the SR2 security standard on selected door sets
astounding. I found a map on storymaps. esri.com where I learnt, according to the site, there were some 1,553 attacks and 8,018 fatalities recorded world-wide during this period.
intercepted or stopped by the security forces, and the scale of the problem becomes evident. The threat types that are commonly experienced today can be extremely wide ranging; from simple criminal attacks focused on the theft of goods or assets, to the extremes of terrorist attacks against onshore infrastructure, offshore piracy and malicious cyber-attacks that may be either politically or criminally motivated. The consequences of any of these events
As a starting point I googled ‘terrorist attacks between January 1st 2018 and
Look deeper, and factor in civil insurrection, civil unrest, riots, violent protests and the like and the number of incidents jumps dramatically again. Keep digging, and add
can be expensive for the companies and very traumatic for the personnel involved - and for their families. Destruction of property, loss of raw materials, pollution and environmental damage, along with the risk of death or injury of personnel feature high on the potential
January 7th 2019’, and the result was quite
in the number of failed attacks that are
risk list.
www.hazardexonthenet.net
32 Plant security
The last major physical attack on oil installations at In Amenas in Algeria in 2013 saw many lives lost, and it is clear that further attacks on high value targets such as oil, gas and petrochemical installations and critical infrastructure can be expected in future. Parallel to this, cyber-attacks against Saudi Arabia’s Saudi Aramco and Qatar’s RasGas could have been intended to cause catastrophic explosions. High risk targets such as these in the Ex world pose very unique challenges to protect, requiring specialist solutions and security measures specifically designed to work in the different zones of hazardous areas.
into a plant’s access control and/or intruder detection system. Traditionally, even basic access control in hazardous areas posed a significant challenge. The ubiquitous mag-bar, so familiar and commonly used in safe areas, simply did not exist in an ATEX or IECEx certified form suitable for use in hazardous area applications.
– 1500 kgf are required, there is right now no real substitute for electro-mechanical bolt technology. Once again, there are now some examples of this technology available that hold ATEX and IECEx accreditation.
Solutions were limited to basic Ex shoot bolt locks, relying on the simple solenoid bolt itself, or an Intrinsically Safe (IS) electronic latch.
For high security applications it is important to look out for systems where the bolt is independent of the actuator solenoid, preventing side loads on the bolt causing damage to the actuator no matter what lateral force is applied. Versions with an independent
This has now changed with the introduction of products such as Excertified electromagnetic locks, which,
thumbwheel and key over-ride mechanism will also ensure the ability for safe egress and entry in the event of a bolt problem and allow extra flexibility in use.
Historically, the layers of security and personnel safety and protection operated independently. However, this has changed and today’s high-risk Ex environments
due to their strength and functionality, are proving increasingly popular and are providing enhanced safety and security for personnel in hazardous areas.
increasingly need holistic solutions capable of both controlling security and enabling a facility ‘lock down’ whilst at the same time
Another new development is the recent introduction of ATEX & IECEx Grade 2
allowing the location of personnel to be known and facilitating safe passage and egress as required in an emergency.
and Grade 3 equivalent security contacts for use in hazardous areas. Previously only basic certified contacts have been available for door status monitoring and
One important aspect of physical security is door security, and new measures that have recently become available can be linked
alarming purposes, and so not being directly compatible with a grade 2 or 3 Alarm panel.
www.hazardexonthenet.net
Moving up the physical security range still further, where holding forces of around 1200
Plant security 33
Locks in this grade should also ideally be to be designed to meet the SR2 security
multitude of functions including panic and emergency escape, mechanical and electro-
So, with the high threat levels outlined at the start of this article and new Ex-certified
standard on selected door sets.
mechanical deadlocking.
Critical National Infrastructure demands something very special with regard to locking technology. It should be designed to be very highly resistant to attempts at forced entry by
Conclusion
products on the market, now is a very good time to review plant safety and security.
physical attack and at the same time provide reliable holding forces in the order of several tonnes.
unauthorised access to a plant would have relied almost entirely on the perimeter security measures, these usually being in the safe area. Get past these and typically there is very little hardened security or access control within the perimeter to protect the really
There are again relatively few examples of locking technology for these applications, with approved locks of this class being only available from very specialist players. High security single point locking systems now exist which can be configured with a
Much has changed over the past two years with regard to the levels of threats. A few years ago, the physical restrictions preventing
About the author
crucial plant where the most mischief could be done once access is gained. In the article above, I have tried to show that this has now changed significantly and that there are now a wide range of locking technologies of different security grades that can be applied to restrict access and slow physical attacks and importantly to show how these physical levels of protection are now available to combat the increased threats. Furthermore, movement can now be restricted and access controlled in hazardous areas using new products and techniques directly comparable to those used in the safe areas.
Doug Woodbridge is a director of SecurEx Technology Ltd, a specialist security business based in South Yorkshire. He has more than 25 years’ experience working with industry and in hazardous environments, in particular within the Oil & Gas sector. During this time he has been involved with supplying specialist automation, business, safety and security solutions around the globe.
www.hazardexonthenet.net
34 Events
Gulf Safety Forum / OPEX MENA 2019 Date: 25 - 28 March 2019 Location: Manama, Bahrain Promoting Safe Operations in Industry The Gulf Safety Forum 2019 will bring together key decision-makers from end user organisations, technology developers and service and equipment providers to encourage a better understanding of how the right corporate culture, best practices and latest technologies and innovations can lead to increased safety performance. Examples
technologies and methods beyond industry boundaries will make participants re-think Oil and Gas industry practices and leverage success factors. With the rapid increase in global energy demand, the oil and gas industry faces serious challenges. Oil and gas companies urgently need to implement the latest information technologies and management processes to reduce costs and ensure safe operations.
Companies well aware of current trends and impending changes find themselves in a much better position to adapt ahead of time. With that in mind we are pleased to announce the next Middle East editions of our Safety & Operational Excellence Conferences www.europetro.com/week/ gsfopexmena2019
of the cross industry learning and transfer of
15th Global Congress on Process Safety Date: 31 March 2019 to 03 April 2019 Location: New Orleans, USA Each year the Center for Chemical Process Safety (CCPS) and the AIChE Safety & Health Division present the Global Congress on Process Safety (GCPS). From its initial meeting in 2005, GCPS has grown into the world’s largest gathering of practitioners from industry, regulatory bodies and academia. Highlights include: • 53rd Annual Loss Prevention Symposium (LPS) The Loss Prevention Symposium (LPS) is one of four parallel symposia that comprise The
Global Congress on Process Safety. Organized by Group 11A of the AIChE Safety and Health (S&H) Division, the LPS has been held annually since 1967. • 8th Process Safety Management Mentoring (PSMM) Forum world of Process Safety. PSMM is dedicated to sharing all aspects of Process Safety Management in the oil, gas, chemical and allied industries with the next generation of professionals. PSMM
Other features: • Process Safety Spotlights • 34th Center for Chemical Process Safety
complements the objectives of the other three established symposia in AIChE’s Global Congress on Process Safety by focusing on
(CCPS) International Conference • 21st Process Plant Safety Symposium (PPSS) • Perspectives on Process Safety from Around
the young practitioners and those new to the
the World
SPE Symposium in Asia Pacific on Health, Safety, Security, Environment and Social Responsibility Date: 23 - 24 April 2019 Location: Kuala Lumpur, Malaysia The past five years have witnessed great shifts in the global energy industry. Stakeholders across the value chain continue to adapt to the new oil price environment and pace of digital advancements by developing innovative technologies, strategies and processes to effectively manage cost and seize opportunities to create value. This symposium is aptly themed “Being Ahead of the Curve”, amidst an evolving business climate where emphasis is placed
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on leveraging lessons learnt and innovations to increase efficiencies and create value. We must examine how the industry can prepare, mitigate and respond to stay ahead of emerging technical, regulatory and societal challenges in a safe, secure and environmentally sustainable fashion. Furthermore with the opportunities that digitalisation and automation are creating, how can the industry take advantage and integrate such innovations to complement
processes and competencies to incorporate wider factors such as human performance and cultural aspects to achieve and sustain good HSSE performance. Being ahead of the curve is not only the ability to anticipate, but to also create sustainable solutions for the future. We look forward to welcoming you to Kuala Lumpur, Malaysia in 2019.
and not compromise on HSSE? HSSE management is going beyond systems,
www.spe.org/events/en/2019/ symposium/20sm01/committee.html
35 Data File/Buyers Guide Connecting you to Global Markets CSA Group is a global organization dedicated to safety, social good and sustainability. We provide testing, inspection and certification services for products in industrial and hazardous locations. We realise our customers need access to global markets and they need it quickly. As such, we’ve evolved our processes to respond even better to the pressures our customers face, while offering the marks needed to access markets around the world. Our large team of certification engineers are focused on completing projects within agreed-to timelines and we consistently start and finish projects with some of the best lead-times within the industry. T: +44 (0) 1244 670900 E: ukinfo@csagroup.org
W: www.csagroup.org
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Eutex International marks 21 years of proven performance Eutex International, a global brand name for International Electrical Cables and a range of Hazardous Area Products, today begins its celebratory year of customer service. The company, founded in Houston, TX, in 1998, has steadily grown into the go-to company for Hazardous Area Products and Services. Eutex is the leading supplier of electrical cables and hazardous area accessories – both for international and domestic applications. Through its subsidiary ATEC, the company is one of the exclusive providers of internationally accepted hazardous-area training, inspections and certifications to a variety of industries worldwide. To learn more, visit the EUTEX web-site at www.eutex.global
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