hazardexonthenet.net
Mining
Taking Industry 4.0 underground
Motors
Hazardous area motors are no longer exempt Process Safety
Certification
Cyber security
Forewarned is forearmed
Indian certification for products used in explosive environments
The cyber-attack risks to process plants
April 2021
the journal for hazardous area environments
LifEx, the shift in the new lighting paradigm.
We have reduced the size, lowered the weight, shortened the time of installation, removed any type of risk, reduced any maintenance intervention, avoided 70% of the components and saved tons of CO2. We have also eliminated the possibility of improving it. www.cortemgroup.com
contents april 2021 As reported in Hazardex March, a 146 billion rouble (£1.4bn/$2bn) fine for Russian mining giant Norilsk Nickel (Nornickel) was upheld in court after one of the country’s worst ever oil spills in May 2020. The incident saw around 21,000 tonnes of diesel fuel leak from a power plant belonging to a subsidiary of Nornickel, the world’s leading nickel and palladium producer. Nornickel repeatedly contested the fine, a record amount of compensation to be paid for environmental damage in the history of Russia, after it said that the country’s environmental watchdog Rosprirodnadzor had miscalculated the damage of the leak. It said the damage caused to water bodies and soil were based on assumptions, leading to a distortion of the true damage estimates.
14 21
receiving its full text but has now announced it will pay the full amount of the fine. A statement from the mining giant said it had paid almost 146 billion roubles into the federal budget as compensation for damage to local bodies of water. It added that it had also paid Norilsk’s municipal government 685 million roubles (£6.7 million) in compensation for damage to soil.
Regulations for hazardous area motors are changing and the new energy efficiency requirements could provide significant financial gain.
Nornickel is owned by Russia’s richest man, Vladimir Potanin, a close associate of President Vladimir Putin. President Putin held a televised government meeting following the incident in May and heavily criticised both the local government and Nornickel for its response to the spill. Shortly after the leak, it emerged that officials first heard about the leak on social media, two days after it had occurred.
In early February, the Krasnoyarsk Arbitration Court ruled that the fine should be upheld. Nornickel said it would carefully study the court decision after
…Alistair Hookway, Editor, Hazardex alistair.hookway@imlgroup.co.uk
20 22
This article looks at the impact that a cyber-attack could have in terms of an incident involving process plant.
in this issue
26
4 News Extra
• Dust explosion kills three, critically injures five others in Singapore • UK chemical company fined £560,000 after employee scalded by boiling water • Fatal Chinese gold mine explosion caused by illegal storage and use of explosives, 45 arrested • Military base explosion kills 105, injures 615 in Equatorial Guinea • Norwegian company fined £2 million for 2019 hydrogen fuel station explosion
21 Hazardous area motors are no longer exempt
A close look at the requirements of PESO certification (product certification issued by the Petroleum and Explosive Safety Organization of India).
22 The cyber-attack risks to process plants 26 PESO: Indian certification for products used in explosive environments
36
28 Notes on the evaluation and avoidance of electrostatic charges 33 Taking Industry 4.0 underground 36 Forewarned is forearmed 41 Events
Healthy competition is welcomed in the Ex market, but only if everyone adheres to the applicable rules.
30 36
the journal for hazardous area environments
hazardexonthenet.net
April 2021
43 Datafiles & Buyers Guide 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
40 Mining
Taking Industry 4.0 underground
Motors
Hazardous area motors are no longer exempt Process Safety
Certification
Cyber security
Forewarned is forearmed
Indian certification for products used in explosive environments
The cyber-attack risks to process plants
Register for weekly email newsletter & up-to-the-minute news at www.hazardexonthenet.net
4
News Extra
Image: Shutterstock
No fatalities in US from grain dust explosions in 2020, new report says A
ccording to new research from researchers in Purdue University’s Department of Agriculture and Biological
is a source of ignition, often from small, unintentional sparks within the facility.
Engineering, there were zero fatalities during 2020 in the United States as a result of grain dust explosions.
According to the report, there were eightgrain dust explosions in 2020, resulting in zero fatalities and nine injuries. The 10-year average for injuries is 8.1; it is 1.7 for fatalities.
compiling these reports each year. “Most companies use this information for training their employees,” Ambrose said. “Regulatory authorities also use incident reports for their
Kingsly Ambrose, Purdue University Associate Professor of Agricultural and Biological Engineering, released the 2020
The grain types identified in the explosions included two cases of corn, two wheat,
training purposes. It helps with creating or spreading awareness on dust explosions and their causes.”
annual grain dust explosions report on February 12 which catalogues the number of deaths and injuries in the US.
two mixed feed, one rice and one dietary fibre. Dust explosions occurred in eight different states, one each in Kansas, Iowa,
In 2019, there were eight agricultural grain explosions in the US, resulting in one fatality
Illinois, Ohio, Texas, Nebraska, Missouri and Arkansas. Four of these explosions occurred in a grain elevator, and the remaining four
and four injuries.
Grain dust is a highly combustible substance and often airborne in handling and processing facilities. Explosions occur when there
in a feed mill, corn mill, rice mill and grain
engineering.purdue.edu/FFP/research
processor for dietary fiber. Ambrose explained the importance of
Read the 2020 report in full, here: https://
Distillery explosion injures three in US A
n explosion at a distillery in the US state of Colorado injured three people on February 27. The blast happened at Elkins Distilling Company in Estes Park, northern Colorado and injured three employees.
Two of the injured employees were transported to the North Colorado Medical Center Western States Burn Center with burn injuries. The seriousness of the injuries was not announced by officials at the time of the incident.
Estes Valley Fire Protection District said it was called to the scene at around 09:00 local time. A fire was extinguished before the scene was turned over to the fire marshal and the building official for investigation, the fire department said.
According to local media, the explosion occurred in a distilling area and caused the roof of the building to partially collapse, making it difficult for firefighters to gain entry to the building. Images taken at the scene show
Representative image: Shutterstock
www.hazardex-event.co.uk
large pieces of debris scattered around the surrounding area. An investigation into the incident is ongoing.
News Extra
5
the blast happened in the industrialised Tuas area in the west of the city-state. The
Image: Singapore Civil Defence Force
incident occurred in a unit belonging to Stars Ergng Ltd. The Ministry added that around 65 people were removed from the local area as a precaution following the explosion. News site CNA reports that a preliminary investigation showed that the incident was a combustible dust explosion. The dust is believed to have been in the form of potato starch powder which is used for production at the site. In a statement, the Singapore Civil Defence Force (SCDF) said its firefighters arrived at the scene to find a smoke-logged building. SCDF firefighters entered the building wearing breathing apparatus and saw that a fire had started involving an industrial mixer.
Dust explosion kills three, critically injures five others in Singapore
The injured workers were taken to the Singapore General Hospital where they received treatment for burn injuries. SCDF said it has started an investigation into the cause of the fire and explosion. CNA reports that there was a lengthy delay in identifying the deceased workers due to the extensive injuries they sustained. The Workplace Safety and Health Council has called for a “safety time-out” to last a
A
injuries on February 25. Five people were said to be in critical conditions while two others were released after receiving treatment in hospital.
half or full day. The time-out would allow businesses to inspect machines and processes to see whether machinery is well-
however three people died from their
Singapore’s Ministry of Manpower said
maintained and being correctly used.
combustible dust explosion killed three people and critically
injured five others in Tuas, Singapore on February 24. In all, 10 people were initially injured by the explosion,
The World’s #1 Issuer of Hazardous Location Certificates Let’s work together csagroup.org/hazloc
6
News Extra
Image: Geograph.org.uk/Photo © Sandy Gemmill (cc-by-sa/2.0)
UK chemical company fined £560,000 after employee scalded by boiling water A
chemical company has been
the pressure in the vessel was released, the
the incident. The processes to clean down
fined £560,000 after an employee was scalded with boiling water while work was being undertaken to clean
scalding water erupted back up and out of the chute severely scalding Mr Brockie, the HSE said. Mr Brockie spent over a month
the plant have been risk assessed to introduce new safer worker procedures.
down part of a production plant in Grangemouth, Scotland in March 2016. CalaChem Limited pleaded guilty to
in Glasgow Royal Infirmary’s burns unit following the incident before receiving a further six months of treatment at home.
Speaking after the hearing, HSE inspector Gerard McCulloch said: “Those in control of working processes have a responsibility
breaching Section 2 of the Health and Safety at Work Act 1974 at Falkirk Sheriff Court.
An investigation by the HSE found that a relatively safe cleaning process
to assess the associated risks. If changes are made, which increase the level of risk, those in control of the workplace have a
In a statement, the UK Health & Safety Executive (HSE) said the cleaning process at
of washing down the charge chute with cold water into the vessel below had evolved and changed over time.
duty to reduce the risk back down to as low a level as reasonably practicable.
The process had developed into the practice of overnight boiling of water in the charge chute, while simultaneously pressurising the reaction vessel below as part of a recirculating cleaning cycle. The incremental changes to the cleaning process were not subject to a review of the company’s risk assessment and the
“If the decision to boil water in the chute instead of hosing it down with a cold water had been the subject of a risk assessment, the danger from the pressurised vessel below would have been identified prior to the incident. This would have prevented the employee severe injury and permanent disfigurement.”
CalaChem’s Grangemouth plant on March 4, 2016 involved involved filling a chemical powder charging chute leading down to a reaction vessel with water that was brought to the boil by immersing a steam hose in it. The water in the chute was boiled overnight and the following day the employee, Colin Brockie, continued with the clean down process. When he tried to empty the boiling water from the charge chute, he opened a valve expecting the water to drain down into the vessel below. However, the vessel below the chute had been pressurised with
danger of pressurising a vessel below a chute of boiling water was not recognised, consequently no control measures were put in place to remove this danger. The practice of filling the powder charge
In a statement following the ruling, CalacChem Limited said it had settled a civil claim with Mr Brockie in early 2019. CalaChem added that it remains fully committed to ensuring the health, safety
nitrogen gas and when the valve was opened
chute with boiling water has ceased since
and welfare of all its employees.
www.hazardex-event.co.uk
News Extra
Image: CSB
7
US Chemical Safety Board provides investigation update into fatal December 2020 blast
T
he US Chemical Safety Board (CSB) has released an investigation update on the December 2020 explosion at a
metal dryer became over pressurised during a chemical product drying operation. The material in the dryer was a chlorinated
causing the powder samples to fail visual inspection multiple times before the incident. The CSB is working to determine the source of
compound used for sanitisation.
these dark specks and their composition.
In an update on its investigation into the incident, the CSB said the explosion occurred
The objective of the CSB‘s investigation is to determine the cause/probable cause of
at the plant, was performing a process to remove water from chlorinated dry bleach.
when Optima Belle was performing a process to remove water from chlorinated dry bleach. Optima Belle was performing a trial batch
the explosion and develop a written report with the facts, conditions and circumstances associated with the incident.
The explosion occurred at around 22:00 local time on December 8 and caused a shelter-in-place order to be issued by police
process operation for the Clearon Corporation and the explosion occurred during the first trial batch. The blast resulted in multiple projectiles,
Optima Chemicals is a tenant on the site in Belle, located around 12 miles (18km) south
which affected around 2,000 people. The 2-mile (3.2km) radius cordon around the plant was lifted on December 9 after emergency
one of which landed on a nearby highway and injured a local resident.
of Charleston, which belongs to Chemours. The company said that John Gillenwater, a chemical operator at the plant, was killed by
responders gave the area an all clear and a fire was extinguished.
The CSB is working with Optima Belle to sample and test the chlorinated dry bleach powder involved in the incident. The CSB said
the blast. Two other chemical operators were also inside the building when the explosion happened. Those two workers were taken to
According to Optima Chemicals, a preliminary investigation indicated that a 1,200 gallon
dark specks were observed in the chlorinated dry bleach powder shortly before the incident,
hospital where they were evaluated and later released.
chemical plant in Belle, West Virginia which killed one worker and injured three others. The blast occurred in an industrial dryer unit while Optima Belle, the tenant
Two injured by explosion at tanker cleaning facility in US
T
wo people suffered burn injuries after an explosion at a tanker cleaning facility in Dallas Pike, West Virginia on February 1. The workers were reportedly cleaning the tanker with chemicals at the time of the incident. The explosion caused a fire to break out
which spread through the facility. The local fire department said the blast happened in the evening of February 1 and that two men were going through the process of cleaning a tanker with chemicals when it ignited.
have been completely destroyed by the fire.
The workers suffered burns and were treated in a local hospital. The building is reported to
to protect the exposures from fire damage. The exact cause of the fire is under investigation.
The Valley Grove Volunteer Fire Department said in a statement that it was called to the scene at around 19:49 local time and began a defensive attack on the main building, working
www.hazardexonthenet.net
Motors | Automation | Energy | Transmission & Distribution | Coatings
WG20 RANGE FOR MAXIMUM
EFFICIENCY & RELIABILITY IN EXPLOSION-PROOF AREAS
Our energy efficient geared motors for hazardous areas are ready for the new legislation in July 2021, are you? Introducing new ATEX-certified WG20 series geared motors that also enable direct motor mounting. In accordance with Directive 2014/34/EU, the geared motors are suitable for explosion proof areas in Category 2, Zone 1/21 and Category 3 in Zone 2/22. In the case of the explosion proof geared motors for Zones 2 and 22 with ATEX motors, the motor can be mounted directly – negating the need for an adapter. WG20 gear units with IEC adapters are available for Zone 1/21. Complementing the WG20 geared motor range, WEG has designed a new EUSAS-EX motor that will be available with outputs of 0.12 to 75 kW in energy efficiency class IE3. The new universal EUSAS-EX motor complies with the upcoming EU directives (EC 640/2009), which will come into force on 1 July 2021.
Transforming energy into solutions.
www.weg.net
News Extra
9
of burn injuries while 15 people were confirmed to have died at the scene.
Representative image: Shutterstock
The injured were taken to several local hospitals for treatment. The exact cause of the blast is unknown, but local news reports that the initial explosion occurred as a result of friction during the mixing of chemicals intended for use in firecrackers. India’s Petroleum and Explosives Safety Organisation (PESO) has said that the unit where the first explosion happened had been illegally sub-leased.
Firecracker factory blast kills 19, injures more than 30 in India
Local police are searching for several people, including the owner of the factory. Firework factory incidents are common in India due to the high number of illegal workshops where safety regulations are not adhered to. Illegally produced fireworks are often much cheaper than the legal variant.
A
afternoon at a small factory around 325 miles (520km) south of Chennai in the state of Tamil Nadu.
Following the incident, Prime Minister Narendra Modi said that families of the
over 30 on February 12. The first of the explosions happened during the
Four workers died in hospital as a result
deceased would receive 200,000 Rupees (£1,975).
series of explosions at a firecracker factory in southern India killed 19 people and injured
your reliable solution partner
Ex e Increased Safety & Ex ia Intrinsically Safe Terminal Boxes and Accessories
sira +44 (0) 1925 811 290 / sales@tempapano.co.uk / www.tempapano.com
10 News Extra Representative image: Shutterstock
February 23 that a provincial investigation revealed that the explosion happened after mining explosives were illegally stored and used. There was also improper work involving fire at the mine’s pithead. CCTV reports that the incident caused a direct economic loss of around 68 million yuan (£7.4m/$10.6m). Authorities said that two explosions, about an hour and a half apart, resulted in around 70 tonnes of rubble blocking several shafts and disabling elevators. Following the investigation, 45 people were arrested and now face criminal penalties. Of the 45 people, 28 are public officials and 15 others are officials from mining, blasting, and construction companies that were involved in making the Hushan gold mine operational. The mine’s owner, Shandong Wucailong
Fatal Chinese gold mine explosion in January caused by illegal storage and use of explosives, 45 people arrested
Investment, as well as the city government of Qixia were found to have delayed the reporting of the explosion in order to avoid penalties. They had said that communications equipment was destroyed in the blast, making it difficult to report, however this was later said to be a lie. On February 16, an explosion occurred at another gold mine in Shandong province, just over a month after the Hushan mine incident. The explosion killed six people and injured four others and prompted the local government to start a campaign to close all unsafe mining facilities.
gold mine explosion in east China’s Shandong province on January 10 was caused by the illegal storage and
A
in a nearby tunnel while 11 others were unaccounted for.
The blast happened at around 06:00 local time during maintenance at the Caojiawa gold mine in the city of Zhaoyuan. China’s
use of explosives, as well as improper operations, Chinese state media has reported. The blast left 22 workers trapped around 2,000 feet (600 metres) underground. In total, 10 of the miners died while 11 others were rescued after two weeks. One miner remains unaccounted for.
One of the injured miners suffered severe head injuries in the blast and fell into a coma. Despite emergency responders sending medicine and instructing the other miners on how to care for the man, he died on January 20. After two weeks of being trapped underground, the 11 miners were lifted to safety on January 25.
state news agency Xinhua reports that 10 miners were trapped by a fire following the explosion and that four miners managed to escape with injuries. All four were taken to a local hospital for treatment.
Rescue workers managed to make contact with the 11 miners on January 17 by drilling boreholes into the mine and communicating with them via handwritten notes. It was discovered that four of the men were injured
A day later, on January 26, rescuers gained access to another part of the mine where they found the bodies of nine other miners. One more miner remains missing.
Emergency Management Bureau to announce a new campaign through which it would start a comprehensive inspection programme until the end of March. The campaign involved the bureau inspecting all non-coal mines in the province in a measure
and that one other miner was trapped
Chinese state broadcaster CCTV said on
to tackle safety risks.
www.hazardex-event.co.uk
Both the Hushan mine and Caojiawa gold mine explosions prompted Shandong’s
News Extra 11
Port of Gibraltar - Image: Wikimedia/Port of Gibraltar
Explosion onboard bulk carrier injures four offshore Gibraltar
A
n explosion on a bulk carrier vessel, the CSSC Cape Town, injured four people on February 19. The blast
21:00 local time. Royal Gibraltar Police (RGP) attended the scene and began a preliminary investigation into cause of
At the time of writing, the vessel is to the east of Gibraltar unable to anchor but in constant contact with port authorities. The
happened while the ship was in Gibraltar’s territorial waters. Two of the injured were flown to hospital by helicopter after they
the blast. The GPA said that pending any contrary conclusion by the RGP in their currently open investigation, there is no
vessel is stable and fully operational with the exception of its anchor equipment. The GPA will continue to work with the
suffered severe burns.
reported reason to suspect that any foul play gave rise to the explosion.
ship’s crew and its agents to assist in repairs, provisioning and, if possible, anchoring.
The Hong Kong registered CSSC Cape Town was carrying coal at the time of the incident. The explosion happened in the area of the vessel’s forecastle, an upper deck
The BPA said that two crew members were treated aboard the vessel by paramedics from the Gibraltar Health Authority. Two
The GPA also confirmed that the CSSC Cape Town is loaded with 112,365 metric
at the front of the ship, the Gibraltar Port Authority (GPA) said in a statement.
other crew members were evacuated for urgent treatment at St Bernard’s Hospital by the GHA. Both have now been transferred
tonnes of coal, loaded at Curtis Bay Coal Terminal in the United States. This cargo does not represent a danger to the vessel
No fire was reported on the ship following the explosion that happened at around
to Seville burns unit suffering from 40% and 25% burns.
or to other vessels in the immediate vicinity, the port authority said.
More for Engineering from EEMUA…
People in engineering work to make businesses, the environment, and everyone’s future prosperous and safe – EEMUA’s publications and other resources help people in engineering to get that work done. EEMUA shares engineering task know how contributed ‘by industry, for industry’ as practical aids for engineers in their work – wherever they are, whatever time they have.
Available to all in industry…
All publications and many other resources are downloadable from EEMUA’s Shop – where you can also register to take part in EEMUA events and training.
Members help yourselves…
Many EEMUA resources are free or discounted for members, so please log in and help yourself to guidance notes, training, e-learning, checklists, live webinars, seminars, recordings, and much more.
Join in…
New Corporate Members are always welcome to share EEMUA’s knowledge and influence.
Call on EEMUA…
www.eemua.org membership@eemua.org +44 (0)20 7488 0801
12 News Extra
Fuel tanker explosion on Afghanistan-Iran border injures at least 60, extinguished after three days A
fuel tanker explosion at a border crossing in western Afghanistan injured around 60 people on February 13. The incident happened in the province
Two explosions occurred during the fire, both powerful
of Herat on the Iranian border and was eventually extinguished on February 16 after firefighters from both Afghanistan and Iran fought the blaze.
both powerful enough to be seen by NASA satellites. Iranian state news reports that around 500 vehicles were destroyed.
by NASA satellites
Afghan authorities are yet to announce the cause of the blast; however, they did confirm that over 2,000 vehicles were saved from the flames after hundreds were rushed through
The explosion started a significant fire that spread between dozens of tankers at the Islam Qala border crossing, around 75 miles
and fire. Estimates suggest around 60 people were injured in total despite the much larger
the border crossing. Authorities said that at the time of the incident, more than 2,500 vehicles were at the border crossing despite the capacity being just 700.
(120km) west of the city of Herat. The border crossing is a key transit route between Afghanistan and Iran. Hundreds of trucks
number of people nearby when the incident happened. Most were transported to hospitals on either side of the border.
After three days of tackling the blaze, firefighters said that only small fire remained
carrying natural gas, fuel, and other flammable substances were caught up in the explosion
Two explosions occurred during the fire,
on February 15. An investigation has been opened to find the cause of the blast.
enough to be seen
New training video:
www.beka.co.uk >
Displays text and graphics
>
Incorporates operator push buttons
>
Modbus, legacy & BEKA protocol
>
RS232 and RS485 ports
>
Up to 8 variables on each of 11 standard screens
>
Galvanic isolator for hazardous area applications
>
Field or panel mounted versions
>
Intrinsically safe Ex i or general purpose models
Modbus_124x86.indd 1
www.beka.co.uk sales@beka.co.uk
+44 (0) 1462 438301
Hitchin SG5 2DA
8/28/2020 8:45:10 AM
News Extra 13
Norwegian company fined £2 million for 2019 hydrogen fuel station explosion N
orwegian hydrogen company Nel has been fined 25 million Norwegian krone (£2 million) for an explosion at a hydrogen fuel station
specific plug in a hydrogen tank in the high-pressure storage unit. Three people were injured during the
Nel’s subsidiary was fined 15 million krone (£1.2m) while another company partially
in Sandvika, near Oslo in June 2019. In a statement, Nel said that two of its units had received fines relating
incident, however this was due to the explosion causing the airbags of nearby cars to inflate. All three were taken to
owned by Nel was fined 10 million krone (£840,000), a portion of which Nel may be liable for.
to the incident in which three people were injured after a hydrogen gas leak ignited.
hospital as a precaution and were later released.
Chief Executive Officer of Nel.
Nel said it would assess the fines and
“Nel conducted a thorough investigation of the incident in 2019 and has cooperated
Since the incident, Nel has changed the assembly procedures of its hydrogen refuelling stations. The blast brought most of the hydrogen vehicle industry in
consider further actions. In its statement, the hydrogen solutions provider said that the root cause of the incident was
closely with the local authorities. We’re surprised by the conclusion and the size of the fines and will evaluate further
Norway to a standstill with both Toyota and Hyundai halting deliveries of hydrogen cars until further information about the
identified as an assembly error of a
potential actions,” said Jon André Løkke,
explosion was released.
14 News Extra will complement Essar’s wider plans to build a green energy industrial cluster at the
Stanlow Oil Refinery - Image: Shutterstock
Stanlow site. Earlier this year, it announced its participation in production of blue hydrogen under the HyNet project. The Stanlow project, named Fulcrum NorthPoint, will create 800 direct and indirect jobs during the design, build and commissioning process and over 100 permanent jobs during its operation. Plans for Fulcrum NorthPoint are expected to be completed at the end of this year and subject to planning consent, will be operational in late 2025.
Essar Oil announces new waste-to-fuel plant at Ellesmere Port E
Essar said that the project is a breakthrough deal to provide dedicated tank capacity for the storage and blending of fuel products from Fulcrum NorthPoint. It will also use direct pipeline access to pump and transport the SAF to UK airports through the Manchester Jet Line and the UK Oil Pipeline network (UKOP).
ssar Oil has announced a new facility at Stanlow Oil Refinery in Ellesmere Port, northwest England, which will convert non-recyclable
The project, which will see an investment of approximately £600m, will use Fulcrum’s waste-to-fuel process, which is already being deployed at its facility outside of Reno,
Stein Ivar Bye, Chief Executive Officer, Essar Oil UK, commented: “Stanlow has produced high quality energy products for over 60 years and we intend to remain a key national
household waste into sustainable aviation fuel (SAF) for use by airlines operating at UK airports. Essar and its
Nevada in the US, where operations are due to begin later this year.
supplier of energy for the UK into the future. Our sights are firmly set on helping to drive the UK’s decarbonisation strategy. This
subsidiary, Stanlow Terminals Limited, will create the new facility in partnership with Fulcrum BioEnergy.
The development will see Fulcrum construct, own and operate the plant within Essar’s Stanlow Manufacturing Complex in Cheshire,
landmark development supports our long term sustainability ambition to deliver the energy solutions of the future and position
UK. This will be the first Fulcrum plant outside the United States.
Stanlow as the UK’s leading sustainable aviation fuel hub. It also complements the announcement last month regarding a
thousand tonnes of pre-processed waste, which would have otherwise been destined for incineration or landfill, into
Essar will assist with the blending and supply the new SAF to airlines, with Stanlow Terminals Limited providing product storage
blue hydrogen development at Stanlow as part of the HyNet project. Together, these initiatives will help diversify the refinery in a
approximately 100 million litres of low carbon SAF annually.
and logistics solutions for the project under a long-term agreement. The Fulcrum venture
greener direction, and help achieve the UK’s decarbonisation goals.”
In a statement, Essar said the innovative bio-refinery will convert several hundred
ZONE 1/21
| CL I / DIV
1
©shutterstock, 75571303 | ISM_MA0117_210120
Always a step ahead!
Smart and innovative Zone 1/Cl I Div1-smartphones and tablets with the most advanced technology.
IS930.1
IS330.1
IS530.1
HMT-1Z1
Your expert for mobile communication solutions in explosion hazardous and industrial areas.
WWW.ISAFE-MOBILE.COM
News Extra 15
Military base explosion kills 105, injures 615 in Equatorial Guinea T
he death toll following a series of explosions at a military barracks in
Vice-President Mangue visits the scene – Image: Equatorial Guinea’s Press and Information Office
Equatorial Guinea on March 7 has risen to 105, the country’s health ministry has said. In a statement, the ministry said that of the 615 people injured, 316 have been discharged and 299 remain in care in the various hospitals in the coastal city of Bata. In a statement, Equatorial Guinea’s Vice-President Teodoro Nguema Obiang Mangue said that a preliminary investigation indicated that the incident was caused by a fire breaking out on land close to the Nkoantoma Military Base in Bata. The fire was started while a farmer was preparing a plot of land for food cultivation, close to powder kegs at the
amongst the rubble on March 8. Images and
comments and negative reports which have
military base. The breeze caused the fire to spread rapidly and reach a part of the base where explosives were stored, causing
footage posted on social media show bodies wrapped in sheets lined up along the side of the road in Bata with more bodies being
appeared on social media regarding the event”.
them to explode. The shockwave caused by the blast damaged dozens of buildings and vehicles in Bata.
recovered from under rubble. President H. E. Obiang Nguema Mbasogo
President Mbasogo said that he has ordered a full investigation into the incident. The former Spanish colony also called
The initial estimated death toll of 31 more than tripled on March 8 after rescue workers
said that the Government would hold an emergency meeting to discuss how the country would help the victims of the
for international support and help with rebuilding. The Spanish Foreign Minister announced on social media that the
and locals began searching rubble for survivors. Around 60 people were found alive
incident. He also called on the population to keep calm and ignore the “hoaxes,
country would dispatch humanitarian aid immediately.
Specialist Training for the Storage Tank Industry Live online or e-learning • • • •
Gain or renew your 5-year Certificates of Competence Courses based on EEMUA Publication 159 English, Dutch, German and French language options Select from courses throughout 2021, including:
EEMUA 159 TankAssessor courses 12-16 April 2021 – in English 17-21 May 2021 – in Dutch 4-8 October 2021 – in French 22-26 November 2021 – in German TankIntro courses 7-9 June 2021 – in English
TankInspector courses 22-25 February 2021 – in English 26-29 April 2021 – in English Storage Tanks e-learning On-demand – in English and in Dutch
More choices, information and registration at www.eemua.org
16 News Extra
Meat processing company fined £176,000 for ammonia leak A
meat processing company in New Zealand has been fined $337,500 (£176,000) for an ammonia leak in February. The leak at the Silver Fern Farms plant in Hawera on the southwest coast of New
One engineer was injured during the incident after they suffered an ammonia burn.
charge of discharging a contaminant into the air and one charge of discharging a contaminant onto land in circumstances that allowed it to enter water when appearing before the Environment Court in Hawera on February 24. TRC Director-
Zealand’s North Island injured an employee and contaminated a local stream, killing scores of fish and eels.
The leak at Silver Fern Farms on February 19 resulted in discharges of ammonia to the air and to the local Tawhiti Stream. The
Resource Management, Fred McLay, said the ruling was highly significant and highlights the serious environmental and cultural impacts on the Tawhiti Stream.
Taranaki Regional Council (TRC), which brought two charges against Silver Fern Farms, said the fine is the largest on record
contaminated water killed scores of fish along a 13km stretch of water – the widest extent of any such incident on record, the TRC said. Although the plant has hundreds
McLay added that: “Staff and others were also put at risk. The agreed facts put before the Court show the Company did not have
for an environmental offence. TRC said the fine sends a very strong message that the community will not tolerate actions that
of employees and contractors, only one engineer was injured during the incident after they suffered an ammonia burn.
adequate contingencies in place to deal with malfunctions in its industrial-grade blast-freezer plants. All consent holders
damage or threaten waterways and the species in them.
Silver Fern Farms pleaded guilty to one
should take note and check their own contingency plans and staff training.”
SafeEx Moves Maintenance Forward
Our passion is smarter maintenance
Digital Inspection & Maintenance Software Solution integrates with any ERP System
Equipment Location Made Easy All documentation at your Fingertips Manage field staff from one single app Save up to 50% on man-hours with smart maintenance Spot trends, predict and make smarter decisions Ease & Improve data quality Full electronic audit trail
SafeEx meets ISO 27001 certification standards
IEC 60079-17 compliant
LET'S START A NEW PROJECT TOGETHER
(safeex@safeex.com www.safeex.com +45 30 807 807
News Extra 17
Navotas - Image: Wikimedia/User: Patrickroque01
in the factory a day later on February 4 after the building had been made safe. Ammonia can be used as a refrigerant and is highly toxic if inhaled. Of the 90 employees and residents who fell ill following the leak, 20 remained in hospital with breathing difficulties and other illnesses as of February 7.
Ammonia leak at ice plant kills 2, leaves 90 sick in the Philippines A
n ammonia leak at an ice plant in
the city of Navotas near Manila killed two people on February 3 and left 90 others injured or sick. The surrounding area was evacuated with hundreds of nearby residents
transported away after employees fell ill at the TP Marcelo Ice Plant.
The area surrounding the TP Marcelo plant was evacuated after fumes were smelt by employees. Several hundred locals were able to return to their homes after a few hours. Navotas City Mayor Toby Tiangco told reporters that an investigation is underway to determine the cause of the leak. Tiangco said investigators had not yet determined whether the leak was caused by a pipe or by a tank explosion. He added that the company, which is part-owned by his Mother, would pay for all medical bills.
An employee at the plant died after being exposed to ammonia fumes while an electrician at the plant was found dead
The TP Marcelo plant will remain closed while the investigation continues.
Explosion-safe Air Conditioners FOR OFFICES, CRANE CABINS AND TLQ’S
Artidor Explosion Safety B.V. | The Netherlands | artidor.com | sales@artidor.com
Suitable for Zone 2 environments Capacity up to 14 kW Cooling and heating 230 or 400 VAC Ambient temperature –27°C to 52°C II 3 G Ex ec h ic mc IIC T4 Gc
18 News Extra
Explosion kills three workers at ArcelorMittal plant in South Africa T
hree workers were found dead at an ArcelorMittal steel plant in South Africa following an explosion on February 17. The bodies of the workers were discovered under rubble after a portion of a 90m stack
local time. In a statement, ArcelorMittal South Africa extended its heartfelt condolences and deepest sympathies to the families and colleagues of the deceased. The families of the employees have been informed and are
statement said that the coke battery affected by the incident is one of five batteries currently in operation at Vanderbijlpark Works.
at one of the site’s coke batteries failed and fell onto a control room.
receiving the necessary support, the company said.
The incident happened in
The steel company added that all three
Union of Metalworkers of South Africa (NUMSA) declared a strike at the ArcelorMittal plant. The Union said that at the heart of the dispute is the
Vanderbijlpark, an industrial city around 43 miles (70km) south of Johannesburg. The three workers were reported missing immediately after an explosion
employees succumbed to injuries sustained when a portion of a 90m stack at one of the operation’s coke batteries failed and fell onto the coke
fact that Arcelor Mittal abuses workers through labour brokers.
caused a portion of a stack to collapse. The bodies were found a day later on February 18 after rubble was moved.
battery control room in which they were working at the time. ArcelorMittal has launched an investigation into the
numbers of its members are employed through contractors but work for Arcelor Mittal and have loyally served
The incident happened at around 02:00
cause of the accident and all relevant authorities have been notified. The
the company despite poor wages and intolerable working conditions.
In response to the incident, the National
A statement from NUMSA says large
WORLD’S LARGEST SELECTION OF
ATEX ZONE 0 CERTIFIED PORTABLE LED LIGHTING
Visit Nightstick.com or call 800-233-2155 for more information © 2021 Bayco Products, Inc.
Digitalisation is king!
Standards 1
1 StandardsStandards 15 Standards Standards 15 19 19 to the business. But why am I giving you the independent verifier to the business. But why am I giving you the independent verifier such basicBut information if, like most of the organisation, with the to the business. why am I giving you the independent verifier as a “person or a basicBut information if, like organisation, with the to thesuch business. why am I giving youmost of the the independent verifier as a “person or a suchreadership, basic information if, like most of the organisation, with the appropriate compete you are familiar with the hazardous in the applied protectio suchreadership, basic information likefamiliar most of the organisation, with the appropriate compete youif,are with the hazardous in the applied protection readership, you are familiar with the hazardous in the applied protection methodology, area business? responsible for the verifi readership, you are familiar with the hazardous in the applied protection methodology, business? the verifi area area business? responsible forresponsible the verificationfor of design area business? responsible for calculations, the verification of design assessme calculations, assessme calculations, assessment and testing who calculations, assessment and testing who I mention these facts to highlight a big issue are separate and distin I mention these facts to highlight big issue are separate and distinct by management I mention these to aahighlight issue aredistinct separate and distinc I mention these facts to facts highlight big issue a bigare separate and by management for manufacturers of explosion protected and other resources inc for manufacturers of explosion protected and other resources including financial, fro for manufacturers of explosion and other resources inc for manufacturers of explosion protected protected and other resources including financial, from products and systems: they couldthey come into come the person responsible for products and systems: could into or organisation the personresponsible or organisat products systems: theyquality, couldthey come into come thetemperature person foro products and could into or organisation the organisat In order toand ensure thissystems: high IECEx andperson ambient or temperature In order conflict to ensure this highcustomers. quality, IECEx temperature and ambientwith temperature o serious with their all the activities associated the design serious conflict with their customers. all the activities associa serious conflict with their customers. all the associated with the design started the Proficiency Test Program (PTP) -40 activities °C)aand two different explosive mixtu serious conflict with their customers. all the activities associa The started equipment establish mobile worker common reply to these concerns the Proficiency Test Program (PTP) -40 °C)aand different mixtu manufacture ortwo sales of the explosive equipment.” The common reply to these concerns establish mobile worker manufacture sales of the equipment.” manufacture or sales o for ExTLs intoo2010. The idea behind this isequipment to (ethylene &orhydrogen) selected accordin concept for process plants, including selected is – don’t worry much. Apparently, manufacture or sales of for ExTLs in 2010. The idea behind this is to (ethylene & hydrogen) accordin On the one hand, end users will not accept a is – don’t worry too much. Apparently, concept for process plants, including On one hand, end users will not accept a select a type test as it is defined in a certain IEC 60079-1. hazardous areas. there willthe be many new jobs available for On the onejobs hand, end users will not accept a(equipment protection level) “a”, th amany type test as itavailable iscan defined in a certain IEC 60079-1. situation in which they establish modern For EPL thereselect will On be new forusers hazardous areas. the one hand, will not accept situation in31which they canend establish modern For EPLa(equipment protection level) “a”, th people of digitalisation. A study– XX) IECin-the TCage standard (IEC 60079 and people inNow, the of digitalisation. A in which they can establish modern For EPL (equipment pro IEC -situation TCage 31processes standard (IEC 60079 – XX) checks. safety assurance willprocedures bestudy carried (September 2019) dealsof with “Hydrogen digitalised and inand the evaluation the equipment has to be don situation in recently which they can establish modern For EPL pro If questions emerge during the work in(equipment by adigitalised UScreate IT consultancy suggested processes and procedures in the evaluation of the has to beofdon to standardised and calibrated test On theduring basis ofequipment two configurations the by a US IT consultancy recently suggested If questions emerge the work in out into three steps safety atand the but generators using water electrolysis – verifiers, industrial, create standardised and calibrated test On the basis of two configurations of“b” the safe areas of– technology theirprocesses process plants, cannot by three independent for EPL digitalised procedures in the evaluation of the equipm the plant, experts or supervisors can several new job profiles in this brave new safe areas of theirtest. plants, cannot by three independent verifiers, for EPL “b” digitalised processes andbut procedures inand the evaluation of the equipm samples this The samples are than Test Sample “EP” can two explosive mixtures several new jobforprofiles inprocess this brave new the plant, experts or supervisors design stage, on-site examination upon commercial, residential applications”. samples for this technologies test. The samples are than Test Sample “EP” two mixtures apply thean same in hazardous two, and forcan EPL oneexplosive independent ver be contacted, pictures be“c”, taken world including designer of their aero taxis, safe areas of process plants, but cannot by three independent apply the same technologies in hazardous two, and for EPL “c”, one independent vervv world including designer of aero taxis, be contacted, pictures can be taken sent to the ExTLs which have to make the two ambient temperatures and five igniti completion of a facility, and annual safety Anotherbut standard, 19880-1 (March their process three sent toe-sport theareas ExTLs have to makeplants, the twoISO ambient temperatures and five igniti and transmitted. After theby job is done,independent planner ofsafe stadiums, smart–home areas because of of awhich lack of applicable modern iscannot enough. planner e-sport stadiums, smart–home and transmitted. After the two, job is –done, areas because ofsame a equipment lack of applicable modern is enough. checks…” 2020) is about Gaseous hydrogen fuelling apply the technologies in hazardous and for EPL typeofand test with their and send the each, a total of 40 explosion tests“c”, musto thehazardous new dataeach, can bea uploaded easily designer recycling specialist forset data apply the technologies in and for EPL type testrecycling with their equipment and the totaltwo, of 40 explosion tests“c”, musto products due to same restrictions by send the safety designer and specialist for data the new data can be uploaded easily stations – Part 1: General requirements. products due to restrictions set by the safety test results to a are notified authority. At be performed by each is participant for the areas because of a lack ofIECEx, applicable modern isby enough. to the database. Notwo more paperwork trash. Very good!On But these jobs realistic test results to athe notified authority. At berequire performed eachthe participant for the standards. other hand, manufacturers The first years after introduction of areas because of a lack ofIECEx, applicable modern is enough. trash. Very good! But these jobs realistic to thestandards database. Notwo more paperwork is The hydrogen story isthe aare good example tomanufacturers Both a “Explosion comprehensive risk Every two months, IECEx Chairman standards. On other hand, The first years after the introduction of Every two months, Prof. Dr. Thorsten Arnhold, the German PTB is this authority, creating and program Pressure”. necessary, the efficiency of work increases alternatives for forklift and truck drivers or Everytwo twomonths, months, IECEx Chairman Prof. Every two months, IECEx Chairman Every IECEx Chairman Prof. products due to restrictions set by the safety the PTB is international this creatinganalysis and at the “Explosion Pressure”. are German obliged to fulfill these safetyorstandards, this new procedure were quite a surprise. N alternatives for forklift and truckauthority, drivers necessary, theprogram efficiency of work increases Every twoThorsten months, IECEx Chairman demonstrate how well the very beginning of a were facility’s 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 cooperation between the standardisation design. All detected dangers shall be removed onThorsten developments within his organisation. Dr. Arnhold provides anupdate update standards. Onthe thedocuments other hand,removed. manufacturers The first twoextension years after 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 organisations ISO and IEC is functioning by means of appropriate safety measures. 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 Despite concerns,assessment Ito cannot the safety standards, areconformity obliged fulfilldeny these this wer of months ago I wroteprovides about and howthese the of IEC Prof. must Dr.couple Thorsten ofare theprocedure results is carrie During theevaluation 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 ajois 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 the megatrend that is the hydrogen support the establishment of a by safethe and documents One of the most important dangers ofCB asked for a an update on developments within can defined theof most frequently asked The participants are than to joist In thewhich meantime, the following seven programs convinced alltime, the supposed so eager toout. introduce theseIECEx new systems digitalisation inbeen theare hazardous area sector. tne theofpresent there are few This has a major concern for IECEx. changed significantly. Now we invited have 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 economy. Thisat simple-structured infrastructure. caused by its and noare question IECEx conferences and reliable in flammability which the results presentt have been conducted or are still running:hydrogen isworkshop mentioned above. as agood. result, certificat blessings of digitalisation. During myand and so far, so his organisation question at IECEx conferences workshop inand which the results are presente 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 chemical element will have its tendency toEx explode. Therefore, explosion conferences or technical trade Three years ago, at its annual Management 10 CBsso and Ex TLs with a respective similar events is about thehuge difference and discussed. Angood. 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. An important part of this similar events is about the difference shows that do not have the Industrial Meeting in The Hague, the extension number of applications. professional career, I have visited However, shiny and new possibilities At itsCommittee basic, toTest keep standards significance a carrier of energy in the – Considering the typical value of Test the isextension a particular in the safety the last ayear, ho •most Spark forthe Exstream “I” Hague, Roundprotection 2010makethese shows doas not have Industrial Meeting in The aDuring number of applications. between ATEX and IECEx. No worries workshop isfocus training common manythat manufacturers in the many different can you forget that all theseto achieve of safety highIgnition throughout whole workshop is training to achieve a common between ATEX and IECEx. worries – the Internet of Things (IIOT) asNo the main organisation launched a consists new procedure to • Flame Transmission for “d” Test Roundstandard. 2013 many manufacturers inthere many different can make you forget that allchanged these of safety high throughout theEx whole tInternet the present time, are few This has been a major concern for IECEx. significantly. N future. Since my article, some important green hydrogen economy, it In both standards, all requirements 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 to give a 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 events have taken place which underline several main elements: electrolysis, the for explosion protection are directly referenced • 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 Three years ago, at itsstandard. annual Management 10 Ex CBs and Ex TLs most of those with the highest levels energy, stored batteries. As acertificates it isand necessary to conduct regular this statement. transport storage of hydrogen, the to the respective IEC TC in 31 standards. There topic now. It is not so obvious but there consequences of this trend are the covers 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, the extension and aPressure numbe are many differences. For The workshop forthan the Explosion • Electrostatic Charge general Test 2015bethe of that automation continue to employ consequence, those products have to meet inspections and But those distribution to theintroduced end users and the final step shall zone classification according shows do not have the Industrial Committee Meeting in The Hague, extension and a numbe are many differences. For interested The workshop for the Explosion Pressure drastically shrinking value chains and which was 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 of Program took place in follow June at thean significant numbers ofare manual all requirements which electrical products responsible might have to manage a couple More and more countries publishing their transformation of the hydrogen chemical IEC 60079-10-1, the installation shall • 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 a new procedure to • Explosion forlaunched Ex fuel “d” Test Round 2017 innovation cycles every sector, and adoption ofPressure new technologies, new materials am confident that many others willand follow. workers, whether in production, intended for use hazardous areas have of thousand products covered by ‘Ex’ Guide: Informative Guide comparing PTB ininthere Braunschweig, Germany, 80 national“An strategies toin develop appropriate energy into electrical energy by cells.or IEC 60079-14 and has be regular • Explosion Pressure for Ex “d”when Test Round 2017 transport or logistics. to fulfil. PTB safety standards, and focus. One“An ofin the most important adopt the new IEC 60079-33 standard. This Atolook in the IECEx onli Guide: Informative Guide comparing functional in Braunschweig, Germany, and 80 especially the process industries. etc. This implements a practice which has transport orthe logistics. to fulfil. and safety standards, focus. Oneelements of most important adopt the newfor IEC standard. This Aaccording look intothe onli hydrogen infrastructures within the next 10 to inspection maintenance IEC IECEx especially in the process industries. etc. This implements aand practice which has • Pressurised Enclosure Exwhen “p”60079-33 est Round 2017 various of both IECEx and ATEX”functional participants from international ExTLs joine paperwork is involved, this can often prove • Pressurised Enclosure for Ex “p” est Round 2017 participants from international ExTLs joined various elements of both IECEx beencovers field-proven in the ATEX area IECEx, this development ismore recognition consequences of this trend areand theATEX”paperwork thethis protection method “s” for “special”, that already than is Committee involved, can often prove 20 years. For Germany published Technical TCthe 105ATEX covers the 60079-17. IfFor theIECEx, installedthis and otheris beencovers field-proven in area For development recognition consequences of this trend arethe theIECEx IEC method “s”IECforand“special”, that already more than which beinstance, downloaded from this event. Inelectrical the eight years the program Every can day we see tens of thousands At 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 tensvalue of thousands At IEC IECEx have on recognised these an impossible task.was the national programme in areas, autumn 2020, cell technology. Thereintroduced is a set of brand equipment must bewe explosion protected, the been useful drastically shrinking chains and fuel which to permit theand quick IEC 60079-33 have In process safe the since 2003. that focus on area has of trucks onfacility ourPublications highways driven by speed issues and their importance for thethat thehave website under beenits running, wethis have seen qualif As an illustration ofintroduced the program,to here is aspecific short drastically shrinking value chains and which was permit the quick on IEC 60079-33 trucks on published our highways driven by specific and their and importance for the website under Publications been running, we have seen the will quali an illustration of the program, here is arealisation short issues ofof adaptation to this atrend is hydrogen restricted the industry levels ofthat safety be South Korea national new As standards dealing with safety of portable shall be according tohigh the respective 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 law at the beginning of 2021, and the UK’s fuel cell systems IEC 62282-5-100 (May standards for protection methods IEC 60079 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, ofworking group maintained. the supermarket, to pay to deal withto questions on level today. hazardous locationsthe is fulfillment of by the innovation ofII am the suppliers Under the ATEXimplements directive, maintained. What I want tothe highlight inhydrogen this article isand the the 2019), the beginning an excellent Round: In the supermarket, happier tostrategy pay equipment in hazardous locationsthe is fulfillment to deal– with questions on level especially inand the process industries. etc. This a practice has publication of national and the safety of stationary fuel cell –working 0 which ff. andgroup IEC 80079 36 f.to What I want to highlight in this article is the the beginning 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 systems theFor general requirements of appendix II with fact that IECEx is not aoflaw like attempt ATEX, it of is an the program “Explosion Pressure - how Testmodern mobile digital devices can be the cashier directly rather than becoming smart. is expected at the end Q1. IEC 62282-3-100 (September 2020). 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. basic health and safety requirements is such executive group is preparing athe promot to use a checkout that only safely transformed to meet thesorequirements organisation acting machine worldwide onwill a voluntary We at IECEx are convinced 2017” thewith general routine procedure The the newRound standard dealing the safety With aThe perfect consistency between the 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 are allow me to pay on my third attempt, and of hazardous area standards. One advantage is the easy identification of obligatory, and standards are just conference the TC sessio All these papers show thatareas, there are notAgius fuel cell modules is harmonised approaching the final standards of two differentduring organisations, it31 is spring In process facility safe the speedofindividual 2003. that its focus on effect this are basis. Our Executive Secretary, Chris importance and the trust-building of is since described bymeans the standard “Explosive then only when a human assistant comes 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 only great expectations for the opportunities stage (CDV) and will soon replace the current possible to integrate elements of the hydrogen 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 said thattoIECEx 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 that IECEx istrend like a franchise system. edition atmospheres - Part 1: Equipment handle substances, potentially IECEx in conjunction with thethe UN, UNECE over tohazardous help! Furthermore, we are making special efforts labels. of Inspection plans, equipment data, presented by hydrogen, but there is also now the 62282-2 Ed. 2(2012). ISO TC value chain in the existing conformity 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 of the suppliers andofthe Under the ATEX the fulfillment ofCroatian maintained. There isconsequences a certain infrastructure and a risks powerful Committee MeetingThe in The by flameproof enclosures “d”” - Bodies IEC 60079to intensifyManagement market surveillance. IECExInstitute. will facility layouts, inspection records, repair severe for ofthe and health To enable thethe IECEx the Standards focus aninnovation appropriate awareness thelife safety 197 mostly covers rest ofCertification thedirective, elements of assessment systems of the IEC. Since 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 that need to be overcome as the hydrogen the value chain mentioned before. IECEx system has been testing and certifying 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 isdevelops. 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. economy As an example, the equipment for use in potential hazardous operators. health and safety requirements isof ExExTLs. The 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, as with all IEC all thoseispeople once are completely products from global markets, a and, new as operators. the basic health safety requirements isof Theand executive group is Certificates based on IEC 60079-33, users Exmarkets, equipment, with all IEC (ExCB) andpeople the Test Labs In the IECEx To get explosion protection is the ability of the thehydrogen all those once we (ExTL). areincompletely products atmospheres from global a and, new following quote was featured an article aexplosion comprehensive overview about for manyand years, it (ExCB) and the Test Labs (ExTL). In the IECEx 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 dealing with these issuesattendance obligatory, and aredealing just with conference during the The equipment intended for with use in areas all IECEx Operational Document OD 233 was International Conferences, attendance is fre enveloped inKorea’s the digital age If an inspection job due, the database workingnot group these issuesabout obligatory, and standards are conference during the T Certified Equipment Program we now More detailed information the progr enclosure tois withstand pressure (clause about South hydrogen law all in these Thehave safety related aspects of theharmonised hydrogen should be toojust complicated to integrate 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 progra 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 Manyhas process sector companies have to one way to do this. Split Croatia on 23 Apr the innovations and consequences we informs the technical management of the started work in May 2019 at the Singapore to fulfill certain in to ordergeneration, developed andispublished, and the second of charge (See:inwww.iecex.com/meeting-a Korea Herald: “Mostsafety importantly, the hydrogen transformation, transport and thethe green hydrogen processes if regulators 57process accepted ExCBs plus 5requirements Applicants and can be found the Operational Documen 15.2.). This of do decisive importance for Many57 companies have one way this. Croatia onDocumen 23 Apri read about daily in the media, such as and plantedition and thehas inspection plans and otherFebruary Meetings of IECEx. accepted ExCBs plus 5 Applicants can be found inSplit the Operational 15.2.). This isto ofavailable decisive importance forMeetings the toread avoid the sector ignition of potentially explosive been since events/iecex). about daily in the media, such as plantedition and the inspection plans and otherFebruary of IECEx. law tackles the safety issues that had long distribution process, the Technical Report require this. to avoid the ignition of potentially explosive has been available since events/iecex). handle hazardous substances, with potentially IECEx in conjunction 68autonomously accepted ExTLs plus 5 Applicants forming necessary OD 202 ed. 2.0 (2017) which can be w design and construction of “d”onproducts. driven trains, ships and information are downloaded handle hazardous substances, potentially conjunction 68 accepted plus 5 Applicants OD 202 ed. 2.0IECEx (2017)in which can be w design and construction of “d” products. atmospheres. These requirements areforming defined ISO/TR 2017. The(2015): central and critical element of both autonomously driven trains, ships and necessary information are downloaded on in aExTLs regulatory blind spot.with Previously, 15916 “Basic considerations atmospheres. These requirements are defined 2017. The central and critical element of So both downloaded the IECEx website. a remained global network for robots testing and 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 life and health of To enable the IECEx Certification the Croatian Standards from the IECEx website. ain global network forstandards testing and certification Therefore, explosion (reference vehicles as well as robots dealing with So me inBodies hazardous areas at least, tablet computers orthe smart phones. the international IEC 60079 and for the standard and the OD ispressure the so-called In IECEx will be holding a series o hydrogen equipment –for electrolysers, portable safety of hydrogen systems” isCertification For thisdownloaded is addition, another example severe consequences the life and health ofthe To enable the IECEx theillustrating Croatian Standards in the international standards IEC 60079 thepressure) standard andbeen the OD is the so-called In addition, IECEx will be holding a series o the entire logistics chain in factories anda and digitalisation is to be welcomed, and ofthe explosion protected products. Such has selected as the quantity entire logistics chain in factories anda digitalisation is to begroup welcomed, the employees inhydrogen their plants. and Test Labs to issue Reports of thisandconference will b of explosion protected products. pressure) has the quantity fuel cells and extractors –Such and highly recommended. Abeen new selected version is asTest the ability and ofworking modern global standard IEC 80079. ‘independent verifier’. meetings in Weimar, Germa the employees in their heavily plants.depends on the These and 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 I wrote this article I was in theGerma final b tobeing be compared inISO the program “Explosion supermarkets. supporting this process will be a crucial These devices together with cameras, fuel cell facilities that directly used hydrogen currently prepared at TC 197. organisations to support technical progress 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 application Certificates based on IEC 60079-33, users Ex competence andtoquality management of every smart stage of preparations forfrom theequipment, 2018 IECExo Pressure - other Test Round 2017”. part of thethe IECEx mission into the of future. glasses and digital weren’t subject periodicmanagement government safety international standard ISO 22734 by maintaining a high level offeedback safety. competence andmight quality of every The Under stage of“s” preparations for thebe2018 IECEx Pressure - Test 3.4, Round 2017”. Interesting, you say, if you are new paragraph the standard defines this Ex 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 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
The Proficiency Proficiency Test Test Program Program The for ExTLs ExTLs -- aa key key trust-builder trust-builder for within the the IECEx IECEx system system within
The pros and cons Safety issues of ofthe digitalisation hydrogen
economy
IA I O O A A
A
NEW
ATES Conference • Workshops • Exhibition • Awards DProgramme ANN OUN
2021
6th & 7th October • Harrogate • Yorkshire • UK
IT IS NOW TIME TO SUBMIT A PAPER 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 unprecedented COVID-19 pandemic causing many of us to work remotely, preventing the usual networking opportunities from taking place, Hazardex 2021 will be an ideal occasion for the industry to once again come together and make up for the lost months of crucial knowledge sharing and networking. The Call for Papers for Hazardex 2021 is now open and 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. COVID-19 regulations and UK Government guidelines will be observed & enforced as required at the time of the event. Visit the website for how to submit a paper: www.hazardex-event.co.uk
Media Partners
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
Supporting Organisations
CED
Motors 21
Hazardous area motors are no longer exempt S
trict regulations are synonymous with hazardous environments. Despite this, changes to legislation can still cause disruption. Marek Lukaszczyk European and Middle East Marketing Manager at WEG, explains the changing regulations for hazardous area motors and how the new energy efficiency requirements could provide significant financial gain. Europe has over 8 billion electric motors in use, consuming approximately 63 per cent of the electricity generated across the continent. Until recently, some of
Unsurprisingly, the electric motor market rapidly reflected the shift in regulation and transitioned to more efficient motors. IE1
Special purpose motors, such as explosion-proof or flame-proof motors were exempt from the previous regulation, out of
these motors, including those designed for hazardous areas, were exempt from energy efficiency regulations — but these regulations are about to change. The
and below, which represented 80 per cent of European market share in 2009, held onto just 17 per cent of market share by 2016. During the same period, IE3 premium
precaution for the higher-risk environments they were used in. From July 2021, new ATEX motors entering the supply chain must be rated IE3 or higher with increased
latest changes to regulation will include a wider scope of motors, and for the first time, variable speed drives are included
class motors rose from 0 per cent to 29 per cent of the market share. Good news for the planet and cost savings for the end
safety motors Ex eb being the exception. These motors will need to be at least IE2 efficiency level by 2023.
to achieve a higher efficiency standard, starting from July 2021.
user. The design of electric motors has seen
Energy efficient motors for hazardous environments have been available for
Minimum Energy Performance Standard (MEPS) was introduced in 2009 by EU Commission Regulation EC 640/2009. The
improvements to maximise on energy saving opportunities. Now, the European Commission’s (EC) ecodesign committee
decades, but with no obligation to implement high levels of energy efficiency in hazardous environments, some businesses
regulation required motors of 0.75-375 kW to reach international standards set by the International Electrotechnical Commission
has approved a new, stricter version of the ecodesign requirements, which take effect from July 1, 2021.
opted for low efficiency motors, possibly due to the cheaper upfront costs.
(IEC) for single-speed three-phase motors. IE1 describes standard efficiency, IE2 is high efficiency and IE3 is used for motors with premium levels of efficiency. Updates to the legislation in 2016 specified that electric motors require an energy efficiency class of at least IE3, or IE2 class
Previously, the scope of the regulations only covered 3-phase motors ranging from 0.75 kW to 375 kW, leaving motors outside this power range excluded. From 2021, this will no longer be the case. The impending regulation requires all new 2-, 4-, 6- and 8-pole motors in the power range of 0.75-
if the motor is used with a variable speed drive (VSD). The regulation, bolstered by improved design and materials for electric motors, brought about huge improvements to the energy consumption related to motor use.
1000kW to meet IE3 efficiency class. The previous legislation allowed for an IE2 motor to be used provided it was controlled by a VSD, but this will no longer be valid. Sizes from 0.12-0.75 kW will need to meet IE2 class.
In energy-intensive industries, such as chemical, pharmaceutical or oil and gas, thousands of motors often operate 24 hours a day. Even a slight improvement in efficiency, extrapolated over the sheer volume of motors and hours of operation, will benefit the businesses’ bottom line. Energy costs for electric motors account for 95 to 97 per cent of total life cycle costs, depending on the application. Investment in energy-efficiency drives and motors, even if it’s not through choice, usually provides a very short return on investment.
www.hazardexonthenet.net
22 Process Safety
Cybercriminals and ransom the cyber-attack risks to proce H
in May 2017, or the cyber-attack on
acking into computer systems,
disabling alarms, and shutting equipment down are often portrayed in the plot of many a Hollywood science fiction movie, however the premise is not entirely fictional. This is evidenced by the cyber-attack on the UK’s National Health Service (NHS)
www.hazardex-event.co.uk
In terms of a process plant, what impact could a cyberattack have?
a process plant in Argentina in the same year. Many parts of the Argentine plant’s control systems were rendered immobile for several days, thus highlighting the vulnerabilities. In terms of a process plant, what impact could a cyber-attack have?
Process Safety 23
However, in a cyber-attack, alarms can be disabled and the controls and signals
However, as is often the case, if you have a limited amount of time and resources to
that workers rely upon to ensure safety are vulnerable to manipulation. If the fuel does not know to stop flowing once the tank is full, your alarms are rendered inoperative and you do not have a physical control that can be used to shut the system down, then your plant could shutdown,
dedicate to this subject then understanding this fundamental point is crucial in a process plant’s fight against any attempt on their systems by a cyber-criminal.
or worse still, potentially explode. In Figure 1, the possible Major Accident Hazards are: • Cyber-attack could close valves and stop waste liquid being taken out.
“defence in depth”. The meaning of this in simple terms is that no single security countermeasure provides absolute protection to a plant from the risk of a cyber-attack; several layers of protections need to be deployed to provide the depth
Liquid fills the vessel, blocks it and suddenly all gas to the plant stops. • Cyber-attack closes the valve before the
that is required in the fight against potential remote attacks. So, whilst the question of which of the standards you use is not
pressure relief valve. On high pressure the vessel could rupture and explode.
How at risk is your plant and what do you need to know?
of particular importance, what is clear is that having defence in depth is of great importance, and to make that effective you should also always aim for diversity in protections.
Whilst it is common knowledge that hackers and cyber-criminals regularly target systems and maliciously disable
Although the standards generally put less emphasis on diversity, defence in depth
computers, steal data, or use a breached computer as a launch point for other attacks; and that the reasons for this range
only works when the defences are different. It is ineffective to have several defences that are all the same because whatever
from financial gain, intellectual challenge, employee dissatisfaction, political or social dissonance; the subject of these cyber-
technique that was used by the cyber attacker to get through the first layer will then work again and again with every other
attacks in a process safety context, as in the aforementioned example, is still in its early stages.
layer thereafter. Only when the protections are diverse does the defence in depth requirement in fact work.
When protecting a process plant against cyber-attacks, there is always value in
mware: ess plants Picture the scene. You are pumping gas through the system to get it to the boiler plant; water is separated from the gas during the process to ensure that only the fuel enters the boiler. Your systems are completely automated to optimise efficiency and it is computerised to shut down when the tank at the end is full.
Figure 1
www.hazardexonthenet.net
24 Process Safety
In the UK, the HSE’s guidance is OG0086 and it makes a statement that is true world-wide. It is a simple statement that
Of the two main standard sets dealing with cyber-attacks, the ISO27000 series covers I.T. systems which means you
matter how credible it is to show that a system is secure it MUST be safe, otherwise the security is only ever half
says: “Defence in depth: No single security
will find I.T. managers very supportive, however, for process plant control, the IEC62443 set is more suitable;
of what is needed. Only security and safety used together will ever work to safeguard against potential risks
countermeasure provides absolute protection as new threats and vulnerabilities can be identified at any
nonetheless, neither is perfect. However, as stated previously, the subject of cyber is still in its infancy. Both the International
effectively.
time. To reduce these risks, implementing multiple protection measures in series avoids single point failures.”
Organization for Standardization (ISO) and the International Electrotechnical Commission (IEC) standards are global,
and other technological innovations are commonly used to optimise industrial process plants; these Industrial Control
This is true everywhere, and it applies to everything wherever you are in the world.
both with a central committee and member committees for each country. We are still at the stage that some
Systems (ICS) are used to optimise efficiency and production.
countries, including very significant ones, talk in terms of cyber security and then lack the solid commitment to take this any further in real safety terms; some have even openly advocated separating security from safety. Yet the risk exists that you can have a
However, these same systems that have been designed to optimise processes, are just as vulnerable as any other digital system. A cyber-attack can result in environmental consequences as well as injuries or even fatalities, and not just financial losses. The scale of the consequences can be substantial and is
system that is secure (even certified as so) but simultaneously unsafe to use. This is a contradiction in terms, but it is one that appears to be happening all too often. The truth is you can have an unsafe system regardless of how
often as a result of criminal activity that targets vulnerabilities in these automated systems. The scope of the damage that can be done when organisations fail to establish robust cyber protections can be considerable; when a plant fails or
secure you think it is. Therefore, no
struggles financially, when the air or water
We don’t even have to talk about “single point failures” when the truth is that the more defence in depth and diversity you can include in the design for any cyber risk, irrespective of the size of the risk, then the less likely it is that a cyber-attack will ultimately succeed. It is also true that we need to review, maintain, and repair the defences continually, given that the risk of potential cyber-attacks can be daily events as opposed to rare occurrences; only the ultimate success of an attack is rare.
www.hazardex-event.co.uk
Digitalisation, automatic control systems
Process Safety 25
is polluted, or employees’ health and safety is compromised, the effects can be far reaching.
cyber-attack, the consequences can be far more devastating than the breach of personal data that is typically reported.
If you are part of a SEVESO/COMAH site anywhere in Europe, then you have
Organisations therefore need barriers that are completely autonomous, along with barriers to protect the data highway.
to respond to the “Control of Major Accidents and Hazards” requirements; in many European countries these are
When considering the possibility and consequences of cyber-attacks to a
regulations. Since 2020, a policy for cyber-attack protections is now required to be stated amongst your Major Accident Prevention Policies (MAPP). Given the risks and subsequent consequences, organisations must understand that cyber threats are just as significant as the ‘traditional’ safety
plant, then looking at how to put things out of reach must form a major part of any Cyber Risk Assessment work; questions to consider include: • Have you identified the areas vulnerable to cyber-attack? • Have you identified what Major Accidents might be caused by a cyberattack?
risks, and cyber-attacks can hijack the conventional safety measures they have put in place. Alarms can be disabled, controls can be manipulated, and signals that workers rely upon to ensure safety,
• Do you have clearly defined safeguards that require controls (cyber-security) to prevent remote access? • Where are your independent barriers? • Can you confidently answer regulator
are all vulnerable to manipulation via cyber-attacks. Historically, the mainstream media has focused on protecting computers, I.T. networks and data highways, however, with an ICS being just as vulnerable to
questions? If you cannot answer the above questions positively, the cyber security of your plant should be of the utmost priority, given the potentially devastating outcomes of an attack.
About the author
Clive de Salis is Process Safety Engineer at Chilworth / DEKRA-Insight. He is the current vice-chair of the IChemE Safety & Loss Prevention Special Interest Group and a longstanding member of the IEC committee that writes the IEC62443 and IEC 61508 groups of standards (on cyber and safety instrumented systems respectively). Clive has extensive experience covering process hazard analysis with well-known tools such as HAZOP and HAZID and has also written/carried out COMAH reports and OBRA analyses (Occupied Buildings Risk Assessment) and Basis of Safety documents covering ATEX and COSHH.
www.hazardexonthenet.net
26 Regulations
Image: Shutterstock
PESO: Indian certification for products used in explosive environments T
he PESO certification (Product certification issued by the Petroleum
and Explosive Safety Organization of India) describes the mandatory approval program for the oil and gas industry or machines that work with gases, are used in the oil industry, or must withstand corrosive environments. It is based on the Explosives
The already mentioned laws and regulations in place for PESO certification list some of the
These lists were successively broadened and further specified in the subsequent
products that require PESO certification, but these lists are mostly focused on mechanical parts:
amendments to the Petroleum and Explosives Rules and the Ex-definition of the ATEX system can largely be used to identify the
• Explosives storage premises
• Storage installations for compressed gases in pressure vessels
• Fireworks manufacturing factories
• Auto LPG dispensing stations
• Fireworks store houses and shops
• LPG bottling units
• Manufacture of Explosives at site in Bulk Mixing and Delivery [BMD] Vehicles
• Petroleum storage installations
The original Department of Explosives (with its
• Authorisation of Explosives & Fireworks
head office in Nagpur and lead by the CCoE) was transformed into the current Petroleum and Explosives Safety Organization in 2010 with the aim of simplifying administration and specialisation. The CCoE is still managing the organisation but is now called the Chief
• Petroleum tank lorries
• Gas Cylinder filling plants
• Petroleum cross-country pipelines
• CNG filling stations
• Petroleum service stations
• Gas Cylinders / Valves / Regulators
• Flame Proof Equipment
• Storage sheds for filled gas cylinders
• Calcium carbide storage premises
Act of 1884 and the Petroleum Act of 1934 and all related legislation thereafter, in particular the Explosives Rules of 2008 and the Petroleum Rules of 2002. It was previously called the Chief Controller of Explosives (CCoE) examination.
Inspector of Explosives.
www.hazardex-event.co.uk
• Explosives manufacturing factories
• Petroleum storage sheds • Petroleum Refineries
Regulations 27
requirement for PESO in India. An important distinction to international systems is that
the documents have been submitted there is nothing more to do for the manufacturer
PESO only considers individual products and not systems as is possible, for example, with ATEX certification. A manufacturer applying for certification of a system consisting of several certification-relevant components needs to apply for PESO certification for
other than to wait for feedback from the authority and answer their questions.
each component individually.
give the applicant an even shorter time for rectifying any issues. It is therefore advisable to make sure you have the most recent versions of all your certificates and other documents as well as consistent information across all application documents. If you fail
However, any issues with documents must be resolved within the same year of the application, and in some cases, PESO will
In order to be able to apply for certification, an Authorised Indian Representative (AIR) is required. This requirement is largely bureaucratic, although some technical qualifications of said AIR are required. While there is no formal requirement as to the type of entity this AIR has to be, this technical requirement limits it to companies such
(in English language with official seal) and technical information on the product and its production process are the most important
to provide adequate resolution of the issue raised by PESO, your application will fail and you will need to start the certification process again from the beginning.
For the application, supporting
required documents. Manufacturers also need to provide detailed commercial information and references, ideally an order from an Indian client is already available.
The process and documentation required for PESO certification still have an arcane feeling, due to the many formal documents that need
documentation needs to be provided. Some of the common documents that must be submitted include:
Without a clear order chain to show the link of the product with India, it will be close to impossible to get approval from PESO. That
to be prepared, signed and submitted, and feedback of PESO can be difficult to manage due to short time frames. PESO has recently
• Product certifications and proof of quality • Technical information on the product, Exrelated • Manufacturing facility setup and proof of
also means that if the Indian end-user is not directly ordering from the applicant, the entire order chain from manufacturer to end user may have to be provided.
started an online application system to start digitalising the process, but for now that is only for the basic application at the very start. If you submit the online application too early,
Additional commercial information such as references from existing clients, reasons
you will not have enough time to answer the formal document requests of PESO. It is therefore strongly advisable to carefully
if available) • Commercial information such as the order from India (stating the installation place and
for any customer callbacks, and expected revenue in India, will also be necessary.
prepare all application-related documentation before you start the online application.
purpose of the equipment) and estimated revenue • A set of formally prepared and signed
Finally, since PESO itself is an old organisation, a series of formally signed documents are required from the applicant.
documents in original as part of the formal application
These documents include an authorisation letter of the applicant to their local representative (aforementioned AIR), a formal
The most important PESO certification requirement is to provide valid and up-todate IECEx or ATEX certificates and recent test reports. However, due to the generally more dangerous nature of the products that fall under PESO, higher diligence is also required by the companies that want to have their products certified. In addition to the
application listing the products and targeted hazardous area, a list of references for the product in the application, a declaration of the conformity of the equipment, as well as the locations of installation of the equipment in India.
certificates and test reports, the most recent Quality Assurance Notification needs to be provided. As the list before indicated, PESO requires a large set of documents beyond just the
however is fairly simple. No additional product tests in India are required and PESO does not conduct any factory inspections (notwithstanding approval commissioning of the equipment locally in India, which is the buyer’s/end user’s responsibility), and
test reports. The applicant’s business license
there are no marking requirements. Once
as a local subsidiary or a trained importer/ distributor of the applicant’s products.
quality qualifications (such as ISO certificates) • Proof of relation to India (Authorised Indian Representative, Indian customer information
About the author
The PESO certification process itself Julian Busch is Managing Director of MPR International GmbH and China Certification Corporation, a company that supports manufacturers worldwide in obtaining product certifications for China, India, Korea and other markets.
www.hazardexonthenet.net
28 Process Safety
Image: Shutterstock
Notes on the evaluation and avoidance of electrostatic charges E
lectrostatic charges can occur when two surfaces are rapidly separated, whereby at least one surface must be
the 13 possible ignition source types to be considered in a plant-related risk assessment. A distinction is made between
Selection of a suitable Big Bag
an insulator. Critical processes, for example, are pneumatic conveyors, Big Bag filling stations, or even silos with the danger of a conical pile discharge. In order to avoid electrostatic discharges at such FIBC filling stations, it is necessary to assess the bulk material and to select the proper
the most varied types of discharge which, depending on the type, can be responsible for igniting gases or dusts (Figure 1).
divided into the types A, B, C, D, which can be categorised according to their protective characteristics as follows:
FIBC Type.
How do electrostatic charges develop, and how does the grounding work? Electrostatic charges and the associated discharges are considered as one of
www.hazardex-event.co.uk
Big Bags, also referred to as FIBC´s, are
Electrostatic discharges and their ignition potential Energy
Discharge type
Hydrogen /
Solvent vapours
Dust > 1 mJ
Acetylene
MIE > 0.025 mJ
MIE > 1mJ
+
+
+
Conical pile discharge
+
+
+
++
Sparks
+
+
+
+
Brush discharge
+
+
-
Ascending
MIE ≤ 0.025 mJ +++
Propagating brush discharges
+++
Figure 1 – Electrostatic discharges and their ignition potential. Source: www.bgrci.de
Process Safety 29
- Avoid brush discharges: Type C and D - Avoid propagating brush discharges: Type B, C and D - Avoid spark discharges: Type B, C and D Type C Big Bags have conductive filaments, which makes it necessary to ground type C Big Bags. Such grounding can be carried out by means of a cable and clamp. Another option is grounding by means of a grounding monitoring system. An approval function enables the Big Bag Type C to only be filled if the grounding is correctly established. Type D FIBCs transfer the resulting charges to the environment via dissipation. However, this requires grounding of all conductive equipment and objects located within reach of the type D Big Bag. Likewise, persons must wear conductive footwear, otherwise these persons will be charged up as well and act as an ignition source themselves.
Figure 2 – Electrostatic charges by means of grounding monitoring device
the truck is properly grounded. Here,
The Big Bag must be selected strictly in accordance with the requirements of IEC
Electrostatic charges during the filling of silos with a pneumatic filling
TS 60079-32-1 “Explosive Atmospheres – Electrostatic hazards, Guidance”, and depends on the minimum ignition energy
Another source of electrostatic charges is in places where a pneumatic transport or the pneumatic filling of
provide an approval system that can be used to control valves or other equipment (Figure 2). In addition to
(MIE) and the zone classification. However, the division also depends on the zone defined on the outside. If a gas zone is
silos by trucks is carried out. If an explosive atmosphere develops outside the truck, and the truck charges up
grounding the truck, care must also be taken to ensure that the conveying line is properly executed. Adequate means
present at the same time, special measures must be considered.
electrostatically due to the conveyance, there will be an acute risk of explosion. For this purpose, always ensure that
that this must be electrically conductive/ conductive dissipating and grounded.
there are also systems on the market that are able to monitor the proper grounding of the truck and, via relays,
Use of the different types of FIBC Bulk Product in FIBC MIE of dusta MIE > 1000 mJ 3 mJ < MIE ≤ 1000 mJ MIE ≤ 3 mJ
Surroundings Non flammable atmosphere
Dust zones 21-22b
Gas zones 1-2b (Explosion Groups IIA /IIB)c
A, B, C, D
B, C, D
C, Dd
B, C, D
B, C, D
C, Dd
C, D
C, D
C, Dd
Measured in accordance with IEC 61241-2-3, ASTM E2019 and EN 13821 with a capacitive discharge circuit (no added inductance) See D.2 for the definition of zones. c See D.3 for an explanation of Explosion Groups. d Use of Type D should be limited to Explosion Groups IIA/IIB with MIE ≥ 0.14 mJ. NOTE 1: Additional precautions are usually necessary when a flammable gas or vapour atmosphere is present inside the FIBC, e.g. in the case of solvent wet powders. NOTE 2: Non-flammable atmosphere includes dusts having a MIE > 1000 mJ. NOTE 3: The MIE limit of 3 mJ is based on the incendivity of cone discharges. Cone discharges might have a much higher energy in a Type B FIBC than in a Type C or D FIBC because the wall of a Type C oder D FIBC will be at close to zero potential. Based on this fact the internal field distribution will be such that in Type C oder D FIBC cone discharges will at most only jump across half the diameter of the FIBC. A calculation with the formula given in A.3.7 for the largest FIBC commonly used (diameter of 1,5 m) yields 3 mJ for powder with a median size of only 0.055 mm in a Type B FIBC, whereas in a Type C or D FIBC the 3 mJ limit is only reached with a coarse powder having a median size of 0.27 mm or higher. However, such coarse powders usually have a MIE higher than 3 mJ. a
b
Figure 3 – Selection of suitable FIBC types depending on bulk material and operating conditions. Source: IEC TS 60079-32-1
www.hazardexonthenet.net
30 Process Safety
Figure 4 – Grounding monitoring of a truck
Insulating intermediate pieces such as sight glasses or similar should be avoided, as these may lead to propagating brush discharging.
Conical pile discharge in silos An often not considered circumstance is the possibility of so-called conical pile discharges in silos. Bulk solids are generally not regarded as conductive
but can be dangerously charged during pneumatic conveying. If the silo is large and the bulk material has large particles, there is a risk that the cloud of dust above the bulk material will ignite due to a conical pile discharge. If the conical pile discharge cannot be excluded as an effective ignition source, a protection through protective systems must be established in case of doubt,
Figure 5 – Explosion protection by means of flameless explosion venting and quench valve on a silo with the risk of conical pile discharge
www.hazardex-event.co.uk
Process Safety 31
such as flameless explosion venting or explosion suppression. The protection
Conclusion
About the authors
Electrostatic discharges are difficult
of adjoining plant components must also be taken into account during the protection design phase. The supply line must be isolated against the pressure and flame of a possible explosion. This prevents the explosion
to grasp as they are not immediately visible and are highly dependent on the operating equipment and bulk materials used. An adequate evaluation of electrostatics as a possible ignition source is therefore all
from striking back, for example into the conveying truck or into the Big Bag loading station. In addition, the silo discharge must be equipped with an appropriately certified rotary valve, e.g. Ex II (1) 2 D, to prevent the explosion
the more important. The guideline to be applied in Germany is TRGS 727 and the international version is the IEC TS 60079-32-1, which provides corresponding assessment methods for the dust and gas explosion safety.
Marius Bloching is Corporate Senior Engineer at REMBE GmbH Safety and Control and works on explosion safety applications for different industries. He mainly focuses on the different legal requirements in regard to explosion protection, which apply around the world and which sometimes significantly differ from each other.
propagation in this direction.
Alexander Kemmling is Sales Executive Explosion Prevention at REMBE GmbH Safety and Control. He is responsible for the sales field of fire and explosion prevention equipment.
Image: Shutterstock
www.hazardexonthenet.net
Conference • Workshops • Exhibition • Awards Programme
2021
6th & 7th October • Harrogate • Yorkshire • UK
Awards nominations open for Hazardex 2021, organisers say
“ act now to enter ”
The 2021 Hazardex Awards for Excellence, to stage on the evening of October 6th in Harrogate, UK, will include six categories for which nominations are now open! The deadline for nominations is August 6 The Hazardex awards programme has long been a benchmark for those supplying products, services and systems within hazardous areas. You can play your part in raising awareness and standards across the sector by nominating for the Hazardex 2021 awards, entering your vote and encouraging your colleagues to do likewise. The Awards evening will take place during the annual Hazardex International Conference and Exhibition, which is widely recognised as the most important global event specific to hazardous area operations across all major industries. The event brings together the international process safety community to review best practice and the latest research in those areas key to managing process safety effectively. To nominate - go to our website www.hazardex-event.co.uk
Sponsor Exhibitor & w available packages no 21 x & PPTex 20 for Hazarde r details contact us fo
Media Partner
Entry is free, and this is the ideal opportunity to reward those companies and individuals you think most deserve recognition for the most innovative products, systems and services. The deadline for nominations is August 6 after which Hazardex readers and website users will be asked to vote for the winners in each category. 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
Supporting Organisations
Mining 33
Operating underground presents a unique set of challenges, particularly when it comes to automation and communication
Taking Industry 4.0 underground O
perating underground presents a unique set of challenges, particularly when it comes to automation and communication. Christian Fimpler, Product & Program
these disparate elements through the development of a universal set of principles and standards.
Manager for Hazardous Area Communications at Eaton, examines whether Industry 4.0 principles around connectivity are achievable in subsurface applications.
digitalisation: the application of information and communication technology (ICT) to enable every component, every machine and every site to be fully connected: from the smallest field device right up to the
work. In some cases, this also reduces risk by removing people from potentially hazardous environments altogether.
Industrial operations around the world are under constant pressure to increase production efficiencies, boost profitability and improve product quality; while at the same time enhancing safety. Industry 4.0 provides a means of addressing
Cloud. The levels of automation and humanmachine interaction that digitalisation can deliver are not yet fully realised: but the potential benefits are already clear. In process terms, these benefits include reproducible complex tasks involving multiple machines and the collection and
desirable in highly mechanized industries where hazards are commonplace, such as mining and tunnelling. However, operating underground throws up some unique challenges: some of which make the adoption of Industry 4.0 ways of working problematic.
A key enabler for Industry 4.0 is
analysis of data in order to spot production trends, anticipate maintenance requirements and save energy. In human terms, workers are freed from boring, repetitive tasks so they can focus on more value-added, skilled
These potential benefits become even more
www.hazardexonthenet.net
34 Mining Below the surface Mining operations – whether for coal,
limited to installing, controlling and maintaining the heavy equipment involved.
Currently, a number of specialist standalone systems are deployed, with safety-critical
potash, diamonds or precious metals – are intrinsically hazardous places in which to work. Working conditions are necessarily restrictive and there is a constant risk of exposure to harmful dust and gases. Similar conditions are encountered by those
In these circumstances, Industry 4.0 connectivity sounds like a silver bullet that will enable the collection and analysis of relevant data in order to relay it out in real time to the people and equipment that need
systems kept separate from automation and operational systems. Often developed by different OEM manufacturers, these systems have only limited options for connectivity and the exchange of information particularly as they can use different
it. But life, as we know, is never that simple.
program languages.
Current state
Both mining and tunnelling were once highly
There are some major barriers to implementing Industry 4.0 levels of connectivity in underground applications.
For reasons of reliability, hard wiring is still preferred over wireless systems in underground installations for critical communications. For example, each
labour-intensive, but mechanisation and automation has largely replaced humans. Thankfully, we are no longer at the cutting edge with picks and shovels or hauling
How can we collect and transfer data in a timely and efficient manner between machines that are operating deep underground and the surface control room,
analogue telephone has its own cable, so if one experiences a fault the other devices are not affected. However, hardwired systems do have some drawbacks.
carts of spoil back to the surface. Machines designed for cutting, drilling and crushing alongside heavy duty conveyor systems have removed much of the physical labour.
and from a surface control room to workers who may be several kilometres along a subterranean tunnel or access road? Let us examine current practice.
Accommodating multiple cables in confined spaces is not easy: and while analogue phones require one cable per device, digital/ fibre optic cable and an IP structure can
involved in the construction of essential underground infrastructure, such as road and rail tunnels, water ring mains and sewers.
Human interventions are now generally
save space and cost.
Image: Shutterstock
www.hazardex-event.co.uk
Mining 35
WiFi, that bedrock of the internet age, also has some issues to overcome when being
simply unacceptable in a hazardous working environment.
applied underground. Electronic devices are known to be affected by dust ingress, high temperatures and interference – particularly from vibration and noise: none of which is a recommendation for reliability. While robust design and IP-rated enclosures can do much to mitigate these effects, the risk
In addition, modern communications devices that most of us would take for granted – such as mobile phones and tablets – are not yet ubiquitous in underground locations. Quite aside from the connectivity issues, they are a potential source of ignition. So,
that one electronic node failure could knock out communications to an entire sector is
any devices of this type need to be equipped with explosion protection.
Industry 4.0 connectivity sounds like a silver bullet that will enable the collection and analysis of relevant data in order to relay it out in real time to the people and equipment that need it – Image: Shutterstock
About the author
Christian Fimpler has more than 20 years’ experience in the mining industry. Based in Germany, he began his career as an electrician in an underground mine. Previous employers include TMP GmbH automation & engineering and FHF Bergbautechnik GmbH. Christian joined Eaton in 2012 and has held a number of roles, with increasing responsibility. These include project engineer leader, business unit leader and product line manager for mining. He is now Product Line Manager for Process Connectivity.
Case study – Integrated solution
O
n this evidence, it may seem as
compatibility between the different functions is
Looking further ahead, the technology may
though further adoption of Industry 4.0 in underground applications has hit an impasse. However, new technology may
guaranteed, greatly improving reliability.
evolve to include ways of tracking each individual as well as each machine. This would enable the nearest available maintenance
trigger the step-change that underground industrial applications need to move forward. What is believed to be the world’s first fully integrated IP-based voice, data, WiFi, interlock and automation system has been developed for underground industrial applications where rugged and/ or explosion proof equipment is required.
end-users can choose to use any or all of the integrated functions that SIMAS offers – and its modular design makes it simple to alter or extend the system as operational demands change. Open interfaces mean it can also be used to link with third party systems as required.
System designers, project engineers and
person to be notified to attend a fault, reducing downtime. Or, in the case of an emergency, it would help to plan rescue efforts because the exact position of the injured or ill person would be known: benefiting them and their rescuers.
While SIMAS represents a major step forward,
In conclusion, the potential benefits of Industry 4.0 ways of working have been clear for
The system is known as SIMAS – System Integrated Mining Automation System – and it can use data gathering via WiFi for non-critical applications, but still offers a safety circuit that is hardwired for the transference of critical
it could also be a springboard for further progress towards implementing “Mining 4.0”. This could be on a practical level, such as finding ways of incorporating WiFi access points into lighting modules or metal roof
some time, but their application in hazardous areas underground has been hampered by a number of factors. This raised the very real prospect of mining and tunnelling falling behind other industrial sectors in their ability
data. This gives users the flexibility necessary to adapt to the challenges of working underground, while offering full integration of automation, communications and safety functions. Because it is designed as a fully integrated system by a single manufacturer,
supports to reduce installation time and space requirements. In the near future, we can already see the potential for adding addressable fire evacuation to this integrated system to enable phased evacuation of personnel, based on proximity to the hazard.
to respond to changes in demand, adopt smart maintenance methods, or implement better safety regimes. The improvement in integration between automation and communication systems now offered by SIMAS is a major step forward.
www.hazardexonthenet.net
36 Certification
Healthy competition is welcomed in the Ex market, but only if everyone adheres to the applicable rules - Image: Bartec
Forewarned is forearmed D
id you know that manufacturers can declare their own Ex products in safety category 3, such as control cabinets and portable devices, safe? And that they can subsequently market these products as CE marked
www.hazardex-event.co.uk
products for zone 2 or 22? There is nothing wrong with that, but it brings to mind the proverb of the butcher
seems that the same product has been approved by a Notified Body. That is not the case, however – it is still
inspecting his own meat. However, through ‘impressive stamps’ and other misleading tactics, it sometimes
the same butcher. For the buyer, it is important to watch out; forewarned is forearmed.
Certification 37
DHZ
Doe Het Zelf BV
UNIT ASSESSMENT CERTIFICATE
(1)
Issued by a qualified body in explosion safety
(2) European Union Declaration of Conformity for Group II Category 3G equipment in accordance with Directive 2014/34/EU Annex VIII
DHZ 20ATEX1234X
(3) Document Number :
(4) We, Doe Het Zelf BV, Montagelaan 11, 1313 AZ Klussendam, The Netherlands, herewith declare that : (5) The apparatus Converted to Type Quantity File Serial numbers
ATEX Zone 2 … II 3G IIC T4 / II 3D IIIC T135°C … 2 pieces TCF… DH-20…-01 /-02
(6) Is in conformity with the provisions of the following European Union directive, including the latest amendments, and with national legislation implementing these directives: - 2014/34/EU (ATEX); concerning equipment and protective systems intended for use in potentially explosive atmospheres (7) And that the following harmonized standards have been applied in design and construction: EN 60079-0 EN 60079-11 EN 60079-15 (8) The marking of the apparatus includes the following: II 3G Ex ic nAC h IIC T3 Gc / II 3D Ex tc IIIC T135°C Dc (9) The apparatus in its basic version is originally manufactured by : OEM (10) Assessment and conversion to explosion safe is carried out by: Doe Het Zelf BV, Montagelaan 11, 1313 AZ Klussendam, The Netherlands. (11) On behalf of: Client Name (12) This declaration does not imply that the apparatus meets all the statutory requirements in any particular industry and/or circumstance. Doe Het Zelf BV, Klussendam, 01-09-2020
Prof. Dr. Van der Knoei IECEx Competent Person (X) Special conditions for safe use are specified in the accompanying user manual of the equipment.
Figure 1 – A voluntary certificate from a genuine recognised Notified Body, DEKRA
Figure 2 – A so-called ’certificate’ from a manufacturer posing as a qualified body with an IECEx Competent Person in service
The ATEX product directive (ATEX 114)
certify at all (this is why independent
only applies to electrical equipment.
has a conformity procedure for safety category 3 whereby manufacturers may independently, without input from a Notified
certification bodies exist for this activity), which brings us back to the proverb of ‘the butcher who inspects his own meat’.
But there is only a ‘certificate’ when a Notified Body is first involved. This may be a ‘Unit Verification Certificate’ (for one-
Body, declare their produced Ex products (such as control boxes or portable devices) safe by means of a self-assessment and
The situation can lead to plenty of negative press and scandals – just think of horse meat being sold as beef!
off production), but it is usually an ‘EU Type Examination Certificate’ (for serial production).
Currently, we see an increasing amount of manufacturers in the market presenting
Voluntary
themselves as Ex manufacturers. Healthy competition is welcomed in the Ex market, but only if everyone adheres to the applicable rules. And that is exactly where attention must be drawn. Does the end user realise that the safety of the product and the correctness of the accompanying documents may be essential in the event of
can also be issued for category 3, but this is done on a voluntary basis and is then called a ‘Type Examination Certificate’ (note: without the indication ‘EU’). But again, ‘certificates’ should be seen as documents demonstrating independent examinations. Even major reputable Ex manufacturers make use of these to get their products
an incident?
subsequently place them on the market as a CE marked Ex product for Zone 2 or 22. So much for the wording dictated by the text, as the ATEX directive must be included in the National Legislation in each member state of the European Union due to the ratification of the Lisbon Treaty. This is how it is regulated in the Netherlands under the Explosion-safe Equipment Commodities Act Decree.
It is also worth mentioning that a certificate
The category 3 conformity procedure is commonly referred to as ‘self-certification’. Some people will of course understand this is actually asking for trouble. This is
For the record, ATEX directive 2014/34/ EU also defines safety category 1 and 2. In the conformity procedure for category 1, there is always mandatory involvement
more easily accepted by more demanding end users and inspection agencies. In all cases the manufacturer applies CEmarking and draws up an EU Declaration of Conformity which, together with the installation or user safety instructions, is
because a manufacturer cannot formally
of a Notified Body; for category 2 this
mandatory with the equipment. Legally in
Self-certification
www.hazardexonthenet.net
38 Certification in almost exactly the same style and context as when it comes from a real Notified Body. Finally, the certificate is also signed with impressive stamps as if it came from a recognised Notified Body... Is this misleading? Keep in mind that you, as a purchaser or user of such a product, is actually being sent up the garden path by the manufacturer. The Ex manufacturer should provide an EU Declaration of Conformity with which it declares and legally signs a ‘Presumption of Conformity
Figure 3 – An Ex certified mobile computer – but always remember: is this device suitable for the relevant zone?
Europe, an EU Declaration of Conformity is more important than a Type Examination Certificate. In fact, the latter certificate is proof only for the manufacturer that
Impressive stamps
the prototype has been approved by an independent party. Nothing more, nothing less.
procedure by manufacturers, without the intervention of a Notified Body, where the manufacturer draws up a ’certificate’
www.hazardex-event.co.uk
Back to category 3. What do we see on the market today? Many products that are subjected to the conformity
with the Essential Health and Safety Requirements (EHSRs) of the directive’. But what do you get? A ‘certificate’ which looks like an independent Type Examination Certificate but is in fact drawn up by the manufacturer itself. It is to be hoped that the user will detect this. For someone who knows the standards well, this kind of manufacturer will quickly be found out; types of
Certification 39
protection are mentioned, which are not always found in the list of applied
Scheme IECEx 05. Marking with IECEx logos is in fact a violation of the IECEx
standards or, even worse, may not apply to the product at all. Furthermore, we often see that the edition of the standard is old or not mentioned at all; apparently they don’t even know the ‘State of the Art’.
Rules of Procedure and therefore punishable as ‘misuse’. One could even openly question the competence of such persons.
Tips
An explanation
• Take a serious look to see what is on offer. • Cheap can be expensive, especially when it comes to the safety of the plant, but even more so when it comes to the safety of the
What also happens is that IECEx terms and ATEX terms are confused. This is unfortunate because IECEx, as a voluntarily applicable system, deviates very strongly from ATEX here; whatever
But what if there is an accident or calamity with the product in question. Who is responsible then? In fact, the answer is simple: the plant owner always remains responsible for what they do or do not allow in their factory.
employees. • Be on the lookout for misleading sales pitches; ‘A large oil company also uses it’. • The larger reputable Ex manufacturers, many of whom have
level of protection you wish to apply under IECEx, from ‘a’ to ‘c’, in all three cases an independent IECEx Certification Body shall perform an assessment and certify
Whether the purchaser or user of the product is insured if it turns out to be a dubious product will have to be made
conformity to ISO or IEC standards. An ATEX related ‘certificate’ (which should be an EU Declaration of Conformity) is therefore indeed misleading if it is signed with titles such as Competent Person according to the Personnel Competency
clear. Should it go wrong, it can go so wrong that there is practically no evidence left. If the cause can be found, the manufacturer will have some explaining to do in court. It would probably mean the end of the company.
been in business for over 50 years, know how things should be done and do everything they can to apply the regulations correctly. • Ask the inspection agencies whether they assess the documents supplied sufficiently in terms of content. Just receiving an impressive document does not mean that it is correct.
About the author Figure 4 – An Ex smartphone in combination with an Ex camera and Ex headset making video meetings between office and hazardous areas possible
Karel Neleman is an Ex authorised person at BARTEC Group. He is a Member of the Dutch National Standardisation committee Explosion Safety and Chairman of the Installations Subcommittee. Karel is also Delegated Ex manufacturer in the Dutch ATEX Comitology Committee, Delegated Ex manufacturer in the international IECEx Management Committee, member of several TC31 Maintenance Teams that bring standards to the desired State of the Art, and a member of the ATEX 153 platform; a repository of knowledge about Ex applications.
www.hazardexonthenet.net
Conference • Workshops • Exhibition • Awards Programme
S NEW DATE RELEASED
2021
6th & 7th October • Harrogate • Yorkshire • UK
Following recent updates from the UK Government, the Hazardex 2021 Conference, Exhibition & Awards will now take place in person, on the 6th & 7th October 2021.
xhibitor Delegate, E packages & Sponsor x for Hazarde le b a il a v a now t 21 - contac 0 2 x e T P P & ils us for deta
Media Partner
The health and safety of all participants remains key in the organisation of Hazardex 2021. With the continued rollout of vaccinations across the UK and Internationally, these new dates will help ensure the event is safe and productive for all. COVID-19 regulations and UK Government guidelines will be observed & enforced as required at the time of the event.
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
Supporting Organisations
Events 41
Hydrogen + Fuel Cells EUROPE (Virtual) Date: 12-16 April 2021 Location: Online Hydrogen + Fuel Cells EUROPE is part of HANNOVER MESSE and will take place between April 12-16. It is the platform where key challenges can be discussed, solutions presented and networks expanded. The digital conference and exhibition will include topics such as: hydrogen generation, hydrogen storage and transport, fuel cell systems and applications, stationary, automotive, mobile, special markets, components and supplying technology, fuel cell and battery testing, and stationary batteries.
The event will include exhibitor livestreaming where you can immerse yourself in bestcase applications and get concrete solution approaches via livestream and video chats. An Interactive Conference Program and digital networking service will allow you to connect with leading hydrogen industry figures. Via a matchmaking service, you can find suitable contacts, arrange appointments, and get into conversations with exhibitors and other participants via video call. The digital event will also include a personal dashboard where you can save your favourite content, access your appointment planner and contact list, or view personal
recommendations based on your interests. Exhibitors include nel, AVL, borit, DANA, Sumitomo Electric, Toyota, Hyundai Mobis, ITM Power, PowerCell, Hexagon, and many more. www.h2fc-fair.com/en/
American Fuel & Petrochemical Manufacturers Annual Meeting 2021 Date: 12-13 April 2021 Location: Online The American Fuel & Petrochemical Manufacturers (AFPM) Annual Meeting assembles key executives, decisionmakers, and technical experts from refining businesses, technology providers, contracting and consulting firms, and equipment manufacturers around the world. This year’s event has gone virtual, potentially connecting even more of the AFPM global network on April 12 and 13.
The mission for the Annual Meeting is to deliver an engaging program addressing both significant opportunities and challenges for US refiners and petrochemical manufacturers. This year it may seem the challenges outweigh the opportunities, but the AFPM is excited to deliver a program designed to arm you with critical information to help you achieve more, go farther, and improve your company’s performance. The AFPM hopes to hold the 2022 meeting in-person.
Chet Thompson, President & CEO of AFPM and Joe Gorder, Chairman, President & CEO of Valero Energy Corporation. There will also be breakout sessions hosted by BASF, Honeywell, Technip Energies, Haldor Topsoe, and any more.
Among the speakers at AFPM 2021 are
www.afpm.org/events/AM21
MEOS 2021 Date: 24-27 May 2021 Location: Bahrain
some of the oil & gas industry’s largest corporations.
The 22nd edition of the Middle East Oil & Gas show and conference (MEOS) has been rescheduled to May 24-27 and will be held in-person at the Bahrain International Exhibition & Convention Centre.
MEOS is also privileged to receive full support from GCC national oil companies including ADNOC, BAPCO, KPC, PDO and Saudi Aramco, who take showcase stands at the exhibition, implement major visitor delegations and play an active role on the conference organising committee.
The MEOS exhibition serves all areas of the oil & gas industry and has done over the last 40+ years. Attended by every oil producing state in the region, the exhibition attracts specialised businesses and
Organised by the Society of Petroleum Engineers (SPE), the parallel conference consists of high quality technical presentations focused on Middle East
issues. The conference typically features over 300 papers, a series of panel sessions led by presidents, CEOs and chairmen of key players, and a high ranking collection of keynote speakers. MEOS 2021 conference will take place under the theme: Shaping the Future of Energy in a Dynamic World. www.meos-expo.com
www.hazardexonthenet.net
the journal for hazardous area environments
ents a environm ardous are
et nthenet.n
hazardexo
l for haz the journa
Mining
derground stry 4.0 un Taking Indu
Motors
are area motors Hazardous empt x no longer e fety Process Sa forearmed Forewarned
is
on Certificatition
ifica Indian cert ts used in for produc ts environmen explosive
April 2021
Like what you see, but not your copy? If you or/and a colleague would like to receive FREE copies of HazardEx Magazine every month, you can register online by scanning the QR code below
rity Cyber secu k risks ttac The cyber-a plants to process
Open the QR code on your phone or launch the camera on an iPhone, scan the QR code above and complete the online form or visit https://data.imlgroup.uk/hazardex-quick-signup/
ety
Data Files/Buyers Guide 27 Buyers Guide and Datafiles 43
Explosion-safe Air Conditioners
Hazardex 2021 Exhibito TEX Zone 2 iPhone 11 (Pro Max) – Increased Intrinsically Safe Apple Smartphone ATEX
SUCO introduces world’s most compact Ex uring, the Netherlands. The Apple switch iPhone 11 pressure
EASY TO ORDER GAS and DUST ATEX FANS
Measurement and Control – ExCABINS Special AND Interest Group FOR OFFICES, CRANE TLQ’S
Product Data file Features: in hazardous locations. The explosion proof • Explosion safetyFerrari level: IIhave 3G ; standardised Ex ec ic IIC T4their Gc Zone 2 and Zone 22 Suitable for Zone 2 environments tured by Apple than converted and certified is certified according to • Charger 110-240VAC ventilation fans to make it easier to enquire and order, The new series 0342/0343 es by Atexxo Manufacturing. makes the andwon • Charger EASY our website contains a simple enquiry form for you to ATEX Directive 2014/34/EU IECExthe scheme TheThis InstMC Ex-SIG Best User engagement at a50/60Hz professional level. Capacity up to 14 kW se in gas /vapor zone 2 hazardous areas. complete with your requirements and can be emailed to for the ex zones gas 1+2,(zone dust 21+22 and mining. Applications: Hazardous material storage, petro Application award at the Hazardex 2020 GAS e installed by the end-user themselves. usand for more information. By reducing the ignition gaps to a minimum, the chemical plants and oil gas extraction sites. Cooling and heating Awards Excellence, which took The qualifi cation is based on peer review in The Zone 2 fans are suitable for general explosive Ex pressure switches assigned the ignition egulations is achieved by modifi cationfor ofare the ATE Atexxo Manufacturing is market leading in the field gases and Zone for non-conductive explosive protection type “Flameproof Enclosure (Ex d)”. 230 or 400 VAC ally safe electrical circuit, which makes the Hazardex of usermanner friendly and to install explosion proof place at the Conference & the same as easy IEng/CEng, with22 a fans similar dusts. They can be suitable for internal and external The Ex pressure switches with protection azardous locations. All features of the original equipment. insuited Harrogate, on February application is overseen by theor internal only, Ambient temperature –27°C to 52°C explosive atmospheres which means insulation “class are for supplyUK voltages up to 250 V. The switching points process, and face scanner can be usedExhibition safely at II” hazardous HazardEx ATEX Ad 8/1/2021 For more information orbe custom solutions can supplied with ATEX rated or safe area can easily adjusted during operation with an designed adjustment screw. Institute’s Professional they 26.beThe Hazardex awards are Registration Committee. please contact our sales department or Heading: visit Keep Hazardous II 3theG Ex ecareh being ic mc IICandT4 Gc Locations Safe, Cool, motors depending on the area classification fans used in.Protected a mounting ofis52 mm at hex 27, the 0342/0343 series are the most Ferrari have standardised their Zone 2 and Zon pro max) comes with aWith black case finishsize and our website www.atexxo.com to Ex recognise excellence in the hazardous compact pressure switches with a broad approval for gas, dust and mining order, our website simple Body (115 words): The ATEX Vortex A/C Enclosure Cooler iscontains certified afor ATEX enquiry Zones 2 fo a rsions. Beside safe use as a phone all versions www.ferrarifantechnologyuk.co.uk be emailed up to us for more information. applications. environments to 80°C and are designed to c ement and or RFID area sector and has become the The Institute has a range of Special Interest temperature rating. The units operate incan lly safe camera scanner. info@ferrarifantechnologyuk.co.uk quietly with their 62 dBA sound level, rather than adding to industrial noise. The unit is b The Zone 2 fans are suitable for general explos www.SUCO Worldwide info:supplying info@suco.de Tel: +49 7142 597 0 ospheres benchmark for those products, Groups, which members of the Institute can join no ambient, dirty, or humid air enters the cabinet. A mechanical thermostat turns the u Tel: 0845 634 2174 explosive dusts. They can be suitable for intern
operating All they Vortex have a sm -SIG) aims services and systems. More details can be for free as a membership benefit, including: necessary, optimizing performance and only, whichcosts. means canA/C bemodels supplied with A that easily mounts on any enclosure andclassification in confined spaces. The EVL series lighting fixtures innovated and enhanced the fans are being used in. and support found at www.hazardex-event.co.uk. • Explosive Atmospheres Information: www.vortec.com |www.ferrarifantechnologyuk.co.uk sales@vortec.com | 800-441-7475 DUST. THE UNDERESTIMATED Keep HazardousContact Locations Safe, Cool, The EVLRISK series of LED lighting fixtures, launched velopment in the • Functional Safety by evelopment OF EXPLOSION Cortem Group in 2015 and available in four sizes,and Protected Image: info@ferrarifantechnologyuk.co.uk nge of activities The Institute of Measurement andhas Control also and enhanced • Flow to offer an even been innovated
0845 634 2174
of risk awareness The ATEX Vortex A/C Enclosure Cooler safer and more performing• product. up is producingThe level offers a professional level qualification in Ex Cybersecurity in food processing is certified for ATEX Zones 2 and 22 • New “Ex op is” certificate o help inform industries matters: for dust‘Registered explosion Explosive Atmospheres with a T4 temperature rating. The units • New multi-LED plate • Digital Transformation is relativelyThis is available to InstMC operate environments up to 80°C • Newmembers range of the ambient temperature to -40°C + 60°Cinand temperature hese are first hazardsEngineer’. • Measurement low. Take advantage of and are designed to cool enclosures classes colder (T5) with gas group IIB+H2 and IIC e SIG before our unmatched who are expert registered with the Engineering Council • Standards • New supply voltages range from 12 to 277V quietly with their 62 dBA sound level, knowledge in preventingand who can demonstrate rather than adding to industrial ble. An example as IEng/CEng, • New powers available start from 20W up to 220W, with steps of 10W and 20Wnoise.
use use Twitter? Twitter? dust explosions and use it
Application Example
Ferrari Fan Technology (UK) recently supplied v Bioprocessing company in Ireland. This project were situated on the roof of the building. The e protection from severe weather and to ensure
The unit is built to ensure no ambient,
• Different lumen outputs ranging from amay minimum of 1,700lm to Institute’s a maximum s included on to protect appropriate ‘competence & commitment’ Further details bedirty, found at the your employees, or humid air enters the cabinet. of 21,000lm in the Ex discipline, together with•ongoing website www.instmc.org plant and machinery. LearnArtidor thermostat turnsfor the unit Explosion Safety B.V. | The Netherlands | artidor.com | Asales@artidor.com Transportable version with electronic driver and a mechanical model specifi cally designed
The fumehood extract fans used were selected FS311/P4 with 1.1kW 4-pole and was selected 2.2kW 4-pole and was selected to achieve 0.71
more about explosion on only discharge when necessary, a rapid and a timely replacement of the old generation lighting optimizing fixtures fans used for wash and autoclave room ext protection on our website performance and operating costs. All Vortex A/C models haveThe a small footprint that installed directly on a pole. impellers, FR561/N4 with 3kW 4-pole and was r-stahl.com. Is your equipment compliant? easily mounts on any enclosure and in confined spaces. www.cortemgroup.com info@cortemgroup.com
enquiries@r-stahl.com | Tel: +44 (0) 121 767 6400 www.vortec.com | sales@vortec.com | Tel: +1-800-441-7475 at @HazardEx yers Guidewww.r-stahl.com |for The fans used for storage cabinet extract were EEMUA Publication 186 - A Practitioner’s at @HazardEx for 0.37kW 2-pole and was selected to provide 0.2 Buyers Guide and Datafi les 51 Handbook for potentially explosive atmospheres and discussions was selected to provide 0.035m3/s at 341Pa an Data files Control Panels to provide 0.739m3/s at 403Pa.
FR251/N4 with 0.55kW 2-pole and was selecte
and discussions afety in the worlds afety in the worlds zard industries MATION & TECHNOLOGY zard CONTROL industries
EEMUA 186 offers guidance for safe installation, inspection and maintenance work in potentially explosive atmospheres. EEMUA 186 focuses on ignition caused by electrical and mechanical sources and interprets relevantCONTROL parts AUTOMATION & TECHNOLOGY of international and European standards, directives and Do regulations. YOU use Twitter? tal Solutions Provider Your Total Solutions Provider EEMUA 186 covers application design engineering and Follow us at @HazardEx for allPerson news s in design and custom build of a wide range of in design and custom build of a wide range of duties of the Responsible Specialists (IEC standards). It includes andFollow discussions related to safety in Areahazardous us at @HazardEx for all s Area Equipment Hazardous Equipmentareas in separate chapters onnews fuel filling stations, andworlds discussions related to water, safety in mechanical ignition sources. the high hazard industries water and waste and the worlds high hazard industries OEM for and Technor Marechal red OEM for Technor Marechal Closely associated withRegistered the CompEx® training competency assessment scheme, this easily navigable resource is available to purchase at: Southampton https://www.eemua.org/Products/Publications/Print/EEMUASO40 9AH azardous area environments Publication-186.aspx +44 (0) 2380 665544
All fans are certified ATEX II 3G IIB T3 with safe
Do YOU use Twitter?
azardous area environments enquiries@trant.co.uk the journal for hazardous area environments trant.co.uk the journal for hazardous area environments
Heaters Heaters
Training Training
Communications Control Panels
To advertise in the Product Datafiles
11/10/2019 15:08 11/10/2019 15:08
CompEx Courses ExF Foundation Ex F Plus Foundation Plus Ex01 – Ex04 Gas & Vapours Ex01 – Ex04 Refresher Ex05 – Ex06 Dust Ex11 Mechanical Ex12 Design Ex14 Responsible Person
Further Accredited Courses in: Electrical Instrumentation Mechanical Health & Safety
+44 (0) 1642 438700 bookings@roxby.com www.roxby.com
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
enquiries@fes-ex.com
.
+44 (0)1472 598987
.
www.fes-ex.com
For ALL of your DSEAR/ATEX Compliance needs…
.
.
.
PROCESS SAFETY CONSULTANCY DESIGN INSTALLATION INSPECTION (INC. NON ELECTRICAL) RECTIFICATION TESTING HAZARDOUS AREA ASSET MANAGEMENT
.