22 minute read
Digitalisation for a new age
In 2020, there have been and will be many developments across all industries where explosive atmospheres mean strict rules need to be adhered to.
There are some particularly exciting developments happening in terms of mobility in hazardous areas, including operating systems/chipset upgrades and new mobile products. However, the certification process for these products can take a long time – up-to 5 years in some cases. This is why the specifications for hazardous area mobiles and tablets, for example, aren’t the same as your desktop/laptop. Certification is for the proposed specification only and they cannot be upgraded (for ATEX/IECEx Zone 1). For Zone 2, there are more options and an I5/I7 Processor similar to the current specifications of ‘mainstream’ desktops/laptops can be used. You can therefore have confidence that the devices are fit for purpose when they are officially released. All are MIL-STD-810G certified and have varying IP ratings. This is only one piece of the ‘jigsaw’ for digital transformation though – it all needs to be linked, accessible, secure and relevant to the job role or use case.
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We have all heard the terms IoT, IIoT, and Industry 4.0 in relation to sectors looking towards the future and key plants looking to become more efficient through the optimisation of assets. The Industry 4.0 market was valued at an estimated US$71.7 billion in 2019 and is expected to reach US$156.6 billion by 2024. The technology advancements related to Industry 4.0 will see much improved Return on Investment for many companies.
For large refineries, downtime is extremely costly and many are adopting new technology to keep operations up and running. A Shell refinery in the Netherlands for example has its equipment and operation monitored by 50,000 sensors that generate 100,000 measurements a minute. Machine learning and AI were implemented to analyse and process this key data – preventing failures, helping maintenance strategies and keeping the plant working. The technology meant large cost savings for the operator and notification periods increased dramatically.
Digital Twins
Digital Twins, where a cloud-based asset is digitally run in the background, also offer ways for production to be improved. Breakages and failures can be seen before they happen, meaning operations teams can optimise the output without risking lives in the field. Edge computers are an ideal solution for companies adopting Industry 4.0 technology as they are more flexible, save costs, and help with innovation. Operating a closed loop system means data/systems can be managed more easily. Key drivers for Edge computing are that as the number of sensors increase, plants gain more insight and data sets. Local devices no longer have the processing power to deliver scaled analytics and the ‘Cloud’ can suffer latency issues. As Digital Twins communicate, low latency is key to make sure processes are done correctly. Edge computers will be heavily used for analysis, data cleansing, and filtering which means only important data is ‘sent’ to the engineering team to ensure all is in order. By using AI/ Machine Learning, algorithms can be used to build in operational limits that, if exceeded, cause an alert to be sent to an alarm system or the control room, depending on the risk associated with that part of the operation.
Onshore and offshore networking
How does this all work? First an initial radio frequency (WiFi) Survey, through proof of concept, then roll-out and integration, before then linking to ERP (back-end databases). There are key milestones that need to be met – initially network. Without a suitable 4G
network, it is not feasible to employ digital devices or technologies in the field. Everything is linked so that data can flow to the right people when it is needed. Without a network, this is not possible. So maximising uptime and having backups in place to ensure 24/7, 365 coverage for key operations and assets are essential. Low latency with LTE base stations are located in all major active areas. VSAT does have limitations on bandwidth and needs expensive receivers at the other side – also high latency. The typical RoundTrip Delay (RTD) is around 580-600ms – the new LTE networks require little hardware in comparison to the older solution and can reduce RTD by 90% to around 35ms – which enables machine-to-machine communication. All this is done with a secure private network with many applications available.
There is key infrastructure supplied by a handful of specialist companies for offshore who offer fibre networking for 4G LTE networks. They offer data and voice SIM cards and all the hardware for building a PTP (Point-to-point) or PTMP (Point-toMulti-Point) where distances covered can be as high as 240 km. There are a handful of options and the technology is a step forward, meaning easier implementation, further distances so fewer links to the Bridge/Link and therefore, in theory, more cost effective.
Data can be sent ‘Full Duplex’ or ‘Half Duplex’ depending on the need. Full Duplex means that data is sent one way only while Half Duplex means data is split and can be sent both ways (VOIP/Data etc). A BATS gyroscopic solution (the large dome you see on top of ships) helps with offshore assets as a straight line of sight is essential for smooth operation.
Once a network is established and connected, the RF (WiFi) survey is conducted, offering an insight into areas where there is not a strong enough 4G network. From here, depending on the ATEX Zone, WAPS (Wireless Access Point Enclosures) specifically designed for use in the Zone are installed and configured to the network. Normally, the main players in the Wireless Access Point market are covered so you can use the same infrastructure for both Onshore and Offshore. This helps integrating and linking to key plants and sensors, as well as giving real time data and analytics for evaluation. Different businesses and sectors will have differing needs and requirements, so systems can be scaled, upgraded, and deployed as and when they are needed as the options available increase and technology develops.
This also links to mobile devices and again these are now beginning to offer better ‘bang for your buck’ with processor speed and chipsets improving and delivering the same ability in a Zoned area as in an office.
Developments in the wearables market, such as asset and personnel tracking, are also enabling data to be sent immediately to the right people for real-time troubleshooting.
All the key players have applications designed for specific job tasks – be it timesheets, P&ID, dates of manufacture, condition monitoring etc. – which provide real-time data. Understanding the needs of a business drives the development of an application and many companies can now design bespoke software in various formats and link it to CRM/ERP so that information is visible to anyone who needs it.
Augmented Reality
Augmented Reality is playing a key role in showcasing the abilities of new technologies as data and knowledge can be shared in real-time across the globe. This means all stakeholders can be made aware of any problems and get a fix in play without having to wait for a specialist team to mobilise. So, time can be saved due to less travel being needed and when coupled with a Digital Twin, a realistic plan of action can be deployed.
Conclusion
There are many steps to digital transformation, but they lead to lower costs (ROI), enhanced efficiency, optimised operations, and offer real-time data which means decisions can be made with clear analytical data that has been fully evaluated, in a shorter amount of time than before.
The global COVID-19 pandemic forcing countries into lockdown will see a major demand for new technology to help deliver the services that we are used to, so it is an exciting period for technology across all sectors.
About the author
Andy Russell has been involved in engineering projects for over 15 years. Initially from a recruitment background, Andy has experience covering many projects within Oil & Gas, Construction, Commissioning, Nuclear, Pharma, MoD and others. Andy has worked with many ATEX technologies with certification from global names to ensure he is at the cutting edge of new technology for Industry 4.0/IIoT. You can find Andy on LinkedIn with #atexandy or feel free to get in contact via sales@atexsolutions.uk.
Hazardex & PPTex 2020 Conference & Exhibition
The Hazardex 2020 Exhibition, Conference and Awards – co-located with PPTex – took place on February 26 and 27 at the Majestic Hotel in Harrogate, the elegant North Yorkshire spa town in north-east England.
All participants were enthusiastic about the change in venue for Hazardex 2020, with the Majestic Hotel – now a Double Tree by Hilton establishment – offering much improved facilities and accommodation.
The Hazardex team would like to thank all attendees for making this year’s event one of the best we have ever had. Hazardex 2020 was a great success for the industry, and we are thrilled to say that plans are already well underway for Hazardex 2021 which is to be held at the same venue on February 24 & 25, 2021.
A special thank you goes to our Event & Awards sponsors, CSA Group and Connectivity, for their support. We are happy to announce that both will be returning as sponsors 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 main focus of the event was the conference which had a distinguished list of speakers sharing their knowledge and expertise. As in previous years, the event included free-to-attend workshops with the Institute of Measurement & Control hosting one on each day of the event. These involved an introduction to the work and activities of the Functional Safety and Explosive Atmospheres Special Interest Groups as well as two Briefing Notes followed by a Q&A session.
Hazardex 2020 Exhibitors
ANT Telecommunications Mutech
ATEXInspect BEKA associates
CCG UK Connectivity CSA Group Dekra NEPIC OBAC
Pepperl+Fuchs Phoenix Mecano
R&M Electrical Group RAS Ltd
Dialight DNV GL
Draeger UK Dynaco Entrematic Exloc Instruments Rheintacho UK Roxby Training Solutions SAFT Site Bright from Shindaiwa SGS Baseefa
Ex-Machinery Tempa Pano
ExVeritas
Trant Engineering F.E.S (Ex) WIKA Instruments Institute of Measurement & Control ZOA Robotics JT Ltd - CompEx
A second set of workshops were hosted by ZOA Robotics which addressed the recent trend towards robotic inspections, the benefits of digitisation, and how ZOA’s robotic platform uses sensors to help clients achieve high operational reliability while improving safety for operators.
Another key element of Hazardex 2020 was the free-to-attend exhibition, with leading hazardous area sector companies displaying their products and services to the assembled professional audience. Exhibitors comprised certification bodies, lighting manufacturers, communications specialists, inspection and asset management experts, cable manufacturers, enclosure specialists, risk management companies, and many more hazardous area focused businesses and organisations.
The conference, exhibition, workshops, free seminar content, networking dinner and awards ceremony are all designed to strengthen and expand the community that looks to the Hazardex website and journal for industry intelligence and information. The 2020 event again provided exceptional opportunities for networking, with attendees from government agencies, regulators, certification bodies & training providers, consultants and product manufacturers meeting up with senior engineers and safety managers from the high hazard and process industries to share their experiences.
The informal, very well attended Gala Dinner at the end of the event’s first day on February 26 helped to further facilitate networking between attendees. The evening consisted of a drinks reception and dinner taking place before the start of the evening’s focal point, the Hazardex Awards for Excellence. The Hazardex awards are designed to recognise excellence in the hazardous area sector and has become the benchmark for those supplying products, services and systems into the industry. An in-depth look at the Hazardex 2020 Awards can be found on pages 28 and 29 of this issue.
Hazardex Conference
Delegates and visitors were able to hear from an exceptional line-up of speakers at Hazardex 2020 which comprised leading high hazard industry figures, regulators, academics, engineers and consultants who offered insights and expertise from a variety of industries. To complement the eminent line-up of presenters, both conference streams had an equally reputable Chairman – Ron Sinclair MBE, Technical Manager at SGS Baseefa, in Stream 1 and Martin Jones, Head of CompEx Global, in Stream 2. Thank you to both Ron and Martin for their tremendous support and we look forward to welcoming them back as Chairmen next year.
Ron Sinclair MBE – Technical Manager, SGS Baseefa – Conference Stream 1 Chairman
Conference Stream 1
Day one of the conference began in Stream 1 where Steve Elliott – CEO, Chemical Industries Association – discussed the challenges that hazardous process industries are facing, specifically those related to the three key topic areas of Digitalisation and Cyber; Climate Change as a threat to hazardous inventories and processes; and Leadership. Stephen Marcos Jones – Director-General, UKPIA – then spoke about the potential role for digital in unlocking efficiencies and improving safety in the downstream oil sector. He highlighted some of the existing uses that are emerging from the use of digital in the downstream space and about the digital opportunities across the sector, including new ways to track people to ensure their safety on site.
Next, Steven Naylor – Associate Director and Technical Lead of Discovering Safety Programme, HSE – offered insights into the Fourth Industrial Revolution and the opportunities and challenges it has created for health and safety. Steven was joined by Rhodri Morgan – Electrical Control and Cyber Security Specialist Inspector, HSE – who spoke about cybersecurity
Steve Elliott – CEO, Chemical Industries Association Stephen Marcos Jones – Director-General, UKPIA Peter Newport – Chief Executive, Chemical Business Association
Martin Jones – Head of CompEx Global – Conference Stream 2 Chairman
implementation and compliance in the oil and gas sector. Chris Agius – Executive Secretary, IECEx – provided an update of the current IECEx Certification Tools that facilitate world trade in Ex equipment, assemblies and Services and how IECEx can also be used to bridge between differing national regulations through its “Fast Track” provisions.
In the afternoon of the first day, Dr. Zsuzsanna Gyenes – Deputy to the Director, IChemE Safety Centre – discussed the lack of consistency in lead metrics across industry and differing levels of understanding and interpretation of lead metrics in different companies. She then spoke about how the ISC has developed guidance to provide context for barrier failures and in particular the lead metric ‘barrier fail on test’ and ‘barrier failing on demand’.
This was followed by Alistair Hunter – Head of Compliance, Brenntag – who spoke about the personal aspect of safety and provided insights into the initiatives Brenntag has implemented to enhance its safety performance. Dr. Hassan ElSayed – Business Manager - Functional Safety, CSA Group – closed the first day of the event by offering guidance on Fixed Gas Detection Systems for use in SIS and the impact of IEC 60079-29-3 on SIS installations.
Peter Evans – Specialist Inspector, HSE – opened day two with an insightful presentation on the Electrical, Control and Instrumentation elements of the investigation into the fatal incident at Chevron’s Pembroke oil refinery on June 2, 2011. The presentation focused on aspects such as gas testing, electronic data recovery and analysis (PV.data), earthing & bonding, portable electronic devices and hazardous area classification. This was followed by Carolyn Nicholls – Director, RAS Ltd – who spoke about the lack of appreciation of the appropriate use of tolerability criteria in risk assessment.
Paulo Oliveira – Associate Director, Engineering Safety Consultants – questioned whether the well-presented stamped paper certificate is an indulgent bureaucratic way to feel good about using equipment in a safety critical application, or whether it actually carries value with regards to evidencing an adequate level of compliance with IEC61508. Then, Harvey T. Dearden – Engineering Director, HTS Engineering Group – explored the relationship between SL and SIL and showed how they may be related through an appropriate risk calibration for a given enterprise.
Stream 1 closed with a presentation on Fire and Gas Detector Mapping by Tim Jones – Principal Consultant, RPS Group – before Bill McDonough and Alison Quinn, Dialight, demonstrated how industrial hazardous-location certified LED lighting can dramatically improve facility safety.
Conference Stream 2
Peter Newport – Chief Executive, Chemical Business Association – opened the first day in Conference Stream 2 with an introduction on the CBA before moving on to a case study addressing a CBAled packaging development project for members covering the background, design, development, UN testing and approval of a new solution for the safe carriage of higher concentrations of ammonia solution. Further details can be found on pages 30 and 31 of this issue.
James Steven – Development & Innovation Manager, DNV GL – explored how common practises have led to threats to the integrity of hazardous area installations and what effects this has had on completion of projects. Chris Thomas – Electrical Engineer, Intertek – informed attendees
Peter Evans – Specialist Inspector, HSE Chris Agius – Executive Secretary, IECEx
about what the various markings typically placed on equipment mean and why certification bodies require certain markings to be shown. Chris also explained what and why certain markings are required.
Sean Clarke – Managing Director, ExVeritas – then looked at why intrinsic safety has always been ‘evolving’ and adapting, the problems that can give rise to and the potential benefits to designers in the future. Sean also considered ‘why’ we assess the way we do, why there may be variability in assessment techniques, and what we are doing collectively or as individual Certification Bodies to overcome that. Dr. Alexander Horch – Vice President R&D and Product Management, HIMA Group – discussed remote access security and security solutions for remote maintenance before Gido van Tienhoven – Director, Ex-Machinery Explosion Proof Equipment B.V. – spoke about the challenges of air conditioning in hazardous areas by focusing on the main challenges and explaining how to technically deal with these issues.
In the morning of day two, Michael Marrington – General Manager, IndEx – presented on facility assessment and certification and Dr. Geof Mood – Technical Director, CCG Cable Terminations – explained what an IP rating means and more importantly what it does not mean (but is usually assumed to mean) as well as offering guidance about what to look for to make sure that the installation meets its intended IP rating.
Glynn Warren – Product Manager, Extronics – then asked why IIoT technologies could pose a risk hazardous areas and Scott Harding – Sales Director, Woodcock & Wilson – discussed the IECEx Hazardous Area certification which now covers non-electrical (mechanical) equipment. Ending Stream 2, Hamilton Smith – Technical Sales Manager, ProGARM – spoke about the importance of layering PPE to protect against Arc Flash and Tony Ennis – Director, Haztech Consultants – clarified the issues which have been raised by the reclassification of Diesel and similar fuels.
In all, the conference covered numerous topics and several interesting conversations and debates were had through the Q&A sessions at the end of each presentation.
Thank you again to all exhibitors, speakers, delegates, and visitors for contributing to another outstanding Hazardex event and we look forward to welcoming everyone back on February 24 & 25, 2021 in Harrogate!
Dr. Zsuzsanna Gyenes – Deputy to the Director, IChemE Safety Centre
Visit www.hazardex-event.co.uk for full presentation details and further information about Hazardex 2021. Click here to watch the Hazardex 2020 Review Video.
Hazardex & PPTex 2020 Awards for Excellence
www.hazardex-event.co.uk
Hazardex 2020 Awards Sponsors
The Hazardex & PPTex 2020 Awards for Excellence took place during a well-attended Gala Dinner on February 26 following a fantastic first day of the Hazardex 2020 Conference & Exhibition. A total of 25 nominations were shortlisted across five categories, designed to recognise excellence in the hazardous area sector. The categories were Technical Innovation, Best User Application, Best Customer Service, Contribution to Safety, plus the additional Delegates’ Award which was voted for on the day by event attendees.
Thank you to our Awards sponsors, CSA Group and Connectivity, for their support! Over the last decade, the Hazardex Awards programme has become the benchmark for those supplying products, services and systems within hazardous areas. The winners were all voted by Hazardex journal and website readers and users, as well as event attendees.
Adam Garner, CSA Group (Centre) with Andrew Reid (Left) and Matt Ogden (Right), Hawke International
An innovative product or system for use in hazardous area environments.
Winner – Hawke International Cable gland conversion kit & tightening guide
Hawke International developed a special conversion kit for its Universal 501/453 cold flow compliant cable gland. The kit enables the Universal to be easily converted into a barrier gland. Essentially this means that Hawke has created a ‘one gland, two applications’ proposition, allowing customers to purchase one gland for both their standard and barrier gland needs.
Hawke also has a patented tightening guide which is integrated into all its glands, as standard. The guide reduces the chance of glands being over or under tightened – a major health and safety issue for companies within harsh and hazardous environments.
Highly commended BEKA associates – New alternative to Ex d indicators Eaton – MTL SUM5
Adam Garner, CSA Group with Max Begley and Karen Jarrett, Pepperl+Fuchs ecom
The best innovation in Personnel Protection Technologies (PPT) equipment incorporating electronic and technological systems that the user can wear, hold or use to improve safety within the process and high hazard industries.
Winner – Pepperl+Fuchs ecom ATEX certified mobile computing and communication devices
Pepperl+Fuchs ecom’s products consists of explosion-protected mobile phones, 4G smartphones and tablets that meet the highest requirements in industrial use. At the Hazardex event, Pepperl+Fuchs ecom showcased its application-oriented range of mobile phones, tablets, PDA’s, two-way radios, remote speaker microphones, headsets and HMI solutions, designed for use in harsh and potentially hazardous environments. There was also an opportunity to try out new products such as the Zone 1 / Div 1 Android 4G/LTE Smartphone Smart-Ex 02, the Smart-Ex Watch 01, the Zone 1 / Div 1 Android 4G/LTE tablet Tab-Ex 02 and the Ex-Camera Cube 800, designed for safe operation in Ex-certified and rugged environments, bringing hands-free collaboration to the world’s toughest locations.
Highly commended RealWear – RealWear HMT-1Z1 Re-Gen Robotics – Explosion proof, robotic tank cleaning technology
Ernest Kyei, InstMC and Adam Garner, CSA Group
Hazardex 2020 Review 29
An application story highlighting the benefits of a product, system or service for use in hazardous area environments.
Winner – Institute of Measurement & Control Ex Special Interest Group
This special interest group is dedicated to the management of Explosive Atmosphere (Ex) hazards, that will be familiar territory for many members. The Ex-SIG is responsible for promoting awareness and understanding of Ex matters. The main focus is the set of associated practices and regulations. These areas continue to develop and represent significant challenges for guidance and understanding. The SIG aims to organise conferences, workshops and seminars on Ex matters, and to prepare papers for publication.
Highly commended WIKA Instruments – Exhibition, training and educational vehicle Pruftechnik – ROTALIGN touch EX
Adam Garner, CSA Group and Barry Thompson, Raytec Alistair Hookway, Hazardex Editor (2nd from right) with Lenny Collins, Tom Irwin and Bruce McHattie (Left to Right), Dron & Dickson Paige West, Connectivity Editor and Darren Lindsay, Librestream
A company or corporate division that has provided excellent customer service in the sector over the last two years.
Winner – Raytec Excellence in customer care
As well as designing and manufacturing a full range of LED Ex luminaires, Raytec also provides outstanding customer service through its free Lighting Design service. The free Lighting Design service helps to bring an application to life. Whether for smaller applications with just a few luminaires, or large, complex sites with vast lighting requirements, Raytec can provide exact models and detailed solutions to help hit the requirements needed. Everything is done in-house at Raytec, and 1-to-1 support is provided throughout the entire process to ensure the perfect solution is achieved.
Highly commended Exloc Instruments Extronics
Category 5 – Contribution to Safety - Sponsored by Hazardex
A product, system or service which has made a significant contribution to safety in hazardous area environments.
Winner – Dron & Dickson Fully integrated hazardous area products and services
Dron & Dickson works towards raising awareness about the importance of hazardous area safety, ignition prevention, and the training and competence of technicians. Dron & Dickson can provide both products (through the Wholesale Division) and services (through the Engineering Services Division) resulting in a fully integrated offering from initial conceptual design, to product selection, through the installation & commissioning, culminating in the ongoing servicing and maintenance of the equipment in field operation. As a result, Dron & Dickson has been working on several different work-streams all with the end goal of making hazardous areas safer and reducing the risk potential of a serious adverse event.
Highly commended ATEXInspect – Cloud-based software asset management system ExVeritas – UKAS Inspection, Learn Ex Online and iEx Online
Delegates’ Award - Sponsored by Connectivity
An additional category, the Delegates’ Award was voted on by attendees to identify which of the nominated entries provides the overall best hazardous area sector product, system or service.
Winner – Librestream Onsight Cube-Ex
The Onsight Cube-Ex intrinsically safe industrial wearable is a uniquely portable inspection device that provides live video, HD pictures, and thermal imaging to guide teams through hands-free inspections in potentially hazardous environments. Using the Cube-Ex, teams can share live visuals to collaborate with remote subject matter experts, capture valuable information, and perform self-guided work.
You can play your part in raising awareness and standards across the sector by nominating a company, product or service for the 2021 awards, entering your vote and encouraging your colleagues to do likewise. Nominations will open later in the year.
Hazardex Awards 2021
* The competition is open to all Hazardex journal and website readers and users * Voters register their votes by sending an email to the organisers and must identify themselves and their company. * Voters are limited to one vote per category * Nominees are not permitted to vote for their own company/organisation * All votes remain confidential Visit www.hazardex-event.co.uk or contact Russell Goater on +44 (0) 1732 359990 or russell.goater@imlgroup.co.uk for further details on attendance, exhibiting or sponsoring the must-attend Hazardex 2021.
