hEX_20_12

hazardexonthenet.net

Asset Management

Process isolation practices: an industry wide view

Storage & Transportation

Managing the safe introduction of hydrogen

Toxic gas

Safety systems

UKCA Focus

A review of the strategy behind BS 60080:2020

Why fitting SIL Systems is only the start of it

Be prepared for UKCA marking from January 1

December 2020

the journal for hazardous area environments

CAL

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FOR PAP Conference • Workshops • Exhibition • Awards Programme ERS OPE

2021

16th & 17th June • Harrogate • Yorkshire • UK

CALL FOR PAPERS NOW OPEN For 20 years, the Hazardex Conference & Exhibition has been the global platform for sharing key industry information and topical discussion on process safety-related topics.

With the uncertainty surrounding COVID-19 and the potential risk to the health of exhibitors and attendees, the Hazardex team has taken the decision to move the event from February to June 16th & 17th 2021. The Hazardex 2021 Call for Papers therefore remains open with a deadline of 29th January 2021. Submit your paper now for the chance to share your knowledge and experiences with the most important peers and stakeholders of the global high hazard industry.

We are seeking submissions from contributors with experience and knowledge of the process safety and high hazard sectors.

Submissions must be non-commercial and could be in the form of research, industry developments, lessons learnt from near-misses, investigation findings, good practice for industry, or case studies, to name just a few of the formats we are looking for.

The 2021 event will include a comprehensive conference for all those concerned with hazardous area operations, personnel, and environmental safety systems.

Visit the website for how to submit: www.hazardex-event.co.uk

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

N

contents December 2020 This December issue of Hazardex marks the end of one of the most tumultuous and unprecedented years that many people have ever experienced. COVID-19 will no doubt have long lasting effects on both our personal and professional lives and I am hopeful that with a new year comes a change of fortune so that we can begin the process of returning to some form of “normality”.

The change forced upon us by the pandemic is just one side of the story, however. The new year will mark the end of the transition period in the Brexit process and important regulatory changes will subsequently be introduced. From 1 January 2021, the UKCA (UK Conformity Assessed) marking can be applied to products or packaging of any goods entering the UK market that are currently subject to CE marking, including the ATEX directive.

14 18

In time for the upcoming changes, we have put together a UKCA Focus (see page 14) which includes key details about the UKCA marking, as well as a select few organisations that will gain UKCA Approved Body status in January and can offer assistance with both CE and UKCA marking.

If you have any queries about the upcoming changes or are still in need of finding an organisation capable of offering either UKCA or CE services, don’t hesitate to get in touch with any of the featured suppliers.

During such turbulent times, it is essential to be prepared, so don’t delay your response to the upcoming regulatory changes.

This paper reviews the strategy behind BS 60080:2020’s approach to addressing toxic gas risk.

20 22

Finally, the Hazardex team would like to wish everyone a Merry Christmas and a happy new year! …Alistair Hookway, Editor, Hazardex alistair.hookway@imlgroup.co.uk

in this issue

While the concept of hydrogen pipelines is not new or inherently impossible, the introduction of hydrogen into existing natural gas networks creates unique challenges.

4 News Extra

24

• Seven arrested after special forces board hijacked tanker off UK coast • Criminal probe opened after explosion on Russian oil tanker kills three • Partnership of six energy majors aims to cut UK carbon emissions in half • Explosion at gas processing station kills two, injures eight in Ukraine • US Chemical Safety Board issues factual update on 2019 TPC Group explosion • Cannabis plant explosion seriously injures two in US

13 Standards: Standardisation and Conformity Assessment at the IEC 14 UKCA Focus 18 Toxic gas management: a review of the strategy behind BS 60080:2020

The risk of being exposed to hazards during maintenance can be prevented by safety procedures and training for an effective lockout/tagout (LOTO) system.

22 Managing the safe introduction of hydrogen

32

24 Process isolation practices: an industry wide view 30 How to choose aircraft warning lights 32 Safety systems – why fitting SIL Systems is only the start of it 34 Events

A look at the importance of carrying out Safety Instrumented Function proof testing of SIL Systems to meet proof test schedules and ensure plant safety.

30 36Asset Management the journal for hazardous area environments

hazardexonthenet.net

December 2020

35 Datafiles Hazardex is a controlled circulation journal published monthly.

Completed print or online registration forms will be considered for free supply of printed issues, web site access and online services. Annual subscription for non-qualifying readers is: UK £147; EU £215.25; Airmail £315 and single copy price is £23.10 plus P&P.

Hazardex content is the property of the publishers or relevant content providers. The publishers and sponsors of this magazine are not responsible for the results of any actions or omissions taken on the basis of information in this publication. In particular, no liability can be accepted in respect of any claim based on or in relation to material provided for inclusion.

Editor 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: events@imlgroup.co.uk ISSN 1476-7376

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

Design Graham Rich Design www.grahamrichdesign.co.uk

Process isolation practices: an industry wide view

40Storage & Transportation

Managing the safe introduction of hydrogen

Toxic gas

Safety systems

UKCA Focus

A review of the strategy behind BS 60080:2020

Why fitting SIL Systems is only the start of it

Be prepared for UKCA marking from January 1

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

4

News Extra

Representative image: Fawley Refinery, Shutterstock

The tanker had been travelling in the direction of Southampton, having sailed from Lagos in Nigeria. It was reported that a number of stowaways had been discovered who then became aggressive and made threats towards the crew. Hampshire Police added that it is investigating the incident and has a number of enquiries to carry out to establish the full circumstances.

Seven arrested after special forces board hijacked tanker off UK coast

T

he UK’s Special Boat Service (SBS) boarded a hijacked oil tanker off

were found safe while the seven Nigerians were handed over to Hampshire Police before

The SBS operation to board the ship was approved by Home Secretary Priti Patel after a police request. Forces boarded the Nave Andromeda via rope from four Royal Navy helicopters after nightfall in an operation that lasted just nine minutes.

According to the BBC, the operation would not

the UK’s southern coast on October 25 and detained seven stowaways who had turned violent earlier in the day.

The boarding of the Liberian-registered

the vessel docked in Southampton.

Hampshire Police issued a statement saying that concern for the welfare of the Nave

have been possible had the crew not followed a maritime drill called BMP5 - Best Management Practice 5th edition. The drill involves the crew of the ship retreating to a strong room called

Nave Andromeda ended a 10-hour standoff between UK authorities and the stowaways, believed to be Nigerians

Andromeda’s crew was raised to the police at 10:04 local time on October 25 when the vessel was situated approximately six miles off

“the citadel” and locking themselves inside before calling for assistance. In similar incidents usually seen off the east coast of Africa, special

seeking asylum in the UK.

the coast of Bembridge, Isle of Wight. A threemile exclusion zone was established around the vessel.

forces would normally only board a vessel once all crew members were locked safely inside the citadel.

All 22 members of the Nave Andromeda’s crew

Official says tilting Venezuelan tanker poses no risk as new images raise concerns of environmental catastrophe

A

the tilting Nabarima online. A team of experts was subsequently sent to the vessel to meet

of spilling or causing an environmental catastrophe, a Trinidad and Tobago official said on October 22. Minister of

with Venezuelan government officials and inspect the tanker.

Energy and Energy Industries Franklin Khan said the Venezuelan tanker, the FSO Nabarima, was stable despite

Khan said the the experts’ report showed that while some pumps were in need of repair, all systems on the Nabarima appeared

damaged and idled oil tanker in the Caribbean poses no significant risk

images posted by an environmental group showing the vessel listing to one side.

The Nabarima is operated by Petrosucre, a joint venture between Venezuelan state oil company PDVSA and Italy’s Eni. It is currently sitting idle in the Paria Gulf between Venezuela and Trinidad and Tobago after Petrosucre suspended output due to US sanctions against Venezuela. The vessel is holding an estimated 1.3 million barrels of crude oil.

www.hazardex-event.co.uk

Image: Fishermen and Friends of the Sea

Minister Khan told reporters on October 22 that the Nabarima has been operating for over 10 years in the area without any issues until the US imposed sanctions on Venezuela.

The sanctions mean Petrosucre is unable to sell to its main buyer, PDVSA’s US-based refining subsidiary Citgo Petroleum.

Khan said that Trinidad and Tobago’s Ministry of Foreign Affairs made contact with the Venezuelan government and raised concerns after environmental group Fishermen and Friends of the Sea (FFOS) posted images of

to be functional and maintenance met the satisfaction of the experts.

The major conclusions from the report were that the Nabarima is upright and stable with no visible tilt, and there is no imminent risk of tilting or sinking, there is no water ingress, and there was no mixing of bilge water and therefore a minimal risk of an oil spill at this time, Khan added.

Venezeula began offloading oil from the Nabarima on October 20 after PDVSA labelled the FFOS’s concerns as “fake news”.

News Extra

5

Azov which connects to the Black Sea off Russia’s southwest coast. The General Azi

Image: Russian Marine Rescue Service

Aslanov had been sailing from Port Kavkaz to Rostov-on-Don without a cargo when the explosion happened. The cause of the blast remains under investigation, however Russian news agency TASS reports that safety violations and hot work could have been causes.

There were 13 crewmembers on board the tanker at the time of the explosion and ten were rescued while the search for the three missing sailors began.

Criminal probe opened after explosion on Russian oil tanker kills three

The Moscow Interregional Transport Investigation Department has said that it believes the explosion was caused after the ignition of a mixture of flammable Naphtha liquid in an empty storage tank.

It is now exploring criminal charges under the Criminal Code of the Russian

A

chance of finding the three missing sailors.

However, on October 27, the Moscow Interregional Transport Investigation

Federation which states that an incident is a crime if the violation of fire safety requirements results in the death of two

tanker explosion on October 24 were found. The search for the bodies had been called off after an unsuccessful search and rescue operation following

Department of the Investigative Committee of Russia announced that it had found the remains of the sailors. Genetic tests were carried out to confirm the identities

or more people. The department added that an investigation team had started work at the scene, including investigators from the Krasnodar Transport Investigation

of the bodies while investigators began to look into possible violations of fire safety requirements on board the General Azi

Department and criminologists with experience in investigating such incidents.

Aslanov.

criminal probe has been opened

by Russian authorities after the remains of three sailors killed in an oil

the explosion on the tanker, the General Azi Aslanov, in the Sea of Azov.

Following an extensive search operation, the Russian Federal Agency for Maritime

The explosion on the tanker happened

After an initial inspection, the General Azi Aslanov was towed to Port Krym where further investigators were able to board and

and River Transport said there was no

at around 19:00 local time in the Sea of

begin a more in-depth investigation.

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6

News Extra

Plans for the offshore infrastructure Image: Northern Endurance Partnership

Partnership of six energy majors aims to cut UK carbon emissions in half B

P, Eni, Equinor, Shell, Total, and the

UK’s National Grid have formed a new partnership, the Northern Endurance Partnership (NEP), to develop the offshore infrastructure to transport and store millions of tonnes of carbon dioxide (CO2) emissions safely in the UK North Sea. With BP as operator, the infrastructure will serve the proposed Net Zero Teesside (NZT) and Zero Carbon Humber (ZCH) projects that aim to establish decarbonised industrial clusters in Teesside and Humberside.

The NEP, which aims to accelerate the

off the coast from Teesside and around 85km

development of an offshore pipeline network to transport captured CO2 emissions from both NZT and ZCH to offshore geological storage beneath the UK North Sea, has submitted a bid for funding through Phase 2 of the UK Government’s £170 million Industrial Decarbonisation Challenge. This is part of the £4.7 billion Industrial Strategy Challenge Fund set up by the government

from the Humber coast) as the most mature and large-scale saline aquifer for CO2 storage in the offshore UK Continental Shelf, that can potentially enable industrial decarbonisation from both clusters.

to address the biggest industrial and societal challenges using UK-based research and development.

is another significant milestone towards developing the offshore infrastructure that will be needed to safely transport and store CO2 from CCUS projects along England’s east coast.

The application follows the approval by the The projects will kick-start decarbonisation of industry in two of the UK’s largest industrial clusters. Both aim to start up in 2026, with realistic pathways to achieve net zero as early as 2030 through a combination of carbon capture, hydrogen and fuel switching.

www.hazardex-event.co.uk

Oil and Gas Authority (OGA) of the addition of BP and Equinor alongside National Grid to the CO2 appraisal and storage licence covering the Endurance reservoir.

This affirms the strategic importance of the Endurance reservoir (located about 145km

Andy Lane, Vice President of CCUS solutions at BP and Managing Director for Net Zero Teesside, said: “The formation of the NEP

“The partnership and our joint bid demonstrate industry’s willingness to come together and collaborate wherever possible to accelerate making CCUS a reality in the UK, helping to decarbonize the local economy and contributing to the UK’s climate goals.”

News Extra decarbonisation and is capable and willing to do more to reach Net Zero, according to a new report published by the United Kingdom Petroleum Industry Association (UKPIA) on October 19.

Transition, Transformation, and Innovation towards Net Zero in UK downstream

T

he UK downstream oil sector

is already playing a significant role in meeting societal targets for

7

and delivering zero-carbon emitting hydrogen; and 3) A systems-based approach and enabling policy framework is required to produce low carbon and eventually Net Zero liquid fuels.

UKPIA has launched the new report,

UKPIA Director-General, Stephen

titled “Transition, Transformation, and Innovation: Our role in the Net-Zero Challenge”, which looks at credible scenarios and proposes an illustrative pathway for the UK downstream sector to achieve government mandated Net-Zero

Marcos Jones, said: “This is an exciting yet challenging period of evolution for the downstream oil sector – we are committed to action on climate change and this report shows that within the right policy framework, this sector can

targets, with practical policy solutions to help overcome this challenge.

transform and deliver Net Zero.

Transition, Transformation, and Innovation

Only with industry and government working hand-in-hand in a systems-

makes three key findings: 1) Low-carbon liquid fuels can play a key role in the UK’s decarbonisation and are doing so already;

based approach will the task of Net Zero be achieved in the UK – as such, this report urges ongoing and rigorous dialogue to ensure optimal results. We

2) Hydrogen is a critical component of meeting Net Zero – the downstream sector is the largest producer of

want to work now across government to make this report a reality.”

hydrogen in the world and can maintain and grow its role in producing

Read the report in full at: https://bit. ly/2JgvuCd

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8

News Extra

Image: National Police of Ukraine

T

wo people were killed and eight were injured in an explosion at a gas processing station near the city

of Kharkiv in the east of Ukraine on October 28. The incident happened in the district of Derhachi, just north of Kharkiv.

Emergency services were called to the scene at 11:47 local time, the Kharkiv Region Police Department said in a statement.

The State Emergency Service arrived at the scene to find that a natural gas explosion had occurred with smoke spreading across an area of around 200m2.

The Derhachi Police leadership team also attended the scene along with an investigative taskforce and a forensic team. A

Explosion at gas processing station kills two, injures eight in Ukraine

criminal case has been opened under the Criminal Code of Ukraine in relation to the violation of safety rules at a potentially explosive location.

Police officials did not indicate what caused the explosion.

Gas line explosion kills three, injures 28 in Thailand

A

gas line explosion killed three people and injured 28 in Thailand on October 22. The blast happened on a natural gas line owned by state-owned oil and gas company PTT PCL and happened in Samut Prakan, southeast of Bangkok.

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According to a statement posted by PTT, the explosion occurred after a natural gas leak from one of its pipelines carrying gas through a residential area to an industrial site.

The fire and explosion happened at around 12:55 local time and a preliminary inspection found 28 injured and three dead. PTT expressed its condolences and said it would take responsibility for the incident.

The Bangkok Post reports that two elderly women were among the deceased. Footage posted online shows the moments after the blast and people running from burning homes. A nearby school was also affected.

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Local police confirmed that 28 people were injured in the blast and were taken to six local hospitals. Four houses were badly damaged and another 12 suffered fire damage.

The Bangkok Post quotes local residents as saying they witnessed a construction vehicle filling in land near to the pipeline before the explosion, but investigators have not indicated if this was the cause.

Between 40-50 fire engines attended the scene and the blaze was brought under control after a few hours.

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PTT said that a full investigation would begin immediately.

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9

News Extra

Baram field, 14 miles off the state of Sarawak on Borneo island.

Representative image: Shutterstock

In a statement, Petronas said that the vessel, the MV Dayang Topaz, was undertaking operational work at the Baram B oil platform when it made contact with platform structures after its anchor wire gave way during adverse weather. The Dayang Topaz was working for Petronas Carigali, the oil exploration unit of Petronas, when the accident happened.

Two killed and over one hundred rescued after offshore support vessel collides with rig T

wo crewmembers of an offshore support vessel were killed near

Malaysia on October 27 after their

ship collided with an offshore oil rig operated by state oil company Petronas. The incident happened in the

There were 187 personnel on board at the time of the incident and as a result of the collision, 125 personnel jumped overboard.

The affected personnel were eventually rescued by emergency responders and evacuated; however, two fatalities were reported.

No marine pollution is thought to have occurred during the accident.

Petronas said an investigation is currently underway and all relevant authorities have been informed.

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10 News Extra

US Chemical Safety Board issues factual update on TPC Group explosion in November 2019

O

n October 29, the US Chemical Safety Board (CSB) issued an interim factual update on its investigation into the November 2019

minute and then vapourised upon release, forming a vapour cloud. The three workers who were in the unit at the time told the CSB after the incident that they saw a pipe

oxygen reacts with butadiene in various areas of a butadiene production plant. When oxygen reacts with butadiene, it forms peroxides which then react with butadiene

explosion at TPC Group’s facility in Port Neches, Texas. The blast caused $500 million of damage to the chemical plant and injured three workers.

rupture, with one of them also identifying a release point.

to form popcorn polymer. This reaction can escalate uncontrollably and increase the volume of the polymer to the point where it can crack steel equipment.

The blast on November 27, 2019 resulted

The workers’ observations are consistent with the unit’s recorded process data, the CSB says, although it has not yet visually

in a four-mile radius evacuation order that impacted around 60,000 people over two days. The CSB’s factual update provides

confirmed the failure location due to the extensive damage and unstable structural conditions at the site. Shortly after the loss

Neches facility’s butadiene fractionator had a dead leg component, a component that is open to a process but does not have flow

background information, a preliminary incident timeline, and the path forward for its investigation. The investigation so far points to the explosion possibly being caused by a loss of containment event that led to the

of containment, the vapour cloud ignited and caused the first of several explosions.

through it, from as early as September 6, 2019. Dead legs are known by the industry to promote popcorn polymer formation and may have contributed to the November explosion.

liquid level in the final fractionation phase to drop rapidly from its operating level.

The liquid, which was primarily butadiene,

called “popcorn” polymer which can form in process vessels containing a high concentration of butadiene. It is a hard,

The CSB is continuing its investigation and will publish a full report upon its completion.

Read the factual update here: https://bit.

emptied from the fractionator in less than a

porous, opaque material created when

ly/35VnPAX

A key focus in the CSB’s investigation is the possible presence of a substance

The CSB investigation notes that the Port

News Extra 11

Cannabis plant explosion seriously injures two in US A

n explosion at a cannabis factory in

The incident comes five years after another

New Mexico, US seriously injured two workers on October 15. The blast happened at a manufacturing facility belonging to New MexiCann Natural Medicine in the city of Santa Fe and was the second incident in the last five years

explosion at the same facility which also severely injured two workers. The employees had been extracting THC, the active ingredient in marijuana, as part of a process that involves soaking cannabis with butane and then heated.

New Mexico’s Department of Health (DOH) said that two employees at the facility were

The company was fined $13,500 by OSHA and cited for 12 “serious” violations in relation to workplace health and safety.

to injure workers at the factory.

warrants to access camera footage from

transported to hospital by air ambulance and that both were in serious conditions. Their identities have not been made public. Local news outlets reported that both workers were

several areas across the facility.

Preliminary reports said that the blast happened near chemical extraction

More recently in May 2020, there was an explosion and fire at an unrelated cannabis oil factory in Los Angeles, California in which

taken to intensive care units.

Santa Fe City Fire Department, the DOH and

equipment and the workers suffered burns to their heads and torsos. New MexiCann’s approval to manufacture cannabis-derived

over 230 firefighters responded to. The incident was classed as a major incident after 12 firefighters were injured by a

OSHA have all opened investigations into the explosion after officials obtained search

products was rescinded shortly after the blast, the DOH said in a statement.

secondary explosion.

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On the other hand, manufacturers The first two years after the introduction of Every two months, Prof.

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Every two months, IECEx Chairman Every IECEx Chairman Prof. products due to restrictions set by the safety the German PTB is these this creatingtests andof thethis program “Explosion Pressure”. are the obliged to fulfill safetyorstandards, new procedure were quite a surprise. alternatives for forklift and truckauthority, drivers necessary, the efficiency ofcan work increases Every twoThorsten months, IECEx Chairman can use specified test procedures same features bewere avoided; IECEx Chairman 2014-2019, provides anProf. update Prof.

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

Dr. months, Thorsten Arnhold Dr. Thorsten Arnhold provides anprovides update Dr. Thorsten Arnhold provides an on developments within the organisation. factory hands? dramatically and sources of failure are producing the test samples and evaluating the an update on developments within which are defined by the documents IECEx CB asked for a scope extension and to evaluate if their product is fulfilling the the bureaucracy and paperwork can be onThorsten developments within his organisation.

Dr. Arnhold provides anupdate update standards.

Onthe thedocuments other hand,removed. manufacturers The first twoextension years afte onondevelopments within hisorganisation. organisation. an update on developments within which are defined On by IECEx CB asked for first aparticipating scope and developments withinIECEx his Every two months, Chairman standards. the other hand, manufacturers The two years after After feedback from ExTLs, a test results. removed. on developments within his organisation. his organisation specifications. reduced significantly.

All this of course Every two months, IECEx Chairman Despite After feedback from participating ExTLs, a test results. mentioned above. Ito as a result, no certificates were published. these concerns, cannot deny the his organisation are obliged fulfill these safety standards, this new procedure we mentioned above. as a result, no certificates were published.

Prof. Dr. Thorsten Arnhold provides statistical evaluation of the results is carrie these concerns, Ito cannot the safety are obliged fulfilldeny these standards, this wer he IEC is based on two strong without anyDuring declinethe ofevaluation the safety level.

Prof. must Dr. Thorsten provides Despite ofare theprocedure results is carrie last year,new however, the situation confess thatArnhold I am not totally No wonderstatistical that process industries fact that we can expect many benefits from During the last year, however, the situation an update on developments within which are defined by the documents IECEx CB asked for ajos must confess that I am not totally No wonder that process industries are fact that we can expect many benefits from ne of the most frequently asked out.

The participants are than invited to In the meantime, the following seven programs pillars:on thedevelopments first is the generation the operators of industrial plants, the an update within For defined the CBthan asked the most frequently asked The participants are toajois In thewhich meantime, the following seven programs convinced of alltime, the supposed so eager toout. introduce theseIECEx new systems digitalisation inbeen theare hazardous areaby sector. tne theofpresent there are few This has a major concern for documents IECEx. changed significantly.

Now we invited havefor more convinced of all the supposed so eager to introduce these new systems digitalisation in the hazardous area sector. t the present time, there are few This has been a major concern for IECEx. changed significantly.

Now we have more his organisation and question maintenance of international to beconducted found in theordefinition importantinelements of at IECEx conferences and benefits workshop which the results are presentt haveare been are still running: What are the mentioned above. as agood. result, no certificat blessings of digitalisation.

During myand and so far, so his organisation question at IECEx conferences workshop inand which the results are present have been conducted orannual are stillManagement running: into their plants, conferences or technical trade Three years ago, at its 10 Ex CBs Ex TLs with a respective sc mentioned above. as a result, no certificat blessings of digitalisation.

During my into their plants, and far, so good. standards dealing with all significant of minimum safetyago, requirements (avoidManagement conformity assessment?

Who thewith major conferences or technical trade Three years at its annual 10 Exdiscussed.

CBsso and Ex TLs a respective similar events is about the difference and Anare important part of thissc professional career, I have visited However, these shiny and new a possibilities At itsCommittee most basic, toTest keep standards During the last year, ho • Spark Ignition for Ex “I” Test Round 2010 and discussed.

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Conformity the last ayear, ho •most Spark Test for Ex The “I” Hague, Roundplayers 2010make shows do not have Industrial Meeting in extension and aDuring number of applications. between ATEX and IECEx. No worries – doing workshop is training common manythat manufacturers in the many different can you forget that all theseto achieve of safety highIgnition throughout the whole workshop is training to achieve a common between ATEX and IECEx. No worries – in Internet of Things (IIOT) as the main organisation launched a “d” new procedure •global Flame Transmission for Ex Test Roundto 2013 manypresent manufacturers inor many different can make you forget that allchanged these of the safety high throughout the whole tInternet the time, there are few This has been a major concern for IECEx. significantly.

N almost every electrical electronic availability of a broad range assessment systems consist of networks of of Things (IIOT) as the main organisation launched new procedure • Flame Transmission for Ex Test Roundto 2013 industries all the world and smart devices are poweredchanged bythe electrical operational life of equipment these tI don`t the present time, there are few This has been aina “d” major concern for devices IECEx. N want toover give a lecture about this understanding of bestsignificantly. working practic industries all over the world and smart are powered by electrical operational life of equipment in these Ifocus. don`t want toother give a to lecture about this of understanding of the best working practic One of the most important adopt the new IEC 60079-33 standard.

This A look in the IECEx online database shows product.

The is make sure products from different manufacturers independent organisations connected by a • Temperature Classification general Test Roundenergy, 2013 normally conferences or technical trade years ago,general at itsTest annual Management 10 Ex CBs TLs mostnow. of those with the highest but levels batteries.

As database a and Exshows areas, it isThree necessary to conduct regular focus.

One most important adopt the new IEC 60079-33 A lookstored in theinIECEx online • Temperature Classification RoundThis 2013 normally topic Itofisthe not so obvious there areas, conferences or technical trade years ago, at itsstandard. annual Management 10active Ex CBs and Ex TLs most of those with the highest levels energy, stored batteries.

As acertificates it isThree necessary to conduct regular the assessment of products, services, with covers standardised safety and functionality kind of franchise system.in The players topic now.

It is not so obvious but there consequences of this trend are the the protection method “s” for “special”, that already more than 20 base • Electrostatic Charge general Test Round 2015 of that automation continue tointerested employ consequence, those products have to meet inspections and maintenance.

But those consequences of this trend are the covers the maintenance. protection method forRound “special”, that already more 20 certificates base shows do not have the Industrial Committee Meeting in“s” The Hague, theday-to-day extension and aPressure numbe are many differences.

For Thethose workshop forthan the Explosion • Electrostatic ChargeMeeting general Test 2015 the of that automation continue to employ consequence, products have to meet inspections and But those manufacturing rules and procedures are features. doing operative business shows do not have the Industrial Committee in The Hague, the extension and a numbe are many differences.

For interested The workshop for the Explosion Pressure drastically shrinking value chains and which was introduced to permit the quick on IEC 60079-33 have been published, an significantshrinking numbers value of manual all requirements which electrical products responsible might have to manage a couple • Intrinsic Safety Test Round 2015 drastically chains and which was introduced to permit thenew quick on IEC 60079-33 have been 2018 published, readers IThings can recommend the IECEx 01A responsible Program took place in June at thean significant numbers ofrequirements manual all requirements which electrical products might have to manage a couple exactly in line with the of with the end customers are the Certification • Intrinsic Safety Test Round 2015 Internet of (IIOT) as the main organisation launched a procedure to readers can recommend IECEx 01A of thousand Program tookthat place in June 2018 the innovation cycles ininevery sector, and adoption of newcovered technologies, new materials amuse confident many others will at follow. workers, whether production, intended for in hazardous areas have products by ‘Ex’ or Internet of IThings (IIOT) asthe the main organisation launched a new procedure to • Explosion Pressure for Ex “d” Test Round 2017 and innovation cycles ininevery sector, and adoption of new technologies, new materials am confident that areas manyGermany, others willand follow. workers, production, intended for use in Braunschweig, hazardous have of thousand products covered by ‘Ex’ or Guide: “Anwhether Informative Guide comparing PTB in 80 the relevant standards.

For regulators, the major benefit Bodies Test Laboratories.

• Explosion Pressure for Ex “d”of Test Round 2017 transport or logistics. to fulfil. PTB safety standards, and when focus.

One ofin the most important adopt the new IEC 60079-33 standard.

This A look Germany, in the IECEx onl Guide: “An Informative Guide comparing functional in Braunschweig, and 80 especially the process industries. etc.

This implements a practice which has transport orthe logistics. to fulfil. functional safety standards, focus.

Oneelements ofin most important adopt the new IEC standard.

This A look in the IECEx onli consists of the transformation especially the process industries. etc.

This implements aand practice which has • Pressurised Enclosure for Exwhen “p”60079-33 est Round 2017 various of both IECEx and ATEX”standards participants from international ExTLs joine paperwork is involved, this can often prove • Pressurised Enclosure for Ex “p” est Round 2017 participants from international ExTLs joine various elements of both IECEx beencovers field-proven in the ATEX area For IECEx, systems, this development recognition consequences ofhow this trend areand theATEX”paperwork thethis protection method “s” infor “special”, that already isismore than is involved, can ATEX often prove I want can to explain thistrend unique symbiosis general requirements hedged in laws other franchise IEC beencovers field-proven in the area For IECEx, this development recognition consequences this are theIECEx of method Like “s”IECfor “special”, that already more than which beof downloaded from the this event.

In the eight years the program Every day we see tens of thousands At and IECEx we have recognised these an impossible task.the protection which can be downloaded from the IECEx this event.

In the eight years the program h In process facility safe areas, the speed since 2003. that its focus on this area has been useful Every day we see of thousands Atproviding IEC IECEx we have on recognised these an impossible task. is creating value fortens different stakeholders. specific and detailed requirements and is the infrastructure forIEC the drastically shrinking value chains and into which wasofintroduced to permit theand quick 60079-33 have In process safe areas, the since 2003. that focus on area has beenthe useful of trucks onfacility ourPublications highways driven by speed issues and their importance for thethat website under beenits running, wethis have seen quali As an illustration the program,to here is aspecific short drastically shrinking value chains and which was introduced permit the quick on IEC 60079-33 have ofadaptation truckswho on represent our highways driven by of specific issues and their importance for the website under Publications been running, wehigh have seen the will quali As anfor illustration the program, here is aCA short ofExperts to this atrend is restricted theBased industry levels ofthat safety be broad range guidelines practical of use. activities. on aand strong brand and responsible drivers. market.

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

We have established a special IEC innovation cycles in every sector, and adoption of new technologies, new materials am confident that many different interested parties develop an name, IEC provides a system of rules, our test has risen from a satisfactory level description of one chapter of the 2017 Test byInthe innovation ofam thehappier suppliers and the equipment Under inthe ATEX directive, the fulfillment ofworking group maintained. the supermarket, to pay to deal withto questions on level today. hazardous locationsthe is fulfillment by innovation ofII am the suppliers Under the ATEXimplements directive, ofworking maintained.

What I want to highlight inhappier this article isand the the International the beginning an excellent Round: Inthe the supermarket, to pay equipment in hazardous locations is of group tooperational deal withto questions onas level especially inand the process etc.

This a practice which has international standard.

They tryindustries. to develop standards define a level procedures andbeginning documents What I want to highlight in this article is the the an excellent today.

Round: financial technical capabilities of the the general requirements of appendix II with especially in the process industries. etc.

This implements a practice which has the cashier directly rather than attempt how modern mobile digital devices can be becoming smart. financial and technical capabilities the safety thewhich general requirements of appendix II with fact that IECEx iswhat notrather athelaw likeshould ATEX,be it of isin an For the program “Explosion Pressure -well Testas the cashier directly than attempt becoming smart. how modern mobile digital devices can be a consensus on norm has to be fulfilled at least standard formats and templates. been field-proven in the ATEX area For IECEx, this develop fact is notmachine a law like it is an the health program Pressure - safely Test operators. theFor basic and“Explosion safetyinrequirements is transformed The executive is preparing a promot to that use aIECEx checkout thatATEX, will only to meetgroup the requirements been field-proven the ATEX area For IECEx, thisofdevelop operators. theRound basic health and safety is transformed The executive group is preparing athe promot to useofa measurements, checkout that will only safely to meet thesorequirements organisation acting machine worldwide onvocabulary, a voluntary We at IECEx are convinced 2017” the general routine procedure terms ratings, to keep the risks to people and therequirements Professional secretary organisations support allow me to pay on my third attempt, and One advantage is the easy identification of of hazardous area standards. organisation acting worldwide on a voluntary We at IECEx are so convinced of the Round 2017” the general routine procedure obligatory, and harmonised standards are just conference during the TC 31 spring sessio In process facility safe areas, the speed since 2003. that its focus on this ar allow me to pay on my third attempt, and of hazardous area standards.

One advantage is the easy identification of obligatory, and harmonised standards areand justcontrolconference during the TC 31 spring sessio performance, safety, reliability andChris sothe on; in commonly accepted limits. the operative business of every In process facility safe areas, speedenvironment 2003. that its focus on effect this are basis.

Our Executive Secretary, Agius importance and the trust-building of is since described bymeans the standard “Explosive then only when a human assistant comes individual products by of digital type basis.

Our Executive Secretary, Chris Agius importance and theApril trust-building effect ofb is way described bymeans the standard “Explosive Many process sector companies have to one to do this.

Split Croatia on 23 2018, to be held then only when a human assistant comes individual products by of digital type of adaptation to this trend is restricted the industry and high le whatever is relevant to a given topic.

By this, standards are comparable to safety CA system.

The CA systems homepage is Many process sector companies have to one way to do this.

Split Croatia on 23 April 2018, to be held thewe PTP that we decided at the 2014 IECE once that IECEx is like a franchise system. labels. Inspection atmospheres - Part 1: Equipment protection oversaid to help! plans, equipment data, protection Furthermore, arethat making special efforts of adaptation this iswith restricted the industry and high leb the PTP we decided at 2014 IECE once thattoIECEx istrend like a franchise system. nets: atmospheres - Part 1: Equipment handle substances, potentially IECEx in conjunction with thethe UN, UNECE oversaid tohazardous help!

Furthermore, we are making special efforts labels.the Inspection plans, equipment data, worker or artist can fail and fall the central communication platform where handle substances, with apotentially conjunction with will the UN, UNECE by the innovation of the suppliers and the the enclosures ATEX directive, the fulfillment of insurveillance. maintained.

There ishazardous a certain infrastructure and powerful Management Committee Meeting in The byUnder flameproof “d”” - IEC 60079facility layouts, inspection records, repair to intensifyIECEx market IECEx by the innovation of the suppliers andofthe Under ATEX directive, the fulfillment ofCroatian maintained.

There isconsequences a certainvoluntary infrastructure and a powerful Committee Meeting in The by flameproof enclosures “d”” - Bodies IEC 60079to intensifyManagement market surveillance.

IECEx will facility repair severe forconsensusthe life and health Tolayouts, enable the IECEx Certification the Standards Institute. focus The well-known but he or she isinspection notthe hurt orrecords, killed. all relevant information, documents and data The Call me old-fashioned, but I can’t help protocols and many other important data be working hand in hand with the EU’s severe consequences for the life and health of To enable the IECEx Certification Bodies the Croatian Standards Institute.

The focusa steering organisation butbut the day to day of the tohand make it the obligatory for all ExTLs 1,the Edition 7.0.

Anrequirements essential data characteristic financial and technical capabilities general ofand appendix IIHague with Call me old-fashioned, I can’t help be working hand in with EU’s protocols and many other important based international standard is available are available 24/7.

Another unique feature steering organisation but the day to day Hague to make it obligatory for all ExTLs a 1, Edition 7.0.

An essential characteristic the employees in their plants. and Test Labs to issue Test Reports of this conference will be on industry and financial and technical capabilities the general requirements ofand appendix II with but wonder what is the going to happen Bodies to of the are stored in special data banks.

ATEX ADCO to quickly ban unsafe mobile the employees in by their plants. andforTest Labs to issue Test Reports of this conference will be on industry and business is done Certification applicant ExTLs. the testing and assessment of the but wonder what is going to happen to ATEX ADCO to quickly ban unsafe mobile are stored in special data banks. for anybody to use and follow.

ConsensusSetting standards is just one side of the is the online certificate database.

All active operators. health and safety requirements isof ExExTLs. Theand executive group is business done by thewe Certification Bodies applicant forthe the basic testing and of the Certificates based onassessment IECand 60079-33, the users equipment, all IEC all thoseispeople once are completely products from global markets, a and, new as with operators. the basic health safety requirements isof Theand executive group is onacknowledge IEC 60079-33, users Exmarkets, equipment, all IEC (ExCB) and thethat Test Labs (ExTL).

In the IECEx coin,Certificates explosion protection is the ability of the thecertificates all those people once we are has completely products from a and, new as with based means every voice been however.

Webased have to are global available from here.

Finally, (ExCB) and the Test Labs (ExTL).

In the IECEx explosion protection is the ability of the The equipment intended for with use all in these areas If anIECEx Operational Document OD 233 standards was International Conferences, is frT enveloped in the digital age inspection job is due, theharmonised database working group with these issuesattendance obligatory, and aredealing just with conference during the The equipment for use in these areas the IECEx Operational Document was International Conferences, attendance is frT enveloped in the digital age with If anfact inspection jobto is withstand due, theare database working group these issuesabout obligatory, and harmonised standards aredealing just conference during the Certified Program we all now have More detailed information the progr enclosure pressure (clause heard, atEquipment least aintended two thirds majority that standards which not OD 233 all the documents and copies of certificates thetoinnovations and consequences wehave informs the technical management of the started work in May 2019 at the Singapore Certified Equipment Program we now More detailed information about the progr enclosure to withstand pressure (clause has fulfill certain safety requirements in order developed and published, and the second of charge (See: www.iecex.com/meeting-a Many57agreement process sector companies have to one way to do this.

Croatia onDocumen 23 Apr the consequences webeen informs the technical management of the started work in May 2019 the toinnovations fulfill certain safety in to orderfollowed developed and the second of charge (See: www.iecex.com/meeting-a by alland interested parties has are worth nothing.

Inthis. this and can be downloaded free ofat charge. accepted ExCBs plus 5requirements Applicants and can be found inSplit the Singapore Operational 15.2.).

This ispublished, of do decisive importance for the Manyhas process sector companies have one way Croatia onDocumen 23 Apri read about daily in the media, such as and plantedition and thehas inspection plans and otherFebruary Meetings of IECEx. 57 accepted ExCBs plus 5 Applicants can be found inSplit the Operational 15.2.).

This isto ofavailable decisive importance forMeetings the toachieved avoid the ignition of potentially explosive been since events/iecex). read about daily in the media, such as plant and the inspection plans and other of IECEx. and anysubstances, sustained opposition sense, similar again to aavailable safety netsince which to avoid the ignition of trains, potentially explosive edition has been February events/iecex). handle hazardous with potentially conjunction 68autonomously accepted ExTLs plus 5 Applicants forming OD 202 ed. 2.0IECEx (2017)in which can be w design and construction of “d”on products. driven ships andforming necessary information are downloaded handle hazardous substances, with conjunction 68 accepted ExTLs plus 5been Applicants OD 202 ed.

2.0IECEx (2017)in which can be w design and construction of “d” products. atmospheres.

These requirements arepotentially defined only 2017.

The central and critical element ofWith boththis backbone, autonomously driven trains, ships and necessary information are downloaded on on substantial issues has overcome. prohibits accidents if it is installed the Certification Bodies atmospheres.

These requirements are defined central and critical element of So both downloaded the IECEx website. a global network for robots testing andlife certification Therefore, explosion pressure (reference vehicles as well as dealing with tablet computers orthe smart phones. inBodies hazardous areas atfrom least, severe consequences for the and health of 2017.

ToThe enable the IECEx Certification thewill Croatian Standards downloaded from the IECEx website. ainAn global network forstandards testing and certification Therefore, explosion (reference vehicles as wellstandard as robots dealing with So inTest hazardous least, tablet computers orthe smart phones. the international IEC 60079 and correctly, the standard and the OD ispressure the so-called In addition, IECEx be holding a series o international not to behealth the enable full value of standards and Labs areareas doingat their with their severe consequences forshould the life and of the To the IECEx Certification Bodies thejob Croatian Standards in the international standards IEC 60079 and standard and the OD is the so-called In addition, IECEx will be holding a series o the entire logistics chain in factories and digitalisation is to be welcomed, and ofthe explosion protected products.

Such a pressure) has been selected as the quantity entire with logistics chain inwhich factories anda digitalisation is to begroup welcomed, and the employees inatheir plants. andif Test Labs to issueasTest Reports and of this conference will b of explosion protected products.

Such pressure) has been selected the quantity confused regulation, is always is only gained there is an ongoing customers independently within the frame IEC 80079. ‘independent verifier’. working meetings in Weimar, Germa the employees in their heavily plants.depends on the These Test Labs to issue Test Reports and of this conference will supermarkets. devices together with cameras, supporting this process will be a crucial IEC 80079. ‘independent verifier’. working group meetings in Weimar, network organisation When Iby wrote this article I IEC was in theGerma final b toand bewhich compared inthey the program “Explosion supermarkets. supporting this process will be a crucial These devices together with cameras, obligatory and generally issued by a national assessment ensures are that is established the contract with network organisation heavily depends on the smart glasses When I wrote this article I was in the final to Certificates be compared in the program “Explosion in June where feedback from application o based on IEC 60079-33, the users of Ex equipment, and other digital part of theinIECEx mission into the future.

June where feedback application Certificates based2017”. on IEC 60079-33, the users Ex competence and quality management of every smart glasses stage of preparations forfrom theequipment, 2018 IECExo Pressure Test Round part the of the IECEx mission into the of future. and- other digital or regional governmental body. followed. and scope of of their activities. competence andmight quality management of every correctly stage preparations for thebe2018 IECEx Pressure - Test 3.4, Round 2017”.

Interesting, you say, if you are new Under paragraph the standard defines this Ex “s” process will also discussed.

The Interesting, equipment intended forquality use of in new these IECEx Operational Document OD 233Management was International Conferenc you might say, you paragraph 3.4, the standard defines Ex “s” process will alsoMeeting beConferenc discussed. single member.

The overall the test areasUnder Committee in Cann The equipment intended forifquality useare in the these IECEx Operational Document OD 233this was International single member.

The overall of test areas Management Committee Meeting in Cann has to certainprocess safety needs requirements in order The developed and published, andwith the second of charge (See: www.ie andfulfill certification to be be high France. explosion pressure is determined www.hazardexonthenet.net has to certainprocess safety needs requirements in order The developed and published, andwith the second of charge (See: www.ie andfulfill certification to be be high France. explosion pressure is determined www.hazardexonthenet.net and uniform, and the results of these processes the Test Sample “EP” for two different www.hazardexonthenet.n to avoid the ignition of potentially explosive edition has been available since February events/iecex). and uniform, and the of these processes theedition Test Sample “EP” for two different www.hazardexonthenet.n to avoid the ignition ofresults potentially explosive has been available since February events/iecex). must be the same or at least comparable I will report on the outcomes of this, the m configurations (single chamber and atmospheres. are defined configurations 2017. The(single central and critical must be the These same orrequirements at least comparable willboth report on the outcomes of this, the m chamber and elementI of

TheStandardisation Proficiency Test Test Program The Proficiency and Program for ExTLs ExTLsAssessment key trust-builder trust-builder for -- aa key Conformity at IEC within the the IECEx IECEx system system within

The pros and cons of digitalisation

IT I O O A A

A

14 UKCA Focus This special UKCA focus highlights the main regulatory changes and a

the UKCA will become mandatory on all goods being placed on the UK market.

summary of organisations that will become UKCA Approved Bodies in January. All six organisations will be able to provide both CE and UKCA services.

To add an extra layer of complexity, Northern Ireland will have its own rules where either CE or UK(NI) markings will be accepted until 2023.

Although the UK formally left the European Union on 31 January 2020, it remains in a transition period until 31 December 2020 to allow for the continued application of rules and regulations surrounding conformity marking and the assessment

For ‘Ex’ products, UK-based Notified Bodies will automatically become a ‘UKCA approved body’ from 1 January 2021 and be able to issue the required certificates needed for selling into the UK market. From the same date, any mandatory third-party

of products. Although there is still time for the UK and EU to negotiate a free trade agreement, a no-deal situation could occur and manufacturers should be considering

conformity assessment for the EU market will have to be conducted by an EUrecognised conformity assessment body.

being placed on the market in Great Britain (England, Wales and Scotland).

It covers most goods which previously required the CE marking, including those

the implications this will have on their operations.

A no-deal situation would mean that the

To help ensure continued market access in both the EU and UK, on the following pages we have provided the details of a select few Notified Bodies

approved under the ATEX directive. From 1 January 2021, the UKCA marking can be applied to products or the packaging

EU will not recognise CE markings issued

by UK Notified Bodies for products to be placed on the EU market from 1 January

capable of offering both UKCA and CE services. If you have any issues or questions regarding the changes,

of any goods entering the UK market that are currently subject to CE marking.

2021. The UK will recognise the CE mark for a transitionary period up to 2022 when

don’t hesitate to get in touch with any of them.

Be prepared for UKCA marking from January 1

T

he UKCA (UK Conformity Assessed) marking is a new UK product marking that will be used for goods

© DNV GL

PROVIDING THE COMPLETE SOLUTION Classification | Verification | Risk Management | IECEx | CE Marking | UKCA | Functional Safety Assessment | Major Accident Hazard Management | Hazardous Area Services (Advisory and Certification) | Due Diligence

Contact us and find out what we can do for you: email. ukverification@dnvgl.com

www.dnvgl.co.uk

SAFER, SMARTER, GREENER

HazardEx publication advert design_v1.indd 1

Navigate market access requirements through the Brexit transition Prepare your business smoothly and swiftly for U.K. and EU market entry with UL’s global scope and local expertise.

Start the conversation today at UL.com/brexit.

03/11/2020 09:14:04

Transfer your Ex certificates and technical files to CML Netherland in the case of a ‘no deal’ Brexit outcome.

With the UK currently negotiating its exit terms with the EU we und about the validity of existing EU certificates and tech

The British government has stated, “products which were tested by a will need to be retested by an EU-recognised conformity assessmen the EU internal market.”

With our focus on innovation and responsiveness, Eurofins CML is uniquely placed to support manufacturers “Alternatively, of Ex products with the manufacturers can seek to arrange for their files t Notified Body to allow for certificates of conformity new UKCA marking requirements coming EU-recognised into force in the UK from Notified Body to continue to be valid.” the 1st January 2021.

CML is maintaining two ATEX notified bodies; one in the UK and the CML UK will handle all enquiries and manage the projects on behalf usual time and cost effective manner.

Discover how manufacturers can benefit from our expertise in By holding ATEX certificates from bo global hazardous area product certification as well as our extensive will be able to continue trading within experience in Ex compliance guidance, and let us provide you with Our simple approach means you can a route to compliance for both new & existing products. people you know and receive the gre

to expect while making sure you are B

Eurofins CML. Trusted Certification, Delivered Newport Business Park New Port Road, Ellesmere Port, CH65 4LZ

www.cmlex.com sales@cmlex.com +44 (0)151 559 1160

8175�

8175�

UKCA Focus 17

UKCA Providers List B

elow you can find a summary of the providers included in our special focus that will become UKCA Approved Bodies from January 1, 2021 and be able to provide UKCA services.

UKCA Approved Body

Approved Body No Website

Contact

CSA Group

0518

www.csagroupuk.org

+44 (0) 1244 670 950

SGS Baseefa Limited

1180

www.sgs.co.uk/sgsbaseefa

sgsbaseefa@sgs.com

Intertek

0359

www.intertek.com

https://bit.ly/3f3mzzZ

Eurofins CML Ex

2503

www.cmlex.com

E: sales@cmlex.com T: +44 (0) 151 559 1160

UL International (UK) Ltd 0843

www.ul.com

Shaun Wilson E: shaun.wilson@ul.com T: +44 (0) 1256 674719

DNV GL

www.dnvgl.com

James Steven E: james.steven@dnvgl.com T: +44 (0) 2038 165744

0097

www.hazardexonthenet.net

18 Gas

Toxic gas management: a review of the strategy behind BS 60080:2020 O

n premises where toxic gas is used, stored or created, a Gas Detection

System may be required to protect the occupants or people on site. In many cases, a Fixed Gas Detection system is required. BS 60080:2020 has been recently published to provide standard guidance to Design Engineers and relevant parties involved with these systems. This paper reviews the strategy behind the standard’s approach to addressing the Toxic Gas risk.

The location of field devices (Gas and Flame Detectors) is challenging and the response by the oil and gas industry was to develop in-house Engineering Technical Practices or standards (ETPs) to fill the gap between legislation/regulations and method for design.

Understandably, these have primarily focused

Figure 1 – Taken from page 38 of BS 60080

on flammable atmospheres.

gas cloud size and the concentration that might cause immediate harm (immediately dangerous to life or health). For the majority of toxic gases, there is scarce comprehensive empirical data

Acknowledging the undefined variables, the new British Standard recommends developing the strategy around providing time to make the occupants safe. See Figure 1, taken from page 38 of BS 60080, which attempts to illustrate the response time versus toxicity on a graph.

The strategy to protect against flammable

about each, and the environments of application are not repeatable for reasonable study. In light of the lack of demonstrable evidence, the

gas accumulations is based on UK HSE publication OTO 93-002 which is addressed in various ETPs with Performance Targets.

question remained, ‘What is the best strategy for deciding the location and number of Toxic Gas Detectors?’

The reader may notice that there are no times or values indicated on the graph. Those values are to be defined by the Design Engineer

The petrochemical industry’s approach to toxic gas has been limited to the specific risks (mostly H2S) with a prescriptive approach.

These are assigned by design engineers to address the appropriateness for each area. The advantage to this scientific

Area 3.1

approach is the empirical evidence of speed and overpressure.

The empirical evidence for toxic gas is more problematic. The UK HSE publication EH40/2005 Workplace Exposure Limits gives guidance on Workplace Exposure Limits which ‘are concentrations of hazardous substances in the air, averaged over a specified period of time, referred to as

3.2

3.3

3.4

Grade First Floor Operational Area

First Floor Pathways

EH40 identifies the toxic substance and the short/long term exposure limits. However, it does not provide specific information about

www.hazardex-event.co.uk

Volumetric Transitional Occupancy

Incoming Scenario Pressurised Supply Cabinet LOC

Operative Area

a time-weighted average (TWA).’ [UK HSE publication EH40/2005 Workplace Exposure Limits – para 3 (page 6)] 3.5

Volumetric Operational Low Occupancy

Filling Cabinet

Volumetric Operational Occupancy

Scenario Ambient LOC

Colour Yellow

Green

Blue

Orange

Magenta

Description Given: • The operation of the HVAC is not monitored.

Proeon recommends: • 75% Coverage of a 7.5m gas cloud.

Given: • The operation of the HVAC is not monitored.

Proeon recommends: • Volumetric detection targets for the pathway (escape route) shall be clouds or plumes of gas of 15m or larger. Within 7.5m of the source of risk.

• 85% coverage of a 15m gas cloud.

Given: • The operation of the HVAC is not monitored.

Proeon recommends: • 85% coverage of a 3m gas cloud.

Given: • The operation of the HVAC is not monitored.

• The close location of 6.2bar pipework.

• The Filling Cabinet is at risk of N2 leaking.

Proeon recommends: • Volumetric detection target for the platform to be clouds or plumes of gas of 5m or larger within 7.5m of the cabinet.

Given: • The operation of the HVAC is not monitored.

Proeon recommends: • 75% Coverage of a 10m gas cloud.

Table 1 – Sample of Toxic Gas Performance Targets

prior to the placing of gas detectors by understanding the site and meeting with site representatives who understand the risk, mitigations and operational procedures.

Understanding risk Identification of the risk or hazard is the first step. This is normally the result of a study or report where the risk of toxic gas has been identified. The risk assessment process is illustrated in BS 60080 with a flow chart that seeks to remove the risk if possible, what risk remains will require additional controls to reduce the risk as reasonably practicable. A Fixed Gas Detection system may be an additional method of control or layer of protection. It is important to understand that in the moment the Gas Detection System has detected gas, all the other

Gas 19

Figure 2 – 3D Layout of a Toxic Gas Risk - The areas marked in orange are occupied frequently during operations

Figure 3 – Zones are defined by areas that are frequently occupied or near the machine that may allow toxic gas to escape

control measures have failed and the site is now having a life-threatening incident. The

the areas will provide greater awareness of the occupants (i.e. designated access routes

A more detailed explanation of risks and mitigation are unpacked in Table 1 on page 39

author encourages sites to take an aggressive approach to control measures prior to the installation of a Fixed Gas Detection System.

will be populated with a greater number of potentially untrained people then a workstation that is manned 24/7).

of BS 60080. The designer should document the agreed risk and validation as a basis for the Performance Targets.

Toxicity – how much is too much?

The occupants- who are we trying to protect

Performance Targets

As stated earlier, EH40/2005 Workplace Exposure Limits gives guidance on Workplace Exposure but does not provide the values that

BS 60080 goes into detail of the expected occupants of the area at risk. How much

The performance targets are set based on the risk (who or what is being protected), environment and mitigations as reported in the

are immediately dangerous to life or health (IDLH). Material Safety Data Sheets from the site provide some information, however, even

knowledge or training each occupant has will impact their response and time required to escape. How long they occupy the area

earlier documentation. Performance targets are a set of detection goals against which success of detection can be measured.

if the IDLH Value can be identified, the toxicity of the gas may be altered by combining with other gasses in the environment. Gas detectors normally measure the toxicity in parts per

will also feed into deciding who is at risk. It is important to understand that if an area is not normally occupied it may not require gas detection. Understanding the means of escape

The targets will state: • Defined areas of detection or mapping zones (graphical plan)

million (ppm). The gas detector setting must be decided by the end user and should provide a margin of error. If the harm caused by the gas is

and procedures will inform the time required to act in the event of an alarm.

• The maximum a gas cloud can grow before being detected • The percentage of the mapping zone that is

deemed to be a greater risk, then lowering the Action Required threshold will be required.

Understanding mitigation

Inventory and supply The amount of toxic gas will impact on the risk assessment, as the inventory may range from

Passive mitigation is part of the installation that is normally structural or part of the process equipment. If passive mitigation is included,

It is at this stage, after the strategy has been decided, that the engineer can begin to design the gas detection system.

a single bottle to a large tank. The designer needs to understand how an uncontrolled loss of containment (LOC) will impact the

then regular inspections should be part of the ongoing management. Active mitigation is an activity or system that is undertaken to prevent

The design engineer should take one of three approaches:

environment. The pressure of the supply will also impact how much gas will be introduced to the environment during LOC. Where the supply is external to the area being assessed, some form of supply pipe/hose integrity check should be undertaken to protect from LOC.

the gas becoming a risk or a system that once activated prevents the risk from escalating.

A site may initiate passive or active systems and procedures to reduce or eliminate the risk.

the target coverage • The set points for the gas detectors

• Prescriptive: placing gas detectors to an agreed rule set.

• Volumetric: detecting a certain size of gas cloud in a defined area.

• Scenario based: designed around a specific risk.

Physical layout

For example, passive mitigation may have vapour sealed doors (fire doors) and fire stopping which prevent the spread of gas beyond the area. An example of active mitigation is powered ventilation (HVAC) which

Understanding the physical space of the site impacts how the risk can escalate. For example, in an area below the floor level with a gas that is heavier than air, the gas has no escape, whereas an external installation with a lighter than air gas may allow the gas to

circulates, dilutes, or extracts the air to prevent the accumulation of gas. For all mitigation, verification or regular inspection is required to include these into the mitigation for the risk assessment. Note: any active system will also need to work in fail-safe mode, i.e. the active

7.6.3 to 7.6.5, the following is a brief summary.

escape. Also understanding the purpose of

system will engage in a fault condition.

because of its simplicity. However, unless the

BS 60080 goes into greater detail in section

Prescriptive: Based on previous evaluation and documentation that will provide rules for the areas at risk. This approach is attractive

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Gas 21

The full title of BS 60080:2020

with continual changes of process and procedures. If there is no review as part of

is “Explosive and toxic atmospheres.

Hazard detection mapping. Guidance on the placement of permanently installed

the management of change, then the site should be reviewed with a frequency of at least every five years or after any significant changes.

flame and gas detection devices Figure 4 – After Gas Detectors are positioned, the mapping software using software tools provides verification of coverage to compare to performance targets and techniques” which isn’t very site has supporting documentation to support captivating, but it does mention software tools.

Legal obligations and responsibilities BS 60080 recommends ‘the Fire & Gas mapping report should be reviewed regularly.’

BS 45444 (Toxic Gas) specifies that gas detector location design requires expertise and the advice of experts having specialist

the strategy and the Design Engineer can verify that the application fits into the criteria the location design may be inadequate.

This strategy does not normally require any

In relation to toxic gas, mapping software is primarily for verification of the proposed design. It also provides the opportunity to try different designs. Assessing the coverage

knowledge. The Management of Health & Safety at Work Regulations 1999 requires that any gas detector location design be undertaken by a competent person

verification software

is key to demonstrating that the system is suitable and sufficient.

Volumetric: Concentrating on the defined area that

Once the design is completed, a form of

with sufficient training and experience or knowledge. These are the legal obligations of the ‘Responsible Person.’ In many cases the Responsible Person (the person who

requires protection. Because the risk gas is three-dimensional, volumetric mapping will require a 3d model of the site area, to visualise

report should be provided to demonstrate compliance, including: • Review of Gas Detection Risk Assessment

is in control of the building) will not have the training, skills or experience to design or review the Gas Detection Locations as

the area and audited by the appropriate software. The advantages and disadvantages are listed on page 43 of BS 60080. The strength of a volumetric approach is the focus

• Recommended Performance Targets • Areas of Detection (details of risks / mitigations / performance targets) with tables and illustrations to demonstrate

required by HSE.

on protecting the occupants and excluding subjective factors which are likely to change.

Scenario Based: This approach is centred on the risk and how the gas might migrate in predefined scenarios, similar to Quantitative Risk Assessments. It sometimes integrates dispersion modelling or Computational Fluid Dynamics (CFD).

Again, the advantages and disadvantages are detailed on page 44 of BS 60080.

This approach carries more risk than the other two detailed above, as it runs multiple scenarios based on assumptions. When protecting individuals from harm or lifethreatening conditions, this approach cannot demonstrate that the design is suitable or sufficient as the conditions of the assumptions may have changed.

Gas Detection location design At this stage the engineer will be able to design the specific gas detector locations based on the risk assessment and agreed design strategy.

detector locations and coverage

Gas Detection system management And finally, while the design of a fixed gas detection system is demanding, installation and ongoing management of the system is required to demonstrate that the system is appropriate to address the risk.

In conclusion, unless your site has the expertise, specialist training, experience and knowledge then it would be wise to contact a suitably qualified business to ensure that the design is correct and appropriate, protects personnel and supports your company and the Responsible Person with their obligations.

About the author

Specifically: • Installation and commissioning (Note: reverification may be required if devices cannot be fitted to the original design).

• Maintenance and Calibration – the frequency will depend upon the environment and detector technology, but the frequency should be at least every 12 months.

• Testing control panel functionality – if this includes executive action (active mitigation) then that functionality should be included.

• Management of change – when a process or significant change takes place in an area of risk, the gas detection system should be reviewed for adequacy.

• Regular reviews – most sites are active

Randall Williams (BSc, GIFireE) has been working in the fire safety industry since 1988 as a Fire Alarm Engineer and Fire Risk Assessor. Randall was a member of the BSI Committee which drafted BS 60080 and he leads the Fire & Gas Team at Proeon Systems Limited in Norwich, (UK).

www.hazardexonthenet.net

22 Storage & Transportation amounts of hydrogen, this can introduce new threats compared to their previous service, and the management, control and mitigation of these threats can be challenging.

To support pipeline operators in this process, the ROSEN Group has developed a holistic hydrogen integrity framework to provide a roadmap for the safe and efficient conversion of existing gas grids to hydrogen and for the reliable operation of hydrogen pipelines in order to extend the lifetime of valuable assets beyond the decarbonisation of the energy system. This comprehensive

Managing the safe introduction of hydrogen

framework is based on the integrated asset management approach and is shown graphically in Figure 1.

Every transmission and distribution pipeline is certainly unique and will have its own specific set of circumstances. However, this structured approach is generic enough to be widely applicable while allowing sufficient flexibility so that tailored integrity management plans can be developed for

transition advances, the gas infrastructure will provide efficient transportation and storage

each pipeline. This integrity approach is founded on extensive, already completed research on issues such as material susceptibility to hydrogen embrittlement

21st century. The Paris Agreement goal to limit the global temperature increase to well below 2 degrees

capacity for renewable energy in the form of gaseous energy carriers and will make the overall energy system more flexible and more

or accelerated fatigue cracking, as well as diagnostic technologies that are already available to map material properties,

requires deep decarbonisation. At the same time, ensuring a sustainable, reliable and affordable energy supply

resilient.

For practical and economic reasons, the

geometry and deformation features where stress levels are elevated, and features that may be starting points for fatigue cracks.

during the energy transition introduces new challenges. Addressing these challenges requires long-term

future renewable gas infrastructure will mainly be based on the conversion of existing natural gas transmission pipelines, either to

The first stage of the integrity framework consists of understanding the potential

energy system planning and a shared determination for all involved in the energy system.

100% hydrogen or to a blend of hydrogen and natural gas. While the concept of hydrogen pipelines is not new or inherently

threats. This aspect is fundamental and requires careful judgement. In essence, the potential threats can be divided into three

impossible – there are already thousands of kilometres of hydrogen pipelines in service – the introduction of hydrogen into existing natural gas transmission and distribution networks creates unique challenges.

main categories.

C

limate change is one of the biggest challenges facing humanity in the

Electricity and gas will continue to fulfil complementary roles in the future integrated energy system. The major primary sources of renewable energy are wind and solar power; these can be used either directly to generate electricity or indirectly to generate renewable gases. Transporting electricity

These challenges need to be taken into account to ensure safe and efficient

First, threats that exist regardless of the medium being transported, such as external corrosion or third-party mechanical damage.

Second, direct threats caused by hydrogen, such as cracking. Finally, hydrogen-induced changes to the pipeline material properties,

directly to sectors where electrification is technically and economically feasible avoids energy conversion losses. For those sectors where electrification is more difficult, renewable gases such as hydrogen enable decarbonisation and can be transported

operation. The vast majority of existing hydrogen pipelines have been purpose built and designed to hydrogen-specific codes and standards, which tend to be significantly more restrictive than their natural gas equivalents. However, if existing natural gas

such as embrittlement and increased fatigue susceptibility. These threats should then be assessed against existing knowledge about the pipeline material properties and welding procedures used during the construction, current pipeline conditions and any known

in existing infrastructures. As the energy

pipelines are repurposed to transport high

features as well as the historical and planned

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Storage & Transportation 23

operating envelope. A major outcome of this assessment will be the identification of any knowledge gaps regarding current pipeline conditions.

These identified knowledge gaps can then be filled using a combination of existing in-line inspection tools and destructive testing techniques. Of particular relevance for in-line inspection services in the conversion process of existing natural-gas pipelines to hydrogen are crack detection and material property determination. Material property determination is particularly important since in

Figure 1 – ROSEN’s Hydrogen Integrity Framework

“traditional” natural gas pipelines, a stronger material was almost always better, leading to pipe mills and operators historically producing and using pipes of significantly higher

since the information can be overlaid and analysed to assist with improvements of the probability of identification as well as feature classification. Depending on existing

A holistic approach like the presented hydrogen integrity framework – involving a sound understanding of potential threats with best practice inspection data – enables the

strength or grade than absolutely required.

In hydrogen service, this “advantage of excess strength” is not always the case, with

knowledge and the current conditions of the pipeline, it may be prudent to run this appropriate combination of diagnostic tools as a baseline inspection in order to facilitate

safe introduction of hydrogen into the existing natural gas network and continued efficient operation of the pipeline for transporting large amounts of hydrogen.

existing construction codes tending to limit the maximum permissible strength. ROSEN’s material property inspection tools include an

efficient comparison and monitoring of any signs of damage or material degradation in the future.

in-line technology that can non-destructively measure the strength of each joint along the length of the pipeline, and a technology to identify martensitic hardspots (Figure 2).

Once the appropriate pipeline inspection runs have been identified and successfully performed, the gathered information can then

These services are able to identify areas of particularly high strength or martensitic hard spots, which may act as focal points

be analysed and assessed. These integrity assessments should both identify immediate threats, which will require targeted verification

for hydrogen-related degradation. Existing features or defects arising either from construction or from in-service damage can

and rehabilitation activities, and provide data for input into fitness-for-hydrogen service activities. Finally, these results will need to

be identified and characterised using crack detection and metal loss tools; this data can then be correlated with material property data

be reflected in an updated risk assessment that serves as input for robust future integrity management plans and processes.

to allow a more accurate assessment of the true threats to the pipeline.

In this context, it is also important to note that synergistic benefits can be gained from running multiple inspection technologies,

Figure 2 – Some inline inspection tools measure the pipe grade strength of each pipe joint, while others (pictured) identify local variations of the pipe wall’s metallurgical hardness, known as hard spots

About the authors Neil Gallon is a Principal Materials and Welding Engineer working for the ROSEN Integrity Services division in Newcastle upon Tyne, UK. He holds a Master’s degree from the University of Cambridge, and is a Chartered Engineer, a professional Member of the Institute of Materials, Minerals and Mining and an International / European Welding Engineer. He has extensive experience in manufacturing and consultancy, including working for companies such as Tata Steel and GE. His current interests include the impact of gaseous hydrogen on materials and welds.

Mario Humbert is a global market strategy manager at the ROSEN Group in Lingen, Germany.

He has a Master’s degree in Industrial Engineering and Management of Energy Economics from the Osnabrück University of Applied Sciences. Mario is currently involved in identifying and evaluating opportunities to support pipeline operators in the process of repurposing natural-gas grids to transporting hydrogen.

www.hazardexonthenet.net

24 Asset Management

Image: Shutterstock

Process isolation practic A

s an experienced risk engineering

energy that can cause a serious incident.

re-energisation of the machine or equipment

manager within the high hazard process industries, Dr Jason Shirley has had the privilege to have a view of the operating practices across multiple energy installations around the globe.

During the work, process isolations are always of interest, and it has been an interesting exercise to collect thoughts

Due to the nature of the energy industry, the hazards associated with the stored energy will always remain. But the risk of being exposed to the hazard during maintenance activities can be prevented by safety procedures and training for an effective lockout/tagout (LOTO) system. The standard for LOTO is in compliance with OSHA

until the isolation is removed. Tags are also applied to inform the operatives of the use of the locks as part of an isolation.

into one place with a view of typical approaches to this process safety element.

1910.147.

Many hazards can exist across a facility or plant of any size, whether it be electrical,

Isolation refers to the process of rendering a piece of equipment to make it inoperable.

Lockout uses locks (and probably chains) as part of the isolation process to hold a device

people lost their lives and was the largest energy industry property damage loss of all time (loss value US$2,088m based on December 2019 values). During the Piper Alpha incident, it was found that there were shortcomings in permit to work (PtW),

chemical, pneumatic, thermal, or other

in a de-energised state and prevents the

isolation, management of change, and shift

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Applying locks to valves as part of an effective isolation system was one of the key findings from the Piper Alpha disaster in the North Sea, UK, 1988 in which 167

Asset Management 25

Image: Shutterstock

ces: an industry wide view handover systems. A large explosion and fire

The emphasis on electrical isolation is

and a further 314 injured) in which isolation

occurred on the offshore platform when a pressure safety valve was removed for routine maintenance. If effective LOTO had been applied to add an effective layer of protection for the removal of the safety valve, then this incident would not have occurred.

understood, as it is clear that if an electrical item of equipment is inadvertently energised whilst maintenance personnel are working on it, then the risk of a fatality is very real and hence good electrical isolations should be upheld at all times. This type of event may have an impact on one to two operatives with the electrical equipment itself failing to a safe

practices were leading causes.

Typical practices In terms of benchmarking isolation practices across the energy industry it is possible to make the following observations:

There are many reasons presented as to why organisations cannot meet process LOTO requirements, popular permutations are: • Operators know what they need to do as this activity has been done before • We just follow the standard operating

LOTO is nearly always applied for electrical isolations, whereas applying full LOTO

state. On the other hand, defective process isolation fails to a potentially dangerous state and can adversely affect many dozens of people, such as in large process safety incidents like Piper Alpha incident or the Phillips Petroleum Houston Chemical

procedure • It is physically not possible to lock or put a chain on a valve An improvement on the above position that is seen with some frequency is that the energy

for process isolations is surprisingly rare.

Complex disaster in 1989 (23 workers killed

installations refer to their isolation procedure

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Asset Management 27

as LOTO, but the plant does not physically lock the valves with chains and locks.

been seen that keys are kept in the PtW issuing offices in a file with the PtW

could cause defective isolations – i.e. a process feature such as a drain line or small-

Instead, the site closes the valves and places “do not operate” tags on the isolation points to indicate that the equipment is undergoing servicing or maintenance and cannot be operated until the tag is removed. This approach is correctly referred to as tag out

documents which is not the most robust means of controlling them. Best practice is to keep the keys in a locked box which is under the supervision of the operation supervisors.

bore instrumentation line could be missed.

which differs from LOTO as the site cannot claim the full benefit of LOTO without locking the valves.

Documents; the paper barrier

A variation on the above approach is for a “sketch” drawing (basically a simplistic drawing showing the main process lines) is given in a standard operating procedure

On the tags themselves, it is rare to see a cross reference to the PtW or isolation

Within large complex energy installations, it is typical to see a reasonable template for the isolation certificate that the company has probably purchased from a consultancy, i.e. not developed in house where the fullness

(SOP). This approach is taken as it is believed to simplify the process for the operator, i.e. they don’t have to refer to complicated process drawings (P&ID), and if this isolation is a frequent operation, then time is said to be saved as it eliminates the

certificate reference numbers, although nearly always there is a designated space on the tag to record such information.

While tagout is a valid method under OSHA

of the requirements may have been better understood through its development. These isolation certificates are nearly always used for electrical isolations, but the use of these

requirement to devise the isolation from scratch each time. The approach to simplify the tasks for the operators is understood from a human factors point of view, but the

regulations for the utility industry, facilities can better safeguard employees by implementing a lockout element.

isolation certificates is not frequently used for recording process isolations.

benefits of simplification may come at the cost of introducing a management of change (MoC) hazard. The site would need to have a very robust change management system to

Where process isolation practices A variation within the lockout element that has been seen is the use of a cable hasp lock. This is when the site has a common

are supported by documentation the following summary is offered for the typical approaches taken.

lock which is kept with the field operators and can be used to unlock all of the hasp locks. No pad locks are used in the hasp system. If there are multiple trades working

It is not uncommon for the isolation procedure to state that the sketches should be produced when devising the process

on different PtWs then additional cable hasps are used. This method would be effective but could be made more robust with full LOTO. For the few sites that do apply full LOTO, it is noted that the management of the keys

isolations. The issue here is that a sketch is not a controlled document and this approach

ensure any process changes are captured in the isolation SOPs. Very occasionally the P&IDs are marked-up with the isolation points and then the P&IDs are appended to the PtW and the isolation certificate – which is best practice. In this case, the P&IDs must be a copy taken from the master “as built” set of P&IDs. It is noted that many energy installations struggle to maintain an as built master set and documentation management is regularly found as an area for improvement.

for the locks could be improved. It has

A memorial to the Piper Alpha disaster in which ineffective process isolation was a cause – Image: Shutterstock

www.hazardexonthenet.net

28 Asset Management As with most management systems, there is a cultural element to the implementation

incident investigations that complacency and over confidence were significant factors.

of these procedures. There is a strong and underlying force that dictates the successfulness of these procedures (or safety barriers). These documents are a critical layer of protection in which the safety of the job should be fully assessed and

It is not uncommon to hear from operators who have said that they previously worked for an organisation that had a LOTO procedure, and do not understand as to why it is not implemented by their current

working under the isolation. The locks can be colour-coded to depict each trade.

2. The keys for the locks should be kept in a locked box under the supervision of the operations supervisor.

3. Tags should be used in the field to denote

challenged. If these layers of protection are not reviewed correctly during the document approval stage, then they will not be correctly reviewed at all. An example for this is cross referencing the isolation certificate to the PtW form (a key finding from the Piper Alpha

employer. It is understood that operators would not necessarily be well placed to implement a change in operating practice, but a suggestion of improvement should be welcomed. This is why companies employ good, experienced and knowledgeable

that a valve is being used for the purpose of isolation. The tags should be marked as “Do Not Operate” and the PtW number / isolation reference number should be recorded on the tags.

4. An isolation certificate should be used

incident), which is intended to inform all operatives working under the isolations as to all of the work being performed and to be completed before the isolations are removed.

operators and this resource should not be overlooked.

which is cross referenced to the PtW forms being used under the process isolation.

5. A copy of the master as built P&IDs should

What does good look like?

machine or equipment until removed.

A lock should be used for each trade

Implementing a best practice LOTO program is an ongoing process that requires routine training and a continuous commitment to safeguarding personnel and plant assets from

be marked-up with the location of the isolations which should be individually numbered (this number can also be added to the tags in the field). The marked-up

experience and professionalism would suggest that errors, lapses and violations do occur. Experience and particularly perceived

the unexpected release of hazardous energy.

Best practice is to:

P&IDs should be appended to the isolation certificate and the corresponding PtWs. Therefore, it is best practice to devise the

experience based upon years served does not necessarily translate into technical competency. It has been stated in many

1. Use a safety lock to hold an energy isolation device in a de-energised state and prevent the re-energisation of the

isolation from scratch to ensure that the information used is up-to-date and nothing is missed.

I know what I am doing!

This may well be the case and technical competency is not in question. But

Image: Shutterstock

www.hazardex-event.co.uk

Asset Management 29

6. To further ensure the accuracy of the information used for the preparation of the

Valves do leak. In fact, they leak by design.

The standards that cover seat leakage for

isolation, it is best practice to line walk the system and check the process features against the P&IDs. It is also best practice to deploy “setting to work” (line walking the system with the issuing authorities and the personnel working under the PtW)

control valves (ANSI/FCI/70-2 1976(R1982)) allows a 4 mL per minute leak rate for a 6” valve for example. These leakage rates do not seem too extreme at first glance, however for an isolation that could be in place for some time before work

prior to commencing the work. This has the added benefit that the final checks are made to the status of the isolations and the personnel working under the isolations are suitably informed of the locations of the isolations, so they can check themselves

commences, then a significant pressure force can build up. The tragic consequences for the energy industry range from fires and explosions that can lead to fatalities and plant damage.

to look for change at the commencement of work each day as part of their tool box talks. The real important aspect of the setting to work initiative is that it is done as

The test element of LOTO(T) can be a local pressure gauge or opening a drain line and bleeding off the accumulated pressure.

Good practice when conducting the required

part of the site’s procedure.

Even for companies with good operational

maintenance is to loosen bolts on the cap ends and cracking the flanges open to prevent cap end blowing off under the excessive pressure force that may have built up.

procedures in highly regulated regions of the world, things can go wrong if the fullness of isolation best practice is not adhered to. A

The observations and issues discussed here are all mitigated with zero capital cost.

developing movement within field equipment isolation is to add a testing element to the procedure.

Yes, training and revising documentation has a cost, but this is not a large capital investment, and in terms of a cost to the

Lock out, tag out and test

business, “if you think safety is expensive, try having an accident” – Dr Trevor Kletz.

About the author

Dr Jason Shirley is an experienced risk engineering manager within the high hazard process industries. He has had the privilege to view the operating practices across multiple energy installations throughout the Middle East and globally. Jason has 10 years of operations management experience within the energy industry. He has a strong background in sharing knowledge and best practice within the industry.

Image: Shutterstock

www.hazardexonthenet.net

30 Signalling equipment

Low and medium inten how to choose aircraft warn A

ircraft warning lights are high-

below 45 metres (148ft). When the use of

intended for lighting obstacles without ICAO

intensity lighting devices designed to make tall structures more visible during both night and day. In general,

type B low intensity obstacle warning lights is inadequate and a special warning is required, medium intensity obstacle signals

painting. During the day they remain on with maximum power (20,000 cd) to highlight the obstacle against the daylight background.

there is no single standard that defines the mandatory minimum requirements governing the design and installation of

should be installed instead.

obstruction lighting.

warning lights should be used when the object has significant extension or its height above the level of the surrounding area

The most common and widespread regulations are the ICAO (International Civil Aviation Organization, a United Nations agency) and the FAA (Federal Aviation Administration, an agency of the United States Department of Transportation).

In the oil & gas sector, three types of signalling lamps are mainly used for the extension and height of obstacles: the low intensity type B and the medium intensity types A and B.

Type A and B medium intensity obstacle

is greater than 45 metres (148ft). Type A medium intensity obstacle warning lights should be used alone, while type B medium intensity warning lights should be used alone or in combination with type B low intensity obstacle warning lights. The flow chart in Figure 1 visually represents when to use each type of signalling equipment.

Type B low intensity obstacle warning lights are intended for buildings with low

Type B medium intensity aircraft warning lights are only turned on at night because during the day the obstacle is highlighted by ICAO painting (equal length stripes of red/ orange and white paint along an object’s

extension and an above ground height

length). Type A medium intensity lights are

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Signalling levels and the number of signalling lights for each level When warning lights are positioned at the top of an object, they must be positioned as close to the top as possible. In the case of cooling towers or other structures with a similar function, the upper obstacle warning lights should be positioned slightly below the top in order to minimise the possibility of smoke contamination.

Where an obstacle is signalled by type A medium intensity aircraft warning lights and the upper part of the obstacle is more than 105 metres (344ft) above ground level or the tops of surrounding buildings, then additional signal lights must be provided at interspersed levels.

Signalling equipment 31

nsity: ning lights

Figure 1

These additional lights should be spaced,

and type B medium intensity warning lights.

Dual systems

as far as possible, between the upper lights and the ground level (or at the level of surrounding buildings’ rooftops) with a

They must also be spaced as equally as possible between the upper lights and the ground floor or from where the tops of

The FAA regulations require the avoidance of any interruption to a safety signal which, if it occurs, must be corrected as

spacing not exceeding 105 metres (344ft).

neighbouring buildings are with a spacing not exceeding 52 metres (171ft).

soon as possible. Beyond the specific regulation, it is common practice to include redundancy into a signalling lamp

intensity aircraft warning lights and the upper part of the object is more than 45 metres (148ft) above ground level or the tops of

In the oil & gas sector where lattice structures, smokestacks, chimneys, cooling towers, or large tanks are

system. This is where so-called dual systems (Figure 2) equipped with a main lamp and an emergency lamp are useful.

surrounding buildings, additional signal lights must again be provided at interspersed levels. These additional lights must alternate between type B low intensity warning lights

common, the number of warning lights required for each level is typically 3 or 4 light points equally spaced in the horizontal plane (every 120° or 90°).

Fault management is then controlled by the control panel of the aircraft warning light system.

Where an obstacle requires type B medium

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About the company Cortem Group has been designing and manufacturing electrical equipment for hazardous areas since 1968. Thanks to continuous technical innovation, it can provide a whole range of products to meet all onshore and offshore applications.

www.hazardexonthenet.net

32 Safety Instrumented Systems

Safety systems – why fitting SIL Systems is only the start of it I

n this article, Matthew Morton,

Technology Director and Functional Safety Engineer (TÜV Rheinland) at Inspec Solutions, looks at the importance of carrying out SIF (Safety Instrumented Function) proof testing of SIL (Safety Integrity Level) rated systems, to meet proof test schedules and ensure continued plant safety, particularly in hazardous

The reality is that from when you have a completed Stage 3 FSA you only hold a compliant SIS until the date of the first cycle of proof testing

environments.

Safety Instrumented Systems and the importance of proof testing Much of UK industry, especially plants with hazardous environments, have an installed base of SIL (Safety Integrity Level) rated systems. There is a good network of consultancies and safety system providers covering the life cycle up to installation and

(Functional Safety Assessment) you only hold a compliant SIS until the date of the first cycle of proof testing.

Following the Stage 3 FSA, the plant operators must follow a defined proof test schedule, performing tests as directed in the schedule and at the requisite frequency, or the SIS will no longer be compliant. More

the system is no longer needed for risk reduction.

Periodic proof testing is not revalidating the SIS as a whole; it is checking that dangerous undetected failures (identified in the earlier stages of the life cycle) have not occurred, and if necessary, perform rectification measures.

Types of dangerous faults found during proof testing might include for example a level switch in a tank which must detect a low level (a dangerous state) sticking above this level. The level sensor spuriously indicating a low level state is not dangerous as this is the trip state, but the switch sticking in the level detected state is dangerous as a genuine low level in the tank would not be signalled.

Although oversimplified, this identifies the need for (and importance of) proof testing to

commissioning. However, there is a common misconception amongst end users that once a SIL rated SIS (Safety Instrumented System) is installed then they automatically have a functional, certified safety system going forwards. The reality is that from

importantly, the real possibility exists that plant is actually unsafe; as you can no longer expect that the SIS will operate correctly on demand.

Proof testing regimes must continue

Taking the above example further, the tank may be located in a hazardous area and the sensor connected to the SIS via an IS

when you have a completed Stage 3 FSA

until decommissioning is completed, or

(Intrinsic Safety) barrier. Another potentially

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identify a fault that may have occurred and be silently awaiting a demand it cannot action.

Safety Instrumented Systems 33

SIF loop testing

dangerous undetected failure here is the IS barrier indicating a healthy output signal to

HSE are now paying particular attention and have specialists with an in-depth

By outsourcing proof testing, plant operators can be confident that fully qualified

the SIS despite the connected instrument driving a trip signal.

understanding of the intricacies of Safety Instrumented Systems and the requisite legislation.

personnel are reviewing their procedures and performing this essential service, ensuring they are compliant with all relevant

Proof tests are designed to check these faults have not occurred, consequently undermining the system’s efficacy to operate safely when a demand arises. Proof tests

With operational demands, de-manning strategies and skill base in-house, such notices from the HSE are prompting

must be undertaken as per a defined procedure developed in line with the Safety Requirements Specification (SRS).

operators to outsource SIF proof testing to specialists to ensure the ongoing integrity of their Safety Instrumented Systems.

A good proof test procedure will clearly describe each test to be carried out, alongside clear pass/fail criteria, with space

The benefit to outsourcing these specialist services is more than simply carrying out the tests. The first element of a service is a

for recording results and signing off the system as returned to normal operation.

thorough independent review of the actual proof testing procedures. Benefits of this include a practical review of the tests from

Defining the frequency at which the testing needs to take place and the expected rate of detection of faults provided by the proof test

a specialist company which understands both control systems and Functional Safety, ensuring proof testing procedures

is part of the SIS design. The onus is then on the plant owners/operators to ensure that testing occurs to this schedule (and as per

are realistic and can actually achieve the intended outcome.

procedure). Proof testing schedules need to be considered with regards to the plant operations. Plant operators need to consider

Previously we have identified proof test procedures which are overly complex and ultimately unnecessary to fulfil the need of

whether they have the resource in-house to carry out the work effectively and, if not, outsourcing is often the most viable option.

the safety life cycle. Over testing impacts on operations by the cost of time to carry out the tests, as well as increasing the likelihood of tests not being carried out properly (or worse, not at all!). In this scenario we have saved operational expenditure over time while still ensuring the validity of the installed system.

Proof testing schedule Proof tests are often carried out during plant shutdown and the lack of process product could reduce the failure detection. It is important to ask the question, does your procedure actually meet the proof test coverage claim?

Increasingly, plant owners/operators are falling foul of HSE inspections by failing to address the aforementioned question. The

Conversely, where we have identified proof test procedures that are missing potentially dangerous faults, the basis of design may need revisiting since there may be a real possibility that the plant/process is not actually safe.

legislation. Ultimately this provides peace of mind and reduces risks.

About the author

Matthew Morton is Technology Director at Inspec Solutions. A master’s level graduate with his BSc (Hons) Computer Science from Nottingham Trent University and MSc Applied Instrumentation and Control from Glasgow Caledonian University, Matthew has over a decade of experience in Safety Systems and industrial Control / SCADA / Telemetry across various industries. He is also certified as a Functional Safety Engineer (TÜV Rheinland). Matthew’s role at Inspec Solutions involves guiding the selection and implementation of complex technology on projects across many industries and providing Process Safety Consultancy both to internal projects and directly to clients. He is a member of the IET and also a registered STEM Ambassador.

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34 Events

All information correct at time of publishing

Middle East Pipeline Summit Date: 14 December 2020 Location: Muscat, Oman

reliable supply of feedstocks provided by pipeline infrastructure.

The Middle East Pipeline Summit is the definitive midstream summit; bringing together regional and international experts to discuss advancements in technologies and concepts for maintaining and operating oil and gas pipelines.

The global oil and gas pipeline market size is projected to surpass $61 Billion by 2022. The oil and gas pipeline market in the Middle East and Africa alone is anticipated to cross $10 Billion by 2022.

The Middle East’s oil and gas new-build transmission pipeline length additions accounts for approximately 43% of the region’s planned and announced pipeline length additions between 2020 and 2023.

address important oil industry issues at technical and strategic levels, in order to provide quality, with special focus on innovation, current challenges and case studies. The Summit will present opportunities to network with qualified experts and professionals across global markets.

The Middle East Pipeline Summit will

www.wpsummits.com/meps/

Pipelines play an integral role in fostering economic growth globally. Numerous investments being made in the petrochemical facilities and LNG terminals being planned today are supported by a

The Oil and Gas IoT Summit Date: 20-21 January 2021 Location: Lisbon, Portugal The Oil and Gas IoT Summit brings together an exclusive community of around 120 major stakeholders from worldwide operators, EPCs, regulators and technology providers to debate and discuss the key issues and trends shaping the digital transformation of the industry.

Success stories, real results and a look to the future. IoT in Oil and Gas is maturing.

Moving from concept to strategy and now to daily applications which are making real, bottom line improvements and delivering process efficiencies.

The Oil and Gas IoT Summit 2021 picks up the industry’s transformation story 12 months on. Focusing on case study evidence and lessons learned, speakers will share their personal experiences,

challenges and real results. With one eye on the future, the event will take a look at the key trends and developments that look set to shape the industry in the next 12 months and beyond. www.oilandgas-iot.com

European Gas Conference (Online Event) Date: 26-28 January 2021 Location: Online Despite the European Gas Conference in Vienna being postponed to 2022, it has been announced that the European Gas Virtual (EGV) Conference will be taking place on 26-28 January 2021.

The event will provide an online platform for C-Level gas executives from across Europe and beyond to discuss the outcome of the 2020/1 winter as well as addressing the longterm role of gas in achieving a carbon

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neutral Europe in 2050.

Across the three days, the event organisers have compressed each day so that it runs from 9am-3pm CET with extra breaks meaning you won’t be exhausted from staring at your screen the entire day.

There will be a focus on an array of live panel discussions to make sure you can interact with and hear the latest industry updates on all things LNG, Pipelines, Geopolitics and Hydrogen.

physical event (around 300 people) as well as the 1-2-1 meetings to make sure you have the best platform to exchange ideas with your peers. If you can’t make a session on the day, you will have full ondemand access to the presentations and panels after the event.

The event will maintain the exclusive senior audience expected from the

www.oilandgascouncil.com/eventevents/european-gas-conference/

ety

Data Files/Buyers Guide 27 Data Files/Buyers Guide 35

ATEX Zone 2 iPhone 11 (Pro Max) – Increased Intrinsically Safe Apple Smartphone Introducing the National Centre for Process &

Non-contact infrared temperature sensors for hazardous

areas – now with multi-channel network capability!

Manufacturing (NCPM) Measurement and Control – Ex Special Interest Group

uring, the Netherlands. The Apple iPhone 11 Features: in hazardous locations. The explosion proof • Explosion safety level: II 3G ; Ex ec ic IIC T4 Gc tured by Apple than and certifi ed Measure surface temperatures from -20°C to 1,000°C • Charger 110-240VAC Theconverted National Centre for Process & Manufacturing (NCPM) is a es by Atexxo Manufacturing. makes theand Process accuratelylevel. and instantaneously with the ExTemp • Charger state-of-the-art Tank Farm PlantBest training facility.

TheThis InstMC Ex-SIG won the User engagement at a50/60Hz professional se in gas /vapor zoneThe 2 hazardous areas. (zone intrinsically safestorage, industrialpetro pyrometer from Calex NCPM is the product of a strategic partnership Applications: Hazardous material Application award at the Hazardex 2020 e installed by the end-user themselves.

Electronics. between Reynolds Training Services and the national skills chemical plants and oil and gas extraction sites. has a linear centre, CATCH. Awards Excellence, which took The qualifi cation is basedThe on sensor peer review in 4-20 mA output for use with a egulations is achieved by modifi cationfor of the Atexxo Manufacturing is market leading in the field suitable Intrinsically Safe isolator or barrier in the safe area.

By bringing together expertise and experience of these ally safe electrical circuit, which makes the the of usermanner friendly and to install explosion proof place at the Hazardex Conference & the same as easy IEng/CEng, with a similar The ExTemp is ATEX, IECEx and TIIS certified for use in two the NCPM offers the UK’s first fullyazardous locations.

Alltraining featuresproviders, of the original equipment.

Exhibition in Harrogate, UK on February application process, and is overseen by the all surface Groups and Zones for gas and dust, including modernised, real-time, real-world emulated training environment. face scanner can be used safely at hazardous For more information custom solutions Zone 0or and Zone 20, and ignition temperatures up to T4.

The state-of-the-art Tank Farm, Process Plant and Simulator Room facility allows 26. The Hazardex awards are designed Institute’s Professional Registration Committee. department or visit new network interface module allows the ExTemp candidates to operate up-to-date equipment emulating the conditions they willplease find contact ourAsales pro max) comes with a black finish and is our website www.atexxo.com to case recognise excellence in the hazardous sensor to be monitored and configured via RS485 in any contemporary bulk storage or processing facility around the world. rsions. Beside safe use as a phone all versions Modbus.

Multiple interfaces can be networked to a The NCPM is based and at CATCH, where Reynolds will be ement and or RFID area sector has become the Training ServicesThe Institute has a range of Special Interest lly safe camera scanner. central Modbus Master. delivering their technical and safety courses.

ospheres benchmark for those supplying products, Groups, which members of the Institute can join www.calex.co.uk/extemp sales@calex.co.uk tel: +44 (0) 1525 373178 enquiries@ncpm.uk www.ncpm.uk -SIG) aims services and systems. More details can be for free as a membership benefit, including: The EVL series lighting fixtures innovated and enhanced and support found at www.hazardex-event.co.uk.

• Explosive Atmospheres

LifEx: the shift in the new lighting paradigm

Asecos Q range – proven fire resistance of

The EVL series of LED lighting fixtures, launched evelopment in the • Functional Safety by Cortem Group in 2015 and available in four sizes,90 minutes range of products from nge of activitiesThe LifExThe Institute of Measurement andhas Control also and enhanced • Flow to offer an even been innovated Cortem Group are compact, safer and more performing• product.

Labtex’s Asecos Type 90 storage cabinets up is producinglightweight offers a professional level qualifi cation in Ex Cybersecurity lighting fixtures that • New “Ex op is” certificate provide extremely safe, regulation-compliant o help inform are easymatters: ‘Registered Explosive Atmospheres • Digital Transformation to install, while also • New multi-LED plate storage of hazardous materials in laboratories being robust and long lasting.

• Newmembers range of the ambient temperature to -40°C + 60°C and otherand worktemperature spaces. Each cabinet variant hese are first Engineer’. This is available to InstMC • Measurement They feature a high-quality anodised aluminium body andcolder a polycarbonate classes (T5) with gasdiffuser group IIB+H2 and is IICfurnace tested in accordance with EN e SIG before which iswho are registered with the Engineering Council • Standards resistant to impact and high temperatures. have an innovative bracket • NewThey supply voltages range from 12 to 277V 14470-1 and proven to give fire resistance of

mechanism, with no fixed and interaxis limitations, which makes them ble. An example as IEng/CEng, whospacing can demonstrate • New powers available starteasy fromto20W up to 220W, with steps of 10W robust and 20W 90 minutes.

Extremely in construction install or retrofit and means the lighting fixture can be rotated to -30°/0°/+30°.

• Different lumen outputs ranging from amay minimum ofmaximum 1,700lm to a maximum torsional rigidity and with tamper s included on The LifEx appropriate ‘competence & in commitment’ Further details befor found at the Institute’s lighting fixtures are available three different configurations for different

use use Twitter?

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of 21,000lm proof lock and indicators built in, every ASECOS cabinet has GS approval and application needs: andwith LifEx-MN. The range comes in different in the Ex LifEx-ME, discipline,LifEx-MT together website www.instmc.org •ongoing Transportable version with electronic driver andCE a model specifiIn cally designed forrange is offered in range of scratch-resistant paint conformity. addition the Q lengths with a wide array of voltage and power specifications.

LifEx series of the old generation a rapid and a The timely replacement lighting fixtures colours discharge and with extensive interior equipment options Warranty cover is available up is ATEX, IEC Ex and TR CU certified and can reach 15,500 lm output, with high installed directly on a pole. to 10 years. efficiency and a guarantee of durability. www.cortemgroup.com info@cortemgroup.com Tel:+44 (0)1484 600200 www.cortemgroup.com/en journal for hazardous area environments Please contact Greg Smith atthe greg@labtex.co.uk Guide EEMUA Publication 186 - A Practitioner’s

at @HazardEx yers

for at @HazardEx for and discussions and discussions afety in the worlds afety in the worlds zard industries MATION & TECHNOLOGY zard CONTROL industries

Handbook for potentially explosive atmospheres Data files Control Panels

Like what you see, but notwhat your you copy?

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EEMUA 186 offers guidance for safe installation, inspection and maintenance work in potentially explosive atmospheres.

EEMUA 186 focuses on ignition caused by electrical the journal for hazardous area environments If you or/and a colleague and mechanical sources and interprets relevantCONTROL parts would like to receive AUTOMATION & TECHNOLOGY international and European standards, directives and Do of YOU use Twitter?

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Offshore safety worldswater highand hazard Magazine every month, UK HSE offshore OEM for and Technor Marechal red OEM for Technor Marechal report safety Closely associated withRegistered the CompEx® training competency assessment you can register online by Food & beverage scheme, this easily navigable resource is available to purchase Selecting motors andat: scanning the QR code below drives for explosive Southampton Open the QR code on your phone or launch s atmosphere https://www.eemua.org/Products/Publications/Print/EEMUASO40 9AH the camera on an iPhone, scan the QR code azardous area environments Publication-186.aspx +44 (0) 2380 665544 above and complete the online form or visit

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area environments

Nuclear

March 2020

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for Robotic technology nuclear decommissioning

incidents Key lessons from during start-up operations

Open the QR code on your phone or launch the camera on an iPhone, scan the QR code HEX Full Page Ad.indd above and complete the online form orRegvisit https://data.imlgroup.uk/hazardex-quick-signup/

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Product Datafiles

AUTOMATION CONTROL & TECHNOLOGY

or Buyers Guide contact

Your Total Solutions Provider Specialists in design and custom build of a wide range of

Hazardous Area Equipment Kathryn Startin

on

Registered OEM for Technor Marechal

+44 (0)1732 359990 or

Southampton SO40 9AH

kathryn.startin@imlgroup.co.uk +44 (0) 2380 665544 enquiries@trant.co.uk trant.co.uk

Conference • Workshops • Exhibition • Awards Programme

ponsor Exhibitor & S w available packages no PPTex 2021 & x e rd a z a H for r details contact us fo

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2021

16th & 17th June • Harrogate • Yorkshire • UK

With the uncertainty surrounding COVID-19 and the potential risk to the health of exhibitors and attendees, the Hazardex team has taken the decision to move the event from February to June 16th & 17th 2021.

All COVID-19 regulation and UK government guidelines will be observed to ensure the safety of all participants.

Contact us for 2021 participation information now!

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