November 2019
the journal for hazardous area environments
hazardexonthenet.net
Acoustics Sound advice for petrochemical plants Downstream European downstream safety performance in 2018
Research
Software
Augmented Reality
HSE calls for partners in wearables research
The role of software In safety
Wearables & PPE in Industry 4.0
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contents november 2019 Nominations are now open for the Hazardex 2020 Awards for Excellence. The Hazardex International Conference and Exhibition in Harrogate, UK, on 26 & 27 February 2020 will feature a hazardous area and process safety awards programme to highlight examples of excellence across the sector. Categories open for nomination are Contribution to Safety, Contribution to the Environment, Technical Innovation, Best User Application and Best Customer Service. Entry is free, and this is the ideal opportunity to reward
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those companies and individuals you think most deserve recognition for the most innovative products, systems and services. The deadline for nominations is 14 December 2019. For further information on the awards, categories, and how to nominate a company, please visit: https://bit.ly/2IIwImC Contact Russell Goater on +44 (0) 1732 359990 or russell. goater@imlgroup.co.uk for further details on attendance or sponsoring this must-attend event.
A look at the digital transformation of safety and the role that software plays in managing and analysing the data produced by PPT
…Alistair Hookway, Associate Editor, Hazardex
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in this issue 5 News Extra & Standards
• US administration issues new pipeline safety rules • BP deploys Mars technology on UK continental shelf • UK HSE calls for partners in high hazard research programmes • Canadian operator to reinforce controversial Great Lakes oil pipeline • Explosion hits Russian research facility harbouring smallpox virus • Top executives cleared of negligence over Fukushima disaster • Hinkley Point C nuclear plant to run almost £3bn over budget
Petrochemical and chemical plants have become increasingly complex and the potential for excessive noise remains high
17 Standards: Further pause for thought
36
20 PPTex Supplement 6 – Products 39 HSE calls for partners in wearables research 23 44 Paving the way for broader adoption of PPT 24 50 The role of software in safety 26 54 Wearables & PPE in Industry 4.0 28
Concawe, the European downstream industry organisation, has published personal safety performance results for 2018
30 Case study - Reliable leak detection in industrial gas pressure-relief stations 40
31 Case study - SOCOTEC UK and Casella 33 Sound advice for petrochemical plants 36 European downstream safety performance in 2018 40 Risk of electrostatic ignition during FIBC discharging operations 44 Play it safe – adhere to the Machinery Directive
A look at why the greatest risk posed by static electricity in a flammable or combustible atmosphere is an explosion due to electrostatic discharge
46 Event previews
36Acoustics
the journal for hazardous area environments
November 2019
30 hazardexonthenet.net
Sound advice for petrochemical plants
40Downstream
European downstream safety performance in 2018
Research
Software
Augmented Reality
HSE calls for partners in wearables research
The role of software In safety
Wearables & PPE in Industry 4.0
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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
Associate Editor Alistair Hookway alistair.hookway@imlgroup.co.uk
Circulation subscriptions@imlgroup.co.uk Tel: +44 (0)1732 359990
IML Group Blair House, High Street, Tonbridge, Kent TN9 1BQ, UK Tel: +44 1732 359990 Email: events@imlgroup.co.uk ISSN 1476-7376
Sales Executive Kathryn Startin kathryn.startin@imlgroup.co.uk
Design Graham Rich Design www.grahamrichdesign.co.uk
Production and Events Holly Reed holly.reed@imlgroup.co.uk
Register for weekly email newsletter & up-to-the-minute news at www.hazardexonthenet.net
4
News Extra
Shutterstock
Strikes on Saudi oil facilities highlight vulnerability of infrastructure to low-tech attack T
he attacks on state-owned Saudi Aramco oil processing facilities at Abqaiq and Khurais in eastern Saudi
Saudi Arabia has US-supplied Patriot anti-missile systems that have shot down a number of incoming ballistic missiles at
damage on theoretically much better-armed Saudi Arabia which is supposedly defended by the US, the world’s greatest military super-
Arabia on 14 September 2019 have been claimed by the Iran-backed Houthi movement, the rebel movement fighting
high altitude, but the destruction at the two refineries illustrates how vulnerable the country’s oil (and other) infrastructure is to
power.
Saudi-led forces in the Yemeni Civil War.
relatively low-tech drones, which the Houthis have in abundance.
And the US and Saudi Arabia are particularly
The attacks caused large fires at the refineries which, according to the Saudi Arabian interior
Billions of dollars spent by Saudi Arabia
hesitant to retaliate against Iran because they fear a counter-attack would not be a cost-free exercise. Iran is now recognised as a drone superpower. Oil production facilities and the
ministry, were put out several hours later. Both facilities, however, were shut down to effect repairs, cutting Saudi Arabia’s oil production
on cutting edge Western military hardware has not so far included equipment to shoot down drones and cruise missiles, which can
desalination plants providing much of the fresh water in Saudi Arabia are conveniently concentrated targets for drones and small
by about half – representing about 5% of global oil production – and causing some destabilisation of global financial markets.
fly beneath the radar and are consequently difficult to detect before they hit their target.
missiles. Nor is this strategic shift limited to potential
Saudi Arabia’s energy ministry said the facilities were expected to be operating back
The United Nations says the Houthis’ arsenal includes anti-ship cruise missiles, waterborne improvised explosive devices, ballistic and
war zones. Between 19 and 21 December 2018, hundreds of flights were cancelled at Gatwick Airport in the UK following reports
at full capacity by the end of September, and the country would tap into its oil reserves to maintain exports in the interim.
cruise missiles and rockets, as well as weaponised drones, according to a Reuters report. A new type of Houthi drone appeared
of drone sightings close to the runway. The reports caused major disruption, affecting approximately 140,000 passengers and 1,000
in mid-2018 which the UN has said can fly up to 1,200-1,500 km - putting Riyadh, Abu Dhabi and Dubai within range.
flights. Similar events in April and May 2019 disrupted flights out of Milan Malpensa in Italy and Frankfurt airport in Germany.
Iran denies arming the Houthis and says it played no part in the recent strikes. President Hassan Rouhani said the attacks were carried out by “Yemeni people” in response to the
And in January 2019, a Greenpeace drone dropped smoke bombs on the French nuclear facility at La Hague to demonstrate its vulnerability.
The USA and Saudi Arabia have blamed Iran for the strikes, which the latter denies. Previous attacks have included a series of explosive blasts on tankers in Gulf waters, including two Saudi vessels in May, and attacks on other Saudi oil assets, including two oil pumping stations. A transformer station near a desalination plant in Shuqaiq in the south was struck in June.
Yemen war.
The previous attacks caused limited damage, but the strikes on Abqaiq and Khurais knocked out 5.7 million barrels per day of
In strategic terms these events illustrate an important development. A middle ranking power such as Iran, under sanctions and with limited resources and expertise, acting
In the wake of these attacks, media commentators and industry experts have emphasised how important it is for operators of strategic facilities and sites all over the world to strengthen their defences against
production.
alone or through allies, has inflicted crippling
low-tech devices of this type.
www.hazardexonthenet.net
News Extra
San Bruno gas explosion 2010 – Image: Wikimedia CC / Mister Oh
5
reconfirming the Maximum Allowable Operating Pressure (MAOP). In addition, the rule updates reporting and records retention standards for gas transmission pipelines. The Hazardous Liquid Rule encourages operators to make better use of all available data to understand pipeline safety threats and extends leak detection requirements to all non-gathering hazardous liquid pipelines. In addition, the rule requires operators to inspect affected pipelines following an extreme weather event or natural disaster so they may address any resulting damage. The Enhanced Emergency Order Procedures final rule adopts the provisions
US Administration issues new pipeline safety rules T
of a 2016 interim final rule (IFR) which established temporary emergency order procedures in accordance with a provision of the “Protecting our Infrastructure of Pipelines and Enhancing Safety Act of 2016” (PIPES Act). An emergency order may impose emergency restrictions, prohibitions, or other safety measures on owners and operators of gas or hazardous liquid pipeline facilities.
he US Department of Transportation’s Pipeline and Hazardous Materials Safety
will modernise federal pipeline safety standards by expanding risk-based integrity management requirements, enhancing
The new rules have been in the pipeline for almost a decade, and were drafted in response to a massive gas explosion
Administration (PHMSA) has adopted three new rules that will strengthen the safety of more than 500,000 miles of
procedures to protect infrastructure from extreme weather events, and requiring greater oversight of pipelines beyond
in San Bruno, California, that killed eight people in 2010, and large oil spills into Michigan’s Kalamazoo River in 2010 and
onshore gas transmission and hazardous liquid pipelines throughout the US.
current safety requirements.
the Yellowstone River in Montana in 2011 and 2015.
A PHMSA statement said the new rules, applicable from October 1, 2019, will enhance its authority to issue an emergency order to address unsafe safety conditions or hazards that pose an imminent threat to pipeline safety. “These are significant revisions to federal pipeline safety laws and will improve the safety of our nation’s energy infrastructure,” said US Transportation Secretary Elaine L. Chao. US pipelines deliver trillions of cubic feet of natural gas and hundreds of billions of tonnes/miles of liquid petroleum products each year. The gas transmission and hazardous liquid pipeline safety rules
The final rules address significant Congressional mandates from the Pipeline Safety Act of 2011 and recommendations from the National Transportation Safety Board. “The tremendous growth in US energy
PHMSA previously required integrity assessments only in certain areas, including high-population places where a critical pipeline failure would cause serious harm. Companies have already begun extending integrity management programs to so-
production will require greater anticipation and preparation for emerging risks to public safety,” said PHMSA Administrator Skip Elliott. “These forward-looking rules will help ensure pipeline operators invest in
called moderate consequence areas, but PHMSA’s rule will offer clarity on where the assessments will be made.
continuous improvements to pipeline safety and integrity management.”
future to release their proposals for pipeline shut-off valves and rupture detection equipment. A separate proposal due sometime next year would extend safety regulations to so-called gathering pipelines that transport natural gas from drilling locations.
The Gas Transmission Rule requires operators of gas transmission pipelines constructed before 1970 to determine the material strength of their lines by
Federal regulators are expected in the near
www.hazardexonthenet.net
6
News Extra
Hyundai Nexo FCV - Shutterstock
South Korea’s uphill struggle to encourage hydrogen cars U
nlike in many other countries where electric vehicles are the
major beneficiary of moves away from fossil fuel-powered vehicles, the South Korean government is encouraging the use of hydrogen cars. President Moon Jae-in is a major proponent of the hydrogen car programme and says he wants to see 850,000 hydrogen fuel cell vehicles
The constraints around refuelling and the limited number of stations are causing much frustration
businesses meant to help shoulder half the costs, delays in finding sites and opposition from residents have also hobbled efforts. And this opposition has multiplied since a fatal FCV filling station incident. Last May, a hydrogen tank explosion killed two people and injured six at an industrial park in the city of Gangneung, 240 kilometres east of Seoul.
Hyundai Nexo, and the corporation itself
A preliminary investigation found the blast
(FCVs) on South Korean roads by 2030. This will be no mean feat given fewer than 3,000 have been sold so far in the country.
plans to invest $6.5 billion by 2030 on hydrogen R&D and facilities.
was caused by a spark after oxygen found its way into the tank.
One of the main problems is building refuelling infrastructure where each
One month later, there was an explosion at a hydrogen refuelling station in Norway.
The government has earmarked $1.8 billion to subsidise car sales and to build refuelling stations for the five years to 2022, according to a recent Reuters report.
hydrogen filling facility costs many times more than an electricity charging point.
Subsidies cover about half the cost of the main South Korean FCV car model, the
www.hazardexonthenet.net
Despite government plans for 114 hydrogen stations to be built by end-2019, only 29 have been completed. Difficulties in gaining funds from local governments or
Safety concerns have fuelled protests by South Korean resident groups worried about hydrogen facilities being built in their areas, and local opposition has led to a number of potential operators withdrawing plans to build refuelling facilities.
News Extra
7
Others cite the difficulty of making such facilities pay when the government
economy is the establishment of a network of hydrogen buses in the south-western
This is compounded by the fact that while refuelling itself takes only five minutes or
stipulates that fuel costs are kept as low as possible to encourage takeup.
city of Ulsan, traditionally a centre for heavy industry.
But the Government is forging ahead with its plans. In August, Moon’s administration announced it would more than double
By 2030, it plans to have 15% of personal vehicles as hydrogen cars and replace 40% of city buses, or 300, as fuel cell buses
so, the next driver must wait another 20 minutes before sufficient pressure builds in the storage tank to supply the hydrogen for a full tank in the vehicle.
spending on the hydrogen economy to over $417 million next year.
powered by hydrogen. The municipal office also plans to set up a total of 60 hydrogen refilling stations within the city in the next 12 years.
That includes $300 million on FCVs and refuelling stations, up 52% from this year and a huge leap from the 29.8 billion won spent in 2018. Hyundai is banking on Seoul’s aggressive targets to help it achieve economies of scale and bring down costs. It aims to cut the cost of a hydrogen car before subsidies to 50 million won once annual FCV production reaches 35,000. It hopes to make 40,000 per year by 2022, compared with plans for 11,000 next year.
In an interview with the Korea Herald,
able to service 100 fuel cell cars a day, compared to up to 1,000 at a regular gasoline stand. In the Asia-Pacific region, other big supporters of FCVs include China and
Ulsan Mayor Song Cheol-ho said: “We will do our best to turn Ulsan as the global mecca of the hydrogen industry by taking the advantage of being the world’s first
Japan.
manufacturing base of hydrogen cars, and our capacity of producing over 60% of hydrogen in South Korea.”
sold annually, is aiming for more than 1 million FCVs in service by 2030. That compares with just 1,500 or so now, most of which are buses.
In the meantime, according to the Reuters report, the constraints around refuelling and the limited number of stations are causing much frustration.
Another leg of the country’s hydrogen
That means that operators might only be
China, far and away the world’s biggest auto market with some 28 million vehicles
Japan, a market of more than 5 million vehicles annually, wants to have 800,000 FCVs sold by that time from around 3,400 currently.
cortemgroup.com
8
News Extra
Clair platform – Image BP
B
P’s North Sea division has successfully executed a pilot project
testing innovative ways of remotely monitoring methane emissions around its offshore assets. This includes the use of drones with advanced sensor technology originally designed by NASA for its Mars exploration programme.
BP deploys Mars technology on UK continental shelf as
part of methane monitoring initiative
had to leave their base onshore. Following the successful results, the specialist drone will be deployed to all of BP’s North Sea assets in 2020, including ETAP and Glen Lyon.
One test involved a fixed-wing remote piloted air system (RPAS) circling the Clair platform at a radius of 550 metres for 90 minutes, travelling for a total of more than 185 km, significantly beating the previous UK drone
This UK continental shelf trial follows the roll-out of a major leak detection drone programme in BP’s US operations. BPX Energy is now using drone-mounted leak detection technologies, which enable up to 1,500 well sites to be surveyed every month
endurance record of 100 km.
across all of its operating basins.
The pre-programmed drone, once airborne, managed itself autonomously. Throughout the
The flights generate data around the location and size of a leak and issue a work order to
flight, the drone live-streamed data collected by the methane sensor, similar to the one installed on NASA’s Mars Curiosity Rover.
fix it. The technicians in the field are quickly dispatched and equipped with Fieldbit’s multisource Augmented Reality (AR) technology – or smart glasses – which enables them to
BP says the test demonstrates the feasibility of this approach to monitoring methane. The Clair field is 75km west of Shetland and the
virtually link to technical support in the office. Through the use of this technology, both are able to see the affected area and work
drone was tracked and remotely controlled by a team of three qualified pilots using satellite
together to fix it, improving safety, accuracy of repairs and productivity.
FX60 – Glamox EX de LED floodlight Designed for long lifetime and high efficiency • Reduced maintenance • Lower operating cost • High quality LED Please refer to our website for information about
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communications and radio link from the Shetland island of Papa Stour. The team never
our 5 year warranty.
News Extra
9
evidence base for further industry guidance. In October, HSE will host a workshop to discuss the options for shared research regarding optimising offshore working patterns. The workshop, to be held in Aberdeen, will provide a forum for discussing key knowledge gaps and identify opportunities for shared research to address them. The basis on which this research can be undertaken will be a key outcome of the meeting.
UK HSE calls for partners in high hazard research programmes H
SE’s Shared Research Programme
supports external investment and collaboration in HSE’s research portfolio. This allows resources and expertise to be shared for the benefit of all. By
Projects - these have a defined aim and objectives, designed to address a specific research question in a clearly defined time frame. Projects would either be offered on an individual or multi-client basis; and
Remote Visual Inspection (RVI) Visual inspection of tanks, vessels and pipework is a cornerstone of the examination process and is often the primary means of defect detection, sizing and diagnosis. Technology now makes replacing the direct human element of visual inspection possible, and remote visual imaging could be used to undertake these parts of the examination process. This is of particular interest in the high hazard industries, where intrusive human intervention, for example vessel entry, could be reduced.
Research Club Memberships - these provide a mechanism to support smaller organisations
The limitations of the technology have yet to be fully explored, and no meaningful comparison has yet been made with the
gain ongoing access to emerging findings and have early sight of draft outputs.
and to increase the reach of the findings of research undertaken via the mechanisms described above as well as for the findings of
established standards for visual inspection. Numerous variables and the impact they may have on defect and corrosion diagnosis, and
Shared research is commissioned and managed through an appropriate range of commercial relationships, depending on
HSE-specific research and HSE operational support activities.
hence integrity, have yet to be considered.
the scale of activity and involvement. These include:
For general enquiries, further information and to express interest in HSE’s Shared Research Programme contact: shared.research@hse.
Partnerships - long term relationships with individual clients, who share key organisational objectives with HSE and covering a large suite of work, addressing joint topics of concern over a number of years;
gov.uk.
supporting the shared research approach, contributing partners will be able to help shape the focus of the research activity,
Programmes - centred on relevant crosscutting themes, which impact both the regulator and regulated. Offered on a single or multi-client basis, programmes would run over a number of years and consist of a series of linked activities or projects around identified topic areas;
Current opportunities: Optimising Offshore Working Patterns Over the past few years, shift rotas have changed significantly on the UK Continental Shelf and there is now more variation than ever in shift patterns and working arrangements.
Integrity of Corroded Bolted Flanged Joints on Offshore Installations Corroded bolted flanged joints are widespread on the UKCS and establishing their condition and ongoing integrity is important for safe and reliable operations. A shared research project is proposed, consisting of a series of distinct but interrelated work packages to provide an evidence base to underpin integrity decisions. Benefits are expected to be safer, more reliable, efficient operations.
However, the health and safety effects of longer offshore tours of duty have received very little attention or research. Given current industry shift pattern trends, there is a pressing
Another project involves Wearable Technologies in the Workplace. Further information on this is available in the PPTEx
need to address these gaps and develop an
section of this edition.
www.hazardexonthenet.net
10 News Extra
Seal Sands site – Image: INEOS
O
n October 3, UK-based chemicals giant INEOS announced its
intention to consult with employees on the proposed closure of its acrylonitrile manufacturing plant at Seal Sands on Teesside in north-east England. The site, which employs 224 people, has
INEOS cites safety and environmental cost concerns as reasons for potential closure of UK plant
“The acrylonitrile process needs careful management and involves handling significant quantities of hazardous material. The company feels that it would not be possible to guarantee the long-term safety of our employees or our neighbours through continued operation of the plant and have thus reluctantly concluded that
been under INEOS ownership since 2008. In the event the plant closes, the company said, not all of these positions will be at risk of redundancy due to the continuation of other activities at Seal Sands.
we should consider the option to close,” the statement said.
In a statement, INEOS said that over the past 10 years, the group had invested almost €200m in the site to try to counter decades of significant under investment. Despite
legislation from an INEOS director to the UK Government threatening to close the plant because of the excessive cost of implementing planned new EU
reinvestment of all profits in the site to reverse this situation, the company took the view that nothing more could be done to ensure that operations were both safe and economically
environmental regulations.
viable. It would require another €200m just to meet INEOS standards and environmental regulations, the company said, and it intends
even, and the compliance costs of meeting the Waste Incineration Directive (by June 2020) and the Waste Water Emission
to consult on any viable alternatives to closure.
Directive (by November 2021) were estimated at €100m.
In October 2018, the Greenpeace blog Unearthed published a letter it said was obtained under freedom of information
In the letter, INEOS said the Seal Sands acrylonitrile plant was only just breaking
News Extra 11
Straits of Mackinac, Michigan, USA
Canadian operator to reinforce controversial Great Lakes oil pipeline
C
anadian pipeline operator Enbridge Energy has received
Enbridge is countersuing following the administration’s withdrawal from the
a permit from the US Army Corps of Engineers to install 54 supports under its Line 5 oil pipeline which runs under the Straits of Mackinac between the lower and upper Michigan peninsulas.
agreement.
The supports are designed to make the current pipeline more secure – in places it is 25 metres above the lakebed.
Safety Administration’s (PHMSA) approval of Enbridge’s spill response plan was arbitrary and capricious. This case is currently before the 6th Circuit Court of Appeals.
The straits connect two of the Great Lakes, Lake Michigan and Lake Huron, and the
According to NPR Radio Michigan, another lawsuit has been filed by the National Wildlife Federation, claiming the federal Pipeline and Hazardous Materials
State of Michigan is suing Enbridge to shut down the pipeline, claiming a leak would cause an environmental catastrophe.
Line 5 carries 540,000 barrels per day of light crude oil and propane and is a critical part of Enbridge’s Mainline network, which delivers the bulk of Canadian crude
Enbridge says it can safely operate the 66-year old pipeline while plans advance to replace the exposed section of Line 5 with a new section inside a tunnel under the
exports to the United States.
lakebed. Under the previous Republican state administration, permission was given for the Canadian company to pursue the
and upon receiving them started work immediately. He said putting the pipeline in the tunnel, 100 feet below the lakebed,
tunnel project, but the current Democrat administration wants the pipeline closed.
would eliminate any span issues and the need for supports.
A company spokesman said Enbridge had been waiting 17 months for the permits
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12 News Extra
Image: Shutterstock
A
n explosion on September 16 caused a fire at the Vector
Russia Today reported that emergency responders were treating the explosion
Institute, a biological research facility in Siberia known for being one of the two sites in the world housing samples of live smallpox virus.
Explosion hits Russian research facility harbouring smallpox virus
and fire as a major incident, given the sensitive work of the Institute.
The US Centers for Disease Control and
The centre is known to be working on many potentially fatal pathogens. In 2004, a researcher died at the laboratory
Prevention (CDC) in Atlanta is the only other place known to maintain live samples of the deadly pathogen.
complex after accidentally pricking herself with a needle carrying the Ebola virus.
The blast at the facility, also known as the State Research Center of Virology and
Smallpox killed about 300 million people in the 20th century and three in 10
Biotechnology, in Koltsovo near the Siberian city of Novosibirsk, injured one worker who suffered third-degree burns.
people who contracted it died. Survivors were often left scarred and blind. The last known smallpox outbreak was in 1977 and the World Health Organization
Local officials told the state-run TASS news agency that the blast was probably caused by a gas explosion in a room on the building’s fifth floor during scheduled maintenance work.
declared the disease eradicated in 1980. This incident follows another explosion at a Russian facility conducting advanced
The news agency quoted the officials as saying there were no biohazard substances
research. In August, an accident at a missile test site killed five nuclear scientists. US officials said they believed
involved and the incident did not pose a threat to the surrounding community.
researchers at the site were working on a nuclear-powered cruise missile.
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News Extra 13
Nuclear energy too expensive and cumbersome to save climate - report N
uclear power is being overtaken by renewables in terms of both cost and capacity as it is increasingly seen across the energy sector as less
as existing fossil-fuelled plants continue to emit CO2 while awaiting substitution.
years, while nuclear and coal are set to retire a net 24 GW.
“To protect the climate, we must abate
China, still the world’s most aggressive
economical and slower to reverse carbon emissions, an industry report has said.
the most carbon at the least cost and in the least time,” Schneider, a prominent international energy consultant and advisor
nuclear builder, has added nearly 40 reactors to its grid over the last decade, but its nuclear output was still a third lower than
to organisations such as the International Atomic Energy Agency and the European Union, said.
its wind generation.
By 2019, new wind and solar generators were beating existing nuclear power plants in cost terms, and grew generating capacity faster than any other power type, the annual World Nuclear Industry Status Report (WNISR) showed.
Nuclear is also much more expensive. The cost of generating solar power ranges from $36 to $44 per megawatt hour (MWh), the WNISR said, while onshore wind power comes in at $29–$56 per MWh. Nuclear energy costs between $112 and $189.
Although several new nuclear plants are under construction, no new project has started in China since 2016.
Over the past decade, the WNISR estimates
Global nuclear operating capacity has increased 3.4% in the past year to 370 gigawatts, a new historic maximum, but with renewable capacity growing quickly, the share of nuclear in the world’s gross power generation has stayed at just over 10%.
competitors cannot meet better, cheaper and faster.”
levelised costs - which compare the total lifetime cost of building and running a plant
In the decade to 2030, 188 new reactors
The report estimates that since 2009 the average construction time for reactors
to lifetime output - for utility-scale solar have dropped by 88% and for wind by 69%. For nuclear, they have increased by 23%, it said.
would have to be connected to the grid to maintain the status quo, which is more than three times the rate achieved over the past
worldwide was just under 10 years, well above the estimate given by industry body the World Nuclear Association (WNA) of between 5 and 8.5 years.
Capital flows reflect that trend. In 2018, China invested $91 billion in renewables but just $6.5 billion in nuclear.
The extra time that nuclear plants take to
In the United States, renewable capacity is
In May, the International Energy Agency warned that a steep decline in nuclear capacity will threaten climate goals, as advanced economies could lose 25% of
build has major implications for climate goals,
expected to grow by 45 GW in the next three
their nuclear capacity by 2025.
“Stabilising the climate is urgent, nuclear power is slow,” said Mycle Schneider, lead author of the report. “It meets no technical or operational need that low-carbon
decade, the WNISR estimates.
www.hazardexonthenet.net
14 News Extra Inside the Fukushima Daiichi plant - Image: Tepco
the risk a huge tsunami posed and had failed to take necessary safety measures. They demanded a five-year prison term for each of the men. The men were present at meetings where experts warned of the threat posed by large tsunamis off the Fukushima coast and had access to data and warning that a tsunami exceeding 10m could trigger power loss and a major disaster at the plant.
Japanese power company top executives cleared of negligence over Fukushima disaster
T
hree former executives of Tokyo Electric Power (Tepco) which owns
In addition, a Tepco internal study, based on a 2002 report by a government panel, concluded that a wave of up to 15.7m could strike after a magnitude-8.3 quake. The earthquake that triggered the March 2011 tsunami was recorded as magnitude-9.0.
The defendants had all pleaded not guilty to charges of professional negligence resulting
The tsunami killed more than 18,000 people along Japan’s north-east coast,
the wrecked Fukushima Daiichi nuclear power plant have been acquitted of failing to prevent the March 2011
in death, arguing that the data available to them before the disaster was unreliable. They apologised for the triple meltdown
including Fukushima.
nuclear meltdown.
at the plant, but said they could not have foreseen the massive tsunami that triggered the disaster.
radiation into the atmosphere and forced the evacuation of 160,000 people living near the plant, some of whom are still unable to return to their homes.
This, the only criminal action resulting from the disaster, saw former chairman Tsunehisa
The nuclear meltdown sent plumes of
Katsumata and former vice presidents Sakae Muto and Ichiro Takekuro accused of failing to act on information that showed the risks
The Fukushima Daiichi plant suffered meltdowns in three of its six reactors after it was struck by a tsunami on 11 March
to the plant from a major tsunami.
2011. Waves reaching up to 14 metres in height knocked out the plant’s backup power supply, causing fuel inside the
cores, although some experts believe decommissioning could take longer.
died as a direct result of the meltdown, the charges related to 44 elderly people who died during or after they were forcibly
reactors to melt. Prosecutors had argued that Katsumata,
The government has estimated that the total cost of dismantling the plant, decontaminating surrounding areas and
evacuated from local hospitals.
Muto and Takekuro should have understood
compensating victims at about $200bn.
While no one is officially recorded as having
Tepco has said it will take 40 years to locate and remove the melted fuel from the reactor
Japan could dump radioactive water from Fukushima into ocean
O
n September 10, Japan’s Energy Minister said storage facilities for radioactive water at the Fukushima nuclear power plant would be full by 2022. As a result, he said, future contaminated water might have to be dumped in the Pacific Ocean. The electric utility overseeing the crippled power plant, Tokyo Electric Power Company (Tepco), is running out of room to store the contaminated water, Energy Minister Yoshiaki Harada said at a news conference.
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Water is flushed around the destroyed nuclear plant’s fuel cores to stop them from overheating and exploding, and Tepco now has a stockpile of more than 1 million metric tonnes of contaminated water.
However, in advance of the panel’s recommendations, Harada said that the country had few alternatives. “The only option will be to drain it into the sea and dilute it,” he said. The announcement has provoked strong
Tepco has already announced that it will run out of room to store the contaminated water from the Fukushima plant in as little as three years. A government panel is expected to offer its recommendations in the coming months.
opposition from environmentalists, fishermen and nearby countries. South Korea’s foreign ministry said in a statement that it expected Japan “to take a wise and prudent decision on the issue.”
News Extra 15
Artist’s impression of new Sizewell C plant - Image: EDF Energy
Hinkley Point C nuclear plant to run almost £3bn over budget
F
rench power group EDF said the new nuclear plant it is building at Hinkley
being funded, taxpayers and customers will not cover the increase in costs. EDF and
Also, EDF said that while it was still aiming to finish in 2025, the chance of the plant being
Point C in south-western England will cost up to £2.9 billion more than previously estimated due to challenging
its partner on the project - China General Nuclear Power Corp (CGN) - will pay.
delayed to 2026 has risen.
ground conditions at the site.
However, the companies are being cushioned by the high fixed price for electricity agreed by the UK government in order to make costs predictable for consumers and to provide
but may affect future nuclear projects. The proposed EDF-built and operated nuclear power station at Sizewell could be financed under a new model where consumers would
leeway for the builders.
see costs of construction added to their energy bills as the project went along.
This raises its estimate for the project, on the Somerset coast, to between £21.5bn and £22.5bn. EDF also said the risk of the project being late had risen.
The cost overrun will not hit UK consumers
Last week, prices for new wind power “Cost increases reflect challenging ground conditions which made earthworks more expensive than anticipated, revised action
delivered by 2025 were set at prices as low as £40 per megawatt hour. By comparison, power from Hinkley Point C is expected to
plan targets and extra costs needed to implement the completed functional design, which has been adapted for a first-of-a-kind application in the UK context,” EDF said in a statement.
cost £92.50 per megawatt hour. The National Audit Office warned two years ago that by agreeing this price, the government had subjected the country to a “risky deal in a changing energy
As the price of zero carbon offshore wind continues to plummet, making a fortyyear bet on another nuclear station with a funding model that exposes consumers to such overruns would be a big call for any
Because of the way that the project is
marketplace”.
government to make.
We are your trusted source for ATEX, IECEx and North American certification csagroup.org
Today’s announcement could therefore make it harder for EDF to get support for building Sizewell.
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Standards 17
Further pause for thought
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
speaking, there are attempts within trade associations and in regulatory bodies to try and share any knowledge gained by experience that can contribute to an
We rely on the engineering judgement of many people to adopt and adapt the standards to the particular situation. At the moment, I am aware of a debate about
increase in safety. But to make that work completely, those involved in an incident need to have at least some protection from litigation if they are to have the confidence to be completely open about what happened.
the reliance of our installation standard IEC 60079-14 on equipment already being suitable for normal industrial installation. Normally, that would be ensured by a reference to, for example, IEC 60364 Low Voltage Electrical Systems, in its
From my work in being part of the committees and working groups writing
various parts. However, most countries have already adapted IEC 60364 to local requirements (for example, BS 7671 in the UK), so the requirements throughout the world are already differing.
wo months ago, I wrote of the
standards, I am well aware that it is impossible to write a coherent set of rules that are future proofed against subsequent developments. We could say that the “safe” policy is to always follow those
potential failure of an old reservoir dam at Whaley Bridge in Derbyshire, and how this caused a reflection on
written rules, but what do we do when we come to a situation that the rules were not intended to address. Do we always
introduced in North America, the construction standards for Ex Equipment apply without change almost everywhere
the need for rigorous inspection and maintenance in any safety critical industry.
need to re-write the rules and apply them to everything? That is not necessarily the best policy.
in the world (I do not consider that the additional marking for ATEX required in Europe is a technical difference in that
I am relieved to say that the dam held long enough for the emergency services
I remember long discussions that our general requirements document for
sense). However, for installation of that equipment, IEC 60079-14 only seems to provide a starting point, with many
to pump the water from the reservoir and just over a week later the residents of Whaley Bridge were allowed to return to
Ex Equipment (IEC 60079-0) should address the requirements for all possible installation locations. All equipment should
different national interpretations and in some cases (North America) it is not applicable at all.
their homes, and the two railway lines, from Manchester to Buxton and from Manchester to Sheffield were re-opened.
be suitable for an ambient temperature range of possibly -50°C to 60°C with relative humidity up to 90%.
Much relief all round, but now the repercussions are starting. The body responsible for the safety of the dam has refused to release details of the recent inspections “on grounds of national
This could be done, but at what cost. Would industry pay double the price for all equipment so that it can be made suitable for installation conditions that would only be seen by less than 5%
security”. This secrecy automatically raises suspicions that there is something to hide, even if there isn’t. How often do we end up in a situation
of all equipment? Clearly not. So, the standards are written to accommodate the most typical conditions that will be encountered, and it is left to the manufacturers and purchasers to agree
where the lack of information given to the public and to directly interested parties can cause rumours to start? This applies particularly to industries where we are handling hazardous materials, whether they are a health hazard or a fire and explosion hazard. Generally
any special requirements. We know that aluminium junction boxes have a very short life if they are mounted on the deck of a production platform in the North Sea, but is that a reason to ban the use of aluminium alloy in all hazardous areas? Clearly not.
T
We are lucky that, barring a very few specific technical differences, primarily
The potential for disaster lies in the installation, not the equipment. Would everyone be open and honest if inadvertent use of the wrong installation rules led to a major disaster? 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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November 2019
Wearables & PPE in Industry 4.0 HSE calls for partners in wearables shared research programme Early product success could pave way for broader adoption The role of software in safety Case study - Reliable leak detection in industrial gas pressure-relief stations Case study: SOCOTEC UK and Casella
20 PPTex – Products
Hazardex announces partnership with Connectivity
H
azardEx has announced that sister title Connectivity – a leading Industry 4.0/IoT online information resource – is sponsoring the annual HazardEx International Conference and Exhibition, co-located with PPTex, on February 26-
Connectivity is a weekly e-newsletter and website offering thought leadership to UK engineers, highlighting the practical benefits of Industry 4.0/IIoT and takes readers through how best to implement them.
industry and provides the latest news and knowledge regarding Industry 4.0.
27 at the Majestic Hotel in Harrogate. The main focus of the two-day event
Engineers across industry are desperate for a better understanding of what the Fourth Industrial Revolution and IIoT can
For more information about the Hazardex and PPTEx event, please visit: http://www. hazardexonthenet.net/article/171764/
is the conference, with 2020 hosting a Personal Protection Technology focused content channel alongside the main Hazardous Area Operations and Process Safety conference.
do for them and their companies. Many are aware of these concepts, but most have little or no knowledge of their potential. Connectivity offers insights and knowledge from key companies from across the
Hazardex-PPTex-Conferences-Exhibition-and-Awards-2020.aspx http://www.connectivity4ir.co.uk/
Smart IIoT glove receives $40M investment I
IoT wearable provider ProGlove has
reduce scanning time by up to 4 seconds
developed a solution to improve the efficiency of scanning processes in a variety of industries. Founded in
per scan. Additionally, the company’s smart glove provides direct feedback to the user via optical, haptic and acoustic
2014, ProGlove released a handsfree barcode scanner in the form of a glove in 2016. ProGlove offers three
signals, helping to eliminate mistakes and improve overall process quality.
variations of its technology – the Mark 2 standard range, the Mark 2 mid-range and the Mark basic range.
Image: ProGlove
“Industrial wearables define the future of assembly, production and logistics processes. Our smart wearables are
The Munich-based company recently raised $40 million to continue its expansion into international markets.
including manufacturing, automotive, logistics, and transportation. The Mark 2 is a replacement for traditional handheld
designed to function as a natural extension of the workers’ tools, strengthening the role of the human in
The Mark 2 scanner glove is designed to improve productivity and efficiency and can be used in a variety of industries
scanners which can be bulky and a nuisance to handle. The small form factor, lightweight, wearable design of ProGlove’s scanner unit allows users to
today’s automated world,” said Andreas Koenig, CEO of ProGlove. https://www.proglove.com/
Everbridge partners with RiskBand to deliver wearable security
E
verbridge has partnered with RiskBand, a provider of wearable, live-monitored safety devices. The alliance is part of Everbridge’s strategy to reach the broadest set of workers, including those that may not always have ready access to a mobile
www.hazardexonthenet.net
phone, such as lone workers in the field. With the additional modality and simple access of the RiskBand
inside the office, working remotely, or traveling the globe.
wearable device, Everbridge is expanding its addressable market for protecting employees regardless of their physical location, whether
Fatal work injuries have increased over the last decade, with 5,147 occupational fatalities recorded in the U.S. in 2017. This challenge is only magnified by an
PPTex – Products 21
increasingly mobile workforce, as well as the prevalence of lone worker scenarios
integrate its Safety Connection platform with RiskBand’s wearables, allowing both
across multiple industries served by both Everbridge and RiskBand.
Everbridge and RiskBand customers to receive emergency messaging and provide detailed reporting of their location. The data from an employee’s RiskBand device is shared back to the Everbridge platform, allowing an organisation to
Designed for enterprise-level personal safety and security, RiskBand’s wearable devices bolster an organisation’s emergency communication and response strategy. A single push of a button provides two-way voice, user profile data, images, and geolocation, in near real-time
Image: RiskBand
deploy the appropriate emergency response.
to a company’s security operations centre. As part of the partnership, Everbridge will
https://riskband.com/
MIT and Eni develop Safety++ wearables
R
esearchers at MIT have been collaborating with Italian oil
rest of the network. An altitude sensor in the jacket combines with the carabiner
company Eni on the Safety ++ project which explores innovative solutions to improve worker safety in extreme environments. The MIT Design Lab
which senses if the user is strapped in or not when working at height. If the user is not strapped in, a warning is sent to the user via haptic feedback in the vest.
has developed an entire ecosystem of connected wearables.
Shoes++ have been designed that use pressure sensors to measure the weight of a
Image: MIT
The most important part of the system is the connected vest – an easy and nonintrusive way of collecting biological data. The Undershirt++ features a series of
of the vest which also acts as a bridge to other wearables. The Jacket++ has multiple sensors integrated into either arm
small vibration motors that permit tactile communication with the user through vibrations which operators recognise
to measure air quality, noise levels, smoke, and any airborne chemical that could cause bodily harm. When the sensors detect
being lifted is too heavy and help is required.
and associate with specific issues after appropriate training. The vest can also monitor the health of the user using
such gases, a warning message is sent via the vest to all operators in the affected area. This warning is also forwarded to the
through a system of interconnected nodes that allow each element of the ecosystem to communicate with each other. The system
biosensors that measure heart rate, breathing, galvanic skin response and spatial position through a gyro.
control room.
is a reliable communication network that dynamically adapts to the areas in which it is used and establishes a solid platform to
The Carabiner++ has a pressure sensor that detects when the carabiner has been engaged and a wireless module which streams data and communicates with the
©shutterstock, 75571303 | ISM_MA0081_190925
The collected information is sent to a central processor located in the back
for
I /21 | CL 1 E N O Z
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load being lifted by the user. If a load is too heavy, the sensors communicate with the vest which then sends haptic feedback to the user and nearby workers that the load
The entire Safety++ system communicates
support the integration of various elements. https://design.mit.edu/eni/safety
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PPTex - Research 23
HSE calls for partners in Wearables in the Workplace Shared Research Programme
A
s part of its cross-industry collaboration safety project series, the UK Health and Safety Executive
regulatory colleagues. Project co-sponsors will have a key role in providing direction, information and industrial application insight.
has called for industry and academic partners to join its wearable technology shared research programme.
Work Package 1: Knowledge Gaps
There is growing evidence that wearable devices can significantly benefit health and
A technical review will be conducted on wearables that can be used for the monitoring of MSDs, personal exposure to hazardous
safety in the workplace through positioning and sensor technologies. The advancement of the Internet of Things has meant that many of these technologies are increasingly being
substances and physical hazards in a work environment. This state-of-the-art review will identify the latest technologies, products, applications and providers, linked to their
analytical approaches and barriers to using data from wearables to help reduce risks.
deployed, helping to improve workplace productivity.
potential value.
source of information on personal exposure to a hazard for any time periods of choice and on MSD risk levels at different work sites for different tasks and for different individuals.
HSE recently hosted a workshop with key industry leaders and technology providers which focused on identifying the potential benefits and challenges of using wearables for health and safety applications. A series of key research questions were developed and areas for research prioritised.
Deliverable: A report categorising the available technologies based on suitability, availability
Deliverable: A report detailing good practice for integrating wearable devices into IT systems.
Work Package 4: Data Analysis A detailed analysis of the data collected will be undertaken to identify the benefits, common
This time resolved data will provide a rich
and costs.
Work Package 2: Device Performance & Evaluation A range of available wearables will be acquired and evaluated. These will be selected by the Steering Group based on the outputs from the
Deliverable: A guide to key methods and approaches to analyse and interpret data from multiple wearables to provide insight to improve health and safety outcomes and controls.
This programme will endeavour to validate the use of the technologies for workplace health and safety and to help find solutions to the
Work Package 1 review.
Work Package 5: Worker Acceptability & Behaviour
The evaluation will be based on the
The introduction of wearables in the workplace
key issues and barriers to effective adoption of wearables in the workplace. The priority areas to be researched within this project
comparison of performances and characteristics (e.g. cost, data access) against standardised and traceable measurement
may be a cause of concern for the workforce. An approach for the evaluation of worker acceptability will be developed through direct
are: (1) Monitoring occupational personal exposure to hazardous substances and physical hazards on construction sites and
technologies in standard conditions relevant to occupational settings.
employee engagement before and during the device trials.
(2) Musculoskeletal disorders (MSDs) in workers identified at greater risk.
Deliverable: A report detailing the performance of wearable technologies and in what circumstances they could be used
Evaluation of improved behaviour and compliance will be undertaken after implementation of the wearables.
Through this Shared Research Project sponsors will be better placed to adopt appropriate wearables technology which can enable better monitoring of worker time spent in hazardous areas, improved exposure prediction, better productivity and immediate feedback on efficiency of control measures.
appropriately to monitor health and safety risks.
Overview of Technical Work Packages
and data velocity through to system integration and data protection.
Work Package 3: Data Collection & Integration This work package aims to provide greater clarity around integrating wearables into IT systems. This will review areas of complexity ranging from data compatibility, data volume
The specific details will be reviewed and agreed on a collaborative basis via a steering committee comprising industry project sponsors and HSE. The work will be led by
Tests and evaluations will be undertaken using suitable wearables selected for use in previous work packages and in line with sponsors’
HSE topics specialists supported by their
specifications.
Deliverable: A guide highlighting common issues experienced surrounding worker acceptance and approaches to enable positive behaviour change though the use of wearables. The final output will be a good practice guide on the appropriate use of wearables to support continuous improvements in workplace health and safety; this will focus on the two priority areas of MSDs and health exposures. For further details, please contact David Johnson at: david.johnson2@hse.gov.uk
www.hazardexonthenet.net
24 PPTex - Market research
Smart and wearable personal protective Early product success could pave way for br I
n recent years, there has been a lot of discussion about connected workers and smart and wearable products
will be products that have the potential to transform workers’ environments through advanced situation awareness.
Every Occupational Health and Safety (OHS) manager has the primary task of ensuring the safety of their workforce and
being the future of the personal protective equipment (PPE) industry. This article by Sanjiv Bhaskar of Frost & Sullivan looks at some of the results from the company’s recent research into this sector and highlights possible future trends.
These products will have real-time direct communication capabilities to mitigate risk and avert life-threatening accidents. Frost & Sullivan’s survey, Personal Protective Equipment (PPE) Voice of the Customer Study 2017, indicated that nearly 75% of buyers were open to
compliance with mandated regulations and enforcement agencies. They also have to work within tight budgets. Any attempt to adopt smart and wearable PPE products will have to address key questions about cost, safety, compliance, employee and business productivity, automation and the impact on network
The development of innovative wearable products, evolving end-user industries, rapid adoption of the Internet of Things (IoT) and related technologies are some of the key factors driving critical investment in next-generation PPE products and
adopting smart and wearable products. Similarly, almost 70% of wearers of PPE were open to the adoption of smart and wearable products. This does indicate that the industry is ready for the adoption of smart and wearable technology if it meets
security. The industry is also highly fragmented, competitive and price sensitive. Commoditisation is prevalent at every product category level. These factors play a major part in hindering smart and wearable PPE product innovation,
solutions. However, the real game-changer
their safety and financial goals.
adoption and growth.
www.hazardexonthenet.net
PPTex – Market research 25
2017 – 2025, estimates that 67.7 billion IoT devices will be in use by 2024. Of these,
communication. Its G7c takes a fraction of the time required for a regular gas detector
almost 11 billion devices are likely to be for factory and industrial automation. Add to this the rapid deployment of 5G platforms, and growth could be significantly faster.
to help in evacuation of workers exposed to hazardous gases. This time lag can be the difference between life and death for a worker.
Larger companies and global corporations
RealWear is offering HMT-1 and HMT-1Z1
are pursuing the adoption of smart and wearable PPE products due to a favourable return on investment (ROI). Major benefits include higher productivity, reduced cost of workers’ compensation insurance premiums, and lower medical treatment costs.
wearable Android tablets for use in almost any industry. These products, in conjunction with its cloud-based Foresight platform, offer a hands-free, voice-activated platform with 95% accuracy, even in environments with high ambient noise. The company is
Frost & Sullivan’s 2016 study, “Wearables and Smart Personal Protection Equipment (PPE) Technologies for the Industrial
e equipment roader adoption
finding increasing acceptance in the market for its offerings. These are a few examples, and their
Market,” highlighted several smart and wearable products. However, not all have advanced in the past three years. Some companies that have advanced in the
success could lead the way for wider adoption of similar products and technologies. Nevertheless, the industry is experiencing rapid change, and the next
marketplace have adopted a “systems approach” and we believe this approach will find better traction in the coming
three to five years will be critical as solution cost reductions and better ROI for end-user industries transform the smart and wearable
years. Companies that help in creating an ecosystem with the lowest cost and disruption and can show enhanced ROI will see better adoption in the coming years.
PPE sector.
About the author
Smart and wearable products can prevent accidents and protect workers, which could be a game-changer. Companies offering their services to the high-risk industries include RealWear, Guardhat, Blackline Safety, Corvex, Kinetic, and Levitate Technologies. These companies attract clients in the oil and gas,
End-user industries where workers are exposed to hazardous environments are incubators for testing and adoption of smart
mining, and manufacturing industries.
and wearable products and technologies. Oil and gas, mining, and firefighting are some examples that are considered “highvalue worker” industries. Due to workers’ exposure to highly hazardous conditions, the adoption of technologies that can help reduce the risk of accidents and fatality is significantly greater.
hardhat with embedded sensors. It offers a full end-to-end situational awareness system that uses its own KYRA platform. Its solution goes beyond its hardware and integrates with any connectable sensor and with a variety of third-party platforms, making it easy to implement solutions for its clients and integrate with Industry 4.0.
Another important factor is the rapid development and deployment of IoT technology in everyday life. IoT products and devices have impacted our lives in many ways. Our recent research, 2019 Update-
Blackline Safety has developed multigas detection equipment with 3G wireless and two-way speakerphone, thereby connecting workers with a live monitoring team. Its devices offer inbuilt cellular and
Total Internet of Things (IoT) device Forecast,
satellite connectivity, allowing two-way
Guardhat is providing a lot more than a
Sanjiv Bhaskar is Vice President of Research, Visionary Science Practice, at Frost & Sullivan. He has been with the company for 20 years and previous positions have included Global Director - Personal Protective Equipment Markets and Director - Environmental and Building Technologies Practice. His expertise includes extensive knowledge of PPE, wearable technology, industrial safety, occupational health & safety, and smart working practice and technology.
www.hazardexonthenet.net
26 PPTex - software
The role of software in safety P
ersonnel Protection Technologies
(PPT) are changing the way that both individuals and companies detect risks in hazardous environments. Their prevalence in industry is increasing as companies look to modernise and improve their safety operations.
To make technology truly effective, ease of engagement and ease of implementation are both essential in understanding how it can improve current operations
is about highlighting and refreshing the vision for what is possible when safety and technology combine.
As PPT becomes a more viable option for use in high hazard industries, there is an increased need for a smarter way of managing and taking advantage of the
The strong demand, growing supply
Safety improves incrementally with every introduction of new standards and improvements can be seen every year. However, safety 2.0 is about the full adoption of new technologies in order to create the next wave of disruptive change in the safety sector where standards and solutions are improved in parallel. Digital safety enables
data produced by smart safety devices. For this article, Hazardex Associate Editor Alistair Hookway spoke to Restrata CEO Botan Osman about the digital transformation of safety and the role that software plays in managing and
and decreasing costs of PPT indicate that a digital transformation of safety is well underway. This next generation of wearable & IoT devices, paired with Cloud-based platforms, is unlocking the potential for the next major chapter in safety
faster access to vital information in order to understand when and how to act to protect lives and assets. It also enables the capture of safety-related data, which means that over time, analytics can be used to impact long term improvements in the way safety
analysing the data produced by PPT.
management. This ‘safety 2.0’ generation
managers operate.
www.hazardexonthenet.net
PPTex - software 27 Software as a Service
Regardless of where an emergency team, crisis response team, or operations team is,
engineer and any other personnel on the site would be to exit that area immediately.
integrate real-time data from IoT sensors and wearables – for tracking, access control, and travel management at either a specific site or for an individual person – with localised site-based management to offer a global view of an enterprise’s
they will be able to get a real-time view of what’s happening in a situation and become completely geographically independent in terms of the way that they respond to incidents.
This feedback could come via a smartwatch or other wearable device and would display a warning to any personnel in the vicinity of where the initial data is recorded. All workers would then be tracked via the enterprise software to ensure everyone is
operations. These platforms are particularly pertinent for lone workers operating in hazardous or restricted environments. Tracking paired with mass communications functionality enables Control Centre Operators to respond quickly and accurately
As with all technological developments, the increased use of PPT has come with its own issues. Just a few years ago, Big Data and network restrictions were difficult hurdles to overcome, but recent improvements to network speeds and the development of
accounted for and been able to retreat to a safe location.
when an alert is raised.
satellite technologies have meant these are no longer major barriers to adoption. This also means that Cloud-based software platforms can overcome unlikely downtime
software is required to be well designed and engaging for the user. Intuitive software that is simple to use and easy to integrate with hardware allows data produced
designed to be hardware agnostic so that it can integrate with almost any type of wearable and provide a seamless view of an entire enterprise, regardless of whether the
restrictions and benefit from the large amounts of data produced by PPT in an effective and continuous manner.
by PPT to be effectively managed and monitored. Together with PPT, software can play a crucial role in developing smarter safety operations and minimising risks in
organisation is using legacy equipment or investing in new technology. This is where the future of wearables will be paramount in the
For some companies, there can be trepidation when engaging with new technology even though this means losing
hazardous environments.
sector. The ability to connect each individual on a site with sensors and understand their exact location, heartbeat, access gas monitors etc., changes the way organisations
out on opportunities to save time and money and improve safety. However, technology adoption is not simply just an implementation of the technology itself.
About the author
are able to detect and manage risk. Enterprise software offers companies a
It’s also important to consider how new technology fits into the wider context of an organisation and how it can help
granular global picture of every site under their jurisdiction in real-time – an indication that paper tick sheets may soon be a thing
change a corporate culture for the better. To make technology truly effective, ease of engagement and ease of implementation
of the past. One of the benefits of Software as a Service (SaaS) Platforms is that they are simple to launch and can be expanded
are both essential in understanding how it can improve current operations.
Cloud-based platforms have been built that
Having associations with multiple hardware vendors means that software can be
across sites rapidly, allowing an enterprise to access data across all their sites holistically.
The future
For example, if a client has multiple sites registered across various access control systems, different Bluetooth systems etc., and were then to open a brand-new site with no hardware whatsoever, handset mobile devices can quickly be deployed with an app-based version of the software, almost overnight. The Cloud-based software
correlates around people, assets and environments. The way those three subjects interrelate will enable insights to improve the way that safety managers respond in the moment, but also enables long-term improvements to safety operations. Of course, it is wearables, smarter software and connected devices that will play huge
paired with the handset app can efficiently register people moving in and out of sites and zones, with the added ability to muster and evacuate. The power of using Cloud-based software
role in obtaining this data. It’s all about the initial, and accurate, data capture at the point of an event along with the relaying of feedback on that data back to the point of the event. For example, if an engineer wearing a gas detector is alerted to high
is that it brings together the total picture.
gas levels, then the feedback for that
Ultimately, the future of safety is all about data and the analysis of such data that
Expectations of software in terms of user experience and design are now higher than ever before. Even industrial safety-based
Botan Osman is CEO of Restrata and was appointed into the position in 2017. He previously served as Global Director for Business Development & prior to that as Country Director Kurdistan. Botan joined Restrata in 2013 from the Kurdistan Regional Government of Iraq, where he founded the KRG Department of IT & served the Head. He also served as the IT Advisor to the Prime Minister. Botan holds a BEng in Software Engineering from Manchester University and has over two decades of experience in Technology & Security Industries in UK, Europe & Middle East. He has also completed executive programmes at Harvard Kennedy School of Government, NDU & the UK Defence Academy.
www.hazardexonthenet.net
28 PPTex - augmented reality
BW CATCHER operates in the North Sea for Premier Oil and will use augmented reality to improve communication with onshore support, enhancing operational efficiency
Wearables & PPE in Industry 4.0 T
seeing changes in every aspect of manufacturing and resource extraction, including worker safety. While 20th century personal protective equipment
with hazardous environments.
Wearables & remote connectivity
Hazardous environments & worker safety
As the cost of IoT sensors has fallen, the capability to extract information from products and equipment has grown at a commensurate
(PPE) will continue to be necessary in hazardous environments, the need for personnel to enter those environments is
Although the UK Health and Safety Executive (HSE) has reported a long-term reduction in the number of workplace fatalities since
rate. This has been coupled with the spread of industrial connectivity, and organisations adopting these technologies have already seen
decreasing. The proliferation of sensors collecting process and production data from vital assets, combined with
1981, the number has remained broadly flat in the last decade. A similar trend can be found in the HSE’s number of working days
considerable returns. In 2016, GE estimated that its Digital Thread – the connection of data throughout its value stream – generated
wearables and platforms for remote collaboration, means fewer trips to hazardous environments.
lost due to workplace injuries, which also saw a general decline until 2010/11, and has been broadly flat thereafter.
$700M USD in productivity gains.
he fourth industrial revolution is
this opens up new possibilities for how to deal
In the field or on the factory floor, the ability
Occupational safety has come a long way since the first industrial revolution. In fact, we
The obvious explanation for these trends is that, as safety standards and PPE have
to leverage this connectivity is the key to bringing experts into hazardous environments remotely. Dario Buccellato, Regional Manager
were well on our way to the second – with the introduction of electricity and emergence of mass production – before seeing any significant progress on worker safety. By the time the third industrial revolution got started in the 1960s, with automation and computerisation, the PPE landscape had changed considerably.
improved, workplace injuries and fatalities have generally declined. However, we may well have reached the point where these numbers can no longer be reduced by passing stricter regulations or requiring more PPE. So long as workers are present in hazardous environments, some level of risk will be present as well.
for Europe, America and Africa – Inspection services at DNV GL, offered the following example: “For Oil & Gas, Hazardous Area Classification (HAC) is a major concern, and that’s where we see the advantage of applying remote technologies to inspection: not having people in workshops where there’s cutting and welding or around equipment that’s running at
Today, we are undergoing a fourth industrial revolution, one driven by connectivity and Big Data. The biggest difference between the factories of today and those of tomorrow is not what’s inside them, but what’s between them: real-time information about industrial processes
The obvious solution is to reduce the number of interactions workers have with hazardous environments, and this is where Industry 4.0 comes into play with two technologies in particular: wearables and
DNV GL has been working with the Onsight augmented reality platform developed by Librestream Technologies to enable its inspectors to visit offshore operations virtually,
and production from all around the globe. And
remote connectivity.
rather than requiring them to be on-site.
www.hazardexonthenet.net
high speeds or temperatures.”
PPTex - augmented reality 29
The result is fewer exposure hours, but the catch is that a facility must have a sufficient
“We have surveyors in Oslo that sometimes have to travel almost two days to reach a
digital instructions, and even enhancing their perception with thermal imaging.
level of connectivity to make remote collaboration possible. “If you look at the environments involved, they might be a factory and an office,” Buccellato said. “Of course, you have a good connection in the office, but you need it when you go to the workshop as well.
vessel in West Africa,” said Gabriel de Moraes, Technical and Maintenance Coordinator, BW OFFSHORE, who is coordinating the Onsight augmented reality platform deployment. “Depending on flight schedules, the surveyor may need to stay onboard for a few days, even
Each industrial revolution has brought new opportunities to enhance worker safety, from machine guarding and respirators to hearing and eye protection. The fourth industrial revolution brings the potential to reduce
Nowadays, many factories are equipped, but there’s still the need for upgrades. Fortunately, digitalisation is one of the first items on everyone’s agenda.”
though their scope onboard may take just a couple of hours.”
Users can also compensate for lower levels of
Buccellato pointed to two related benefits of remote collaboration. “There’s also the environmental impact,” he said. “Not having
connectivity by selecting an augmented reality platform that can operate in such conditions. Some remote expert solutions are designed to maintain functionality at connection speeds of
people flying and travelling means you don’t just reduce the cost of travel, but the carbon footprint as well. Plus, we can have an inspector who’s available for eight hours, instead of having
less than 100kbps. It’s an important feature in many industrial use cases, especially those in remote locations.
someone traveling for six and working for two, so you can manage your resources in a different way.” This fits well with the trend towards as-a-service (aaS) models, which brings with
Beyond safety with remote collaboration
exposure hours in a way never before possible, with wearables as the next generation of personal protective equipment. About the author
it increased expectations regarding customer support and expert availability.
While the opportunity to reduce the total number of exposure hours is perhaps the most obvious advantage of using wearables for remote collaboration, there are several ancillary benefits to doing so as well. For example,
Finally, remote collaboration enabled via wearables and augmented reality provides a new avenue of response to the impending skills gap in manufacturing. The now infamous study
remote collaboration can significantly accelerate the time it takes for inspections and verifications on offshore assets. BW OFFSHORE recently
from Deloitte and the Manufacturing Institute projecting 2.4 million unfilled positions in manufacturing over the next decade has raised
announced that it will be deploying an augmented reality platform for just this reason on the Floating Production Storage and
pressing questions about how to respond. Wearables present a potential technological solution to this problem, enabling expert
Offloading (FPSO) vessel, BW CATCHER.
support for connected workers, providing
Ian Wright is a philosopher-turnedwriter, with bachelor’s and master’s degrees in philosophy. Ian was Managing Editor at engineering.com and is now a freelance writer covering topics within digital transformation, such as augmented reality.
Offshore technician shares data and video with an onshore expert using a wearable thermal camera and augmented reality software for immediate diagnosis and repair
www.hazardexonthenet.net
30 PPTex - Case study your customer, then an image is much more convincing.” The gas that needs to be detected at Tessenderlo Kerley Ham is CH4 (methane). The uncooled FLIR GF77 can visualise these methane emissions in real-time.
Camera ergonomics The camera is much smaller than the cooled GF-Series units, and much easier to carry around. This camera was built for intensive use and with the goal of making leak inspections as comfortable as possible.
Case study - Reliable leak detection in industrial gas pressure-relief stations
“The rotating optical block also makes it easier to inspect areas that are high up or difficult to reach,” said Van Hout. This type of OGI camera enables an operator to inspect over railings and underneath components without strain or uncomfortable positioning.
Reliable image quality
T
essenderlo Kerley International is a chemical group that supplies valueadded liquid, soluble, and solid plant
Pressure-relief stations
nutrition for agriculture applications. At its production unit in Ham, Belgium, the company focuses on the production of potassium sulphate, which is
inspection. The pressure of the natural gas that arrives in the oven station is reduced from 65 to 5 Bar in a pressure-relief station, which needs to be monitored thoroughly for leaks.
plume movement to make tiny gas leaks more visible.
predominantly used as a fertiliser for flowers, fruits, and vegetables.
The station has about 150 potential leaking sources at weak points such as valves and other connections.
the pressure-relief stations, Van Hout and Schraeyen were able to find a leak at one of the connections. “The gas leak is clearly visible
“One of the biggest differences between using optical gas imaging cameras versus other
in the HSM image and the image quality is surprisingly good for such a compact, cost effective camera,” said Van Hout.
devices is speed,” said Schraeyen. “With a Flame Ionization Detector or FID for example, this inspection job would take longer. With an
Both inspectors also made good use of the GF77’s 1-Touch Level/Span functionality. This
This case study examines how Belgian inspection company The Sniffers used the FLIR GF77 uncooled optical gas imaging camera during a leak detection job at Tessenderlo Kerley’s plant.
Gas ovens An essential part of the potassium sulphate production process involves combining raw
Philip Schraeyen and Jan Van Hout, project leaders at The Sniffers, carried out the
OGI camera we can inspect the entire station in two minutes.”
The GF77 has three imaging modes: IR, visual, and the FLIR proprietary High Sensitivity Mode (HSM), which accentuates
During a thorough inspection of one of
feature allows users to choose a small area of interest in a gas image – with one touch of the screen – enabling the camera to auto-adjust
materials in a furnace that is heated above 600° Celsius, creating a reaction between potassium chloride and sulphuric acid. In 2018, Tessenderlo Kerley decided to make a serious investment to reduce its carbon footprint and to convert nearly thirty oil-fired ovens into natural gas ovens.
Visual power
Natural gas is now supplied to the site in Ham via a brand-new pipeline that branches off to the different furnaces and these are inspected for leaks on a regular basis. For this highly specialised inspection work, Tessenderlo Kerley relies on third parties such as The
from a distance without the need for an aerial platform.
risk or prevent product loss.”
In contrast to FIDs, optical gas imaging cameras provide a visual image of the leak. “This says so much more than numbers,”
FLIR Systems designs and produces thermal imaging cameras, components and imaging sensors. For more information go to: www.
Sniffers.
said Schraeyen. “If you need to report to
flir.co.uk
www.hazardexonthenet.net
An FID or other contact-based device requires the inspector to carefully hold the sensor very close to the leak source. This can be a time-intensive task and can also cause a safety hazard, having to be close to the gas cloud to identify the leak. Optical gas imaging cameras allow inspectors to scan for leaks
the level and span based on the contrast at that spot in the image. “All in all, the FLIR GF77 is a reliable and highly ergonomic camera for leak detection jobs,” said Schraeyen. “And it’s an ideal camera for inspections at industrial companies like Tessenderlo Kerley that want to reduce safety
About the company
PPTex - Case study 31
dBadge2 noise dosimeter
critical that we are able to identify airborne contamination quickly and effectively to put it right.” Rob and his team are responsible for conducting exposure monitoring and providing assistance and advice to protect against physical and chemical agents in the workplace, relying on their sampling equipment to accurately detect harmful dusts, gases, airborne metals in the atmosphere. “Using Casella’s Apex2IS we monitor for a number of harmful substances, for example silica dust, toxic volatile organic compounds, airborne metals, and we need to have complete confidence in the solutions we use, and in the integrity of the samples we collect. The Apex pumps are a huge asset to our team and in our experience the accuracy, durability and
Case study - SOCOTEC UK and Casella A
reliability of the solutions are second to none,” he says. In addition to air monitoring, SOCOTEC employs Casella Sound Level Meters and dBadge personal noise dosimeters to measure for occupational and
n effective method of protecting workers against harmful exposure to hazardous substances is through
conduct a range of services to assist clients in monitoring, assessing and controlling human exposure to health risks, helping
environmental noise. Rob says: “Some of our biggest clients are in the quarry and mining industry based around the UK.
personal monitoring. Personal sampling pumps offer an enhanced monitoring system to identify, assess and control
employers and employees to minimise or eliminate these hazards. To help address its needs for measurement of exposure to
When we go out to these sites, we are always equipped with our Casella kit.”
health hazards in the workplace whilst providing quantifiable data records.
harmful particulates and vapours, SOCOTEC has looked to Casella for its air sampling monitoring solutions.
Travel is a frequent part of the job for Rob and his team, so equipment reliability and ease of use is essential. “A concern for us
Since 2004, SOCOTEC has equipped its occupational hygiene team with the
when we have remote work,” says Rob, “is the failure of kit, which could result in significant loss of time and money. If
Casella’s Apex1 and Apex2IS air sampling pumps, and Casella’s occupational & environmental noise kits since 2010. The organisation has over 90 Casella products and most recently introduced the Casella Flow Detective Plus in conjunction with Apex2IS Plus air sampling pump.
equipment is faulty and unreliable this means repeat visits to the site are required. In our experience, however, using Casella pumps this is very rarely an issue and we can trust in the ability of the kit. It’s for this reason we continue to work with Casella and why it’s a partnership built on trust and confidence.”
SOCOTEC’s fleet of occupational hygienists offer the assurance of compliance with legislation and regulations, including COSHH Regulations, Control of Noise at Work Regulations and Control of Vibration
Rob Preston, Occupational Hygienist Team Leader at SOCOTEC, says: “We carry out a lot of occupational hygiene assessments across a number of high-risk industries, in large industrial manufacturing sites, automotive, nuclear and waste and recycling.
Casella is dedicated to reducing occupational health and environmental risks, and supporting businesses in solving their monitoring and analysis needs. For more information go to: www.casellasolutions.com
at Work Regulations. SOCOTEC’s team
We visit many environments where it is
SOCOTEC UK is a provider of testing, inspection and compliance services, with comprehensive solutions across a number of sectors from infrastructure and energy through to environment and safety. Delivering seven million tests a year to more than 5,000 clients, SOCOTEC offers a wide range of testing, inspection and compliance services in the UK and the international SOCOTEC Group has operations in 25 countries and 7,800 employees.
www.hazardexonthenet.net
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Acoustic enclosures for industrial blower units on Malaysian project
Noise control & acoustics 33
Sound advice for petrochemical plants P
exposes personnel to several health, safety
Innovative solutions
have become increasingly complex and the potential for excessive noise remains high. Rob Lomax, Sales Director at Wakefield Acoustics, looks at noise
and environmental hazards. Whilst these hazards are mainly due to the highly toxic chemicals and associated gases – including sulphur oxide, carbon monoxide and nitrogen
Forward-thinking plant operators across the industry should be considering ways to utilise noise mitigation technologies throughout their facilities on a greater scale. Thankfully, several
control technologies and the opportunities presented by installation in petrochemical and chemical plants.
oxide – the health impacts of excessive on-site noise are increasingly being recognised by plants around the world.
solutions exist that will transform operations.
Petrochemical and chemical plants produce many important building blocks and products
To implement best practice and comply with noise legislation, operators should be taking
careful consideration must be given to each system’s function, location, permitted noise levels and much more in order to determine
for industry processes. These plants are multifaceted – containing large numbers of industrial plant items and often moving
a proactive approach to implementing noise management and mitigation measures within high-risk petrochemical and chemical plants
the most effective noise control solution for the application. As a result, when it comes to specifying noise mitigation products for on-site
high volumes of air or gas, while operating at elevated pressures and temperatures. All this combined means that such areas can be
to reduce on-site noise and ensure employee health and safety.
equipment in such environments, there is no one-size-fits-all solution and a number of factors must be deliberated.
exceptionally noisy.
In the UK, the most recent noise legislation is under The Control of Noise at Work Regulations 2005, whereby the upper and lower daily noise exposure action levels have been reduced by 5 dB from 90 and 85 dB (A) in the previous directive, to 85 and 80 dB (A), respectively.
etrochemical and chemical plants
With noise control and environmental legislation becoming more stringent and employee health and safety remaining at the forefront of all processing practices, ensuring that noise is effectively mitigated has become a key concern for process plant operators across the petrochemical and chemical processing sector.
Noise regulations The intrinsic dangers of petrochemical processes are far reaching. Countless studies have shown that the petrochemical industry
Today there is also an increased emphasis on controlling noise at source wherever possible, a sizeable shift from the focus of earlier legislation on assessment and quantification of exposure levels, and recommendations for hearing protection.
As no two plant installations are the same,
A key noise mitigation solution available to the petrochemical and chemical sectors – and one that generally offers the best level of noise mitigation – is full acoustic enclosures. Ranging from drop-over canopies to site-assembled modular units, acoustic enclosures are manufactured with a range of access options, such as hinged removable panels, personnel access or sliding doors, and framed lift-off roof sections for major maintenance operations. Full acoustic enclosures can ensure noise levels fall below those set by the Control of Noise at Work Regulations, however, there
www.hazardexonthenet.net
34 Noise control & acoustics are other considerations which also need to be made before installation can take place.
to external surfaces to further reduce breakout noise, and given the high heat levels which
A case in point
For instance, plant operators must carefully consider the installation location, taking account of hazardous area conditions and temperatures such that appropriate ventilation and gas /fire detection system are considered.
can sometimes be generated in process air and gas lines, they can be treated with a heat resistant paint finish after fabrication.
complex plant operation in Malaysia, the process of early identification and noise mitigation proved central to their drive for reduced on-site noise.
Unique challenges
For a major petrochemical operator with a
Petrochemical plants cause some acoustical
The company embodied the problems faced
When required, electrical installations and ventilation systems are normally integrated into the enclosure design, and the latter can include run and standby axial/centrifugal fan arrangements with ATEX certification where required. Enclosures can also be painted
engineering challenges. Petrochemical processes operate largely outdoors, with the processing equipment located in close proximity on open-frame steel structures. These operations, which include pumps, compressors, blowers, agitators and coolers,
by many of the world’s leading petrochemical enterprises, with a large expanse of wideranging noise sources located on a single site, leading to high noise levels. As with many similar operations, the excessive noise levels were a cause for concern, prompting
with a variety of high specification finishes for corrosive environments.
run out in the open, with limited barriers in place to restrict equipment noise from carrying beyond the confines of the plant.
the provider to seek an innovative solution to reduce noise, protect the workforce as well as provide easy access for maintenance.
Attenuators and silencers offer another solution and are designed to suit a variety of air-movement applications, including openinlet units complete with air filtration, and in-
Compounding this is the sheer size and scale of these operations, which incorporate a large and varied amount of stationary sound sources, along with miles of complex,
A detailed noise survey showed that a high level of noise was being experienced by operators across the entire workspace. Such were the levels of noise on site, that the entire
line silencers for reducing breakout noise from process pipework.
intertwined piping systems. As a result, the noise levels generated by these facilities can often be significant.
facility had become a mandatory ear protection zone when the machinery was in operation.
The sound of silence
These units are generally manufactured to client specifications, and can be fully welded where required, determined by system operating pressures and temperatures. Depending on the level of acoustic performance required, silencers can be designed with a layer of acoustic lagging
www.hazardexonthenet.net
Whilst it is particularly difficult to provide a complete solution to address all noise, identifying key contributors is fundamental to reducing the noise impact on site and on the surrounding community.
In addition to hearing protection reducing the operators’ noise exposure, it also presented several operational issues, including the necessity for regular hearing assessments, instruction and training on noise, and the requirement to display signage in relevant high noise zones.
Noise control & acoustics 35 Excessive noise levels An analysis of the noise emissions produced by plant equipment enabled the process design engineers to identify six blowers as one of the major sources of noise. The company was aware that if left untreated, the noise levels from these blowers could reach 100 to 105dB(A) due to the breakout from the casing alone. This was further compounded by the fact that multiple plant items were installed in close proximity on the site, meaning it was quite conceivable that overall noise levels in the plant areas could reach 110dB(A), posing significant risk of hearing damage for operators and maintenance personnel.
Noise attenuation package for industrial blower units, Flue Gas Desulphurisation Plant, Saudi Arabia
low level quick release access panels for
reductions exceeded all expectations,
As with most large petrochemical plants and refineries, the noise emissions from processes and equipment are highly regulated due to the potential impact they can have on employees,
viewing of the oil sight, integrated cable entry and internal lighting for ATEX zone 2.
reducing the noise levels by around 25dB(A) to 85dB(A) across the plant.
Due to the high heat loads from the enclosed
In addition, with integrated access panels
the nearby community and the environment. Additionally, the company needed a system
blower casing, enclosures were fitted with a forced ventilation system comprising of an axial flow fan, with a suitably sized attenuator
installed in the enclosure housing, the plant operator has been able to reduce downtime for maintenance.
that was easy to install, simple to access should maintenance be required on the blowers, and compliant with the health and safety requirements of the plant.
unit to limit noise emissions. In this instance, for the petrochemical site the ventilation fans were supplied with ATEX-rated motors, in a run-and-standby arrangement.
Noise control
Additional considerations
Noise control measures for industrial plant
A number of other factors were carefully
items can be particularly complex to design from an acoustic perspective, given the large number of noise transfer paths. In addition,
considered throughout the design and implementation of the acoustic enclosures. As the main drive motor was not enclosed,
any housings fitted around the equipment can present significant challenges for the ventilation of the equipment.
which itself generated approx. 82dB(A), this ‘half’ enclosure approach meant that noise emissions from the exposed mechanism
Following initial consultation with a leading industrial and environmental noise control
About the author
would need to be considered in the overall acoustic requirement.
manufacturer, the company opted to control the noise by installing close-fitting acoustic enclosures. The enclosures were designed to be close fitting around the blower body itself and incorporated a sealing plate around the drive shaft to the motor, enabling it to be naturally cooled.
To overcome this issue and meet the required noise level of 85dB(A), the industrial and environmental noise control manufacturer had to over attenuate the noise emissions from the main enclosure unit in order to guarantee the resultant levels met the limits set by the petrochemical company.
The careful consideration of ventilation ensured that only the main blower casing required cooling. This not only improved safety, but also reduced operational costs for cooling. Bespoke acoustic enclosure design was necessary as the plant operator required an acoustic lined
Breakout noise from associated pipework was treated by means of in-line absorptive silencers, along with external acoustic lagging.
tunnel section and guard for motor coupling,
measures across all six blowers, initial noise
As a result of the implementation of acoustic enclosures and other effective noise control
Rob Lomax is Sales Director at Wakefield Acoustics, one of the UK’s leading manufacturers of advanced industrial, commercial and environmental noise control systems. With over 20 years’ experience as a noise control engineer, he has extensive knowledge of designing and estimating noise control equipment for industrial and building services applications.
www.hazardexonthenet.net
36 Downstream
European downstream sa C
This represents a significant rise in annual number of fatalities following two
organisation, has published personal safety performance results for 2018. This article is based on selected
consecutive years of the lowest number of annual fatalities recorded (two fatalities in both 2016 and 2017). The 2018 data
sections of Concawe Report 6/19 – ‘European downstream oil industry safety performance - Statistical
indicates that continued efforts are essential to achieve the target of zero fatalities in the downstream industry.
summary of reported incidents 2018’ - and provides comparisons with the industry’s safety performance over
Concawe members study lost workday injuries (LWI) in addition to fatalities to
oncawe, the European downstream industry
previous years Table 1 - Fatalities by sector 2009-2018
identify further opportunities for continuous safety performance improvement.
In 2009, Concawe began to compile Process Safety Performance Indicator (PSPI) data. These describe the number of Process Safety Events (PSE) expressed as unintended Loss of Primary Containment (LOPC). The 2018 PSE data represents 40 out of 42 of the manufacturing companies.
1. Fatalities There were ten fatalities reported for 2018. Six contractors died following a single explosion at a fuel loading terminal serving a refinery. A further three fatalities were recorded as a result of road accidents. All were engaged in marketing activities. A tanker truck driver (own staff) was fatally
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injured when the vehicle left a motorway and overturned. Equipment reliability and human factors were identified as causal factors in this incident. One contractor died as a result of losing control of a vehicle on a straight road and another contractor died following collision with a stationary vehicle on a highway. Both incidents reported
2018 has seen a severe reversal in the downward trend over recent years in numbers of fatalities in European downstream oil industry figures. Annual fatalities in 2018 are at the highest level since 2012 for manufacturing and since 2016 for marketing.
human factors as the sole causal factor.
Increased focus on understanding causal factors and putting in place clearly defined preventative actions are required to achieve and sustain our objective of zero fatalities.
A single manufacturing contractor was also fatally injured in an incident categorised as ‘Struck by’ - no further details of this incident have been provided.
In 2013, the membership agreed to adopt 15 incident categories to describe both
Downstream 37
afety performance in 2018 fatalities and lost workday injury
of cause and better benchmarking, but
(LWI) in an attempt to learn more from the actual incidents. These categories allow for better
risked losing information on longer term trends. However, by revisiting pre-2013 data, a reasonably consistent pattern
benchmarking and alignment with other industry organisations, particularly the IOGP that
can be seen.
represents the upstream sector of the oil and gas industry.
Accidents are the most prevalent fatal incident categories recorded in the period 2009-2018. Road accidents
Figure 2 summarises the categories of all fatalities which were allocated by participating
have declined as an overall percentage of all fatalities compared to 1998-2008 when they represented almost half of
Explosion or burns and Road
Figure 1 - Number of fatalities by category 2013-2018
companies in the period 2013 to 2018. As new information regarding fatality categorisation for historic incidents has been provided to Concawe throughout 2018, Figure 2 does not compare directly with previously reported data in the Concawe 2017 report. There are two additional manufacturing Explosion or Burns fatalities
against the same 16 categories as lost workday injury in 2013, Explosions or Burns (twelve fatalities), Road Accident (seven fatalities) and Struck by (six fatalities) have been the largest contributors to fatalities in the industry. Together, the three categories account for approximately 74% of the fatalities experienced in the industry since
all fatalities. No fatal road accidents were recorded in 2016 and 2017 but in 2018 three people were fatally injured in separate road accidents.
in the period 2013-2017, not included in the 2017 report. A manufacturing Falls from Height fatality which had been erroneously assigned to marketing has now also been corrected.
2013. Two of the 34 fatalities in this period have not been allocated to a category.
fatalities over the last 10 years.
Until 2013, Concawe compiled fatality data against broad categories that could change year to year. Expanding this to 16 distinct
In 2018, there were a total of 586 lost workday injuries, with 56% of these in manufacturing and 44% in marketing.
Since Concawe moved to reporting fatalities
categories provided for greater transparency
Manufacturing LWI are split evenly across
Falls from Height and Stuck by categorised incidents are the next most prevalent, the former category accounting for over 10% of
2. Lost workday injuries
www.hazardexonthenet.net
38 Downstream staff and contractors whereas marketing LWI are more prominent among staff (59%), than
therefore essential for the creation of a supportive safety culture and the fostering of
contractors (41%).
the right organisational behaviours necessary to achieve zero incidents or accidents in operations.
There was an overall increase in lost workday injury frequency (LWIF) compared to 2017. The LWIF went from 0.97 LWI/Mh in 2017 to 1.02 LWI/Mh in 2018 across all workers.
Table 4 indicates a relatively small number of categories contribute to most LWIs
between the sectors emerge between less frequent LWI categories. Concentrating on the most frequent categories of these incidents offers the opportunity to address prevention of lost workday injury across both sectors.
Thirty-five companies reported LWI in both 2018 and 2017. Of these, 17 companies (49%) reported a lower overall LWIF in 2018 than in 2017, 4 companies had the same LWIF in 2017 and 2018 (11%) and 14 companies (40%) had a higher LWIF in 2018.
reported. Slips and Trips (same height), Struck by and Falls from Height together account for almost 54% of all LWIs reported in 2018 and this holds true for each sector, manufacturing and marketing, as detailed in Table 5. Other frequent categories include
For the first time in 2018, Concawe collected causal factors where available for each LWI. Causal factors are described in alignment with API RP754 (2016) and multiple factors may be recorded per LWI. Causal factors were not available for 23% of LWI (135
Manufacturing staff are the sector with the highest LWIF (1.50 in 2018, compared with 1.53 in 2017) and marketing contractors
Explosion and Burns and Caught in, under or between in manufacturing (9.8% and 8.9% of manufacturing LWI) and Cut, Puncture, Scrape and Overexertion, Strain (9.0% and
LWI incidents). In many cases, this reflects ongoing investigations and causal factors for such incidents may be recorded by Concawe in future.
have the lowest recorded LWIF of all sectors in 2018 and the largest improvement in LWIF since last year (0.73 in 2018, compared with 0.81 in 2017). Marketing staff LWIF rose
6.7% of marketing LWI). Slight differences
modestly from 0.95 to 0.97 in 2018. For comparison purposes, the LTIF (frequency of LWIs + Fatalities) has been calculated for each category of workers, compared with the LWIF and presented in Table 3 below. There is little difference between the two measures when the total number of fatalities is lower relative (10) to the number of LWI (586).
Table 4 - Categories of lost workday injuries in 2018
Table 3 - Comparison of LWIF and LTIF in 2018
It has long been accepted that to achieve a sustainable zero-fatality safety performance a company must continually work to reduce lower level safety incidents (such as lost workday injuries, restricted workday injuries, medical treatment cases, first aid cases and near misses). Although lower level incidents such as slips and trips can result in relatively minor consequences, the actual root causes behind both minor and major incidents generally prove to be very similar. The effective investigation of all incidents (near miss, minor and major) to obtain a full understanding of their root causes is
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Table 5 - Categories of LWIs in 2018 - manufacturing vs. marketing
Downstream 39
The most commonly reported causal factors across all LWI are Human Factors (34% of
The latter category was more prominent in 2018 than in 2017, while incidents related to
incidents * Operational Safety focused on Struck
causal factors reported), Safe Work Practices & Procedures (13%), Risk Assessment (10%), Procedures (7%) and Design (7%). There was little difference in the application of these factors in manufacturing and marketing related incidents with Human Factors and
Overexertion and strain were less frequent in 2018 (5.5% compared to 9.5% in 2017). However, the pattern of categories is broadly consistent year to year and similar across both manufacturing and marketing.
by, Caught in under and between and Working at Height * Road Safety
Work Practices & Procedures, consistently the first and second most frequently reported factor, respectively. Manufacturing incidents reported Risk Assessment and Equipment Reliability as third and fourth most frequent causal factors. Procedures and
For the first time in 2018, Concawe collected information about LWI incident categories split between staff and contractors. For the most frequent LWI incident category, Slips and Trips, the staff / contractor split is 65 / 35%. Other LWI incident categories provide
10 years across all workers. Fatal accident rate FAR is 1.73 in 2018, the highest since 2012. The Lost Workday Injury Frequency LWIF of 1.02 is the highest since 2014 when it was 1.08. Similarly, the All Incident Frequency AIF of 2018 is 1.89, similar to
Risk Assessment were the third and fourth most frequently reported causal factors in marketing incidents.
a more equal split. The percentage staff / contractor split for Explosion or burns is 42 / 58, Struck by 52 / 48, Road Accident 50 / 50 and Falls 46 / 54.
that in 2017 (1.90) and higher than the best performance of 1.59 in 2016.
There was little difference between the most frequently reported causal factors in some of the most commonly occurring incident categories. Human Factors was
While there is no direct correlation between categories of LWI and fatalities, the data suggest that focus on reducing LWI in three
the most commonly assigned causal factor in Slips and Trips, Falls from Height, Road Accident and Struck by LWI incidents
areas could have the potential to address the causes of the majority of fatal incidents reported in recent years.
in both manufacturing and marketing. Risk Assessment, Safe Work Practices & Procedures, Procedures and Design were also commonly reported causal factors
These areas are: * Process Safety to address Explosion, Burns and Pressure Release-related
Figure 3 shows the historical evolution of the main performance indicators over the past
The Road Accident Rate has decreased from 0.41 in 2017 to 0.29 in 2018, the lowest rate ever recorded. This is accompanied by an approximate 9% rise in km driven since 2017. It is not clear to what extent this observation is impacted by changes in reporting activities. For the full report, go to: www.concawe. eu/wp-content/uploads/Europeandownstream-oil-industry-safetyperformance.pdf
in these incident types. Manufacturing Explosion and Burns LWI incidents most frequently reported Risk Assessment as a causal factor.
3. Performance trends over the last 10 years Performance indicators are particularly useful for identifying trends and patterns when considered over time. The historical trends for the European downstream oil industry over the past ten years are summarised in this section. Ten years has been chosen as a period reasonably representative of actual operating conditions and practices in place within the industry.
Figure 2 - Frequency of causal factors assigned to lost workday injury incidents (note: more than one causal factor may be assigned to an incident)
Since Concawe began collecting LWI data against the 16 categories in 2013 a pattern has been emerging in the data. As in fatalities, a limited number of causes contribute to most LWIs. In 2018, almost 70% of LWIs were caused by the following, Slips & Trips (same height) 33%, Struck by 11.5%, Falls from Height 9.6%, Cut, Puncture, Scrape 8.6% and Caught in under between 7.2%.
Figure 3 - Performance indicators over the last 10 years 2009-2018 European downstream oil industry
www.hazardexonthenet.net
40 Electrostatics
Risk of electrostatic ignition FIBC discharging operati I
n this article, James Grimshaw of Newson Gale looks at why the greatest risk posed by static electricity in a flammable or combustible atmosphere is an explosion due to electrostatic discharge.
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Flexible Intermediate Bulk Containers (FIBCs) have long been considered a great innovation in the transportation of dry flowable material since their introduction in the sixties. Commonly referred to as a “bulk bag”, “big bag” or “tote”, FIBCs have a body
high strength thermoplastic, polypropylene, along with a linear insert. FIBCs are efficient, and transportation of dry bulk goods such as sand, fertilisers, plastic granules, seeds, resin and powder coatings, to name a few, can be unloaded at a fast rate, with
made of flexible woven material, typically the
anywhere between 300 – 500kg typically
Electrostatics 41
However, the use of FIBCs are not without their risks and when filling and emptying
hoisted above the tank using a fork lift and the resin was dumped through a circular
FIBCs in hazardous areas, electrostatic charge can accumulate on both the contents (product) and the fabric of the material itself. It is common under these circumstances for the rates at which static electricity charges are generated to exceed
port on a hinged tank cover. There was no independent venting of displaced vapour and the tank lid was not gas tight. Despite the operator reporting that the ground wire was missing from the FIBC, it did not stop him proceeding to unload the container
the rates at which the charges can relax, allowing the accumulation of a static electric charge to develop within the process.
regardless.
Incident A**
The danger to plant personnel and the surrounding environment is if the charge
Although the operator himself was not grounded, the nature of the operation involved making a lacquer, meaning that
is released in the presence of a flammable atmosphere, an ignition can occur. Since many products are combustible, the inherent electrostatic discharge hazard from the
static dissipative footwear would probably have been ineffective as there was possibility of a film of lacquer on the floor around the tank. Common in processes
material cannot be overlooked. Eliminating* the potential risk of an electrostatic ignition is of paramount importance.
where coatings are prevalent, a build-up on the sole of the shoe regularly occurs. A cleaner sole will typically give off a lower resistance. Despite this, he was
Case Studies
not considered a likely source of ignition.
The tank lid was open allowing solvent vapour to readily escape into the operating area. Although it was not categorically determined whether the fire occurred immediately or after the FIBC was nearly completely empty, as the operator was standing within the vicinity of the tanker during the operation, he turned away when he observed the flash. An operator typically stands within close proximity of the FIBC during emptying, first to untie the strings and later to shake out residual powder. In this scenario an ignition occurred and the operator was caught in the flash-fire zone and severely burned in the process.
n during tions in 30 seconds or less. Used in agricultural, chemical, food and pharmaceutical industries, FIBCs have proven to be simple to use, cost effective and strong, and are more convenient than rigid IBCs for powder transfers because they can be collapsed after use and stored away.
In the first incident an FIBC Type C bag was used to transfer resin to a 6,000 gallon mixing tank. This operation involved making lacquer for can coatings. The mixing tank was equipped with thin conductive wires running lengthwise through the spout and connected to a bare stranded aluminium wire and alligator clip. The FIBC was
Minimum Ignition Energies (MIE) of regularly transported gases, vapours & dusts in millijoules (mJ)
Use of different types of FIBC
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42 Electrostatics not believed to be a contributing factor as there was no fire or explosion inside it.
Incident B** In the event of an ignition during an FIBC operation, plant personnel that are usually within close proximity are likely to be caught in the flames. The operator once again was in the vicinity of the FIBC but not touching it. As a result he received second and third degree burns to his stomach and face. The sprinkler system installed above the tank did not emit water; however, pallets of resin bags were singed at a distance of 20 – 30ft from the tank. A major hazard in any explosion is when material is dispersed into the general plant area and a secondary ignition occurs. Although the hinged lid was closed there was again no provision for venting either the purge gas or the air entrained into the tank by the powder flow. A significant displacement of flammable vapour therefore took place into the operating area.
Findings However, the use of FIBCs are not without their risks and when filling and emptying FIBCs
Unlike the first incident, in Incident B it was reported – but not conclusively determined – that a grounding connection had been properly made ensuring continuity to earth to dissipate static charge. However, it was not possible to completely ascertain
The investigation into the incident made
Unfortunately, this incident involved the same operator and was not dissimilar
whether this was the case as the grounding clamp was unavailable for examination. As a result, an FIBC operational error causing
the assessment that a spark discharge had occurred from the ungrounded FIBC during emptying. The lack of continuity to ground
to the first. The main difference being the FIBC was designed with an internal conductive aluminium liner bonded to
loss of continuity could not be ruled out since the FIBC involved was destroyed in the fire. Although polypropylene has a
meant that charge could not be dissipated. Charge on an insulated object is retained because of the resistance of the material
the polypropylene in the spout. This was connected to an external grounding tab to which a grounding clamp was to be
unique blend of qualities and characteristics that make it an ideal material for the construction of FIBCs; it is also highly
itself. For a conductor, such as the FIBC, to remain charged, it has to be isolated from earth. As it was known that the resin had low minimum ignition energy (MIE), it was assumed that flammable vapour was a significant factor in the ignition process reaching well in excess of an acceptable level.
connected by the operator. The FIBC was suspended over the tank as before, and after applying the grounding clamp the discharge spout was pushed through the port in the tank manway so that it is extended 10-12 inches inside the tank. The draw cord was then cut to open the spout and release resin into the tank.
flammable and susceptible to ignition via a spark discharge. If we are to generalise failures for FIBC operations, these typically occur due to manufacturing defects, operator error or disabling continuity to a verified earth via a grounding clamp.
Findings
Materials with low MIE will regularly reach the minimum explosive concentration (MEC) in an FIBC emptying operation such as the one described due to the flow-rate and ability to charge, and may be at risk of combustion by several sources of ignition. In this incident
The FIBC was not opened at the top to vent the contents and prevent drawing vapour into the FIBC. On this occasion flow was delayed and the operator “puffed” the FIBC to free the flow. Within 10 seconds of flow a
electrostatic discharge was the ignition source.
flash occurred. Failure to vent the FIBC was
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What actions could have been taken to prevent these incidents? With any incident the first place to start is to determine why electrostatic charge was “permitted” to accumulate. Charge generation normally occurs due to the process of contact and separation of
Electrostatics 43
the material which takes place between particles and the equipment, known as
However, the complexity of dissipating static effectively requires careful planning
triboelectrification. Any material will naturally become charged by triboelectric action. Particle separation within FIBC processes occurs between conveying equipment and the bulk bag during filling and emptying. The nature of FIBC operations means that
and a sound approach to risk management. The correct bag and grounding system can always be negated by plant personnel that purposely or inadvertently circumvent safety procedure; however, as documented in Incident A, the effects far outweigh the time
they are particularly susceptible to charge accumulation.
it takes to perform the necessary checks and conclusively confirm visually that (a) the operator has clamped on, and (b) the system has confirmed a resistance to ground of 1 x 107 ohms or less.
Tips for correctly grounding Type C FIBC bags
In these incidents electrostatic charge had been allowed to accumulate because the FIBC was isolated from ground, whether this was through the negligent actions of the plant operator or inconclusive grounding methods. As grounding wasn’t achieved, charge was allowed to accumulate. Had grounding been accomplished via a Type C bag with either passive (single pole clamp and cable) or through active means (monitoring systems), connection to a true earth ground would’ve been verified and charge subsequently dissipated. In accordance with industry guidelines such as NFPA 77 “Recommended Practice on Static Electricity” and IEC 61340-44 “Electrostatics – Part 4-4: Standard
• Ensure that the grounding system selected can check and continuously monitor the full range of resistance through the bag. • Ensure the grounding system not only check the condition of the bag’s static dissipative threads, but also ensure that the ground circuit includes a direct monitored connection to a verified True Earth grounding post. • Ensure the grounding system does not monitor a limited percentage of the permitted range of resistance as they may pass faulty bags and reject acceptable bags. • Ensure Type C bags are manufactured in accordance with the electrostatic recommendations of IEC 61340-4-4 / NFPA 77 or CLC/TR: 50404
Regular static hazard awareness training combined with grounding equipment that displays compliance with industry guidelines will go a long way to eliminating fires or explosions caused by static electricity.
Footnotes * “For the avoidance of doubt. ‘eliminate’ shall have the meaning that the likelihood of electrostatic discharge will be eliminated or mitigated to a low level where the risk and harm will be eliminated, in line with the internationally recognised recommended best practice. We would like to clearly outline that static electricity as such can
test methods for specific applications – Electrostatic classification of flexible intermediate bulk containers (FIBC)” the
electricity does not accumulate on the bag. Once the connection of two grounding clamps has been made onto the grounding
never be completely eliminated.”
resistance through the bag should be less than 1 x 107 ohms (10 meg-ohm).
tabs, the FIBC system will identify if the bag is operating in accordance with the relevant standard. This is achieved by sending an
Britton, L (1983). Static Hazards Using Flexible Intermediate Bulk Containers for Powder Handling.
Given the magnitude of charge that can build up on bags, an active grounding system is the recommended – and safer
intrinsically safe signal through the bag. The system verifies the grounding of the bag by ensuring the signal returns via a verified true
choice. This is because the system can determine whether or not the bag’s construction complies with the relevant
earth ground (static ground NOT verified by the FIBC). Should any charge have accumulated on the bag, it will leave via
standards and will also ensure the bag is grounded for the duration of the filling/ emptying operation.
the static dissipative threads to the verified ground.
Some systems are able to validate and monitor the resistance of Type C bags ensuring that conductive elements of the bag are capable of dissipating charges in
The static dissipative loop system check continuously monitors the resistance of the bag so that if it rises above 1 x 107 ohms, a red LED on the remote indicator station illuminates to tell the operator the system
compliance with the necessary guidelines. Type C bags are designed to dissipate static electricity through static dissipative threads that are interwoven through the bag’s material. Grounding tabs located on the bags are points where grounding
has gone non permissive.
systems can be connected to ensure static
eliminate the risk posed by static electricity.
Summary Of course, recognition of the hazard is only the first step. It is easy to assume that the use of simple clamps will automatically
Incident A** and Incident B** - Reference
About the author
James Grimshaw is Marketing Manager at Newson Gale, a position he has held for over two years, and is a member of the Institute of Leadership and Management. Prior to his current role he was Marketing Manager at offshore sensors manufacturer Guidance Marine.
www.hazardexonthenet.net
44 Automation
Play it safe - adhere to the Machinery Directive T
he Machinery Directive sets a high and common safety level for a broad classification of equipment in terms of design and use. While the directive also governs the movement and operation of compliant machines throughout EU member states, its primary objective is to ensure worker
Anyone involved in the specification, design, manufacture, import, supply, purchase or modification of machinery should be familiar with the directive
safety. In the modern era, as industry continues to leverage advanced equipment to optimise productivity and efficiency, safety responsibilities must not be compromised.
Although first published in 1989, it was in
In this article, Linda Caron, Global Product Manager Factory Automation at Parker Hannifin, discusses what the Machinery Directive entails, how to adhere to it, and what qualifies as a ‘safety component’.
2009 that the Machinery Directive 2006/42/ EC became law in Europe. The publication’s primary role is to ensure common safety levels for any machines introduced to the market and put into use. Today, the Machinery Directive sets out the foundation and regulatory basis for the harmonisation
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of Essential Health and Safety Requirements (EHSR) in the field of machine building. Importantly, the directive is unified with CE requirements and spans almost 21 EN standards to help guide machine OEMs on safety requirements. In short, the publication has become the foremost authority on the design of safe machinery. Among the many unique qualities of the Machinery Directive is its broad coverage of machinery design. Moreover, the publication mandates a technical file be maintained on the machine to outline its initiation and the risk avoidance measures deployed to maximise safety. Of course, a safe machine demands the use of safe components. However, what is actually meant by the term ‘safety
Automation 45
component’? Well, in terms of the directive, a safety component is one which: serves to fulfil
downstream; high B10 value (life expectancy in switching cycles); and comprehensive
are available that can read spool position sensors and actuate pump unloading valves
a safety function; is independently placed on the market; and if it fails and/or malfunctions could endanger the safety of persons.
monitoring capability to achieve the highest level of diagnostic coverage. Only by selecting a proven product from a reputable supplier is it possible to ensure that machine safety attributes are maximised.
to have a second hydraulic shutdown path.
Directive is to ensure common safety, it stops short of mandating the use of safety-rated products. The publication does, however, clearly differentiate standard components used in a safety application against those designed and intended as safety-rated
The Machinery Directive also points out that to meet enhanced safety levels, redundancy and monitoring must be included in the controls in accordance with EN ISO 138491, as well as validation of the system in line with EN ISO 13849-2.
box’ exercise is one thing, but ensuring the safety of machine users is a far more important objective. Anyone involved in the specification, design, manufacture, import, supply, purchase or modification of machinery should be familiar with the
products. Also highlighted is the need for common sense strategies, such as the use of e-stop buttons, the removal of air in a pneumatic machine to protect from
The market’s latest intelligent, scalable controllers exemplify how the state-ofthe-art is evolving when it comes to safety
For the machine builder in particular, imagine the cost of non-compliance, which could
unexpected movement (where safe to do so), and the addition of technical measures where risk cannot be designed out.
control systems, in this case for hydraulic mobile machinery. Such controllers are more run-time efficient and can execute larger applications in a quicker cycle time.
see sales bans, large fines, adverse publicity, warranty and/or product liability claims, claims for unfair practice and even criminal consequences in the case of personal injury.
By definition, safety-rated products are classified separately and subject to more demanding requirements, testing and
Moreover, modern controllers can offer features that include the execution of safetyrelated applications in the lockstep core,
Armed with these thoughts, the peaceof-mind provided by using safety-rated products from a reputable supplier, is little
expectations for performance. A case in point are safety exhaust valves which meet the needs of the directive to remove air from pneumatic machinery during either an e-stop
ECC-protected Flash and RAM, and the implementation of a safety-certified RealTime Operating System (RTOS).
short of priceless.
or a fault condition event. As part of the purchase decision, safety
By adopting some of the larger modules available, design engineers have the option to use one certified controller on all sections
valves should tick a number of major criteria, which include: fast exhaust time to faulted condition; fast switching time; utilising series-
of a hydraulic directional control valve. This choice provides a cost-effective way to meet safety function PLc without introducing
parallel flow so that both valve elements (redundant design) shift to supply air
additional hydraulic components. For functions requiring the higher PLd, controllers
An interesting observation is that although the primary purpose of the Machinery
Ultimately of course, there is no margin for error or oversight when it comes to safety. Meeting the stipulations of the Machinery Directive as some kind of ‘tick-
directive.
About the author
Linda Caron is a Global Product Manager for Parker Hannifin Corporation in Factory Automation, Pneumatic Division, Motion Systems Group in Richland, Michigan. Linda is a CMSE, Certified Machinery Safety Expert (TÜV Nord) and has held various roles over 27 years in both Fluid Power (with Parker and Festo) and the within the Electrical industry, serving global markets from Oil & Gas to the Food & Beverage industry. Linda’s focus is on the IIoT space, network connectivity and machinery safety.
www.hazardexonthenet.net
46 Events
National Oil Companies Assembly Date: 4 December 2019
As the transformation of the existing NOC
Location: London, United Kingdom
model continues, the Assembly will allow attendees to: - Maximise margins, maximise profits: Find out how to optimise CAPEX/OPEX decision making in light of external disruptions - From maintaining volumes to securing
The Oil and Gas Council National Oil Assembly returns to London this December. The forum offers a unique platform for national and international oil companies and their partners to engage with their peers from around the world and discuss the key energy issues of the day. Supported by key representatives from national champions Saudi Aramco, ADNOC, NNPC as well as the world’s biggest investor Blackrock, it provides the only international gathering solely focused on national oil companies and SOEs.
markets: Using tech to maximise reserve recovery and expand focus into petrochemicals and carbon capture & build a strong portfolio of international investments - Remain competitive in a changing landscape: Understand the implications of the evolution of the energy mix on your organisation
- Access the capital markets: Explore alternative means of funding capital requirements - Promote employee buy in & generate excitement amongst managers about strategic change Website: https://oilandgascouncil.com/ event-events/noc-assembly/
European Conference on Plant & Process Safety Date: 11 – 12 December 2019 Location: Cologne, Germany The conference will bring the technical safety specialists and managers from Seveso sector companies together to learn and network. The event is broadly supported by the European industrial chemical associations. The conference will be held at the Maritim
Hotel in the heart of Cologne. Suppliers to the hazardous processing industry with specific knowledge on process safety are invited to participate with a stand at the Network Forum. Topics at the conference include: - Learning from incidents - Risk reduction tools - Plant monitoring & Integrity - Human Performance
Website: https://safetycongress.eu/
The Oil and Gas IoT Summit Date: 22 – 23 January 2020 Location: Lisbon, Portugal Returning to Lisbon The Oil and Gas IoT Summit brings together an exclusive community of around 120 major stakeholders from worldwide operators, EPCs, regulators and, technology providers to debate and discuss the key issues and trends shaping the digital transformation of the industry. IoT in Oil and Gas is maturing. Moving from concept to strategy and now to daily applications which are making real, bottom line improvements and delivering process efficiencies.
www.hazardexonthenet.net
The Oil and Gas IoT Summit 2020 picks up the industry’s transformation story 12 months on. Focusing on case study evidence and lessons learned our speakers will share their personal experiences, challenges and REAL results. With one eye on the future, we’ll also take a look at the key trends and developments that look set to shape the industry in the next 12 months and beyond. Join us to: - Explore the business drivers powering this digital sea change - Take an in-depth look at emerging trends and technologies
- Benefit from strategic insights into new change management methodologies - Discover implementation best practice strategies - Meet new solution providers - Make powerful new industry connections
https://www.oilandgas-iot.com/
Data File/Buyers Guide 47 Goennheimer Equipment protection by pressurized enclosure Ex p
NEW! iWAP XN3 universal wireless enclosure system
The smart solution to integrate standard hardware in hazardous areas. Since more than 35 years, Gönnheimer offers marketleading-technology in pressurized enclosure solutions. The product range covers controllers and systems for ATEX and IECEx Zone 1/21 and 2/22, as well as Div.1/2 areas. The intelligent controllers offer PID-regulated pressure and flow, integrating purging and various pressure- and flowrate-ranges. They allow smart purge solutions of standard cabinet applications and also special-purposes like analyzers, sensors, robot-systems, printers, etc. Comprehensive Gönnheimer purge solutions also contain OEM cabinets for qualified Ex-p applications.
The new iWAP XN3 is a safe, reliable way to use the latest wireless technologies in ATEX, IECEx, and North American Zone 2 and Division 2 hazardous areas. Fully certified: ATEX and IECEx Zone 2 and 22, cMETus Class I, II Division 2 and Zone 2 Universal system: Use any wireless technology including Wi-Fi access points, UHF RFID readers, LTE routers, IoT gateways including LoRa and more Optimised features: Building on the success of the market-leading iWAP107 Zone 1 universal enclosure system, the iWAP XN3 is a practical and cost-effective way to deliver strong performance. Enable your digital transformation – contact Extronics today! info@extronics.com | +44 (0)845 277 5000
T: 0049 6321 49919 14 E: info@goennheimer.de W: www.goennheimer.de
Schmersal launches first ex-proof RFID safety sensor At Motek 2019, the Schmersal Group is showcasing the first RFID-based safety sensor which has been designed in accordance with ATEX Directive 2014/34/EU and can be used in EX zones 2 (gas EX, category 3G) and 22 (dust EX, category 3D). This means that the EX-RSS16 combines two important properties for system safety: functional safety in accordance with ISO 13849 and explosion protection. At the same time, the sensor features ignition protection classes Ex ec and Ex tc, covering the explosion protection function without requiring another energy-limiting device. Schmersal launched this new development this year. The wear-free safety sensor is perfect for position monitoring of various kinds of safety equipment, including the monitoring of doors, position monitoring of machine axles or other rotating, lateral shifting or removable safety equipment. Three different actuation directions also allow a flexible choice of installation position.
Heaters
The EX-RSS16 is available with or without latching. For example, the variant with a magnetic latching ensures that a door is held closed even when there is no voltage. Because of the built-in RFID technology, the EX-RSS16 enables individually coded variants with a coding level of high in accordance with ISO 14119, thus offering excellent tamper protection. T: 01684 571980 E: uksupport@schmersal.co.uk W: www.schmersal.co.uk
Buyers Guide
Communications
EX AT
SAFE TALK ST-1
EX MOBILE APPLICATION:
CAMERA:
3G/4G Android 6.0
SIZE:
127 X 63 X 27 MM
5MP Rear Camera
WEIGHT:
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<200 gms
SPECIFICATION: • • • •
Ex ib IIC Gb T3 tb IIIB Db IP67
FCG Flameproof Control Gears P Ltd.
..Safety First.. Training
Cable Glands
contact
PROTECTION:
8GB Internal 32 GB Expandable -20 0 C to +60 0 C Amb. Temp. 1000 mAH battery
Mumbai, India +91 22 2366 3200 RP@fcg-india.com www.fcg-india.com
To advertise in the Product Datafiles or Buyers Guide Kathryn Startin on
+44 (0)1732 359990 or
kathryn.startin@imlgroup.co.uk
Control Panels
AUTOMATION CONTROL & TECHNOLOGY Your Total Solutions Provider Specialists in design and custom build of a wide range of Hazardous Area Equipment
Registered OEM for Technor Marechal Southampton SO40 9AH +44 (0) 2380 665544 enquiries@trant.co.uk trant.co.uk
| PI11-01E |
Automation and process technology in a single system: with PC-based Control
www.beckhoff.com/process With a comprehensive range of components for explosion protection and the common interfaces in TwinCAT, Beckhoff offers the possibility to integrate automation and process technology in a system without barriers into Zone 0/20. The range extends from the narrow, intrinsically safe EtherCAT Terminals from the ELX series and the high-grade Control Panels and Panel PCs from the CPX series through to EtherCAT, the fast process technology fieldbus, and the TwinCAT control software with specific process technology interfaces. This allows users to directly connect intrinsically safe field devices and to realise integrated control architectures with barrier-free process technology.
Hall 7, booth 406
TwinCAT 3: with process technology interfaces
Complete EX range: from Panels and Panel PCs to the I/Os