hEX_21_06

May 7, US pipeline operator

Pipeline was struck by a cyber attack and forced to shut down its entire network (see pg.8). Colonial’s network transports around 2.5 million barrels of gasoline per day, representing around 45% of the US East Coast’s gasoline, diesel, and jet fuel. The attack highlights the vulnerability of even the largest companies to cyber attacks and the potentially devastating consequences that these attacks can have.

The attack is thought to have been carried out by an Eastern European-based organisation called DarkSide. The group, which is thought to be based in the CIS region due to its software targeting only non-Russian language computers, wrote on its website following the attack that it was only interested in making money rather than causing wider problems to society. The effects of the incident could easily have been much more severe if the perpetrator had wanted to do more than just make a quick buck.

While the timeline of events leading up to the incident are still unclear and the exact method of infecting Colonial’s system

remains unknown, it has been confirmed that DarkSide managed to steal data on May 7 before the ransomware attack on May 8. Some news outlets have quoted cyber security experts as saying the likelihood of a successful attack would have been greatly increased since the beginning of the COVID pandemic due to the number of processes now being conducted remotely. Without speculating too much without evidence, it seems feasible that an engineer working remotely from home would be a greater target for a cyber attack than an engineer working at a site on a secure network.

Whichever way the attack was carried out, it highlights the importance of taking cyber security seriously, no matter what size an organisation may be. An unscrupulous hacker or group will waste no time in stealing data and hijacking computer systems if they know there is an easy way in. It is therefore important to remember the value of strong cyber security in a time when an ever-increasing number of processes are becoming increasingly digitalised and performed remotely.

…Alistair Hookway, Editor, Hazardex

Bosley Mill owner cleared of manslaughter, mill managers cleared of health and safety breaches following fatal 2015 explosion

Manslaughter charges against the owner of a wood mill in Cheshire, UK where four people died in a 2015 explosion were dropped on April 29.

A day later, on April 30, two mill managers were cleared of health and safety offences as well, bringing an end to a 12-week trial.

George Boden, a Director of Wood Treatment Ltd in 2015 when the blast happened at Wood Flour Mills in Bosley, was cleared of gross negligence manslaughter on April 29. Corporate manslaughter charges against Wood Treatment Ltd were also dropped.

The exact cause of the 2015 explosion is still not known because the damage caused to the mill by the blast made it extremely difficult for investigators to determine one. However, during the trial, the jury was told that the incident likely involved a wood dust explosion. Four people died in the incident: cleaner Dorothy Bailey, 62, maintenance fitter Derek William Barks, 51, mill worker Derek Moore, 62, and chargehand Jason Shingler, 38, whose body was never recovered.

A four-storey building was destroyed in the blast and large fires broke out at the mill. At the time, a firefighter described the aftermath of the explosion as “a scene of

devastation”. Dozens of staff members were injured in the explosions and fire. Fires at the site continued to burn for weeks after the explosion with crews not leaving the site until more than a month after the blast, which had reduced the mill to rubble and left some employees “horrifically injured”, the court was told during the trial.

The trial, which had been sitting for almost 12 weeks since February, also heard that employees had raised safety concerns in the years leading up to the explosion. The prosecution alleged that the blast was caused by negligence and that the mill management had known about “excessively high” dust levels.

After being cleared of four counts of gross negligence manslaughter, Boden pleaded guilty to a health and safety offence under the Health and Safety at Work Act 1974. Wood Treatment Ltd had admitted a health and safety offence before going on trial.

Judge Mrs Justice May told the jury on April 29 to return not guilty verdicts over the manslaughter charges against Boden and Wood Treatment Ltd. The charges were dropped after an application to dismiss at the end of the prosecution’s case. In her judgment, Justice May ruled there was not enough evidence to prove that gross negligence caused the explosion.

Justice May said: “The Court of Appeal has directed that the company and Mr Boden are not guilty on counts one to eight, inclusive on the indictment, that’s to say the four corporate manslaughter and four gross negligence manslaughter charges.”

On April 30, mill manager Peter Shingler and operations manager Phil Smith were cleared of health and safety offences after the jury was directed to return not guilty verdicts. Tony Badenoch QC, prosecuting, said: “Following the events of yesterday and adjournment overnight, the position has now been reached that the prosecution will not continue to seek guilty verdicts in the case of Mr Smith and Mr Shingler.”

Sentencing of both Boden and Wood Treatment Ltd in relation to health and safety offences will take place on June 18.

INEOS fined £400,000 for 2017 Grangemouth gas leak

Petrochemical giant INEOS has been fined £400,000 after a gas leak from a cracked pipe created a potentially explosive gas cloud over its Grangemouth plant in May 2017. INEOS admitted in court that its safety inspections had failed to identify a 10 inch (25cm) long corroded section of pipe which allowed a leak of ethylene gas.

Around 17 tonnes of flammable ethylene gas leaked from the pipe over a period of several hours, Falkirk Sheriff Court heard. The leak was first detected at around 11:50 before the cloud eventually dispersed around 21:45.

At the time of the incident, 97 workers were on site and had to be led to safety by emergency services. Several local roads were closed as firefighters worked to create a “wall” of water to prevent the ethylene gas from reaching the Grangemouth plant’s furnaces. No one was injured in the incident.

Falkirk Sheriff Court was told that the section of corroded pipe had been wronglyidentified as “not high-risk” and was therefore not subjected to insulation strips as part of the site’s inspection programme. This caused a process of “chloride-induced stress load corrosion cracking.”

Health & Safety Executive (HSE) and Crown Office and Procurator Fiscal Service (COPFS) investigators found that the initial alarm was raised by an INEOS employee who heard safety valves being triggered automatically. The employee attempted to manually close an emergency operating valve but was told that several gas detectors were sensing a leak at ground level and the plant was being evacuated.

The HSE investigation identified that the immediate cause of an unplanned shutdown on the compressor was due to a ‘non-routine’ maintenance activity related to the changeover of a redundant electronic control card in the compressor anti-surge system. The line should have been designed for all potential operating conditions and should not have failed as a result of the rapid opening of the valve and the sudden inrush of hot gas.

Prosecutor Gavin Callaghan told the court that the leak precipitated the formation of a flammable gas cloud of around 65,000 cubic metres, roughly the equivalent of 26 Olympic-sized swimming pools. The cloud reached ground level, but the plant’s emergency plan was implemented to ensure that there was no ignition, Callaghan added.

Solicitor Paul Marshall, representing INEOS, said that the company’s emergency response had minimised the risk of explosion and the “isolated incident” was the result of “shortcomings in what was otherwise a comprehensive inspection regime.”

In court, Sheriff Wyllie Robertson said the incident was categorised internally as the highest category of major incident where there is a risk beyond the site and boundaries. Robertson added that the significant risk was of the ethylene gas igniting, particularly in light of the proximity of the furnaces. If the vapour cloud had ignited, thermal effects and a blast wave could have been generated, resulting in a risk of death, Robertson said.

INEOS pleaded guilty to failing to take steps to prevent the incident which goes against the 2015 Control of Major Accident Hazards Regulations. IENOS’s fine was reduced from £500,000 after the company submitted an early guilty plea.

Speaking after the court hearing, HSE inspector Mac Young said: “While there were no injuries as a result of this incident and it was brought under control relatively quickly, the level of fine reflects the seriousness of what happened. It is important that operators of high hazard sites remain vigilant and control the risks that arise as a result of their processes to prevent major incidents.”

Head of the Health and Safety Investigation Unit of COPFS Alistair Duncan said: “Hopefully this prosecution and the sentence will remind other duty holders that failure to fulfil their obligations can have serious consequences and that they will be held to account for their failings.”

The Grangemouth site, located by the estuary of the River Forth in central Scotland, covers about 1,700 acres and employs more than 1,300 people. The site includes petrochemical plants and an adjacent oil refinery with a capacity to process about 200,000 barrels of crude per day.

Chemical

The Chemical Business Association (CBA) has announced a new Chief Executive, Tim Doggett. Tim took the reins of the Chemical Business Association on May 1 following the retirement of the previous CEO, Peter Newport.

Tim Doggett has a thirty-year career in logistics and distribution and has held a number of senior positions in national and international companies. He was latterly Managing Director of Clugston Distribution Services Limited, a road tanker and logistics company with annual sales of £17 million. The company has a fleet of more than 100 HGVs operating throughout the UK and Europe, annual sales of £17 million, and 150 employees.

Tim joined the Association on 9 September 2020 and served as Chief Executive Designate during the handover period.

The announcement follows the news of the CBA electing a new Chair – Kate Mingay, Managing Director, Dakram

Materials Limited. She was elected by the membership of the Association at its Annual General Meeting on 28 April 2021. Richard Gilkes, Managing Director, Stort Chemicals Limited, was elected ViceChair.

In relation to Tim Doggett’s appointment, Kate Mingay said: “I am delighted to formally welcome Tim and look forward to us working together. His skills and international experience will make an important contribution to the continued growth and influence of the Association and the profitability of its member companies.”

Tim Doggett, said: “The Chemical Business Association is the leading Association for the UK’s chemical supply chain and it is an honour to assume the role of its Chief Executive. I hope to build on the foundations laid by my predecessor and work towards making the Association the business organisation of choice for companies in the chemical supply chain.”

Chemical factory blast injures two in Iran

Achemical

factory explosion and fire injured at least two firefighters in Iran on May 2. The incident happened at the Movaledan chemical plant near to the central city of Qom.

Around 20 fire engines attended the scene with over 150 firefighters battling the flames, the ISNA news agency reports. Two firefighters were injured while fighting the blaze. One of the men is reported to be in a critical condition.

According to ISNA, the Qom fire department said firefighters managed to prevent flames from reaching alcohol tanks located in the factory, however several explosions were reported elsewhere on the site.

The incident occurred against the backdrop of other incidents happening in Iran in recent months, many of which the country has blamed on its neighbour, Israel. On April 11, Iran blamed Israel for an explosion at the Natanz nuclear plant. According to the Times of Israel, the explosion caused damage to 6,000 centrifuges, setting back enrichment at the site by six-nine months. Israel has neither confirmed nor denied its involvement.

Tim Doggett, Chief Executive

Wacker plant in US fined $3,200 (£2,300) for 2020 explosion that killed one, injured four

AWacker Polysilicon plant in Tennessee, US has been cited for a “serious violation” and fined $3,200 (£2,300) in relation to a November 2020 incident which killed one worker and injured four others. The Tennessee Department of Labor and Workforce Development’s Division of Occupational Safety and Health (TOSHA) proposed the fine after

its report found improper personal protective equipment (PPE) was used during maintenance activity.

According to the Chattanooga Times Free Press, TOSHA said that the correct type of PPE was not selected to protect the affected workers from hazards identified during an assessment for a safe-work permit.

The incident on November 13 involved a release of around 15 pounds of hydrochloric acid (HCl). The Wacker facility in Charleston, Tennessee makes polysilicon for use in solar panels.

The Chattanooga Times Free Press was told by a Wacker spokesperson that the company would not be appealing the fine. The spokesperson said that Wacker had cooperated fully with TOSHA and would implement all measures required by the safety agency.

Wacker opened its $2.5 billion Charleston plant in 2016. Since then, the plant has experienced several safety incidents, such as in July 2020 when four workers suffered chemical burns while performing maintenance tasks in a process building.

In 2017, an explosion at the Wacker Polysilicon plant resulted in eight people being treated in local clinics and was the second incident at the plant in eight days. The blast was caused by a mechanical incident that resulted in a hydrogen chemical release, according to Wacker, while the previous incident left five workers with chemical burns. Chemical production was halted for almost eight months as Wacker investigated the incident, hired a thirdparty investigator, and made safety improvements to the facility.

Major US pipeline network shut down after cyber attack

Acyber attack on US pipeline operator Colonial Pipeline led to the shut down of its entire network on May 7. The Colonial Pipeline network transports around 2.5 million barrels of gasoline per day – around 45% of the US East Coast’s gasoline, diesel, and jet fuel.

Colonial Pipeline made the decision to close its entire network after learning of the cyber attack which is believed to have involved ransomware. Ransomware is a type of malware that blocks access or threatens to publish data unless a ransom payment is made. One of the most infamous examples is the worldwide ‘WannaCry’ ransomware attack in 2017 which affected a number of institutions including the NHS in the UK.

The attack on Colonial Pipeline is not expected to have an immediate effect on oil prices in the US, however a prolonged closure could cause significant problems due to the importance of the 5,500 mile (8,850 km) network of pipelines which carries fuel from refiners on the Gulf Coast to consumers

along the US South and East Coast, including several major airports.

In a statement, Colonial Pipeline said it proactively took certain systems offline to contain the threat after learning it was the victim of a cyber attack. Colonial said these actions temporarily halted all pipeline operations and affected some of its IT systems, which it is now actively in the process of restoring.

The pipeline operator is in contact with thirdparty cybersecurity experts, law enforcement, and other federal agencies, including the Department of Energy which is leading the Federal Government response. “Maintaining the operational security of our pipeline, in addition to safely bringing our systems back online, remain our highest priorities. Over the past 48 hours, Colonial Pipeline personnel have taken additional precautionary measures to help further monitor and protect the safety and security of its pipeline,” Colonial said.

According to Reuters news agency, Colonial has brought in cyber security firm FireEye

to respond to the attack. FireEye has been involved in several high-profile malware responses before, including in 2019 when the company found evidence of ‘Triton’ – a malware linked to an attempt to sabotage a Saudi petrochemical plant in 2017 – in a second, unnamed Saudi critical infrastructure facility. FireEye’s investigation traced the malware, which targets industrial control systems by gaining access and maintaining persistence inside IT and OT networks, to a Russian research laboratory.

The identity of the perpetrator behind the cyber attack on Colonial Pipeline was not officially known until May 10 when the FBI confirmed that an Eastern European-based cyber criminal gang called DarkSide was to blame. The gang is believed to have encrypted around 100GB of data which it said would be released on the internet if a ransom payment is not made. On its website following the cyber attack, the group wrote: “Our goal is to make money and not creating problems for society.”

US President Joe Biden was briefed about the incident on May 8. The White House

Some petrol stations,

Florida,

Press Secretary Jen Psaki issued a statement saying: “The Administration is continually assessing the impact of this ongoing incident on fuel supply for the East Coast. We are monitoring supply shortages in parts of the Southeast and are evaluating every action the Administration can take to mitigate the impact as much as possible.

On May 9, the US government issued emergency legislation to relax rules on fuel being transported by road. The legislation means fuel truck drivers can now work extra or flexible hours if they are transporting gasoline, diesel, jet fuel, and other refined petroleum products in 18 states across the South and East of the US. While the waiver issued by the Department of Transportation means oil products can be shipped by road, it is not close to matching the pipeline network’s capacity.

During a speech at the White House on May 10, President Biden said he was being given daily updates about the incident. Several news outlets have reported that DarkSide could be a Russian-based organisation as

their malware avoids encrypting any computer systems which have the language set as Russian. In his speech, President Biden said these reports were concerning and that he would meet with Russian President Vladimir Putin, although there is no evidence that the Russian state was directly involved.

As of May 11, Colonial’s pipeline network remains largely shut except for some smaller lateral lines between terminals and delivery points. The company has not given any further details of how long the closure would continue.

Buxton

Colonial Pipeline network on US East Coast - Image: Colonial Pipeline

Dust Safety Science releases 2020 Combustible Dust Incident Report

Dust Safety Science has released its annual Combustible Dust Incident Report which captures and details combustible dust incidents from around the globe. The report shows that in total, 165 fires and 60 explosions caused 88 injuries and 10 fatalities during 2020.

The statistics from the report show a decrease in incidents and injuries relating to combustible dust incidents compared with 2019, however a slight rise in fatalities. In 2019, 250 fires and 75 explosions resulted in 118 injuries and 8 fatalities. Before that, in 2018, 213 fires and 68 explosions caused 114 injuries and 23 fatalities.

The report lists some of the most severe incidents that occurred in 2020, including the December 3 explosion at Wessex Water’s treatment plant near Bristol which killed four people and injured one.

2020 saw a decrease in incidents and injuries relating to combustible dust incidents compared with 2019, however a slight rise in fatalities.

In terms of the materials involved in combustible dust incidents, food and wood products made up over 75% of incidents and resulted in 57% of the injuries and 40% of the fatalities. Similarly, wood processing, wood products, agricultural activity and food production also make up a large portion of the overall fire and explosion incidents, a historical trend when it comes to combustible dust incidents.

The report shows that storage silos had the highest percentage of combustible dust incidents in 2020 with 30 fires and 13 explosions reported. This differs from 2017 and 2018 which found collections systems to have the highest number of incidents.

Read the 2020 Combustible Dust Incident Report in full by visiting: https://bit.ly/3uFA67I

US lumber producer fined $108,000 in relation to fatal September 2020 explosion

Cal/OSHA Deputy Chief Debra Lee. “Employers must identify and evaluate potential hazards before assigning employees to perform work on this hazardous machinery and equipment.”

Cal/OSHA cited Sierra Pacific Industries $108,300 for nine violations, including three serious accident-related, three serious, and three general in nature. The serious accident-related violations were cited for the employer’s failure to:

- Test the discharge piping prior to operating the Quincy 300 compressor and ensure proper connection.

- Ensure a pressure relieving safety device was installed in the line between the compressor and block valve.

- Ensure all pressure piping for the compressor was designed and fit in accordance with good engineering practice.

The California Division of Occupational Safety and Health (Cal/OSHA) has fined lumber producer

Sierra Pacific Industries $108,000 (£77,800) in relation to a pressure vessel explosion in September 2020.

A maintenance worker was killed and another employee was injured by the blast at Sierra Pacific’s lumber mill in Lincoln, California while the two men worked on an air compressor.

In a statement announcing the fine, Cal/ OSHA said that on September 17, a Sierra Pacific Industries employee was setting up a Quincy 300 Compressor when a pipeline on the air compressor exploded. Pieces of the pipeline hit two employees nearby, injuring one and killing another.

“Working on equipment attached to pressure vessels such as air compressors requires special precautions,” said

The serious violations were cited for the employer’s failure to ensure the energy within the pipeline system was controlled to prevent release during repair, and failure to ensure group lockout/tagout procedures were used and employees worked under supervision of a qualified person. The other citations were issued for violations related to uncertified employees welding, failure to establish hazardous energy control procedures and operating equipment under conditions of stress.

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process in the absence of a colleague, said he warned Gonzales about replacing the hot plate and that it was set at too high a temperature.

Alderete was assisted in the extraction process by Josh Martinez who did not have the proper training. As a result of the fire and explosion, Alderete suffered burns on 37% of his body while Martinez spent several weeks in a hospital burns unit.

“The indifference shown to worker safety by this company is inexcusable,” said NMED Cabinet Secretary James Kenney. “Wilful violations of worker safety requirements must have consequences for employers –every employee deserves to come home from work healthy.”

The explosion in October came just five years after another explosion at the same facility which also severely injured two workers. The employees had been extracting THC, the active ingredient in marijuana, as part of a process that involves soaking cannabis with butane

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

In relation to the October 2020 incident, New MexiCann has 15 business days from the date the citations were issued to pay the assessed penalties or contest

the citations before the New Mexico Occupational Health and Safety Review Commission.

Following the announcement of the fine, NewMexicann wrote on its website that the New Mexico Department of Health had decided to revoke the company’s license, effective immediately.

Representative image: Shutterstock

Australian miners left “fuming” as mining giant restarts coal mine following 2020 explosion

Workers at mining giant Anglo American’s Grosvenor coal mine in Queensland, Australia have been left “fuming” as a result of the company’s decision to restart operations following an explosion in May 2020 which seriously injured five people. According to Reuters news agency, a union official has said that Anglo American has not kept workers informed about the plans to restart the mine, a claim disputed by the company.

Operations at the Grosvenor coal mine are undergoing a staged restart after Anglo American secured regulatory approval on April 22. The mine has been closed since an explosion on 6 May 2020 seriously injured five workers. Four of the workers were in critical conditions following the blast and had to be airlifted to hospital after suffering significant burns to their upper bodies and damage to their respiratory systems. The explosion was the second safety incident at Grosvenor in the span of 15 months.

Reuters quotes a statement from Stephen Smyth, the Queensland President of the CFMEU Mining and Energy union, saying that miners at the Grosvenor mine have repeatedly called for their union safety inspectors to be kept informed about any plans to restart operations. However, Smyth says that representatives have not been given any notice or information about the staged restart, which has “left workers fuming”.

Reuters says that Anglo American called Smyth’s comment “unfounded” and said union representatives were part of the team planning the mine’s restart. A statement from Anglo American said they have kept workers closely informed about re-entry planning over recent months, however the plans could not have proceeded until the regulator had lifted the directive that was keeping the mine closed.

Smyth has also raised issue with the oneon-one interview process being conducted by Anglo American with its workers in

which they are questioned about their mental health and ability to work safely underground. Smyth said it was unfair for the company to put workers on the spot and make them fear that they will be targeted or lose their job. He added that everyone wants the Grosvenor mine to re-open, but Anglo American should look to build trust with its workforce rather than breaching it.

The findings of an inquiry into the May 2020 explosion were meant to have been released in November, however they are now expected at the end of May. Mine safety inspectors visited the Grosvenor mine in early May to conduct an inspection after Anglo American sealed off the area of the explosion.

Anglo American will not be able to fully restart operations until it is able to demonstrate to the state’s mine safety watchdog that suitable controls are in place to prevent similar incidents from happening again.

Tanker explosion kills two workers at railcar repair facility in US

An explosion at a railcar repair facility in Wyoming, US killed two people on April 21. The two men were found unresponsive inside a tanker railcar by emergency responders after the incident was reported at around 15:20 local time.

The incident happened at Wasatch Railcar Repair near the town of Shoshoni in central Wyoming. Due to the presence of hazardous

gases, a specialised confined quarters team from the Casper Fire Department were called to the scene to help retrieve the bodies of the two men, aged 18 and 28. Their identities have not been confirmed by the local police department.

Shoshoni Police Chief Chris Konija said in a statement that emergency services were called to the site after reports of a loud explosion at

Wasatch Railcar Repair and possible injuries. Konija added that the bodies of the men were recovered by the specialised firefighter team.

The cause of the blast remains unknown, and an investigation has been opened by the Shoshoni Police Department in coordination with the Occupational Safety and Health Administration (OSHA) and the Federal Railroad Association (FRA).

Engen to convert “financially unsustainable” Durban refinery into import terminal

Engen has announced that it will be converting its 120,000 barrelper-day Durban refinery into an import terminal. Engen began to consider the refinery’s future in October before a December explosion closed the plant. Repairs have been estimated to cost as much as 800 million Rand (£39.1m), however Engen has said global product supply surplus and depressed demand were the primary reasons behind the company’s decision.

In a statement on April 23 announcing its intention to proceed with its Refinery to Terminal (RTT) conversion initiative, the South African energy company said its decision was not taken lightly and follows an extensive strategic evaluation of Engen’s refining business, in which every facet of the refinery was scrutinised and assessed against market demand, future growth potential and the ability to contribute sustainably. The substantive cost of investment for upgrades required to bring the refinery in line with evolving quality and

emissions regulations were also part of the strategic review considerations, Engen added.

After consulting local authorities, Engen also commissioned an independent refinery viability study and an independent socioeconomic impact assessment. The reports confirmed that the refinery is not financially viable and indicated relatively minor impact on overall GDP and taxes, while identifying upside benefits such as better security of supply, trade balance improvements and positive environmental impact.

In the statement, Engen Managing Director and CEO Yusa’ Hassan, commented: “The conclusion of the strategic assessment is that the Engen refinery is unsustainable in the longer-term. This is primarily due to the challenging refining environment as a result of a global product supply surplus and depressed demand, resulting in low refining margins, and placing the Engen refinery in financial distress. Furthermore, unaffordable capital costs to meet future

CF2 [Clean Fuels 2] regulations compliance continues to be a challenge for the longterm sustainability of the refinery.

“The RTT is part of a long-term business sustainability strategy to ensure Engen is resilient against future market threats and can respond with agility to new opportunities. It also has a knock-on benefit of a reduction in emissions and carbon footprint that will contribute towards Engen’s environmental stewardship commitments.”

The Engen refinery, located in the south of Durban and commissioned in 1954, is the oldest refinery in the country and is responsible for approximately 17% of the country’s fuel production. The closure of the refinery in December, together with the closure of Astron Energy’s Cape Town refinery following a fatal explosion in July 2020, has resulted in a steep increase of oil product import demand as South Africa struggles with meeting production and supply targets.

Pemex refinery explosion injures seven

An explosion at a Petroleos Mexicanos (Pemex) oil refinery in the city of Minatitlan, eastern Mexico injured seven people on April 7. The incident is reported to have occurred in a transfer pump house.

In a series of Tweets, Pemex said that specialised staff were attending a fire in a pump house at the Lázaro Cárdenas

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Refinery. National and State Civil Protection Agencies were alerted shortly after the incident started at around 17:00 local time. Local news sites report that the initial explosion was caused after a leak in the refinery’s charge pump. The pump’s mechanical seal failed, causing the leak which then ignited.

The 285,000 barrel-per-day Lázaro

Cárdenas Refinery receives gasoline to produce aromatics. The Executive Director of Mexico’s safety, energy, and environment watchdog, Angel Carrizales, tweeted: “The ASEA agency is tackling the incident that is currently ongoing at the Lazaro Cardenas oil refinery in Minatitlan, the state of Veracruz. The incident is associated with the inflammation of a fuel pump.”

After initially saying that no one was injured, Pemex later confirmed seven people had suffered injuries. One worker suffered burns, another worker suffered from poisoning, and five firefighters were injured while attempting to control the large blaze. All the injured were taken to hospital in a stable condition and are expected to make a full recovery.

Pemex said that the fire was contained by 01:00 local time on April 8 but that cooling of the site would continue to prevent any fires reigniting.

A series of images and videos posted on social media show a significant fire and plume of black smoke rising from the refinery while several explosions can be heard.

The incident follows another explosion at a Pemex refinery in December. That incident happened in the northern state of Nuevo Leon at Pemex’s Cadereyta refinery. Pemex said that no one was injured in the incident, however the Nuevo Leon State Governor reported that five people suffered minor injuries.

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CNOOC builds China’s first smart offshore gas field cluster

On April 29, China National Offshore Oil Corporation (CNOOC) announced the completion of China’s first ‘smart’ offshore gas field project. The Dongfang Gas Field Group consists of 10 offshore production platforms, one land processing terminal and several subsea oil and gas pipelines. It is currently the largest self-operated gas field group in the western South China Sea.

After nearly 20 years of development and construction, the gas field’s annual output of natural gas has exceeded 5.7 billion cubic metres, making it a vital source of gas for Hainan province, CNOOC said.

“After the completion of the intelligent gas field group, production can be remotely controlled to realise ‘one-key gas distribution’. On the one hand, the distribution of different types of gas can be completed instantly according to the needs of different users, and the production efficiency can be greatly improved; on the other hand, under severe and extreme weather conditions, it ensures the safety of personnel while ensuring the stability of the people’s livelihood gas supply,” said Tang

Guangrong, Deputy General Manager of CNOOC Hainan Branch.

Through intelligent transformation, the offshore gas field’s production will be safer and more efficient, CNOOC said. The smart offshore platforms have shortened the time it takes to resume production after shutdown by one-sixth of the original time. The system can analyse and diagnose the entire upstream and downstream flow conditions of the gas field group, making the gas distribution speed nearly 10 times faster than before. Intelligent inspection robots and real-time monitoring equipment have also been used to give higher precision and accuracy than traditional manual inspections.

As more offshore gas field platforms become digitalised, the number of offshore personnel on duty will be significantly reduced. A large number of offshore employees will become technical talents with one specialisation and multiple capabilities, and the team of technical engineers in the control centre will gradually grow. At the same time, smart oil and gas field production will promote high-quality development with production costs being

drastically reduced as more high-tech personnel are deployed to the control centre, CNOOC said.

The intelligent gas field group project consists of three parts: an unmanned offshore wellhead platform, an unmanned transformation of the central platform, and the construction of an onshore production control centre, including nearly a hundred transformation projects.

CNOOC Dongfang Operations began its digital renovations in 2018. In 2019, CNOOC built China’s first unmanned wellhead platform that can be remotely controlled to resume production. Automating the process has reduced the time it takes to resume production from two hours down to just 20 minutes.

The intelligent production control centre, which was connected to the grid and put into use on April 29, integrates IoT, Big Data, and AI. It conducts real-time monitoring, early warning and diagnosis, remote control, integrated sharing, collaborative operation and auxiliary decision-making for the entire process of oil and gas field development and production.

“The production operation centre is the brain of the entire intelligent gas field cluster. In terms of safety, it can monitor high-risk operations on site, track the improvement of hidden dangers, monitor various mechanical equipment, and implement fault diagnosis, etc. In terms of production, it can analyse and process production data, realise coordinated production of multiple gas fields, one-key gas distribution, etc., and implement management and decisionmaking on gas field groups in an all-round and multi-angled manner,” said Cui Rong, General Manager of Dongfang Operations Company, who works in the intelligent production control centre.

CNOOC has so far achieved the unmanned transformation of 29 platforms in China with 11.3% of its offshore platforms now unmanned. In its next steps, CNOOC will step up the construction of smart gas field clusters and continue developing China’s offshore oil and gas facilities by adopting intelligent equipment and digitalisation.

UK government urged to deliver ‘world-leading’ geothermal sector to secure Green Recovery

Anew report has urged the UK government to provide targeted support for the deep geothermal sector to aid the ‘green recovery’ and help deliver a ‘world leading’ industry. On May 13, the Association for Renewable Energy and Clean Technology (REA) and ARUP published a report, ‘Deep Geothermal Energy: Economic Decarbonisation Opportunities for the United Kingdom’, which underlines the environmental and economic potential of deep geothermal.

The report estimates that, should the Government establish a Geothermal Development Incentive, 12 deep geothermal projects could be operational by 2025, creating 1,300 jobs and generating more than £100 million of investment, predominately in towns and cities in the North of England, Midlands and South West. The scheme would provide a catalyst to the industry, with 360 sites being established by 2050. This would provide an additional £1.5 billion of investment, 10,000 direct jobs and 25,000 indirect jobs,

ZONE 1/21

and an annual carbon saving of 3 megatons, the report argues.

Deep geothermal energy is a space efficient, utility scale renewable heat resource that can be deployed in urban areas, specifically with the potential to heat thousands of large commercial and other properties for generations, REA said. Heat accounts for around 40% of the UK’s energy consumption and nearly a third of UK greenhouse gas emissions. According to the report, it is estimated that there is currently enough deep geothermal heat energy to supply all of the UK’s needs for at least 100 years.

Dr Nina Skorupska CBE, Chief Executive of the Association for Renewable Energy and Clean Technology (REA), said: “As this report demonstrates, deep geothermal must be central to the Government’s energy policy for the next 30 years, but with real and tangible benefits in the immediate future. Deep geothermal has the potential to become a world leading industry here in the UK, provide

a stable transition away from oil and gas, and help meet the Government’s net zero ambitions by decarbonising heat on a mass scale. It would also create 1,000s of new jobs and generate tens of millions of pounds in new investment.

“The REA believes that urgent work is required to aid the roll out of all heat technologies, however, with the right support from the Government, deep geothermal will play a major role in Britain’s heat generation for decades to come.”

In a press release, REA said there is a significant opportunity to create a world leading geothermal industry in the UK which could export internationally in terms of expertise, as with the North Sea. As the Government looks to deliver a ‘green recovery’ and meet their net zero ambitions, deep geothermal would act as a catalyst for new green jobs and investment.

Germany’s use of deep geothermal energy reduced the country’s emissions by more than 1.7 Mt CO2 equivalent in 2017, REA says. In addition, there is the creation of skilled jobs, the industry is estimated to have created more than 22,000 jobs and added €13.3 billion to the German economy since 2000.

The success of geothermal developments in countries such as Germany, France and the Netherlands is closely linked to their governments’ commitment to supporting this technology through policies, regulations, incentives and initiatives, the report says. This success is specifically linked to the availability of a long-term, stable regulatory framework and the willingness of the state to share economic risks during the early stages of development.

Always a step ahead!

and innovative

with the most advanced technology.

Always a step ahead!

and innovative

with the most advanced technology.

Protecting people and equipment explosions: IEC Technical Committee

Martin Thedens is the Chair of IEC Technical Committee 31: Equipment for explosive atmospheres. The Technical Committee publishes safety standards relating to equipment used in hazardous areas, where flammable liquids, vapours, gases or dusts are likely to occur in quantities sufficient to cause an explosion.

Many of these standards serve as a basis to IECEx, the IEC System for Certification to Standards relating to Equipment for Use in Explosive Atmospheres. IECEx assesses the conformity of equipment to International Standards such as the IEC 60079 series, which includes many parts, starting with Part

0 which specifies the general requirements for Ex equipment used in explosive atmospheres.

Martin Thedens won the IEC 1906 award in 2012, which is granted in recognition of exceptional recent individual achievements in helping to advance IEC activities in a significant way. He is also an expert in pre-normative research work, especially for electrostatics and ignition by optical radiation, high frequency or mechanical sparks. After being a convenor for several working groups inside TC 31, he has recently been nominated Chair of the committee, while at the same time chairing the German mirror committee DKE/K 241.

In this interview, Martin discusses IEC TC 31 as it continues its busy work despite the difficulties linked to the COVID-19 pandemic.

How was TC 31 affected by COVID-19 in 2020?

There were a few remote meetings with some subcommittees, project and maintenance groups where the discussions were a bit difficult, especially at the beginning of the pandemic. People had to get used to online meetings and the different time zones were a real problem we had to deal with. Despite all of that, our work was not really affected. We released several publications, including IEC 6007910-1, which is a new proposition from the IEC, a commented version (CMV) of the standard.

This new edition concerns the classification

of explosive areas, where an explosion might occur due the possible presence of flammable gas or vapour. We have already been using a similar system in our standards process for some time, to explain the changes we include in our publications. In our existing process, we inform manufacturers who might use our standards whether the document represents a major technical change, just an editorial change or an extension of the standard. We include this information in the foreword of our publications. Implementing the CMV was therefore not too difficult for us. It is a more systematic and global tool, which enables users to really understand the principles that guide a publication and changes to the previous edition.

Can you explain how TC 31 works with other IEC Technical Committees?

Our aim is for our standards to be seen and used as horizontal publications across the IEC. We are working on a Basic Safety Publication, which has been accepted by the IEC Advisory Committee on Safety (ACOS), and which will serve as a guide for all IEC TCs. We have also set up several joint working groups, which enable us to work very well with many TCs. For instance, with TC 18, which develops standards for electric installations onboard ships and mobile and fixed offshore units. Another example is the setting up of a joint maintenance group with a subcommittee of TC 61 which prepares standards for the safety of household appliances. We work together on the maintenance of IEC 62784 and the specifications for vacuum cleaners and dust extractors for use in explosive atmospheres.

How does TC 31 work with IECEx?

The previous Chair of TC 31, Mark Coppler, established a formal liaison between IEC TC 31 and IECEx, and this very important step was the reason he received the Thomas Edison Award in 2020. IECEx can assign people to our working groups and each decision sheet issued by IECEx is examined in TC 31, so that we can ensure that it is written in conformity to our standards. We also take IECEx demands for updates as well as requirements for new standards

into account. For instance, conformity assessment experts require a standard for the IECEx Scheme for Certification of Personnel Competencies. We are currently working on the third committee draft of IEC 60079-44. The document aims to identify the minimum level of knowledge and skills required to work in hazardous areas and the specific competence required for work associated with equipment for explosive atmospheres.

What new areas are of interest to IEC TC 31?

Hydrogen is an interesting topic we are looking into. There are so many different aspects that can be covered by standards. We have a liaison with ISO on hydrogen but it is not really active. We plan to activate it. Hydrogen is a very dangerous substance that can be ignited by a spark and the required ignition energy is very, very low. One topic we need to explore is conditions for storage and distribution.

Just to give you an example, it is often said that hydrogen could be delivered just by using the natural gas pipelines. In our view that is impossible without implementing several technical changes as the safety requirements for natural gas are very different. This is where TC 31 could step in and prepare standards.

(This article originally appeared on the e-tech website and is re-published here with kind permission)

Martin Thedens is the Chair of IEC TC 31

Mobile support is one of the advantages of using mobile devices in an industrial environment. Video calls or augmented reality applications can be used for this purpose

Remote support for plant maintenance

Challenges such as the Covid-19 pandemic, personnel costs and shortage of specialists are putting companies under an increasing amount of pressure. It is becoming more and more difficult to maintain extensive facilities efficiently and in line with requirements, and to solve problems in a timely manner.. Predictive maintenance is intended to remedy this situation and avoid downtimes

with less effort. Mobile devices play a key role in the implementation of predictive maintenance concepts in many companies.

Executing demanding workflows is becoming even more challenging, especially in industries with a large number of sites or extensive facilities in need of monitoring and maintenance. Increasingly complex facilities also make it impossible

for employees to have the specific knowledge required to maintain every single component. Furthermore, experts are not always available at every location to the extent they are needed.

A major advantage of using mobile devices in an industrial environment is the ability to remotely assist technicians with complex inspection procedures. For this purpose, video calls or augmented

maintenance – anytime, anywhere

reality applications via smartphones or tablets can also be used in hazardous areas. Technicians on site can thus contact experts or even the manufacturer if necessary and request their support for complex issues. This saves time and resources.

Digital devices currently available include various features such as an electromagnetic gyroscope, GPS and

cameras, which allow for an assessment of the site and enable experts anywhere in the world to precisely assess the situation. This also enables the use of digital stepby-step instructions, remote support or customised tools that can be used for a variety of tasks from asset management to plant inspection, as well as digital training. This gives employees instant access to all the information required to work better and faster. They gain direct contact with

the appropriate support expert, and an overview of all cases, both in-progress and completed.

What is required of digital devices for more efficiency in maintenance?

To ensure flawless support through remote experts, digital drawings or maintenance instructions, a multifunctional end device is required that can display complex

applications effortlessly. Tablets are now available which do just that while offering excellent image quality, even in bright sunlight. Some explosion proof tablets, such as the Tab-Ex Pro, have pogo-pin charging as well as a powerful replaceable battery with a capacity of 7,400 mAh for up to 15 hours of use. As with any mobile device, a better battery means a longer operating time which is vital for operators working in the field on large and extensive sites. A high-resolution screen on explosion proof mobile devices also guarantees a crisp picture when an operator is being assisted through remote maintenance or video tutorials.

There are also accessories available to compliment mobile devices which can keep workers’ hands free for unhindered performance of tasks. Thanks to suitable carrying devices, headsets and cameras, workers can be guided by experts in real time, even through complicated applications, without being restricted in their work. Great importance can therefore

be attached to the comprehensive range of peripherals now available on the market that are not only tailored to digital devices, but also to the needs of workers in industrial or hazardous environments. In this way, tasks can be carried out without errors and faults can be quickly rectified by employees on site.

The smart future of maintenance

In recent years, remote support has been taken to the next level with companies focusing on the development of additional products to be used in combination with smartphones and tablets. Smart glasses in particular are the focus of development, as they allow for optimal hands-free operation via voice control by the employee on site as well as an optimal view of the processes by the remote expert. The expert can thus provide support or instructions, while information and instructions are displayed directly in the worker’s field of view in real-time.

Comprehensive insights thanks to unrestricted device communication

Digital products and services enable staging, management and real-time monitoring of mobile devices. In this case, providers rely on the combination of comprehensive mobile device management with corresponding device analytics. This makes it easy to configure and manage the growing number of mobile devices. An analysis of historical and current data is possible at any time and allows conclusions to be drawn about functioncritical correlations. Enterprise mobility management systems, which are managed centrally by the provider, are ideal for a comprehensive overview of complex systems. This relieves the strain on IT departments and provides greater security in ongoing operations.

Mobile devices and suitable peripherals provide employees with all information they need at any time during maintenance work, enabling them to act quickly and autonomously

Maintenance in an agile environment

Instructions from experts at other sites and digital workflows support technicians in performing complex tasks directly in the plant. The integration of mobile devices and tools helps to get one step closer to the goal of digital production, maintenance and repair.

Smartphones and tablets must appropriately support technicians in their daily work and at the same time meet the requirements of a harsh industrial environment and potentially hazardous atmospheres. Worldwide usability of the devices also requires, in addition to general availability, compliance with various requirements and the ability to be used with many different infrastructures and networks.

Mobile devices are more than just tools for communication. As part of an overarching digital solution, they support mobile technicians in retrieving real-time data, recording and evaluating data, and reacting quickly and autonomously to any eventuality.

About the author

Sebastian Kaul works as Product Portfolio Manager at ECOM Instruments and as such knows the requirements of customers from heavy industries. The Pepperl+Fuchs brand ECOM provides holistic solutions for mobile computing and industrial communication in potentially explosive atmospheres. ECOM has played a key role in the development of explosion protection for mobile devices since 1986, offering explosion-protected mobile phones, smartphones and tablets.

Comprehensive proof-testing can require operators to enter hazardous locations or work at height to access level measurement devices, causing a potential safety risk

Remote partial proof-testing of overfill prevention systems supports safer operations

Overfill prevention systems must be periodically proof-tested to confirm their ability to perform correctly when required. AnnCharlott Enberg, Global Functional Safety Manager at Emerson, explains how the digital technology in advanced

level measurement devices enables partial proof-testing to be performed remotely rather than on location, and describes the benefits this provides.

Overfilling storage tanks containing hazardous, flammable or explosive

materials can have devastating consequences. Product spills can cause injuries or even fatalities, as well as significant damage to plant assets and the surrounding environment.

To minimise the risk of an overfill

occurring, best practice involves employing several independent layers of protection. The first line of defence is the basic process control system (BPCS) that monitors and controls the production processes. This first layer of protection is critical, because if the BPCS is functioning correctly, there is no need for the other layers of protection to become active.

An independent second layer of protection is provided by an overfill prevention system (OPS), which is normally dormant but operates when the BPCS fails to prevent the tank level from passing the critical high point. The OPS will alert an operator, close valves and/ or shut down pumps to stop the situation from escalating.

A third layer of protection is typically provided by a dyke or concrete wall that surrounds the tank, to contain a spill. Traditionally, such containment areas have been monitored through visual inspection by site workers on patrol. However, recent developments in guided wave radar technology now enable these devices to provide automatic level monitoring in these areas, thereby increasing the safety of both the environment and personnel. If required, the fourth and final layer of protection would be alerting the emergency services.

OPS compliance requirements

The design and implementation of an OPS should comply with the main global safety standards that relate to overfill prevention. These are:

• The International Electrotechnical Commission’s IEC 61511 standard, which outlines best safety practices for implementing a modern OPS within the process industry. IEC 61511 is an industryspecific adaptation of the IEC 61508 standard for functional safety.

• The American Petroleum Institute’s API 2350 standard, which provides minimum requirements to comply with modern best practices in the specific application of nonpressurised above-ground large petroleum storage tanks. API 2350 can also be applied to certain tanks outside this specific scope.

The need for reliability

An automated OPS includes three basic elements for each of its safety instrumented functions (SIF). These are a sensor to monitor the product level, a logic solver to poll the sensor and act when necessary, and a final control element to safely shut down the process. A formal methodology has been established to assess the reliability of each of these components and then calculate the overall reliability of the OPS. The term probability of failure on demand (PFD) is used to indicate reliability. PFD is the likelihood that the component or system could fail

The remote partial proof-testing capabilities of the modern devices provide a safe, quick, simple and cost-effective means of establishing their integrity

when it is needed. Implementing robust and reliable hardware reduces PFD and risk, and therefore increases the reliability of an OPS.

The importance of proof-testing

Hardware becomes more likely to fail as it ages. However, periodically checking the functionality of OPS components confirms their ability to perform as required when there is a safety demand, and verifies that they are operating at the necessary safety integrity level (SIL) for the application. Such checks are known as proof-tests and involve testing each component of an OPS individually as well as the complete SIF. The PFD of a SIF increases over time after commissioning.

Partial proof-tests bring

of a device back to a percentage of the original level and ensure it

Performing a proof-test resets the PFD to a lower value and ensures that the SIF provides the risk reduction it was designed to do.

Advanced level measurement instruments for OPS applications incorporate diagnostic software that detects a failure and takes the device to a safe state. However, some failures that prevent the device from performing its primary function remain undetected by the device during normal operation. These are known as dangerous undetected failures (DUs) and are identified during proof-testing. DUs are expressed as failures in time (FIT) and measured in DUs per 109 hours in operation. Given the importance of DU rates, the reduction of DUs has been a specific aim in the design of the latest

level measurement technology. Advanced diagnostics capability enables the electronic and mechanical health of these devices to be monitored continuously, with the result that the number of DUs is significantly reduced.

The effectiveness of a proof-test in finding DUs is known as the proof-test coverage factor, and this should be as high as possible. Ideally, it would reach 100%, but the reality is that proof-tests are not 100% effective. A high proof-test coverage factor does not always ensure a low PFD, but all things being equal, a device with a lower FIT rate will achieve a lower PFD.

Two types of proof-test – comprehensive and partial – may be performed in compliance with both IEC 61511 and API 2350.

Comprehensive proof-tests

Comprehensive proof-tests achieve the highest proof-test coverage and involve testing the entire SIF in a single procedure, to ensure all its parts are functioning correctly. This will return the PFD of the SIF back to, or very close to, its original level. These tests are traditionally performed manually by technicians in the field, with another worker stationed in the control room to verify the reaction of the system.

To provide proof that a level sensor is functioning correctly, the product level in the tank can be raised manually to the activation point of the device under test. The danger of this approach is that if the device is a high-level sensor and fails to activate during the test, this could lead to a spill that

The latest digital technology available enables operators to initiate remote partial proof-tests by issuing a command from the control room

would constitute a safety risk. This method is also time-consuming and can lead to the process being offline for an extended period, with significant cost implications.

An alternative approach is to remove the instrument from the tank and perform a simulated test, known as an immersion test, in a different environment, such as a bucket. A significant disadvantage of this method is that it can involve workers having to climb tanks to access an instrument, thereby putting their safety at risk. Performing proof-tests in this way is also prone to human errors and can lead to tanks being taken out of service for an extended period, thus affecting profitability. In addition, if the instrument is removed from a tank containing a hazardous or unpleasant

product, the test would be performed in water instead. This would then fail to prove that the device would work in the specific application, and the proof-test coverage would consequently be reduced.

Partial proof-tests

Partial proof-tests have a reduced scope compared to comprehensive tests and are performed to ensure an individual device has no internal problems. Partial tests bring the PFD of a device back to a percentage of the original level and ensure it fulfils its specified SIL requirement. Whereas a comprehensive proof-test verifies all three functional elements of a device – output circuitry, measurement electronics and sensing element – a partial test verifies only one or two of them. However, a combination of partial tests that covers all three functional elements will reach a proof-test coverage close to that of a comprehensive test.

Partial tests do not replace comprehensive tests – they complement them. As a partial test detects only a percentage of potential failures, a comprehensive test must eventually be carried out after a given time interval to return a device to its original PFD. However, partial testing is quicker to perform, requires less interference with operations, and can crucially provide a technical justification for extending the time interval between comprehensive tests, while remaining within regulatory requirements. This then provides organisations with the freedom to schedule testing around planned shutdowns, which can reduce costs significantly.

Remote partial proof-testing

Proof-testing has traditionally been performed on location. However, the digital technology available in modern level measurement devices enables operators to perform partial proof-testing remotely instead. As an example, let us consider vibrating fork switches, which typically provide high and low limit detection in an OPS. In the latest advanced devices, remote partial prooftesting can be performed by issuing a HART® command from the control room. Upon receiving the command, a device enters test mode, whereby its fork frequency is simulated for on, off and alarm conditions. It then cycles though the different current

output levels, verifying that there are no faults preventing the device from switching from the on state to the off state, or vice versa. If the proof-test detects an issue, this is reported upon its completion. The device then automatically returns to operational mode, eliminating the risk of it accidentally being left in test mode.

Remote partial proof-testing can be performed very quickly, with the device remaining installed and overfill conditions being simulated to activate the detector and generate an alarm signal. This simulation eliminates the risk of spills, saves time, and means that workers do not need to climb tanks and/or be exposed to their contents, thereby increasing safety. The ability to perform partial proof-testing remotely has consequently become a key selection criterion when implementing OPS level measurement technology.

About the author

AnnCharlott Enberg began working in functional safety 20 years ago, as CEO for SILTECH AB. She was then business unit director for DEKRA AB and SRE site responsible process safety engineer for Akzo Nobel AB, and is now global functional safety manager at Emerson. Her focus has been to work closely with the industry to ensure safe processes in engineering systems through HAZOP, FMEA and LOPA, to ensure risk reduction and optimise personal/human design processes. AnnCharlott’s goal is to continue to make SIS devices easier to implement and to increase safety globally. She was selected as Global Manager of the Year in 2020 by the International Association of Top Professionals (IAOTP).

Why thermal mass meters offer for accurate and safe biogas

After years of heavy reliance on fossil fuels, societal and environmental pressures are leading governments worldwide to look for new ways of meeting their energy demands. One of these alternative fuel sources is biogas, a side product of anaerobic digestion in wastewater treatment processes. In this article, David Bowers, Process Flow Products Manager for ABB Measurement & Analytics, explains why thermal mass

flowmeters offer water and sewage treatment utilities the ideal solution for safely and accurately measuring biogas flows.

Recent declarations about the urgent need to reduce global greenhouse gas emissions have made it increasingly apparent that fossil fuels are no longer an acceptable or sustainable solution to meeting the world’s energy requirements. As a result, there has been a growing

movement towards finding alternative methods of generating energy at scale whilst minimising environmental impact.

One solution that is finding favour is biogas. Classified as a renewable energy source, biogas is produced when organic matter is digested down by microorganisms through a process of anaerobic digestion. As the organic matter is broken down, it produces biogas – a mixture of methane, carbon dioxide and traces of

convert it into biogas. At the same time, the sludge is stabilised and its dry matter content is enhanced.

Accurate measurement of biogas production enables the efficiency of the anaerobic digestion process itself to be calculated. For optimum efficiency to be achieved, it is particularly important to strike the right balance. Adding excessive biomass may inactivate the biomass, requiring a cost-intensive restart, while administering too little can impair electricity and heat generation, potentially reducing revenue.

The ability to correctly measure biogas flows is also important where Combined Heat and Power (CHP) plants are used to help generate on-site electricity and heating. In order to maximise the electricity and heat generated from biogas, there needs to be a consistent supply of biogas to the CHP plant from the anaerobic digestion process. For this to happen, the flow of biogas needs to be accurately measured in order to achieve a balance and calculate the amounts of natural gas that may be needed to increase the biogas heating value.

In both cases, difficulties can arise that can affect many of the technologies commonly used to measure biogas flows.

offer the solution

other contaminant gases.

This mixture can be combusted to produce energy, either through burning in boilers or recycling through a combined heat and power system. Often the electricity and waste heat generated from these processes are used to warm the digesters or to heat buildings, with excess being sold to suppliers or fed back into the local grid, providing an additional revenue stream.

How is biogas produced?

Utility companies and sewage treatment works use anaerobic digestion as part of their wastewater treatment processes to treat biodegradable waste and sewage sludge, also known as biomass.

Anaerobic digestion is a proven technology for sewage sludge treatment. During the anaerobic digestion process, microorganisms break down the organic matter contained in the sludge and

In many cases, variations in the quantity and pressure of the biogas produced can be caused by factors such as the time of year, temperature changes during the digestion process and the amount of sewage sludge entering the treatment works. This can make it difficult for flowmeter technologies that measure volume flow and rely on pressure and temperature compensation to obtain an accurate mass flow measurement.

The quality of the biogas itself can also pose problems, with high levels of particulates and moisture that can impair the performance of orifice plates or meters with moving parts such as turbine flowmeters.

With biogas containing a potentially explosive mix of gases including methane

(CH4), there is also the need to ensure that any devices used to measure flow provide suitable protection to help guard against damage to plant and equipment and injury to personnel.

These problems can be overcome by using well installed thermal mass flowmeters which are suitable for use in potentially explosive applications. Capable of measuring mass flow directly, they can provide a mass flow rate in kg/h without any additional measurements or calculations.

How do thermal mass flowmeters work?

Thermal mass flowmeters for biogas applications work on the hot film anemometer, or thermal dispersion principle.

A heated platinum resistor is maintained at a constant over-temperature in relation to an unheated platinum sensor that is the same temperature as the gas flow. One of these resistors assumes the temperature of the flowing gas, whereas the other resistor is electrically heated and, at the same time, cooled by the gas mass flow.

A control circuit applies heat to the resistor so that a constant temperature difference exists between the resistors. With a known and constant gas composition, the mass flow can be determined based on the relationship between the heater current and flow rate with no need for additional pressure and temperature compensation.

With no moving parts, thermal mass flowmeters are ideal for handling challenging conditions characteristic of biogas, eliminating the need for

maintenance to deal with problems such as clogging.

As well as being suitable for measuring low flow rate, thermal mass flow meters are better suited to monitoring the anaerobic digestion process due to their low pressure loss. Because thermal mass flowmeters take measurements using two small probes on the end of an insert, they form only a minor obstruction in the surrounding flow. This means that correctly sized thermal mass flowmeters offer an extremely small pressure drop, which is important in this application where the gas pressure can drop to very low levels.

With a turndown of 100:1 they can also offer highly accurate measurement at particularly low and variable loads, with the resulting data able to be used to help

optimise the efficiency of the anaerobic digestion process. It is incredibly important to have this low turndown particularly when working with flammable gases such as methane. These need to be operated at a low pressure to reduce the likelihood of a fire. Using an ATEX rated thermal mass flowmeter provides an added safeguard against the risk of explosion in biogas measurement applications.

Installation tips for top thermal mass metering performance

To optimise measurement performance in anaerobic digestion processes, it is important to ensure thermal mass flow meters are installed correctly. Installation should be behind a foam trap and gravel filter to maximise measurement accuracy and reduce contact with condensate.

Classified as a renewable energy source, biogas is produced when organic matter is digested down by micro-organisms - Image: Shutterstock

Installing the meter in a 90° position can also afford protection against measurement interference caused by condensate. Further interference can also be avoided by fitting a water trap to capture water and moisture build up.

Summary

With the cost of energy produced by conventional sources continuing to escalate, the use of biogas to help address on-site energy requirements and as an additional potential revenue stream offers an increasingly attractive proposition for water utilities looking to save costs and boost profits.

With their inherent operational benefits, plus a low cost of ownership through the elimination of peripheral temperature and pressure equipment and the reduced need for maintenance, thermal mass flowmeters offer the ideal solution for biogas measurement applications.

About the author

David Bowers has been Product Manager

UK and Ireland for Pressure and Process Flow at ABB Measurement & Analytic for the past seven years. In total, David has 31 years’ experience in the instrumentation industry.

Biogas contains a potentially explosive mixture of gases including methane (CH4) - Image: Shutterstock

Displaying important real-time information clearly in hazardous environments

Being aware of critical process variables is important in most manufacturing environments. In the past, measurements were limited to true physical variables, such as pressure, temperature, weight, and speed.

Nowadays, many modern production processes also rely on teams being aware of computed variables, such as OEE, Takt time, Down time, Actual Total versus Target etc. This awareness allows teams to respond quickly to events which could affect the plant’s ability to achieve target performance. But the team needs to be able to see the information in order to act upon it.

Most existing display systems have limited viewing distance

Most industrial PCs, annunciators and touch screens for hazardous areas have a practical reading distance limit of a few metres. This means that operators who need to know an important value must walk over to a display, which could be an appreciable distance away from their working position.

If they are busy, they may not have time to go to the display, so could miss important changes in process performance. This is becoming increasingly important as plants reduce workforce size; fewer team members are available to access the data, so the chance of missing important changes becomes even higher, if data is not easily accessible.

Making data clearly visible over long distances

Display technology for hazardous areas has advanced greatly in the past few years, with the introduction by various manufacturers of Atex En nR rated large digital displays and large message displays.

These large format displays can be mounted in prominent locations and have a choice of character heights to suit viewing distances up to 200 metres.

They are often suitable for indoor and outdoor

use, with a choice of colours, thanks to the latest high contrast, high brightness LED display technology.

Flexibility of signal types

Recent versions of Atex EXnR large digital and text displays can accept most industrial sensors directly. They tend to be fully self-contained, which makes installation, commissioning and maintenance simple and economical.

For example, most displays only need power and a sensor in order to display weight, total, speed, takt, temperature, time etc.

They can also act as slave displays, if preferred, accepting RS485, TCP/IP, Ethernet/ IP, Profibus etc., allowing safety information and other important news items to be shared with the staff.

Modular systems allow multiple displays in one ATEX enclosure

Every process is different, with different key requirements, so displays which can be configured to each installation’s needs are becoming more readily available and more affordable.

Bright, clearly visible large displays attract attention

By their very nature, large format ATEX displays are intended to be attention-grabbing.

They ensure staff know what is happening on the plant so that they can act quickly in response to critical process changes.

Whilst ATEX rated large displays were something of a rarity in the past, mainly being custom-built and quite costly, the current state of technology means that almost any process in an ATEX Zone 2 environment can benefit from readily available real-time large display technology.

The benefits help to ensure that the process operates to peak efficiency, maximising profitability and competitiveness for the owner.

Graham Laming is Technical Marketing Manager at London Electronics, a designer and manufacturer of digital panel meters, large digital displays, electronic text displays and custom factory efficiency monitoring systems. Graham has been in his current role for 29 years, designing and managing new product development. He is the patent holder for the company’s latest core instrumentation technology and a qualified Electronics Design Engineer, member of the IET, and Fellow of the Chartered Institute of Marketing.

Typical 6-digit numeric ExnR rated displays, awaiting installation

ExnR display being tested for offshore installation in the Gulf of Oman

6th & 7th October • Harrogate • Yorkshire • UK

2021

now

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

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.

2nd American LNG Forum (In-person Event)

Date: 7-8 June 2021

Location: Houston, Texas – US

The American LNG Forum is your gateway to learning about the US LNG export industry, LNG pricing and finding top-notch modern technology for projects as well as connecting with the right people for business. The US is living through the great times of energy renaissance and LNG industry faces numerous exciting opportunities as well as challenges in order to be able to thrive. Many questions related to building a sustainable

LNG export industry, LNG pricing and finding top-notch modern technology for projects lie ahead. The American LNG Forum is your gateway to tackling these issues, connecting with the right people for business and learning about the latest developments, projects and innovations in the LNG sector. Taking place in Houston, the event will not be limited only to the local participation, the attendees will have the chance to meet people from different parts of the world, who are interested in business opportunities in US LNG sector.

Topics at the event will include LNG Production and Exports, LNG Market Outlook, LNG Projects, and Latest Innovations and New Technologies in LNG Sector.

3rd Global LNG & Hydrogen Forum (In-person Event)

Date: 22-23 June 2021

Location: Milan, Italy

The LNG sector has been impacted by several unforeseen challenges in a short period of time –the outbreak of pandemic and subsequent global oil price shocks will certainly have a role in shaping long-term implications for the business. These new circumstances are predicted to influence the supply and demand in LNG markets, some experts claim that the demand from Asia might weaken and the sector might get burdened with oversupply. The raising competition of renewables should also be considered when discussing challenges and competitors in the energy industry. Nonetheless, a prosperous LNG market growth is still expected in coming years, and investments in LNG plants, infrastructure development projects

are steadily continuing.

You will be joined by many established industry experts and practitioners from different LNG areas, who will share current developments and challenges within their organisations, future plans, technical solutions and market insights. We will provide an interactive platform, where participants will be able to engage in a discussion with the speakers and the audience. We invite all stakeholders to join the conference, get valuable insights and share their experience.

The 3rd Global LNG Forum is expanding an array of topics and will dedicate some special attention to the new promising energy carrier of the future. The LNG industry has necessary potential and offers advantages to develop

the hydrogen industry. Lessons learned and good practices created in developing the global LNG market and technologies can be used for embarking on the new hydrogen journey. Even according to the International Energy Agency findings, energy industry stakeholders should use the opportunity to develop hydrogen as future fuel in the next decade. An action and policy plan should be established to lay the commercial and technological foundations for the cleanest energy source of the future.

www.lng-global.com

An Introduction to the Process Sector with NEPIC

With over 300 member companies, NEPIC is the gateway to so many business opportunities within the process sector. As a partner of Supply Chain North East, NEPIC wants to work with you and your business to ensure you are armed with the knowledge, skills and tactics that will allow you to access a pipeline of fresh business opportunities in the process industry sector.

This interactive, webinar will provide you with a comprehensive introduction to the process sector – past, present and future; helping you develop an understanding of the process industry sector with a focus on supply chain needs and opportunities.

Clare Wheeler of Business Cogs will facilitate

this workshop, sharing the breadth of industry knowledge and experience, to help you assess how you can branch out and grow your business in the process sector. Claire will also be offering one to one sessions to help develop your action plans!

To find out more or to have a chat before booking, contact Glen Kelly – glen.kelly@nepic.co.uk These events are being delivered in association with the ERDF funded Supply Chain North East of which NEPIC is a partner. Supply Chain North East has been established to help the North East (LEP) small business community achieve growth via diversification and supply chain development opportunities. Through the Supply Chain North East network of experts, NEPIC wants to help you take your business idea forward, overcome growth barriers and seek success both here and overseas.

Eligibility Criteria:

- Size of the company must be between (1-250) employees.

- Turnover must not exceed ¤50 million or an annual balance sheet total not exceeding ¤43 million

- You must be located within the North East LEP area

www.www.nepic.co.uk/event/anintroduction-to-the-process-sector-withnepic-2/

and Datafiles

Tab-Ex® Pro by ECOM – the world’s first 10” Android tablet for hazardous areas

The Pepperl+Fuchs brand ECOM Instruments expands its tablet series for Zone 2/22 and Div. 2. Tab-Ex® Pro combines ease of use with a rugged construction. Thanks to its convertibility to a desktop computer via Samsung DeX mode, the Tab-Ex® Pro enables workers to easily transfer from the field into the office. Its large display makes it perfectly suitable for use in demanding operations and for viewing web-based content. Samsung KNOX and Android 9 guarantee high data and device security. Further features include Google AR Core, facial recognition and a Qualcomm SDM670 Octa-Core 64 bit 2.0 GHz, 1.7 GHz processor. Visit the ECOM Instruments website www.ecom-ex.com and feel free to contact us.

ATEX Certified Humidity/Moisture and Temperature Sensors

ROTRONIC Intrinsically Safe sensors and measurement transmitters with analogue outputs are suitable for use wherever there is a risk of explosion due to dust or gas in the environment. HygroFlex5-EX transmitters and probes from ROTRONIC conform to the latest international ATEX standards. The transmitter is Intrinsically Safe (secondary side), there are two channel outputs, the housing is heavy duty. Interchangeable probes are available for all applications, including those at pressure and low dew point.

Asecos Q range – proven fire resistance of 90 minutes

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

Tel:+44 (0)1484 600200

contact Greg Smith at greg@labtex.co.uk

Technical

Body (NB) for the EU ATEX Directive for approval of equipment used in Explosive Atmospheres

We are pleased to announce that LabTest Certification Inc. has been accredited as a Notified Body for the ATEX Directive 2014/34/EU, to carry out evaluation of equipment used in Explosive Atmospheres and issue EU Type Examination and Quality Assurance Notification (QAN) Certificates and for the European Union.

With the Canada-European Union Comprehensive Economic and Trade Agreement (CETA) coming into effect, one of the benefits of the agreement is that it allows for Canadian Conformity Assessment bodies to apply for Notified Body accreditation for selected EU directives.

As an accredited Notified Body (NB No.: 2815), LabTest will now be able to provide:

o ATEX Technical Files

o EU Type Examination Certificates

o QAN Reports & Certificates

“This is a very exciting time for LabTest” says Kavinder Dhillon, President of LabTest Certification Inc. “As the world starts to recover from COVID-19, the timing couldn’t have been better. With the addition of the new ATEX accreditation for the European

Union, LabTest is now able to provide a complete, in-house package solution to its clients who manufacture equipment for use in Explosive Atmospheres. This will allow us to provide faster results and improved service deliverable. With our IECEx, ATEX, and North American accreditations, we are now able to offer product approvals for most global economies.”

LabTest Certification latest accreditation as an ATEX Notified Body, in addition to the previous combined accreditations for Hazardous Locations Equipment approvals, will provide manufacturers with one single solution to global markets.

For inquiries related to ATEX, IECEx, or North American approvals for Hazardous Locations Equipment, contact LabTest Certification Inc. at info@ labtestcert.com.

LabTest