hEX_20_04

hazardexonthenet.net

Fire safety Updating flame detection and releasing systems Offshore Improving safety and efficiency of ship-to-ship transfers

Safety management UK HSE releases report into fatal 2011 Chevron refinery explosion

Valves Using position transmitters on automated valves

Non-electrical ignition Non-electrical equipment and own potential source of ignition

April 2020

the journal for hazardous area environments

cortemgroup.com

contents April 2020 The Hazardex 2020 Exhibition & Conference took place on February 26 & 27 at the Majestic Hotel in Harrogate, UK. The event was a great success for the industry, and I’m thrilled to say that plans are already well underway for Hazardex 2021 at the same venue on February 24 & 25, 2021.

The event was my first as Editor and it was a pleasure to meet with exhibitors, speakers, delegates and visitors alike. The Hazardex team would like to thank all attendees for making this year’s event one of the best we have ever had. A special thank you also to CSA Group who will return as Event Sponsor in 2021!

The first Hazardex event was held in 2002 and each year we have sought to bring together the finest members of the process safety and hazardous area operations community – this year was no different.The exhibition comprised leading suppliers of equipment and services for hazardous areas, while the conference was put together to provide key industry information

14 22

and topical discussion on process safety-related topics.

The eminent roll call of presenters included speakers from the HSE, Chemical Industry Association, IECEx, Chemical Business Association, InstMC, UKPIA, Brenntag, and many more worthy contributors.

During the Gala Dinner on February 26, the Hazardex 2020 Awards for Excellence took place. The Hazardex Awards has become a benchmark for those supplying products, services and systems within hazardous areas.

Read more about the winners and runners-up at www.hazardex-event.co.uk

Despite the clear benefits of a ship-to-ship transfer, it can be a particularly complex process with a very real risk of a spill or fire if poorly planned or executed

14 26

An in-depth review of Hazardex 2020 will be published in the May issue. Details about the 2021 event will be made available soon.

For details about exhibiting at this must-attend event, please contact Event Director Russell Goater on +44 (0) 1732 359990 or email events@imlgroup.co.uk. …Alistair Hookway, Editor, Hazardex alistair.hookway@imlgroup.co.uk

The increased use of automation within process industries has had a significant effect on the nature of valves supplied into the sector

in this issue

28

4 News Extra & Standards

• UK HSE releases report into fatal 2011 Chevron refinery explosion • Explosions and fires at two of the largest refineries in the United States • Operating licence issued for Arab world’s first nuclear power plant • UK grants funding for first low carbon hydrogen production plants • South Korea chemical plant explosion injures 31 • US gas company pleads guilty to violating safety laws, agrees to pay record $53 million fine • EU imposes sanctions over Turkey’s offshore drilling near Cyprus

A look at ultra-high-speed flame detection and releasing systems and why upgrading these systems must be considered

21 Standards: Hydrogen is the solution 22 Improving safety and efficiency in the ever-evolving STS transfer sector

33

26 Using position transmitters on automated valves for enhanced safety 28 Updating flame detection and releasing systems 33 Non-electrical equipment and own potential source of ignition 37 OTC 2020 Houston Preview

This article explores the issues associated with non-electrical equipment and its potential sources of ignition

30 36Fire safety

the journal for hazardous area environments

hazardexonthenet.net

April 2020

38 Event previews 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 Alistair Hookway alistair.hookway@imlgroup.co.uk

Group Publisher Russell Goater russell.goater@imlgroup.co.uk

Sales Executive Kathryn Startin kathryn.startin@imlgroup.co.uk

Circulation subscriptions@imlgroup.co.uk Tel: +44 (0)1732 359990

IML Group Blair House, High Street, Tonbridge, Kent TN9 1BQ, UK Tel: +44 1732 359990 Email: hazardex@imlgroup.co.uk ISSN 1476-7376

Production and Events Holly Reed holly.reed@imlgroup.co.uk

Design Graham Rich Design www.grahamrichdesign.co.uk

Updating flame detection and

40releasing systems

Offshore Improving safety and efficiency of ship-to-ship transfers

Safety management UK HSE releases report into fatal 2011 Chevron refinery explosion

Valves Using position transmitters on automated valves

Non-electrical ignition Non-electrical equipment and own potential source of ignition

Register for weekly email newsletter & up-to-the-minute news at www.hazardexonthenet.net

4

News Extra

help everyone in major hazard industries, not just those involved in tank storage or

Pembroke Refinery: Shutterstock

tank cleaning, learn from this incident.

Lassey hopes that readers will gain an understanding of what went wrong and apply lessons to their own organisations.

While it has been almost nine years since the incident, the information contained within the report remains highly relevant today.

In June 2019, Chevron paid a £5 million fine and court costs of £1 million as part of a deal it struck with Valero Energy UK Limited, which bought the site shortly after

UK HSE releases report into fatal 2011 Chevron refinery explosion

T

he HSE has released its report into

the disaster. Specialist tank cleaning firm B&A Contracts, which employed the four contractors who were killed, was fined £120,000 and ordered to pay £40,000 in legal costs. Other than the fatalities, a fifth worker caught in the fireball survived but with life-changing burns.

contained flammable material, Chevron

the June 2011 explosion at Chevron’s Pembrokeshire refinery which killed four people and left one other with life

failed to train staff and update systems.

The HSE says in its report that any change of plant operation should be critically risk

When passing sentence on the defendants at Swansea Crown Court on 6 June 2019, the Judge, the Honourable Mr Justice Lewis,

changing injuries. The report gives an overview of the incident and details the underlying causes behind the explosion, as well as offering safety management

assessed, adequately controlled and relevant systems updated accordingly, to ensure the significance of a newly generated hazard is not lost over time.

stated: “The fact is that the serious nature of the failings, the number and range of failings, and the length of time over which certain of the failings occurred demonstrate serious errors

On June 2, 2011, an atmospheric storage

A further learning point from the incident comes from the fact that two days before

and serious failures within the organisation to address the risks to health and safety. All major hazard industries should look carefully,

tank within the amine regeneration unit at the Chevron Pembroke Refinery exploded. The force of the explosion ejected the five-tonne

the explosion, a gas test indicated a potentially explosive atmosphere within the tank, but this information was either not

both at their own operations and the control of contractors, in the light of the systematic failings that lay behind this tragic incident.

steel tank roof over 55 metres through the air. After narrowly missing a multi-fuel pipe track, the roof crashed onto a pressurised

shared or acted upon by those planning or carrying out the job. The report says that companies should reflect upon this failure

“I hope that this prosecution will serve as a reminder to those with a responsibility

storage sphere containing extremely flammable butane. Good fortune prevented the airborne roof from puncturing the butane

and review their own systems to ensure that they provide training and arrangements for the recording and communication of

for employees and contractors, to actively monitor their safety management system arrangements to ensure they are effective in

storage vessel, which would have led to an uncontrolled release of liquified petroleum gas (LPG).

important safety-critical information.

keeping workers safe.”

The HSE concludes that the incident was not merely the consequence of errors by individual employees, but because of the failure of safety management systems to ensure a safe place and safe systems of work. Therefore, the HSE believes that both

The report is available in full on the HSE website: https://www.hse.gov.uk/comah/ chevron-pembroke-report-2020.pdf

the explosion and resulting fatalities were avoidable.

Despite it being apparent on several

In the report’s foreword, HSE Director of Chemicals, Explosives and Microbiological Hazards Division Jane Lassey writes that

at the HSE, explored the EC&I elements of the investigation into the fatal Chevron incident during his presentation at the Hazardex 2020 Conference & Exhibition in Harrogate, UK. Find out more about the Hazardex event by visiting: www.hazardex-

occasions that the tank in question

the complex investigation’s findings can

event.co.uk

lessons for industry.

The explosion was caused by the unintended ignition of a flammable atmosphere within the tank, during what should have been a routine cleaning operation conducted in preparation for maintenance. The investigation revealed a longstanding and widespread failure to understand and control risks posed by the flammable atmosphere inside the tank.

www.hazardexonthenet.net

Peter Evans, Electrical, Control and Instrumentation (EC&I) Specialist Inspector

News Extra

Exxon Mobil Refinery in Baton Rouge, Louisiana - Image: Wikimedia/WClarke

5

Explosions and fires at two of the largest refineries in the United States T

wo of the largest refineries in the US caught fire in February. In the

In November 2016, four people were injured at the same ExxonMobil refinery after a fire

first incident, a blaze broke out at the ExxonMobil refinery in Baton Rouge, Louisiana on February 11. Then, on

broke out at the alkylation unit while workers prepared to restart it following repair work.

February 25, a portion of the Marathon Petroleum Refinery in California, the largest refinery on the US west coast,

Elsewhere during February, an explosion and subsequent fire also erupted at the Marathon Petroleum Refinery in California. Local media

more than 360,000 barrels of oil a day.

closed following an explosion and fire at the plant in Los Angeles. No deaths or injuries were reported in either

reported that the blast was heard up to 25 miles away and caused a significant fire at the centre of the refinery.

opened in order to find the causes.

incident.

The ExxonMobil refinery in Baton Rouge is the country’s fifth largest, with an input capacity of around 503,000 barrels per day.

The fire broke out at around midnight before it was extinguished at 05:45 on February 12.

ExxonMobil’s volunteer fire team responded to the incident and managed to contain the fire until it was put out. Despite the incident, operations at the plant continued.

there were potentially up to three explosions that preceded the fire.

The Marathon Petroleum Refinery is located in Carson, south Los Angeles and produces

Investigations into both incidents have been

Local fire officials told the media that early

Interstate 405, one of the busiest freeways in the US, was shutdown overnight before

signs indicated that the incident at the Marathon refinery was a propane explosion.

Fire officials continued to monitor air quality

firefighters were able to bring the blaze under control in the early hours of February 26. The LA County Fire Department said

in both Baton Rouge and Los Angeles in the days following each fire, but there were no signs of any toxic gas releases.

Exxon’s automated notification system sent a warning to local authorities and all resident’s living within one mile of the plant shortly after the blaze was reported. Police, firefighters, a HAZMAT team, and the Louisiana Department of Environmental Quality (LDEQ) attended the scene.

Air monitoring was conducted with readings showing that no harmful gases were released as a result of the fire.

Marathon Petroleum Refinery, California - Image: Shutterstock

www.hazardexonthenet.net

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News Extra

Cheney Manor warehouse - Image: Swindon Borough Council

7

glue fumes and a lack of ventilation in the warehouse.

Those working in the section of the warehouse, which was an unregistered activity, were equipped with faulty or broken face masks that were not of the classification required for the working conditions. The Swindon Advertiser reports the workers were susceptible to cancer-causing wood dust and that upon discovering the working conditions, council investigators immediately issued a Prohibition Notice.

UK furniture retailer fined £400,000 for safety breaches J

B Global, the parent company of UK furniture manufacturer Oak Furnitureland, has been fined £400,000 for breaching health and safety regulations, including DSEAR. Swindon Borough Council said that there was a significant risk of explosion at the Cheney Manor warehouse in Swindon, southwest England.

JB Global pleaded guilty to six breaches of health and safety

JB Global pleaded guilty to six breaches of health and safety regulations in 2019. In court, it was said that the firm had failed to communicate the risks to staff of working in a potentially explosive environment with dangerous substances.

The manufacturer was also accused of disregarding the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR) by failing to classify areas in the warehouse where an explosive atmosphere may be present.

JB Global was sentenced at Aldershot Magistrates’ Court on March 4 where it was fined £398,000 and ordered to pay around £95,000 in council costs.

According to the Swindon Advertiser, the

made by a worker. Officials found that

In a statement, JB Global said: “Around four years ago, in order to support the rapid growth of the business, a small workshop where parts of our shop fittings were produced was opened. Regrettably at this time certain health and safety aspects of this

local council’s compliance team started an investigation into the Oak Furnitureland warehouse in 2016 following complaints

the company, based in South Marston, was manufacturing room partitions in a highly explosive environment created by

new workshop were not fully understood. We fully accept we could and should have done better on this aspect of our operation.”

regulations in 2019

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News Extra

Hinkley Point C’s next major milestone is the completion of the base for Unit Two in the summer of 2020 – Image: EDF

UK’s electricity and enough to power around six million homes. EDF is aiming to build Sizewell C more cheaply than Hinkley Point C by reusing the designs, supply chain, and skills.

In September 2019, EDF said Hinkley Point C would cost up to £2.9bn more than previously estimated due to challenging

EDF set to submit planning application for £16bn Sizewell C nuclear power plant

ground conditions at the site. 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.

DF is finalising its formal planning

If approved, Sizewell C will be a copy of the

While the cost overrun was not expected to hit UK consumers, it was possible that EDF’s announcement could affect its

application to build a new nuclear power station on the east coast of Suffolk in Sizewell, UK. According to The Telegraph, the French energy company will submit a Development

plant currently being built at Hinkley Point in Somerset. Both plants will include two EPR reactors and are both backed by the China General Nuclear Power Group (CGN), a Chinese government-controlled energy

proposed plans for Sizewell C. There have been suggestions that funding for the new plant in Sizewell could be financed under a new model where consumers would see the costs of construction added to their energy

Consent Order (DCO) in the next few weeks as part of the final stages in the planning process for the new £16 billion

company.

bills as the project went along.

Sizewell C would be capable of generating

Government funding for Sizewell C is yet to

nuclear power station, Sizewell C.

3,260MW of electricity, around 7% of the

be announced.

E

News Extra

Barakah Nuclear Energy Plant in May 2019 - Image: Emirates Nuclear Energy Corporation

9

The plant’s owner, Nawah Energy Company, has been granted a 60-year operating licence by the Federal Authority for Nuclear Regulation (FANR). Nawah Energy is now able to begin loading nuclear fuel into its first reactor, a process which will take several weeks, as preparations for commercial operations begin.

Operating licence issued for Arab world’s first nuclear power plant

T

he United Arab Emirates issued an operating licence on February 17

around $24.4 billion (£19.5 billion).

Christer Viktorsson, Director-General of FANR, told a news conference on February 17 that Nawah will need to conduct tests before any power production can begin, however if these go well then production could begin by May or June. He added that it would take eight to 12 months for the first reactor to reach its full

for the Arab world’s first nuclear power plant. The licence opens the way for the Barakah power plant to begin production

Having originally been scheduled to open in 2017, start-up of the Barakah plant’s first reactor has been delayed several times. When

production capacity. Hamad al-Kaabi, Deputy Chairman of FANR said that construction of the plant’s second reactor was 95% complete

later this year.

completed, the plant will have four reactors with a total capacity of 5,600 megawatts (MW).

and that FANR had started looking into an operating license for it.

The plant is still under construction and is being built by Korea Electric Power Corporation (KEPCO) in Abu Dhabi. Once operating, it will

The UAE is building the Barakah plant as part of its move to diversify its energy mix. The oil

In January, UAE state news agency WAM said that the Atlanta Center of the World Association

be the first nuclear power station in the UAE and the Arabian Peninsula, as well as the first commercial nuclear power station in the Arab

rich nation wants nuclear power to make up around 6% of its energy supply by 2050 in order to meet rising demand for electricity and

of Nuclear Operators (WANO) had conducted an operational readiness assessment and concluded that the first of the four planned

world. Its construction cost is expected to be

free up more crude oil for export.

reactors was fit for its start-up phase.

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10 News Extra

Royal Dutch Shell consortium announces plans for Europe’s largest hydrogen plant A

consortium comprising Shell, Gasunie, and Groningen Seaports

and the announcement of subsidies for green energy from the Dutch government

infrastructure – which is currently used for natural gas and green gas.

has announced plans for the NortH2 project which will see a green hydrogen plant built in the Netherlands within the next decade. The plant will be fuelled by a new wind farm off the coast of Groningen province and will

and EU, Reuters reports.

According to the consortium, NortH2’s new wind farms would be able to gradually grow to a capacity of around 10 gigawatts which would be sufficient to meet the

Marjan van Loon, President-Director of Shell Netherlands, said, “Together, we are launching an ambition that puts the Netherlands at the forefront of hydrogen globally. This project offers opportunities

be able to produce 800,000 tonnes of hydrogen per year by 2040.

current electricity consumption of 12.5 million Dutch households. The first wind turbines could be in place by 2027.

throughout the entire hydrogen chain. In order to realise this project, we will need several new partners. Together we will have

The consortium hopes that the plant will help cut the Netherlands’ CO2 emissions by around 7 megatons a year. The plans are still in the very early stages and the group will now look for additional

The plan includes a large electrolyser unit, where wind energy is converted into green hydrogen. The consortium may also consider the possibility of placing

to pioneer and innovate to bring together all the available knowledge and skills that are required. The energy transition calls for guts, boldness, and action.”

industry partners to help develop the NortH2 project. The project still requires government permits, the assignment of

electrolysers offshore. Once complete, hydrogen would first be carried to industrial customers in the Netherlands and

The NortH2 project is expected to start this year with a feasibility study. If the outcome is successful, the consortium hopes to

new wind farm locations in the North Sea,

northwest Europe via Gasunie’s natural gas

start producing hydrogen by 2027.

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News Extra 11

Stanlow Oil Refinery - Image: Shutterstock

UK grants funding for first low carbon hydrogen production plants T

he UK government has granted funding towards Europe’s first low carbon hydrogen energy production

project will see a plant developed at Essar Oil UK’s Stanlow refinery in Ellesmere Port.

The project involves Johnson Matthey,

hydrogen at the new production plants will be captured and stored. When operational, the Stanlow facility will capture around

plants. The Department for Business, Energy and Industrial Strategy (BEIS) announced £90 million of funding on

SNC-Javelin, and Essar Oil UK. The plant will produce around 3TWh of low-carbon hydrogen for local industrial customers.

600,000 tonnes of CO2. The hydrogen will be distributed by a new pipeline network which is currently being developed by

February 18 as part of its efforts to cut carbon emissions to “net-zero” by 2050.

The second plant will be developed at the St Fergus Terminal in Aberdeenshire.

Cadent Gas. This network will also provide a pathway for renewable hydrogen use in the future.

£70 million of the funding will go towards projects involving hydrogen, including Europe’s first-ever large scale, low carbon

Elsewhere, a St Helens-based glassmaker will use hydrogen in its glass-making process, a world first, and Unilever’s Port

hydrogen production plants – the first on the banks of the Mersey in Cheshire, the second planned for near Aberdeen.

Sunlight will trial the use of hydrogen in a commercial scale boiler. These pilots were allocated £5.2 million in funding.

The hydrogen production plant projects are led by the HyNet consortium. The Cheshire

According to HyNet, over 95% of the carbon used in the process of producing

BEIS says hydrogen is a low or zeroemission alternative to fossil fuels which could power future industry and transport.

The investment will also fund projects to trial cutting-edge technologies for switching industrial production from fossil fuels to renewables in industries such as cement and glass production.

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12 News Extra

Representative image: Shutterstock

South Korea chemical plant explosion injures 31

A

n explosion at a Lotte Chemical

brought under control and contained by

naphtha crackers in South Korea, producing

plant in Seosan, South Korea injured 31 people on March 4. The blast was caused by a fire at a compressor in the plant’s naphtha cracker unit which has now been shut down.

firefighters after a few hours. A naphtha cracker dissolves naphtha, a flammable liquid made from distilling petroleum, to produce chemical products.

around 2.3 million tonnes of ethylene a year.

The explosion in the northwest of the country happened at around 03:00 local

In a statement, Lotte Chemical said that operations were halted at the plant while an investigation began to find the exact cause

The injured include both workers at the plant and local residents. No deaths were reported. Around 240 firefighters and 38

time and caused a fire which was eventually

of the blast. The chemical company has two

vehicles responded to the incident.

Lotte Chemical suspended seven of its 10 facilities at the plant.

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News Extra 13

Province suggested that hydrogen sulphide gas emissions from an oil terminal in the

Port of Karachi - Image: Wikimedia/Sana Sneha

port may have been the cause of the deaths and illnesses. However, the province’s chemical science laboratory offered a further contradiction and said the deaths may have been caused by methyl bromide, a gas used in the fumigation of large vessels.

14 dead and hundreds fall ill after gas leak in Pakistan

A

There have even been suggestions that the leak didn’t originate from Karachi port at all. In a statement, the Karachi Port Trust Chairman, Jameel Akhtar, said: “All terminals and berths have been checked. Even private terminals, the oil piers, oil installation areas have been checked.

gas leak in the port city of Karachi, on the south coast of Pakistan, has killed 14 people and left hundreds of people sick. The origin of the leak, which

Locals reported that they were experiencing breathing difficulties, chest pains, and burning eyes.

was first detected on February 16, has yet to be determined with local officials giving conflicting explanations as to

The deaths and illnesses all occurred in Kiamari, a neighbourhood situated on the coast of the city near to Karachi’s main port. Schools and

No gas or chemical leakage. If there was a gas leak at the port the first affected would have been the people who work near the court.”

what happened.

factories in the area were closed in response to the toxic gas and Pakistan State Oil temporarily suspended operations at the port. Some officials said that the deaths and illnesses were caused by soybean dust that may have spread

At the time of writing in March, government officials are still yet to make an official statement about the incident.

Some officials said that the odourless gas was coming from the city’s port. Scientists and chemical experts from the army and navy were brought in to help find the source of the leak. Local hospitals said that around 650 people had been treated for sickness with

during an unloading operation at the port.

Contradicting those reports, the

The contradicting reports and theories coming from federal and provincial officials have fuelled demonstrations, with some locals suggesting a

some being taken to intensive care units.

Environmental Protection Agency of Sindh

cover-up was taking place.

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14 News Extra told a news conference that the $53 million fine was by-far the largest imposed

Image: National Transportation Safety Board

since the introduction of the Pipeline Safety Act in the 1960s. Lelling said that following an investigation into the incident in 2018, it was clear that Columbia Gas of Massachusetts had acted with a flagrant disregard for the safety of the public.

Authorities won’t be criminally prosecuting any individuals.

Lelling said, “Sometimes you just have a complete organisational failure, in which you have generally well-meaning people

US gas company pleads guilty to violating safety laws, agrees to pay record $53 million fine C

working inside a company that has not bothered to implement procedures to maintain safety. That is what you have here.”

As part of the plea deal, prosecutors will not pursue charges against NiSource and all profits from its sale of Columbia Gas to Eversource will go to the government.

A third-party will monitor the gas utility until the sale is finalised.

In a statement, Columbia Gas said, “We take full responsibility for the tragic events of September 13, 2018 that so impacted our customers throughout the Merrimack Valley. Today’s resolution with the US Attorney’s Office is an important part of addressing the impact. Our focus remains on enhancing safety, regaining the trust of our customers and ensuring that quality service is delivered.”

In October 2018, the National

olumbia Gas of Massachusetts, a subsidiary of utility group NiSource, has agreed to pay a $53

pay $143 million to resolve class action lawsuits brought forward by thousands of residents and businesses affected by the

Transportation Safety Board said that an investigation found Columbia Gas was replacing ageing cast iron gas pipes

million fine – the largest penalty imposed under the federal Pipeline Safety Act – and to sell its business in the state as a result of the September 2018 gas explosion disaster in northeastern Massachusetts which killed one person and injured 22 others.

blasts.

without proper safety supervision when high pressure gas flooded the network, causing the explosions and fires.

The series of explosions, which occurred while Columbia Gas was replacing castiron pipe with plastic lines, also destroyed many buildings in Lawrence, North Andover and Andover as well as forcing the evacuation of thousands of residents.

announced that it had made a deal with Eversource Energy, a New England based electric services company, to sell Columbia Gas. Andrew E. Lelling, the United States

and another settlement between Columbia Gas and the family of a teenager killed during the gas explosions. The settlements were part of the $1 billion NiSource has dedicated to addressing the needs of customers, residents and communities

In July 2019, NiSource said it would

attorney for the District of Massachusetts,

affected by the disaster.

www.hazardexonthenet.net

As part of the plea agreement with the US Justice Department, NiSource agreed to undertake its best reasonable efforts to sell Columbia Gas of Massachusetts and end all its gas pipeline operations in the state.

As a result, on February 26, NiSource

The $53 million fine is separate to the $143 million settlement in July 2019, an $80 million deal that NiSource reached with the three communities in May 2019,

16 News Extra

Representative image: Shutterstock

Research reveals tubes and piping are most failureprone components in oil and gas and maritime industries

The research is based on cases from DNV GL’s global network of five

To obtain the data for its research, DNV GL’s laboratory experts applied

laboratories in the United States, Europe and Asia, which specialise in failure investigation. The laboratories identified that, of the components they examined, more than a quarter (27%) of failures occur in tubes and piping, and a fifth (20%) in rotating machinery. Fasteners,

several methods to analyse data and documentation to assess failure trends and predict what components are most likely to fail. This included innovative approaches applying advanced search engine technologies combined with technical subject matter expertise. DNV

and mooring and lifting components also appear in the top five components most prone to failure.

GL continues to enhance this approach with its customers.

Fatigue (30%) and corrosion (19%) make up nearly half of the primary failure types occurring in the cases DNV GL analysed. Brittle fracture, overload and wear are also in the top five.

This systematic analytical approach means high volumes of data can be examined far more rapidly than using traditional databases and spreadsheets.

The accumulation of more and better

R

esearch conducted by DNV GL has revealed that tubes and piping are the most failure-prone components in the oil

“The cost of prevention, monitoring, repair or replacement as a result of these forms of component degradation can run into billions of dollars. Potentially, financial

data and learnings from failures can be applied in the front-end engineering design phase of development projects to engineer more robust assets. During operations, learnings can enhance

and gas and maritime industries. Based on 1,000 failure cases, the research shows that fatigue and corrosion are the

penalties can occur if major incidents and loss of life result from such a failure,” said Koheila Molazemi, Technology and

optimisation of inspection, repair and maintenance for more efficient and safer use of capital and people.

most common failure types.

Innovation Director, DNV GL - Oil & Gas.

News Extra 17

BP quits three trade associations over climate policy, including main US refining lobby

Image: Shutterstock

O

through collaboration, particularly in areas such as safety, standards and training. This

For the AFPM and WSPA, BP found misalignments that could not be reconciled

approach should also be brought to bear on the defining challenge that faces us all – supporting the rapid transition to a low

relating to policy positions on carbon pricing.

BP said it would also be leaving the WEA due to material differences around the

policies and activities with BP’s own positions.

carbon future. By working together, we can achieve so much more.”

federal regulation of methane, as well as asset divestments in the states in which the organisation is active.

The three associations are the American Fuel

Over the past six months, BP has conducted

and Petrochemical Manufacturers (AFPM), the Western States Petroleum Association (WSPA) and the Western Energy Alliance

a review of how key trade associations’ climate-related activities and policy positions align with BP’s positions. Thirty associations

BP has identified a further five organisations with which it is only partially aligned on climate and has communicated these

(WEA). The announcement comes after BP said it was aiming to become a net zero company by 2050 or sooner, as well as to

– concentrated in North America, Europe and Australia – were selected for review and their current and recent policy positions, based on

differences to these associations.

help the world get to net zero.

publicly available information, were assessed.

As a result, they were determined to be aligned, partially aligned or not aligned with

that they would not be renewing their memberships in the AFPM. The AFPM consists of around 300 US and international

BP’s positions.

members, including Exxon Mobil and Chevron.

n February 26, BP announced that it would be leaving the main

US refining lobby and two other trade groups after a review of the alignment of 30 trade associations’ climate-related

Making the announcement, BP CEO Bernard Looney said: “Trade associations have long demonstrated how we can make progress

Last year, Shell and Total also announced

Eight agricultural grain explosions occur in US during 2019

R

esearchers from the Department

to 12 grain explosions in 2018 and a 10-year

the facility,” Ambrose adds. “If there is an

of Agriculture and Biological Engineering at Purdue University in the US have calculated that there were eight agricultural grain explosions in the US during 2019, four fewer than in 2018.

average of 8.5 explosions.

ignition generating spark, maybe due to the malfunction of a machine, friction or an electrical failure can ignite the dust. Although the primary explosion might be quite small, due to the amount of existing dust, the

Kingsly Ambrose, agricultural and biological engineering professor, collects annual statistics on the number of agricultural dust explosions in the US. The results for 2019 show that the eight explosions resulted in one fatality and four injuries. This compares

“There are many substances you might not think are explosive that, under the right conditions, actually are,” says Ambrose.

“When the grain is getting handled or processed, dust gets separated and suspended in the air and settles around

The explosions in 2019 occurred in six different states: three in Iowa and one each in Indiana, Illinois, Minnesota, Ohio and Georgia.

secondary explosions can be catastrophic.”

The best way to avoid grain dust explosions, Ambrose says, is for grain facilities to follow rigorous housekeeping practices, regularly maintaining equipment and providing extensive employee training.

www.hazardexonthenet.net

18 News Extra of Northern Cyprus, which is recognised only by Turkey, and is internationally isolated.

Drillship Yavuz – Image: Shutterstock

At the time, EU leaders warned Turkey to halt its gas drilling in disputed waters or face action from the bloc.

Now, two unnamed individuals have been targeted with travel bans to the EU and asset freezes, Reuters news agency reports. In a

EU imposes sanctions over Turkey’s offshore drilling near Cyprus

O

statement, the European Council said: “These persons are responsible for or involved in planning, directing and implementing offshore hydrocarbon exploration activities in the Eastern Mediterranean which have not been authorised by the Republic of Cyprus.”

Cyprus first discovered offshore gas in 2011 but has since been in dispute with Turkey over

n February 27, the European Union imposed sanctions on two people for their roles in Turkey’s drilling operations off the Cypriot coast. In June 2019, Turkey stoked tensions with the

government of Cyprus have overlapping

EU after it sent a second drillship, the Yavuz, to Mediterranean waters thought to be rich in natural gas where both

areas in Cyprus’s offshore maritime zone, known as an EEZ, fall under the jurisdiction of Turkey or of Turkish Cypriots, who have their

The recent sanctions stopped short of targeting specific companies. The Yavuz drilling ship is owned by state oil and gas

Turkey and the internationally recognised

own self-declared state, the Turkish Republic

group TPAO.

maritime claims.

Turkey, which does not have diplomatic relations with Cyprus, claims that certain

maritime claims. Turkey has been negotiating with the EU for many years about joining the bloc but has run into opposition in recent years with some EU member countries.

Modbus displays

Photo: Øyvind Hagen / StatoilHydro

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10/22/2019 2:09:56 PM

News Extra 19

The Fluor Pilot Plant app - Image: University of Surrey

Google Play Store, or ‘CPE Digital Chemical Plant UoS’ on the Apple App Store.

ChemStor Another app, currently under development, is an open source computer program called ChemStor developed by engineers at the University of California, Riverside.

Improperly mixed chemicals can cause fires and explosions, often when they are inadvertently combined in a waste container.

New apps to help with process safety training

ChemStor draws from an Environmental Protection Agency library of 9,800 chemicals, organised into reactivity groups. Each chemical is given a colour and organised into a graph so that no two chemicals that are able to interact are the same colour.

T

heat exchange and CO2 capture by gas absorption.

ChemStor next assigns all the chemicals of each colour to a storage or waste container after confirming there is enough

developed by the University of Surrey allows users to control a simulated plant environment while another app,

The app allows users to learn about the whole chemical engineering process by operating a digital replica of the real Fluor

space. Chemicals with the same colour can be stored together without a dangerous reaction, while chemicals with different

Pilot Plant. On the app, users can operate equipment such as the main reactor, filter and feed hopper, making decisions like

colours cannot.

controlling flow rates, with an alarm alerting them if they do something wrong.

in the same cabinet or added to a waste container without forming possibly dangerous combinations of chemicals,

Fluor Pilot Plant, a learning space within the Department of Chemical and Process Engineering which gives students access to

The app was developed by Professor Sai Gu’s team in the Department of Chemical and Process Engineering, and is available for

ChemStor determines the configuration is safe. ChemStor also indicates if no safe storage or disposal configuration can be

state-of-the-art equipment that replicates what they will eventually use in industry.

The facility is a fully operational chemical process plant that demonstrates all of the main functions of an industrial plant: chemical reaction, solids handling, filtration,

free in the Google and Apple app stores. It is designed to be used by university students at Surrey and around the world as well as working engineers and school students.

To download the app, search ‘CPE Digital Chemical Plant University of Surrey’ on the

found.

wo new apps could help prepare the next generation of process safety engineers for the field. An app

made by the University of California, Riverside, finds the safest way to store and dispose of reactive chemicals.

The University of Surrey’s app enables students and engineers to benefit from its

If two or more chemicals can be combined

Updates are forthcoming to make ChemStor a user-friendly smartphone app which uses the camera to gather information about chemicals and storage options.

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11/10/201

Digitalisation is king!

Standards 1

1 StandardsStandards 15 21 to the business. But why am I giving you the independent verifier Standards 15 to the business. But why am I giving you the independent verifier basicBut information if, like organisation, with the to thesuch business. why am I giving youmost of the the independent verifier as a “person or a basicBut information if, like organisation, with the to thesuch business. why am I giving youmost of the the independent verifier as a “person or a suchreadership, basic information likefamiliar most of the organisation, with the appropriate compete youif,are with the hazardous in the applied protectio suchreadership, basic information if,are likefamiliar most of the organisation, with the appropriate compete with the hazardous in the applied protectio readership, you areyou familiar with the hazardous in the applied protection methodology, area business? responsible for the verifi readership, you are familiar with the hazardous in the applied protection methodology, business? the verifi area area business? responsible forresponsible the verificationfor of design assessme area business? responsible forcalculations, the verification of design calculations, assessment and testing who calculations, assessme calculations, assessment and testing who I mention these facts to highlight a big issue are separate and distinc I mention these facts to highlight a big issue are separate and distinct by management new technologies for energy supply in to thehighlight If we aestimate the total production and I mention these facts bigare issue aredistinct separate and distinc I mention these facts to highlight a big issue separate and by management for of explosion protected other inc post-fossil fuelmanufacturers age. fossil resources fuelsand during the resources for manufacturers of explosion protectedconsumption andofother including financial, from for manufacturers of explosion protected and other resources inc for manufacturers of explosion protectedlast and other resources including financial, from years, we can or roughly products and systems: they couldthey come into150come the person organisation for products and systems: could into the calculate personresponsible or organisat In order to ensure this high quality, IECEx temperature and ambient temperature o products and systems: they could come into the person or organisation responsible for In Germany, we decided totheir shut down they could that in come totalallmankind has used the energy products and systems: into the person or organisat serious conflict with customers. the activities associated with the designo In order to ensure this high quality, IECEx temperature and ambient temperature serious conflict with their customers. all the activities associa started the Proficiency Test Program (PTP) -40 activities °C)aand two different explosive mixtu nuclear power plants following the equivalent ofestablish 700 billion people!

Compared conflict with customers. the associated with the design equipmentall mobile worker The serious common reply to thesetheir concerns serious conflict with their customers. the associa manufacture orall sales ofactivities the explosive equipment.” started the Proficiency Test Program (PTP) -40 °C) and two different mixtu The common reply to these concerns equipment establish a mobile worker Fukushima disaster in 2011.

Now, Germany with the estimated figure of 100 billion manufacture or sales for ExTLs in 2010.

The idea behind this is to (ethylene & hydrogen) selected accordin manufacture or sales of the equipment.” o concept for process plants, including is – don’t worry too much.

Apparently, On the one hand, end users will not accept a manufacture or sales o for ExTLs in 2010.

The idea behind this is to (ethylene & hydrogen) selected accordin is – also don’t worry too much. concept forareas. process plants, including has decided tonew shutjobs down its coalpeople ave lived, this is an select aone type test as itApparently, is defined in a accept certain IECever 60079-1. hazardous there willthe be many available forusers On hand, end users will not a who On the one hand, end will not accept a(equipment situation in which they can establish modern For EPL protection level) “a”, th select a type test ashand, itavailable is defined in a certain IEC 60079-1. there will be new jobs forusers hazardous areas. fuelled power stations by 2038.

The idea impressive figure.

But what does this the one end will not accept a(equipment people in-On the age of digitalisation.

Aestablish study IEC TCmany 31which standard (IEC 60079 – XX) and situation in they can modern For EPL protection level) “a”, th in the which they establish For EPL pro digitalised processes and procedures inand the tell modern evaluation the people inIT the of digitalisation.

A study behind this is age to31 provide majority of can figure us?

It meansofthat if equipment wework wantin(equipment to has to be don IEC -situation TC standard (IECsuggested 60079 – XX) If questions emerge the by adigitalised UScreate consultancy to standardised andprocedures calibrated test On theduring basis ofequipment two configurations the situation inrecently which they can establish modern For EPL (equipment pro processes and in the evaluation of the has to beofdon by asafe UScreate ITdigitalised consultancy recently suggested Ifthe questions during the work in German power by renewable continue comfortable in the future, areas of so-called theirprocesses plants, cannot by three verifiers, for EPL andbut procedures inemerge thethe evaluation of the equipm to and calibrated test On basislives of two configurations of“b” the plant,our experts orindependent supervisors can several new jobstandardised profiles inprocess this brave new samples for this test.

The samples are than Test Sample “EP” two explosive mixtures safe areas of their process plants, but cannot by three independent verifiers, for EPL “b” digitalised processes and procedures in the evaluation of the equipm several new job profiles inofthis brave new the plant,toexperts or the supervisors can sources, i.e. wind and solar power (due to we have increase efficiency of our apply the same technologies in hazardous two, and for EPL “c”, one independent ver be contacted, pictures can be taken world including designer aero taxis, samples for this test.

The samples are than but cannot Test Sampleby “EP” two explosive mixtures safe areas of their process three independent sent tothe thesame ExTLs which have makeplants, the two ambient temperatures and five igniti apply technologies intohazardous two, and for EPL one independent verv world including designer ofhave aero taxis, be contacted, pictures can be“c”, taken our geography we doof not significant power supply chains significantly, reduce of their process but by three independent v the job is done, planner stadiums, smart–home areas because awhich lack of applicable modern iscannot enough. sentofsafe toe-sport theareas ExTLs have to makeplants, theand transmitted. two After ambient temperatures and five igniti apply the same technologies in hazardous two, and for EPL “c”, o type test with their equipment and send the each, a total of 40 explosion tests must planner of e-sport stadiums, smart–home and transmitted.

After the job is done, resources of water power).

So far, so good the amount of waste dramatically, and we areas because of a lack of applicable modern is enough. thehazardous new data can be uploaded easily designer specialist forset databy the safety products due to restrictions apply the same technologies and for EPL type and testrecycling with their equipment and send in the each, auploaded totaltwo, of 40 explosion tests“c”, musto designer and recycling specialist for data the new data canperformed be easily (but not inresults agood! physical have todatabase. find a be new carrier for all the energy test to asense). notified authority.

IECEx, by each participant for the products due to restrictions set byAt the safety areas because of a lack of applicable modern is enough. to the No more paperwork is trash.

Very But are these jobs realistic standards.

On the other hand, manufacturers The first two years after the introduction of test results to a notified authority.

At IECEx, be performed by each participant for Every two months, Prof. Dr. Thorsten Arnhold, areas because of a lack of applicable modern iswork enough.

Every two months, IECEx Chairman trash.

Very good!

But are these jobs realistic to the database.

Notwo more is introductionthe we need. the German PTB isother this authority, and “Explosion Pressure”. necessary, theprogram efficiency ofpaperwork increases alternatives for forklift and truck drivers orcreating standards.

On the hand, manufacturers The first years after the of Everytwo twomonths, months, IECEx Chairman Prof.

IECEx Chairman 2014-2019, provides Every IECEx Chairman Prof. products due to restrictions set by the safety Every two months, IECEx Chairman are obliged to fulfill these safety standards, this new procedure were quite a surprise.

N thehands?

German PTB isGermany this creatingnecessary, and program “Explosion Pressure”.

Prof.

Dr. Thorsten Arnhold provides alternatives forklift and truckauthority, drivers the efficiency of work increases Too often weforforget that isand notor Every twoon months, IECEx Chairman Prof.

Dr.update Thorsten Arnhold provides an the update dramatically and sources of failure are factory Every two months, IECEx Chairman Prof. an developments within products due to restrictions set by the safety producing the test samples evaluating the are obliged to fulfill these safety standards, this new procedure were quite a surprise. N Dr. Thorsten Arnhold provides anprovides update Prof.

Dr. Thorsten Arnhold Dr. Thorstenon Arnhold provides an update an update developments within which are defined by the IECEx CB asked for a are scope and onThorsten developments within his organisation. dramatically and sources ofThe failure hands? standards.

On thedocuments other hand,Now, manufacturers first years after afactory typical sunshine most of the evaluating to my preferred topic andtwoextension producing thestate testand samples and theI come organisation.

Dr. Arnhold provides anChairman update removed. on within his organisation. organisation.

Every two months, After feedback from ExTLs, a test results. an update on developments within which are defined On by the documents IECEx CB asked for first aparticipating scope extension and ondevelopments developments withinIECEx his standards. the other hand, manufacturers The two years after his organisation removed. on developments within his organisation. mentioned above. as a result, no certificates were published. wind can just be harvested offshore.

To the reason why I am writing this column Every two months,Arnhold IECEx Chairman After feedbackthis fromnew participating ExTLs, a testthese results.

Despite concerns, Ito cannot deny the safety standards, are obliged fulfill these procedure wer hisDr. organisation Prof.

Thorsten provides statistical evaluation of the results is carrie mentioned above. as –a hydrogen result, noiscertificates were published.

Despite these concerns, Ito cannot deny the safety or the last few weeks, coronavirus buffer the volatility of both energy sources, for Hazardex the solution! are obliged fulfill these this new procedure wer the last year, however, the situation must confess that I am not totally Nostandards, wonderDuring that process industries are fact that we can expect many benefits from Prof.

Dr. Thorsten Arnhold provides statistical evaluation of the results is carrie an update on developments within Germany which arehuge defined by seven the documents IECEx CB asked fortoajois ne of the dominating most frequently asked out.

The are than invited In the meantime, the following programs During theparticipants last year, however, the situation must confess that I am not are totally fact that we can expect many benefits from No wonder that process industries are been both political would need storage Hydrogen an energy content of 33.3 convinced all the supposed so eager tohas introduce these new systems digitalisation inbeen the hazardous area sector. t has theof present time, there few This has a major concern for documents IECEx. changed significantly.

Now we havefor more an update on developments within are defined by the IECEx CB asked ne theofmost frequently asked out.

The participants are than invited toajoist In thewhich meantime, the following seven programs his organisation question at IECEx conferences and workshop in which the results are present have been conducted or are still running: convinced of alltime, the supposed digitalisation the hazardous area sector. so eager tochanged introduce these new systems t the present there are few This mentioned has been a major concern for IECEx. significantly.

Now we have more t agendas and media headlines capacities.

A in good image to visualise this kWh/kg which is and almost 3 times higher above. as agood. result, no certificat blessings of digitalisation.

During my into their plants, so far, so conferences or technical trade Three years ago, at its annual Management 10 Ex CBs and Ex TLs with a respective sc his organisation question at IECEx conferences and workshop in which the results are present havementioned been conducted or are still running: above. result, certificat blessings digitalisation.

During my into their plants, and far, so good. around theofworld.

ForItechnical me, crisis is that if Germany built aat pumped-storage than the energy content of as 1kg of crude similar events is about thethe difference andExdiscussed.

Ana important part of thissc conferences or trade Three years ago, its annual Management 10 CBsso and Ex TLs with ano respective professional career, have visited However, these shiny new possibilities At its most basic, to keep standards During the last year, ho • Spark Ignition Test for Ex “I” Test Round 2010 shows that do is not havethe thedifference Industrial Committee Meeting in The Hague, the extension and a An number of applications. similar events about and the discussed. important part of this professional I in have visited At itsCommittee basic, toTest keep standards However, shiny new possibilities is clearly showing both the global plant to cover thefor whole Remember energy equivalent of applications. last ho workshop is training to the achieve ayear, common between ATEX andhave IECEx. worries – power •most Spark Ignition Ex whole “I”country’s Test the Roundoil.

2010 shows that docareer, not theNo Industrial Meeting in The Hague, extension and aDuring number of many manufacturers many different can make these you forget that all these of safety high throughout the Internet of Things (IIOT) as the main organisation launched a new procedure to • Flame Transmission for Ex “d” Test Round 2013 tbetween the present time, there are few– energy This has been awhole major concern formake IECEx. significantly.

N workshop ismen training to achieve a common ATEX and IECEx. No different worries many manufacturers inworld many of safety high throughout the in can you forget that allchanged these interdependencies and vulnerabilities needs during the night and windless crude being 16are strong for a year? industries all over the and smart devices powered by electrical operational life of equipment these understanding of the best working practic It don`t want to give a lecture about this Internet of Things (IIOT) as the main organisation launched a new procedure to • Flame Transmission for Ex “d” Test Round 2013 the present time, there are few operational This has been a general majorstandard. concern for devices IECEx. changed significantly.

N focus.

One of the most important adopt the new IEC 60079-33 This A look in the IECEx online database shows • Temperature Classification Test Round 2013 industries all over the world and life of equipment in these smart are powered by electrical of our societies. days, it would require a storage facility With hydrogen, that figure is tripled.

Even if understanding of the best working practic I don`t want to give a lecture about this conferences or technical trade years ago, at itsstandard. annualThis Management 10 Ex CBs and Exshows TLs mostnow. of those with the highest levels energy, normally stored inIECEx batteries.

As adatabase it isThree necessary to conduct regular topic Itofisthe not so obvious but there areas, focus.

One most important adopt the new IEC 60079-33 A look in the online • Temperature Classification general Test Round 2013 conferences or technical trade years ago, at its“s” annual Management 10 than Ex CBs and Ex TLs most of those with the highest levels areas, it isThree necessary to of conduct regular energy, stored in batteries.

Asmeet acertificates consequences of this trend arebut the covers thethe protection method forRound “special”, already more 20 base a• capacity size Lake Constance we take normally thethat 30% power consumption away topic now.

It is not so obvious there with Electrostatic Charge general Test 2015 of that automation continue tointerested employ consequence, products have to inspections and maintenance.

But those shows do not have the Industrial Committee Meeting in“s” The Hague, thethat extension and aPressure numbe are many differences.

For The those workshop for than the Explosion consequences of this trend are the covers the protection method for “special”, already more 20 certificates base • Electrostatic Charge general Test Round 2015 of automation continue to employ inspections and maintenance.

But those consequence, those products have to meet Sometimes Inumbers think aofFor little more (Bodensee) lifted tohave around 800m high. for the liquefaction or the pressurisation ofpublished, drastically shrinking value chains and which was introduced to permit theRound quick 60079-33 been an shows that not that have the Industrial Committee The Hague, theon extension and aPressure numbe significant manual all requirements which electrical products responsible might toMeeting manage a in couple are manydo differences. interested TheIEC workshop forhave the Explosion • Intrinsic Safety Test 2015 readers I can recommend the IECEx 01A Program took place in June 2018 at the drastically shrinking value chains and which was introduced to permit the quick on IEC 60079-33 have been published, an Internet of Things (IIOT) as the main organisation launched a new procedure to significant numbers of manual responsible might havecovered to manage a couple all requirements which electrical products consideration of “oldin values” and a littleand the hydrogen gas, we still haveareas 32 strong • Intrinsic Safety Test Round 2015 innovation cycles every sector, adoption of new technologies, new materials am confident that many others will follow. workers, whether in production, intended for use in hazardous have of thousand products by ‘Ex’ or readers IThings can recommend the IECEx 01A Program took place in June 2018 at the Internet of (IIOT) as the main organisation launched a new procedure to • Explosion Pressure for Ex “d” Test Round 2017 PTB in Braunschweig, Germany, and 80 Guide: “An Informative Guide comparing innovation cycles ininevery sector, adoption ofstandards, new technologies, new materials amuse confident many others will follow. workers, production, of thousand products by ‘Ex’ or intended for in hazardous areas have more control oflogistics. the worldwide traffic of and men left. Hydrogen and allthat products transport or to2017 fulfil. safety focus.

One ofwhether the important adopt thecovered new IEC 60079-33 standard.

This Athelook in the IECEx onli • Explosion Pressure for Ex “d”when Test Round especially in the most process industries. etc.

This implements aand practice which has PTB in Braunschweig, Germany, and 80 Guide: Informative Guide comparing functional • Pressurised Enclosure for Exwhen “p”60079-33 est Round 2017 transport orthe logistics. safety standards, and to fulfil. focus.

One“An of most important adopt the new IEC standard.

This A look in the IECEx onli various elements of both IECEx participants from international ExTLs joine persons and products could be goodand for ATEX”functional which can be produced out of it, such as Establishing especially in the process industries. etc.

This implements a practice which has paperwork is involved, this can often prove been field-proven in the ATEX For IECEx, this development ismore recognition • Pressurised Enclosure for Ex “p” area est Round 2017 consequences of this trend are theATEX”paperwork covers thethis protection method “s” for “special”, that already than various elements of both IECEx and participants from international ExTLs joine is involved, can often prove the balance of our liberal life.

On the other Methane, Methanol, synthetic fuels etc., are which can be downloaded from the IECEx this event.

In the eight years the program been field-proven in the ATEX area For IECEx, thisthat development ismore recognition Every day we of seethis tens of thousands IECEx we have recognised these an impossible task. consequences trend are the covers the protection method At “s”IECforand“special”, already than h such huge, new In process facility safe areas, thethe speed since 2003. that its we focus this area hasthe been useful which can be downloaded from IECEx this event.

In on the eight years program h Every day we see tens of thousands an impossible task.

At IEC and IECEx have recognised these hand, if I remember my previous stay in all flammable and explosive. drastically shrinking value chains and which was introduced to permit the quick on IEC 60079-33 have ofprocess trucksunder onfacility ourPublications highways driven the by speed their importance for thethat website beenand wethis have seen the quali As an 2003. illustration of the program, here is aspecific short issues In safe areas, since that itsrunning, focus on area has been useful drastically shrinking chains and which wasofintroduced to permit the quick onhigh IEC 60079-33 have of adaptation to thisvalue trend is restricted the industry and levels ofthat safety will be hydrogen supply of trucks on our highways driven by specific issues and their importance for the website under Publications been running, we have seen the quali As an illustration the program, here is a short Shanghai last October, I think that even and drivers. market.

Wethe have established afrom special IEC however, thanks tochapter digitalisation, innovation cycles in every sector, and Now,description adoption of new technologies, new materials am confident that many our test has and risen a satisfactory level of one of the 2017 Test ofexperienced adaptation to responsible this trend is restricted industry high levels of safety will be byextensive the innovation the suppliers and the Now, Under the ATEX directive, the fulfillment of maintained. experienced and in responsible drivers. however, thanks tochapter digitalisation, market.

We have established afrom special IEC that many control the country would not There currently an annual global hydrogen innovation cycles inof every sector, and adoption of newbe technologies, newis materials am confident our test has risen aon satisfactory level description of one of the 2017 Test In the supermarket, I am happier to pay working group to deal with questions equipment in hazardous locations is chains cannot a the beginning to an excellent level today.

What I want to highlight in this article is the Round: by the innovation of the suppliers and the Under the ATEX directive, the fulfillment of maintained. especially inand thetechnical process industries. etc.

This implements a practice which has In supermarket, I aminhappier pay in hazardous locationsofisappendix working group to deal with questions onbe level today. have the outbreak ofarticle thetodisease. production of around 50 million financial capabilities of the equipment the general requirements II with thethe cashier directly rather than attempt how modern mobile digital devices can becoming smart.

What I prevented want to highlight this is the the beginning to antonnes. excellent Round: especially in the process industries. etc.

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Split Croatia on 23 April 2018, to held global challenge basis.

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The Proficiency Test Program The Proficiency Test Program Hydrogen is the solution for for ExTLs ExTLs -- a a key key trust-builder trust-builder within within the the IECEx IECEx system system

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22 Offshore

Improving safety and effi in the ever-evolving STS trans S

hip-to-ship (STS) transfer is becoming increasingly popular throughout the shipping industry, opening up new trade routes and making new and more efficient logistics processes possible. Most of the headlines have tended to focus on large, milestone transfers, such as

stated at the end of 2018 that it had transferred nearly 2,334,000 barrels of oil in the Gulf of Oman by STS within its first six weeks of operation, and opened new premises in the region in

One of the main forces driving demand is

This trend of using larger ships to reduce the cost of transporting liquid cargo, is evidenced in the sharp increase in the number of Very Large Crude Carriers (VLCCs). VLCCs are used to transport oil across oceans at a lower marginal cost, but are too large for most ports and some key channels – including much of the Gulf of

Scheldt River performing the first STS LNG bunkering operation in German waters last year; these underpin an

logistics efficiency. It is more efficient to use a very large ship to transfer liquid cargo for the bulk of a long journey, and transfer cargo

Mexico. The economics of this have led to a boom in STS oil transfers taking place, often in designated STS locations designed to

ongoing, significant rise in the number of STS transfers taking place. This rise in oil transfers is evidenced by

to another, smaller ship either when draught restrictions require a smaller ship or if there are multiple offload points for the cargo at

cope with the rise in demand.

SafeSTS Middle East FZE, which

several ports.

be a particularly complex process. There

www.hazardexonthenet.net

November 2019.

Despite the clear benefits, STS transfer can

ficiency sfer sector

Offshore 23

are very real risks of a spill or a fire if an STS transfer is poorly planned or executed.

to raise standards across the industry by contributing their expertise as much as their

It requires proper planning, coordination, equipment and approval to perform a transfer safely and ethically. There are clearly risks associated with operating equipment between two independently moving ships at the best of times, so planning must

products.

mitigate the risks of hazardous weather and hose management must mitigate the risks associated with the stresses exerted on the equipment by the external pressures alongside the internal pressure associated with the transfer.

efficiency, safety and ease of operations are heightened, while equipment must be rated to safely and efficiently operate in the face of environmental challenges.

In any liquid cargo transfer, equipment must improve both efficiency and safety while functioning in a way that is easy for a crew to operate. In STS transfers the need for

Hose solutions for oil and LNG STS transfers

A 2018 incident involving a faulty hose highlights the dangers of poor hose management in STS transfers. In that

require different specifications and features to ensure safety and efficiency due to their relative temperatures and viscosities. There are design philosophies whose benefits

incident, a faulty hose ruptured and sprayed oil on deck and overboard, raising serious questions around the safety and operability standards of STS transfers around the world.

cover both LNG and oil. These designs are based on technology originally developed for truck tyres, with the internal carcass providing resistance to the internal pressure,

The UK P&I Club, investigating the incident, noted that the hose used was not provided with valid records of test and inspection

and the outer carcass providing resistance from the external pressures and loads inherent in STS transfer while preventing

which contributed to the failure of the hose.

The Club issued a recommendation stating that all cargo hoses must be fit for purpose and provided with valid records showing

leaks. This enables the hose to withstand accidental kinks or crushing forces that can occur during the process, and different designs using this philosophy create

that they have been appropriately tested and inspected.

bespoke solutions for both LNG and oil transfers that optimise safety and efficiency.

The incident demonstrates the need for all parties involved in an STS transfer operation to ensure that the process is conducted

Overcoming specific challenges in LNG transfer

safely and efficiently. The investigation additionally highlighted the need for suppliers to ensure that they are helping

transfers, especially in open seas. LNG needs to be kept at a low, cryogenic temperature which in itself can cause wear

LNG poses a unique challenge in STS

www.hazardexonthenet.net

24 Offshore to some hoses. It also creates new risks in transfers, as any spillage is dangerously cold

at -196 °C / -321 °F – demonstrating their ability to withstand fatigue resistance in even

transfer, this is multiplied by the external pressures exerted on the hose as two ships

and rapidly changes state into an extremely flammable gas. Additional measures are required to ensure that a hose is more durable, and that there are adequate failsafe systems in place to capture and funnel off any leaked LNG.

the most hazardous conditions.

move independently of each other and by accidental kinks or knots in the hose.

This is why so much effort has been spent in developing robust means of safely loading and unloading LNG in STS operations. One example is floating cryogenic hoses, where vessels can be moored as much as 100

Boil-off gas generation during transfer presents another challenge for operators in offshore conditions, often causing valuable energy loss during the transfer process.

Technology has therefore been developed with insulated hoses that can reduce boil-off by as much as 60% – equating to a saving of 10 billion btu’s of energy saved over the course of 500 transfers.

STS oil hoses are typically qualified to the EN 1765 standard, however some hoses are qualified to the higher GMPHOM 2009 standard. This standard requires more indepth testing – including for higher torsion loads and pressures – and means that the hose has a longer than typical service life.

A higher level of assessment provides a superior level of certainty and confidence

to 300 metres away from a storage unit, allowing for STS transfer in deeper waters in even the most challenging conditions.

Overcoming specific challenges in oil transfer One specific challenge when it comes to STS oil transfer is how to handle internal

when it comes to STS transfers, in line with best practice regulations, alongside better performance indicators offering more accurate estimates of service life and

During the development of our Cryoline hosein-hose technology, several full-scale hose prototypes were successfully tested in both static and dynamic conditions – with most

pressure on a hose. Internal pressure can cause a hose to wear or rupture quickly, which in turn can cause a serious accident that either endangers crew or discharges

resistance. Capital expenditure investment in this higher specification ensures smoother operations, less expensive maintenance, and ultimately fewer expensive replacements

tests taking place in cryogenic conditions

oil into the environment. In an STS oil

over a project’s lifespan.

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Offshore 25

Standard STS oil transfers use hoses with nipples connecting sections of

The nippleless hose design philosophy used in these hoses been constantly updated since

the tube. These long metal connectors create a sudden change in hose flexibility which concentrates bending stresses in particular, increasing the risk of failure. To combat this risk, the KLELINE STS hose has a unique nippleless design.

1975 and used around the world in offshore projects. The technology is now poised to have the same impact in improving safety and reliability standards in the STS market.

About the author

As suppliers, it is our duty to ensure that we

In contrast to a standard nipple hose design, there are no large, stiff metal connectors. Instead metal connectors between sections of hose are kept very compact compared to a nipple-design

are helping to raise standards across the industry. As experts, it is our duty to contribute our expertise alongside our products.

Particularly in hoses, investing in higher specification products has a big impact; reducing the need for maintenance, increasing

hose. This makes the hose more flexible, while the continuous inner liner and integrated gasket create a perfect sealing solution. The design means that there is

operability, and lessening the number of costly replacements over the lifecycle of a project reduces operational expenditure alongside reducing risk of accident. As the industry

no need for gaskets at each connection, increasing the simplicity of installation, resulting in a hose that can withstand stresses and strains for longer.

evolves, it is crucial we continually evaluate the long-term effectiveness of oil transfer solutions at each part of the value chain, along with operability.

Nicolas Landriere is Product Manager for Trelleborg’s oil hose applications, providing technical support to new and existing customers and expert advice throughout the various stages of each project. As a technical specialist for hoses and offshore offloading applications, Nicolas also contributes to the development of new products.

www.hazardexonthenet.net

26 Valves

Using position transmitters on automated valves for enhanced efficiency and safety O

ver the past 30 years, globalisation, pressures on costs and the desire for greater efficiencies

function. Control valves will typically employ a Positioner to initiate a valve movement and potentially a Position Transmitter to

applications. This potential safety impact has accounted for some developments in On/Off valve technology, particularly in

have led to a significant reduction in manpower and an explosion in the automation of processes. Increased

confirm valve position matches required position. On the other hand, an On/Off Valve will connect using a Solenoid Valve

the area of diagnostic methodologies (for example Partial Stroke Testing). Generally, On/Off valves have seen relatively few

automation has allowed plants to operate more efficiently and, importantly, more safely.

to allow a change in a digital output status in the PCS to operate the valve and a Limit Switch Box to confirm the valve is in the

developments.

required position.

Reasons for using Position Transmitters on valves

As the requirement for automation has

Many operators have recognised that the use of independent valve position feedback

effect on the nature of valves supplied into the sector. At plant level, there has been a move away from manually operated valves to automated valves where valve actuators move a valve in response to a condition change within the Plant Control System (PCS).

increased, significant resources have been allocated to Control Valves, particularly with the advent of smart positioners. In contrast, the Position Transmitter on a Control Valve has been largely overlooked and hence many control valves suffer performance issues solely because of the limitations of the position feedback mechanism. Similarly,

transmitters (IVPT) could offer operational benefits to their plant when employed on valves. Benefits include: • Independence from Valve Positioner to limit common fault issues in the control loop • Independent valve position verification to enhance control accuracy

Whilst the functions of the valve and valve actuator are fundamentally the same regardless of whether the automated valve is being used for control (modulating) or for On/Off operation, the equipment that interfaces between the control room and

because On/Off valves are often viewed as less critical than control valves resulting in reduced technological development. On/ Off valves that fail to perform can have a significant effect on both plant productivity and plant safety particularly when

• Increased valve reliability • Constant feedback ensuring the actual status of the valve is known • Reduced I/O requirements • Diagnostic alarms if irregular movement is observed

the valve differ depending on the valve

employed in Emergency Shut-Down (ESD)

• Predictive maintenance

The increased usage of automation within process industries has had a significant

www.hazardexonthenet.net

Valves 27

All too often, these potential benefits are not fully realised because of the poor product

Easy set up

options available for IVPTs and the selection of the wrong type of transmitter.

requiring the use of tools or a laptop to complete the setting of zero and span.

Smart IVPTs simplify the calibration by allowing the user to calibrate through push buttons built into the transmitter unit. In addition, where the smart IVPT is equipped

The common problem The vast majority of Position Transmitter products currently available use a

Traditional IVPTs are often tricky to calibrate,

potentiometer. Whilst a relatively cheap and fast acting device, potentiometers have several limitations when used on valve applications. Potentiometers are susceptible to wear and liable to contamination from foreign particles such as dust, sand or

with the ability to interface with a digital protocol such as HART, the device might also be calibrated remotely.

water. In addition, they are easily affected by vibration, are tricky to set correctly and will often need their resistive signal converting to either a Voltage or Current feedback input.

electronics can have very slow update rates which compromises their effectiveness.

Smart IVPTs have fast update rates, typically in the range 50 to 100 ms.

The signal conversion is typically performed by a Control Card or an Electronics Module.

Whilst providing the interface (typically 4-20mA) and the instrument calibration

Fast update rates Traditional IVPTs, particularly those using

Valve specific characterisation When mounting a rotary transmitter on a linear valve, a non-linear output is

facility required, these conversion products will have their own limitations.

often generated due to a linear to rotary conversion kit being used. Smart IVPTs have recognised this issue and provide the

These issues, along with those encountered with other transmitter technologies (such as Hall Effect Sensors and Optical Encoders) are often not

means to adjust the output from the device.

For example, one transmitter is available with the ability to set up to 20 intermediate feedback points to linearise the output.

appreciated by the plant operator until the product is already in service and performance is not as expected.

Diagnostics Smart IVPTs put intelligence in the field

A few specialist companies providing

device. Some transmitters analyse the stroking speed of the valve every time it moves and compares this information with

Valve Position Monitoring solutions have recognised both the potential benefits to plant operators for using IVPTs on valves but

a stored ‘as new’ profile of the valve. These devices are then capable of sending a warning signal via the HART communication

also the severe limitations of the products currently available. For this reason, new ‘smart’ solutions, designed specifically for

interface, flagging when the valve has started to slow down by a user defined amount.

valve applications, are now being offered that solve the traditional issues of IVPTs and enable plant operators to maximise their

Conclusion

The way forward

returns from these devices. So, what is different about these smart IVPTs?

With the ever increasing need to improve

The new generation of smart IVPTs employ

plant efficiency and safety, Independent Valve Position Transmitters provide a simple and cost-effective method to deliver these demands. However, it is critical that the right IVPT technology is selected to

more robust feedback mechanisms. For example, some use inductive sensor technology in non-contact, solid state feedback devices that are both highly accurate and largely impervious to challenges presented by the environment in which they operate.

eliminate the issues traditionally found with these types of products. By employing the latest generation of ‘smart’ IVPTs, plant operators are able to dramatically improve their efficiency and safety by gathering information on valves that permits targeted preventative maintenance.

Feedback technology

About the author

Paul Turner is Engineering Manager and a Director of Imtex Controls and has worked there for nearly 30 years.

Paul is based in the Deeside Factory and is instrumental in developing Imtex’s range of products, as well as providing bespoke solutions to help with specific customer or market challenges.

www.hazardexonthenet.net

28 Fire detection

Updating flame detection and releasing sy industrial plants that make or use energetic mater E

nergetic materials are defined as those with a high amount of stored chemical energy that can be released.

involve large amounts, while the processes – filling shell casings or pressing materials into forms – can cause a rapid deflagration

Materials classes included are explosives, pyrotechnic compositions and propellants. For manufacturers

of the materials that requires an immediate response.

that handle these materials, time is critical for dealing with events that may endanger personnel and property.

Similarly, the materials used to activate automotive airbags may be present in significant quantities near airbag

Process control setups in these facilities must include systems that respond in milliseconds when certain

manufacturing machines. If these energetic materials catch fire, damage can result to the process machinery

materials catch fire, because of their potentially rapid burn rate and the damage that may result should the materials ignite.

This article, by Mike Hosch of Det-Tronics, looks at the components of ultra-high-speed flame detection and releasing systems and explains why plant managers and safety engineers should consider upgrading to the latest versions of these systems.

Figure 1 – Because there is little international code guidance available for the ultra-highspeed industry, US codes can be applied to these systems

to detect a flame in its incipient stage and then quickly apply large volumes of water to extinguish or help to control the spread of the fire. Facilities that require these systems are those that use, process and/

Energetic materials are also a danger in plants that fill aerosol spray cans. To make spraying possible, a propellant is added to the mixture inside the can. If a can isn’t sealed properly during the manufacturing process, a cloud of propellant can form in

In hazardous manufacturing settings,

Not surprisingly, a major user of energetic materials is the munitions industry. Machines

the air near production machinery – which can possibly ignite and start a large flash fire. In a case like this, it’s important to stop the machine as quickly as possible so more propellant isn’t released into the environment causing the situation

ultra-high-speed fire systems are designed

that process energetic substances often

to propagate.

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or manufacture “energetic” materials such as explosives, gunpowder, propellants and pyrotechnic compositions.

within the plant.

Fire detection 29

Atmospheric Opacity

The Electromagnetic Spectrum

Figure 2 – A broad view of the electromagnetic spectrum depicting the infrared (IR) and ultraviolet (UV) regions that are favourable for the detection of flame

ystems: What rials need to know

the flame detector to an initiating device

(NRTL). For instance, UFC-3-600, 9-18.12

circuit of an ultra-high-speed fire system can help reduce the potential damage to the facility by increasing the speed with

requires panels used for fire suppression system control or release to be listed by a NRTL. Another example is NFPA 72: 2016,

which the system can respond.

23.11, which requires releasing devices for suppression systems to be listed for use with releasing service alarm.

Applicable codes and standards Energetic material manufacturing environments aren’t the only places where ultra-high-speed fire detection can

There is little international code guidance available for the ultra-high-speed industry.

In the United States, codes that address

Besides being designed for reliable performance at a critical time, fire-protection equipment listed by an NRTL has been

help avert disaster. Consider high-voltage direct current (HVDC) electric power transmission stations, which house

requirements for ultra-high-speed flame detection and releasing systems include: • Unified Facilities Criteria: UFC 3-600-01,

approved by a third party. Properly accredited third-party testing and certification provides potential users with an independent

large transformers and switch gear.

If a fire breaks out at an HVDC station, it’s imperative to shut down the equipment as quickly as possible so that large amounts of voltage and current are stopped as quickly as possible to prevent further damage to the equipment. For this reason, ultra-highspeed fire systems may be connected to

Fire Protection Engineering for Facilities.

This code applies to facilities that are owned by the United States federal government.

• National Fire Protection Association: NFPA 15, Standard for Water Spray Fixed

through a paint booth, a spark from static electricity produced by paint moving through the spray nozzle may direct fire at the vehicle along with paint. The applicable standard in this case requires that flame detectors respond to such a fire within 500 milliseconds. Connecting

safety and performance criteria.

Over the last 30 years, codes and standards

Systems for Fire Protection, and NFPA 72, National Fire Alarm and Signaling Code.

related to fire protection in industrial settings have evolved and are now more stringent.

These codes and standards cover important

NFPA 15:2017 Chapter 12 states that an ultra-high-speed flame detection and releasing system must respond in no more than 100 milliseconds (a tenth of a second)

topics such as the supervising of system inputs and outputs (I/O). In addition, system requirements such as those for protection from electromagnetic and radiofrequency interference (EMI/RFI) are more stringent.

the shutoff equipment in these stations.

Another possible application for ultrahigh-speed fire systems is in automated vehicle paint booths. As a vehicle moves

and unbiased product evaluation. A number of independent organisations test fire protection equipment using documented

from the presentation of an energy source at the detector to the flow of water from the deluge nozzle.

The codes and standards also require fire alarm systems to be “listed” by a Nationally Recognised Testing Laboratory

In countries where no specific codes and standards for ultra-high-speed fire systems exist, the aforementioned US standards can provide guidance on good engineering practices and what constitutes an effective fire-protection system. Facilities that have

www.hazardexonthenet.net

30 Fire detection determined that an ultra-high-speed fire system may be beneficial within the application may find that US codes and standards for ultra-high-speed fire systems can help to provide guidance for system design attributes.

UV sensor

UV sensor

A look at the systems Typical components of ultra-high-speed fire systems include flame detectors, a central control system, a solenoid, a pilot-operated valve, a pre-primed deluge piping system with nozzles, and a water supply.

respond in a matter of milliseconds.

In addition, the solenoid takes time to

UV and UVIR Optical Flame Detection

relieve the pilot pressure from the deluge valve. Lastly, water requires time to travel out of the nozzle.

IR sensor

To optimise the speed of response: • Detectors designed to detect the

Figure 3a – Both UV and UVIR optical detection technologies are capable of detecting flames rapidly enough for use in ultra-high-speed applications

spectral emission of the material of interest should be considered • Detectors should be installed as close as possible to the potential hazard • All air should be purged from within the piping of the hydraulic system

Optical flame detectors are used to detect a fire from a given material of interest.

These devices sense and analyse the electromagnetic radiation emitted by a flame.

Ideally, an optical flame detector should be performance-tested with the fire type of interest to determine its effective

• The fastest possible solenoids should be used • Deluge nozzles should be installed as close as possible to the potential hazard

When burning, different types of materials emit differing spectra of light energy that allow their detection. The region of spectral emission to which a detector is sensitive,

detection range. Flame performance testing can also determine a detector’s coverage area, or field of view (FOV). In ultra-high-speed applications, detectors

Those who take these steps may achieve optimal performance at the outbreak of fire, meeting or exceeding response time

must be tightly controlled in order to minimise the effects of spectral emission from non-fire sources such as sunlight, ambient light,

are installed as close as possible to the area that requires monitoring, typically at distances of less than three metres.

requirements.

machinery and processing equipment.

Optical flame detectors require a clear line of sight to the area being monitored, so they must be installed in locations with no obstructions between the detector and

While older ultra-high-speed fire systems currently in use by munitions and other manufacturers may respond quickly enough to comply with codes and standards, these

(UV), infrared (IR), ultraviolet / infrared (UV/ IR) and multi-spectrum infrared (MIR). MIR technology, however, cannot respond quickly

the area of interest.

Under ideal circumstances, ultra-high-

older systems may present challenges in terms of product support. In some cases, the manufacturers of older systems

enough for ultra-high-speed applications.

When selecting from among the remaining options, potential users must match the

speed flame detectors can detect a rapidly developing fire in approximately 30 milliseconds. The response speed of the

may no longer offer service support and replacement parts may not be readily available. When a component of the safety

spectral response of the detector to the spectral emissions of the fires to be detected.

detector, however, is only a small subset of the response time of the entire system.

The speed of response of the entire

system fails, this could lead to a ‘line down’ situation until the issue can be resolved.

In high-demand applications, waiting to

Optical flame detectors employ several sensing technologies, including ultraviolet

system is the most critical metric. Other system components that must be taken into account include the releasing service

Ultra-High-Speed Detection and Releasing System Components EQP Safety System Controller

fire alarm control unit, which may also

Input/Output Module Notification Appliances

High Speed Deluge Module

Suppression/ Deluge X-Series Flame Detector

Source

Figure 4 - An example of today’s ultrahigh-speed flame detection and releasing systems and the NFPA standards that apply

www.hazardexonthenet.net

Why an upgrade makes sense

Fire detection 31

Detectable event

Detector alarms

Presentation of an energy source

Control system activates

20ms

Solenoid activates

2ms

Pilot-actuated valve activates

25ms

Water flow

53ms

Figure 3b – Per NFPA 15, Standard for Water Spray Fixed Systems for Fire Protection, response time for an entire ultra-high-speed detection and suppression system from presentation of an energy source at the detector to flow of water from the water spray nozzle cannot exceed 100 milliseconds (ms).

replace the safety system until it no longer functions may lead downtime.

The latest ultra-high-speed fire systems are designed to retain more information

Whether working as a stand-alone system or in conjunction with life-safety systems,

Besides being up to date in terms of codes and standards, today’s new systems offer

about a hazardous event than older systems. New systems include a log that records and stores critical information

new ultra-high-speed flame detection and releasing systems upgrades are an important consideration for any process

more features, such as EMI/RFI protection and I/O monitoring. The latest systems are designed to be much more user-friendly than their older counterparts. Those systems

such as the date, time and duration of an event, as well as which detectors were activated during the event. These systems can also transmit event data to a

that requires a split-second response to hazardous situations.

typically communicate via LEDs and numerical displays, requiring plant personnel to be well versed in interpreting what they

computer to facilitate review and analysis by plant personnel.

mean. New systems typically display easily understandable event information through text on the controller screen.

Another key feature of the latest systems is their ability to integrate with a facility’s existing life-safety system. If a high-

About the author

hazard event occurs, new systems can output information about the event to a connected life-safety system, which then carries out the appropriate alarm and notification functions in the building.

Michael J. Hosch is Lead Applications Engineer at Det-Tronics in Minneapolis, Minnesota. He has worked with optical flame detection for Det-Tronics for over 30 years and has developed extensive experience in the application of flame detection in high hazard environments ranging from the oil and gas industry to aircraft hangars and munitions manufacturing.

www.hazardexonthenet.net

don’t go unprotected Our fan systems provide valuable protection for your equipment.

Your operations, Your site and your team.

Safeguard your system with our solutions:

• ATEX certified fans • Up to IP68 protection • Fume Extraction • Dust Extraction • Corrosion Resistant

Visit: www.axair-fans.co.uk Call: 01782 349 430 Email: sales@axair-fans.co.uk

Fundamentals of Process Safety

22–26 June, Edinburgh, UK 12–16 October, Reading, UK

IChemE’s flagship process safety course explores the key principles of process safety and its management.

Essential for anyone who is involved in the design, modification, operation and maintenance of a major hazard or process plant, or those who want to gain a thorough understanding of process safety.

Full details and registration www.icheme.org/fundamentals This course can also be run in-house, email courses@icheme.org to request a quotation.

IChe

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y

MB0043_20

E

Safet

n Ce

ISC

Non-electrical ignition 33

Non-electrical equipment and own potential source of ignition A

s a process, safety and equipment consultant I have been involved in several projects where a client (the end-

required level of protection.”

The guidance also states, “If the only source

potential source of ignition, such as a mechanical spark or hot surfaces or that can generate static electricity from moving non-

user) has integrated a number of items of powder handling equipment to form an assembly. These assemblies have

of electrostatic charging comes from the process, such items are not considered to have their own source of ignition, and they are

conductive parts, must be in compliance with the ATEX Equipment Directive and as a result must be εx and CE marked.

included electrical equipment and nonelectrical equipment.

not in scope of Directive 2014/34/EU. In these cases, they should not be εx or CE marked according to Directive 2014/34/EU.”

With the exception of “simple apparatus”,

On the other hand, it also indicates that there is some equipment that is on the borderline between requiring certification under the

it is generally recognised that electrical equipment has its own potential source of ignition. However, this is not so clear cut

On the other hand, the guidance states, “could become charged … by the intended use of the equipment … if they are placed on

ATEX Equipment Directive and not requiring it because it does not have its own potential source of ignition. This is particularly true

with non-electrical equipment and this article explores the issues associated with nonelectrical equipment.

the market specifically for this intended use.”

From this guidance, it is clear that non-

for equipment placed on the market with a specific use where the process can generate static electricity. The following examples

electrical equipment, which has its own

examine two borderline cases in more detail.

ATEX Equipment Directive 2014/34/EU includes the following in its definition of equipment covered by the directive: “which are capable of causing an explosion through their own potential sources of ignition.”

Potential ignition sources are equipment related ignition sources which are a subset of the possible ignition sources defined in EN 1127-1 and include electric sparks, electrostatic discharges, hot surfaces, flames, mechanically generated sparks etc.

EU guidance “ATEX 2014/34/EU Guidance” states, “equipment can be said to have its own potential source of ignition, if, when operated as intended … in a potentially explosive atmosphere, it is capable of igniting the latter unless specific safety measures are taken. Therefore, equipment must ensure the

www.hazardexonthenet.net

34 Non-electrical ignition IBC that contains powder and is being used for powder blending. It is to be expected that filling the IBC and tumbling powder in the IBC could generate static electricity. If this is the case, and the IBC is not earthed via the blender machinery, the IBC could generate an electro-static spark powerful enough to ignite a dust cloud inside the IBC. Calculations 2, 3 and 4 provide estimates of the potential spark energies.

Calculation 2 shows the estimated spark energy for an unearthed IBC that becomes electro-statically charged during filling.

Calculation 3 provides an estimate of an electro-static cone discharge from the powder itself. In both cases, the electro-static discharge could ignite a powder with a low minimum ignition energy. Calculation 4 shows that tumbling the powder in an unearthed IBC could lead to a powerful spark that could ignite many powders.

Since an IBC Blender would be specifically placed on the market for an application that could have an effective source of ignition, unless protection measures are taken it is reasonable to suggest that the IBC Blender as a system should be ATEX certified.

DSEAR and the EU ATEX Workplace Directive Borderline Example 1 – Hand Operated Valves Hand operated valves move slowly, with no possibility of forming hot surfaces or mechanical sparks. Some valve designs incorporate polymeric parts, which could become electrostatically charged, but the EU guidance specifically states that these are not covered by the directive.

However, it is clear (see calculation 1) that if a valve is included in a process system that could generate a large electro-static charge, for example a pneumatic conveying system or an isolated metal part, such as the ball in a

certificate for the whole system) including any manual valves that are part of the system.

Borderline Example 2 – IBC Blender BS EN ISO 80079-36 “Non-electrical equipment for explosive atmospheres - Basic method and requirements” states that, “Static autonomous process equipment includes items such as tanks, vessels, fixed pipework and hand operated valves which do not have their own source of energy that could create a potential ignition source during operation.”

This indicates, as would be expected, that a static metal intermediate bulk container

These two borderline cases indicate that it is difficult to decide if a complete process system should be ATEX certified. Powders that can form an explosive atmosphere are dangerous substances as defined by the Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) and therefore employers must comply with the following regulation: “Elimination or reduction of risks from dangerous substances 6.—(1) Every employer shall ensure that risk is either eliminated or reduced so far as is reasonably practicable.”

ball valve, could become sufficiently charged to ignite the powder being conveyed. Since the pneumatic conveying system, as a whole, could be placed on the market specifically for a use where it has its own potential source of ignition, it seems logical that such a

(IBC) is not covered by BS EN ISO 80079-36 (which is a standard harmonised to the ATEX Directive) and hence it is not covered by the ATEX Directive since it would not have its own potential source of ignition.

The EU ATEX Workplace Directive 1999/92/ EC states: “Article 3 Prevention of and protection against explosions With a view to preventing, within the meaning

system would need to be ATEX certified (one

However, this would not be the case for an

of Article 6(2) of Directive 89/391/EEC, and

www.hazardexonthenet.net

Non-electrical ignition 35

providing protection against explosions, the employer shall take technical and/ or organisational measures appropriate to the nature of the operation, in order of priority and in accordance with the following basic principles: — the prevention of the formation of explosive atmospheres, or where the nature of the activity does not allow that, — the avoidance of the ignition of explosive atmospheres, and…”

It is clear from this that to comply with these regulatory requirements, it is necessary to minimise the sources of ignition no matter whether it is the equipment or the process that is the potential source of ignition.

Recommended approach To comply with DSEAR and the ATEX Workplace Directive, my recommendation is that a full global ignition hazard assessment is carried out using the method presented in BS EN ISO 80079-36 Explosive atmospheres Part 36: Non-electrical equipment for explosive atmospheres — Basic method and requirements.

Once this global ignition hazard assessment has been carried out, it is possible to go the whole way to ATEX certifying the complete process system. To achieve this, a conformity assessment covering the essential safety requirements of the ATEX Equipment Directive, the compilation of a Technical File and the drawing up of an EU Declaration of Conformity are required.

About the author

This task is not too onerous and in the case of the Zone 21 (nonelectrical equipment) and Zone 22 (all equipment), this certification process can be carried out by the company that created the integrated process system including the case where this is the end-user.

The final step is that the Technical File must be lodged with a notified body who need to acknowledge receipt and hold the file for a minimum of 10 years. There is no requirement for the notified body to read or comment on the Technical File.

Since going to full ATEX certification does not add significantly to the cost, my recommendation is that this certification is carried out so that the doubt that surrounds borderline cases can be eliminated.

The BPE team have the experience and detailed knowledge to guide our clients through this process and ensure the required certification can be carried out by the manufacturer/integrator/end-

Keith Plumb Eur Ing, CEng, CSci, FIChemE, is a process and equipment consultant at chemical and biochemical engineering design company BPE. Keith has more than 40 years’ experience covering the pharmaceutical, biopharmaceutical, fine chemical industries and food/beverages. His MBA, continued involvement with MBS and work with the media has given him a much wider prospective than most engineers. Keith has been involved with all stages of the manufacturing process.

He is familiar with process safety, notably HAZOPs and risk assessments, Hazardous Area Classification, and the requirements for ATEX, Pressure Equipment Directive, Machinery Directive and for CE Marking.

user of the process system.

www.hazardexonthenet.net

Conference • Workshops • Exhibition • Awards Programme

ponsor Exhibitor & S w available packages no 1& PPTex 202 for Hazardex r details contact us fo

2021

24th & 25th Feb • Harrogate • Yorkshire • UK

The 2021 event will include a comprehensive conference for all those concerned with hazardous area operations, personnel, and environmental safety systems, alongside the exhibition, workshops, free seminar content, networking dinner and an awards ceremony.

The event aims to strengthen and expand the community that looks to the Hazardex brand for essential industry intelligence and information.

Event Sponsors

Contact us for 2021 participation information now!

Media Partners

Email: hazardex@imlgroup.co.uk Tel: +44 (0)1732 359990 www.hazardex-event.co.uk www.hazardexonthenet.net

Event preview 37

OTC 2020 Houston Preview gain knowledge from scientists, engineers, researchers, and executive-level speakers on technological advances, safety, and environmentally focused solutions, and economic and regulatory impacts. The event is an opportunity to participate in four days of learning, sharing, and networking.

Top speakers at the 2020 include Harry Breckelmans, Projects and Technology Director at Shell, Starlee Sykes, Regional President - Gulf of Mexico at BP, and Mark Hatfield, Vice President of Chevron.

T

he Offshore Technology Conference (OTC) is taking place between May 4-7, 2020. OTC Houston is where energy professionals meet

to exchange ideas and opinions to advance scientific and technical knowledge for offshore resources and environmental matters.

Celebrating 50 years since 1969,

OTC’s flagship conference is held annually at NRG Park (formerly Reliant Park) in Houston, US. OTC

has expanded technically and globally with the Arctic Technology Conference, OTC Brazil, and OTC

Asia. OTC is sponsored by 13 industry organisations and societies, who work cooperatively to develop the technical programme.

OTC has played a major role in connecting people from more than 100 countries to encourage collaboration and discussions on the challenges and successes encountered

entrepreneurs will meet to develop business partnerships and learn about the latest advances in the offshore sector.

Top reasons to attend OTC 2020 OTC 2020 will include over 350 peer-

Some of the highlights of the programme include the Around the World Series where attendees will find presentations, panel discussions and special sessions with a focus from international development and marine renewables to safety aspects and new areas of opportunities. The subjects

selected technical presentations, leveraging 13 societies’ collective knowledge and covering topics from the wellbore to

covered are pertinent, timely and important to the offshore sector.

topsides and everything in between. The show has over 500,000 sq. ft. of exhibition space which will feature technological

Faster Deployment of New Technologies will highlight solutions to reduce the development timeline and create project-

innovations and more than 2,000 leading providers of products and services in one place, at one time.

ready technologies which meet current industry challenges. Cost Reducing Tools and Techniques will show ways to decrease

More than 60,000 energy professionals from over 100 countries will be in attendance, offering a great opportunity to connect with global C-suite leaders and more than 100 speakers to discover what innovations we can expect over the next 50 years.

in the offshore sector. Attendees include engineers, technicians, executives, operators, scientists, and managers from more than 100 countries and all fields in the offshore energy sector.

OTC’s sponsoring organisations use revenue to provide many other important programmes for its members, such as training and technical journals.

Visitors will be able to learn about the latest technological advances, meet vendors and suppliers, gather industry contacts, and network with people across a wide range of disciplines. For four days, key decision leaders, investors, buyers, and

OTC brings together offshore energy game changers from across the globe to share best practices, technical innovations, and emerging trends. The conference has a strong reputation for a world-class technical programme. When you attend OTC, you will

Technical programme

costs and improve overall value, while maintaining high standards for safety, operability, and reliability.

OTC Distinguished Achievement Awards The OTC Distinguished Achievement Awards Event will be held on May 4, 2020 at the NRG Center in Houston, Texas, USA. The awards recognise the OTC Distinguished Achievement Award recipients and present an opportunity to network with colleagues from around the world, all while raising funds for a worthy cause. Because of the faithful support of industry-leading companies, more than $2 million has been donated to worthy organisations over the past nine years.

For more information, visit: 2020.otcnet.org

www.hazardexonthenet.net

38 Events

Process Safety Congres Date: 13 May 2020 Location: Dordrecht, Netherlands Process Safety Congres aims to improve process safety culture through networking and sharing of information.

Through the years, personal safety has obtained a lot of attention. The disaster in 2005 at the Texas City Refinery showed just how necessary process safety also is for avoiding these catastrophic incidents.

During the year, individual companies are strongly internally focused. Learning together speeds-up the process and so Process Safety Congres looks to bring together world class speakers and interesting topics so that experiences and learnings can be shared.

Furthermore, a network forum supports the knowledge exchange at an individual level. The process safety conference is aimed at technical safety specialists, managers and inspectors that are

related to companies that are dealing with hazardous chemical processes. www.pscongres.nl

Hazards 30 Date: 18-20 May 2020 Location: Manchester, United Kingdom Hazards 30 will explore every major aspect of process safety and help you to learn from the experience of others.

The event is taking place in Manchester, UK and offers a chance to stay up to date with process safety good practice, discover new techniques and approaches, and explore lessons learned from past incidents and near misses.

You’ll also have an opportunity to network with other process safety professionals.

2020 marks 60 years since the first Hazards conference was held, also in Manchester.

Conference features: - 100+ process safety presentations and posters from industry practitioners, regulators and researchers - Variety of plenary speakers - Panel discussion - Workshops exploring key topics - Trade exhibition of process safety

products and services - Social events and networking opportunities www.icheme.org/career/events/ hazards-30

Safety & Health Expo 2020 Date: 19-21 May 2020 Location: London, United Kingdom

iHASCO, Master Lock UK, Kineo, GfG Gas Detection, and Martor UK.

Safety & Health Expo is a dedicated event for health & safety professionals. The show returns to ExCel, London on 19-21 May 2020. With a CPD-accredited seminar programme and thousands of solutions from hundreds of exhibitors, you are able to connect with the entire health & safety industry.

Access the 8 additional co-located shows for free: IFSEC International, FIREX International, Facilities Show, Intelligent Building Europe, Workplace Wellbeing Show, Counter-Terror Expo, Ambition, and Forensics Europe Expo.

Meet some of the leading suppliers of health and safety solutions such as Draeger, Bolle Safety, Safety Media, Evac + Chair, ABUS (UK), RRC International, Vismo Lone Worker Solutions, MSA Britain,

Unearth new insights and understand the latest legislation updates by attending seminars from leaders behind the transformation. This gives you the chance to discuss the most pressing issues in the industry with fellow peers, whilst earning CPD points to help advance your career.

With over 14,000+ visitors, the entire health & safety supply chain is in attendance. From health and safety consultants to managing directors and CEO’s, you will have ample opportunities to build upon your network or catch-up with old friends. www.safety-health-expo.co.uk

* All dates shown are correct at the time of writing, but are subject to change depending on coronavirus/COVID-19 developments.

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Data files 39 Explosion proof ATEX Zone 2 iPad 10.2

New range of explosion proof AC units

Atexxo Manufacturing has released an Apple iPad 10.2 which is suitable for use in safe use in gas/vapour Zone 2 hazardous areas (Zone 22 on request). The explosion proof iPads are originally manufactured by Apple then converted and certified according to the ATEX directives by Atexxo Manufacturing. Sim-card can be installed by the end-user themselves.

Compliance with ATEX / Ex regulations is achieved by modification of the casing together with the intrinsically safe electrical circuit, which makes the tablets suitable for safe use in hazardous locations. Even the fingerprint scanner can be used safely in hazardous locations.

Features: - Explosion safety level: II 3G ; Ex ec ic IIC T4 Gc - 32Gb or 128 Gb WIFI+4G - Charger 110-240VAC - Charger 50/60Hz For more information, visit: www.atexxo.com

An all new range of explosion proof AC units (ATEX and EAC-EX) developed for Technical cooling in moderate and extreme hot/cold climates. These EX-Proof AC units are developed for safe use in ATEX Zone 2 gas explosive atmospheres (Zone 22 on request).

The cooling ac units are certified according to the latest European ATEX Directive 2014/34/EU and are future ready for all gas groups IIA/IIB and IIC. The sets consist of explosion proof outdoor unit, indoor unit and remote controller.

Features: - Explosion safety level: II 3G ; Ex ec ic nC h IIC T3 Gc - 200-240VAC (wider voltage input range on request) - 50/60Hz - Hydrogen ready - Standard “Blue Fin” anti-corrosion treatment For more information, visit: www.atexxo.com

The new online catalogue from Schmersal showcases over 7000 safety and automation products Through the website, Schmersal is showcasing more than 7000 safety and automation products, from straightforward electro-mechanical safety switches to programmable safety control systems and software. The catalogue also includes switchgear for use in potentially explosive atmospheres and components for lift technology.

Buyers Guide

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

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The new online catalogue has a modern design and a clear, concise structure plus user-friendly search and selection functions.

A new feature is the option of access to the external CADENAS and ePlan platforms, allowing designers to transfer the 3D data for selected products directly to their CAD applications. In addition, UL certificates for components can now be downloaded with ease.

Users of the online catalogue can pencil selected products in the notepad function and request price information and additional information for products quickly and easily by sending an e-mail to the sales teams at the respective Schmersal national organisations. The online catalogue is available in 16 languages, including Chinese and Japanese.

More information... http://www.products.schmersal.com/en_GB

Asecos Q range – proven fire resistance of 90 minutes Labtex’s Asecos Type 90 storage cabinets provide extremely safe, regulation-compliant storage of hazardous materials in laboratories and other work spaces. Each cabinet variant is furnace tested in accordance with EN 14470-1 and proven to give fire resistance of 90 minutes. Extremely robust in construction for maximum torsional rigidity and with tamper proof lock and indicators built in, every ASECOS cabinet has GS approval and CE conformity. In addition the Q range is offered in range of scratchresistant paint colours and with extensive interior equipment options Warranty cover is available up to 10 years.

Tel:+44 (0)1484 600200 Please contact Greg Smith at greg@labtex.co.uk

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