QPSS 2013 Program by Texas A&M at Qatar

11 – 12 March 2013 Doha, Qatar

welcome

Delegates,

On behalf of Texas A&M University at Qatar, welcome to the Qatar Process Safety Symposium. This conference has become one of Qatar’s premier safety-focused events and a fixture on our calendar, and we are proud to be able to continue organizing it. Our move to a larger venue at the Qatar National Convention Centre is evidence that this topic is attracting high-profile attention across a broad audience.

It is my pleasure to welcome you to the Second Annual Qatar Process Safety Symposium in Doha, hosted by Texas A&M University at Qatar and ConocoPhillips.

The theme for this year’s symposium, “Investing in Process Safety for a Sustainable Future,” speaks to the mission of Texas A&M at Qatar and to the goals of the Qatar National Vision 2030. Together, we are working to ensure that Qatar has the expertise and knowledge base for sustainable — and safe — growth and prosperity. Our partner for this symposium is ConocoPhillips, whose support is a catalyst for today’s discussions and tomorrow’s discoveries in process safety. I thank ConocoPhillips and its leaders for their generosity that makes this important conference possible. And thanks to you, our symposium speakers and delegates, for your commitment to this field and its progress. Your dedication to advancing knowledge and application of process safety serves our academic community and the industrial sector in Qatar and beyond. Thanks for being part of our mutual investment in process safety for a sustainable future. I offer my best wishes for a productive and engaging symposium.

This Symposium builds on the foundation of last year’s inauguration Symposium, a successful endeavor that we intend to continue over the years to come. The 2013 gathering of Doha’s safety experts seeks to further expand the sustained exchange of knowledge on industrial safety, enhance awareness, develop important fields of research and cooperation as well as substantiate existing and new industrial safety measures. It is an important venue for networking among professionals and academics, enabling a substantive dialogue on best practices, individual and corporate achievements, incident case studies, and the latest innovative technology and research on process safety. Our support of the Annual Process Safety Symposiums falls right within our field of interest and top priorities. Safety is a core value at ConocoPhillips’ and is integral to everything we do. Moreover, throughout our presence in Qatar since 1993, we have diligently supported the State of Qatar’s interest in instituting safety as a core value for its national strategy to develop the energy industry. As ConocoPhillips joins hands once more with Texas A&M University at Qatar in co-hosting this symposium, we trust that such gatherings will continue to enhance Qatar and the industry’s drive towards furthering the cause of safety. Finally, I would like to reiterate our sincere welcome to all Symposium participants, wishing you all an enjoyable and beneficial gathering.

Sincerely, Safety, always, comes first. Mark H. Weichold, Ph.D. Dean and CEO Texas A&M University at Qatar

Fire Protection

Systems

Process Safety

Research Agenda

Learning from Incidents

Integrity

Operator Training

Management

Organisational Incident investigations Reliability

Investing in Process Safety Business case for Safety Consequence Analysis LNG Safety Research

11 – 12 March 2013 Doha, Qatar

Program

Operational Safety Challenges

Process

Safety

Culture

Regulatory Framework

Program monday, 11 March 2013 8:00 – 8:45

Registration, refreshments

10:40 – 11:00

Track I: Safety Management Systems

Track II: Research and Technology in Process Safety

11:00 – 11:30

Qatar Shell GTL Process Safety – Focus on Front Line Leadership Hasan Abunada Qatar Shell GTL Ltd

Source term modeling for LNG spills on land Dr. Tomasz Olewski Texas A&M University at Qatar

11:30 – 12:00

Integrity Management Of Critical Safety Systems Dr. Stephen Ciaraldi Applus-Velosi

Safety Research at ExxonMobil Research Qatar: An Overview Hazem Abdel Moati ExxonMobil Research Qatar

12:00 – 12:30

The Case for a Professional Safety Society in Qatar Khalid Al-Hetmi American Society of Safety Engineers in Qatar, Qatar Petroleum

Design of Fire Protection Systems For LNG Facilities Charlie King Angus Fire Engineering, UK

Introduction 8:45 – 8:50

8:50 – 8:55

Sarah Hamad, Texas A&M University at Qatar (English) Khadeja Abuhaliqa, ConocoPhillips (Arabic)

Welcome and Opening of the Symposium Dr. Mark Weichold, Dean & CEO, Texas A&M University at Qatar

8:55 – 9:00

Gary R. Sykes, President of ConocoPhillips Qatar

keynote Address 9:00 – 9:15

Dr. Ali Hamad Al-Mulla Corporate Health, Safety & Environment of Qatar Petroleum

Plenary Keynote Speaker 9:15 – 9:45

Process Safety for a Sustainable Future Michael Ferrow, ConocoPhillips

Panel Discussion

9:45 – 10:30

10:30 – 10:40

Building a business case for Process Safety – Challenges and Benefits Facilitator: Dr. Simon Waldram, Waldram Consultant Panelists: Mike Ferrow, ConocoPhillips Hussain A. Al-Baloshi, Qatar Petroleum Steve Norton, Qatar Shell GTL Ltd Doug Brown, JMJ Associates

Award Ceremony

Coffee Break / poster session

12:30 – 13:30

Lunch and networking / poster session

13:30 – 14:00

Safety Case Framework in Qatar’s Energy Industry; Technical HSE Framework and the Safety Case Approach Saif Al-Naimi HSE Regulations & Enforcement Directorate, Qatar

14:00 – 15:25

Case Study: Prevention is Better Than the Cure – The Longford Fire and Its Aftermath Allan Hollonds, Rasgas

15:25 – 15:30

Wrap up – end of the first day

Chair Prof. Sam Mannan, MKOPSC, Texas A&M University

Program Tuesday, 12 March 2013 8:30 – 9:00

Registration, refreshments

9:00 – 9:30

Process Safety & Asset Integrity Management Operational Safety Challenges in the Oil & Gas Industry Randy Stadler, Qatargas

9:30 – 10:00

The Time to Learn to Dance is Not the Night Before the Party Mhorvan Sherret, Matrix Risk Control

10:00 – 10:30

Process Safety Research Agenda for the 21st Century Dr. Sam Mannan, Mary Kay O’Connor Process Safety Center

10:30 – 11:00

Coffee Break / poster session Track III: Safety Management Systems

11:00 – 11:30

11:30 – 12:00

12:00 – 12:30

Track IV – Research and Technology in Process Safety

Aspiring to Organisational Reliability Dr. Caroline Sugden, Health & Safety Laboratory

CO2PIPEHAZ: Quantitative Hazard Assessment for next generation CO2 pipelines Dr. Haroun Mahgerefteh, University College London

Broadening the Safety Culture: Gaining Employee Ownership of Process Safety Carl H. Poldrack, Qatar Chemical Company Ltd

Simulator-based Training for Operators and Engineers Donald C. Glaser, Simulation Solutions, Inc.

Process Safety Management – An HSE Foundation Jassim Salem Al-Malki / Donna Abatte Dolphin Energy, Qatar

Development Of Focused Training Programs And Decision Support Systems On Risk Assessment Dr. Konstantinos Kakosimos Texas A&M University at Qatar

12:30 – 13:30

Lunch and networking

13:30 – 15:30

Tour of ConocoPhillips Global Water Science Technology Center at Qatar Science and Technology Park

11 – 12 March 2013 Doha, Qatar

speakers

Speakers Dr. Ali Hamed Al Mulla, Ph.D Manager of Corporate Health, Safety and Environment Qatar Petroleum (QP)

Plenary Keynote Address BIOGRAPHY: Dr. Ali Hamed Al Mulla, Ph.D. is currently holding the position of the Manager of Corporate Health, Safety and Environment at Qatar Petroleum (QP). He is also the Manager for the Corporate Environment and Sustainable Development Department of QP since 2004. Before joining QP, Dr Ali was holding the post of Vice-Chairman of the Civil Aviation Authority (CAA) and Director of Meteorology, State of Qatar. During his tenure at CAA, he was Permanent Representative of Qatar to the World Meteorological Organization of the United Nations. Dr. Ali has obtained his BSc. In Meteorology (1986) from St. Louis iniversity, Missouri (USA) and both his Masters (1992) and Ph. D. (1997) degrees from Boston University, USA. He has about 15 scientific and technical papers to his credit, published in various national and international peer reviewed journals. In addition, he has seven technical papers published in the proceedings of the International Conferences. Dr. Ali has widely travelled across the world for attending various international conventions, conferences and official delegations. He is currently associated closely with the Conference of Parties (COP) to the United Nations Framework Convention on Climate Change (UNFCCC). Dr Ali is a member of the National Climate Change and Clean Development Committee for the UNFCCC. He is also National Project Coordinator for the subject of Climate Change contributing to the UNFCCC. Dr Ali Al Mulla was instrumental in preparing the first National Communication (1999) of the State of Qatar to the UNFCCC.

Hazem Abdel-Moati Research Engineer ExxonMobil Research Qatar

BIOGRAPHY: Hazem Abdel-Moati is a research engineer in the LNG Safety Research Program at ExxonMobil Research Qatar (EMRQ). He received a BSc in Chemical Engineering from Texas A&M University at Qatar in 2009 and is currently pursuing a MSc in Chemical Engineering from the same university. Since 2009, Hazem’s research role at EMRQ is focused on progressing two research projects: 1. Advanced 3D immersive training solutions where virtual reality is harnessed to develop ultra-realistic simulators for use in oil and gas industry personnel training/competency assessment. 2. Autonomous gas detection techniques where Infrared technology is utilized to develop an early warning system that could detect gas releases. In addition to his research role, Hazem is actively involved in ensuring safe operations at EMRQ’s Facility and once served as EMRQ’s functional controls advisor.

Title: Safety Research at ExxonMobil Research Qatar: An Overview ABSTRACT: The EMRQ research program is developing an advanced 3D immersive training platform where individuals working in the oil and gas industry can step into a realistic environment that simulates actual work scenarios. This element of realism makes training more effective, and ultimately enables personnel to perform their jobs more safely. Additionally, EMRQ is conducting research focused on the development of a Remote Gas Detection system that can autonomously scan for and identify hydrocarbon gas emissions. This system will be highly beneficial in oil and gas production and transport facilities, as early detection can help avert potential safety hazards and can reduce emissions into the environment.

Speakers Hasan Abunada Technical HSE Manager Qatar Shell GTL LTD

BIOGRAPHY: Has over 14 years experience in the oil and gas field. Graduated from University of Texas at Arlington with B.S. in Industrial and Manufacturing Engineering in 1997. Earned his Masters degree in Process Safety and Loss Prevention Engineering from Sheffield University in 2001. Started his career with Qatargas Operating Company as a loss prevention engineer. In 2003 was appointed as the lead loss prevention engineer looking after technical safety design and Risk management matters for the Qatargas 2 Development project which was one of the first integrated gas projects with facilities that included offshore production , onshore processing, common facilities, Shipping , and UK receiving terminal. Then after was appointed as the Safety and Risk Department Manager; responsible for occupational safety, crisis management, and process safety & risk management for Qatargas operated facilities that includes 7 LNG trains, Loading Facilities, and Condensate Refinery. Recently he joined Qatar Shell as the Technical HSE Manager with big focus on Process Safety and Risk Management for Shell Operations in Qatar.

Title: Qatar Shell GTL Process Safety – Focus on Front Line Leadership ABSTRACT: As Process Safety is becoming an integral and core part of HSE management system, critical focus on Process Safety culture and leadership of organizations is maturely growing. This presentation is going to highlight the importance of such culture for the Front Line Leaders, and basic principles on how to set-up such a culture. In addition, the presentation will try to introduce mindsets, such as Chronic Unease and understanding Risk Normalization that can help the Front Line Leader to better comprehend and be prepared for managing process safety hazards.

Khalid Al-Hetmi Senior Loss Prevention Engineer, Qatar Petroleum Co - Founder And Chairman of American Society of Safety Engineers – Qatar Section

BIOGRAPHY: Khalid Al-Hetmi has joined Qatar Petroleum in 2002, and has been in his current role as a Senior Loss Prevention Engineer within the engineering department for the past 4 years. He has a Chemical Engineering background from Western Australia and holds a Master’s degree of Science of Process Safety and Loss Prevention from the University of Sheffield, UK. He is a current member of Qatar Leadership Centre an organisation under the patronage of HH Sheikh Tamim bin Hamad Al-Thani, Heir Apparent. QLC aims to advance and nurture Qatar’s leadership talent pool by directing investment of resources and champions best leadership development practices from around the world, enabling high-achievers to succeed as leaders for the benefit of Qatar as a whole. Khalid is the co-founder and current chairman of the American Society of Safety Engineers – Qatar Section.

Title: The Case for a Professional Safety Society in Qatar ABSTRACT: The last 12 or so years have seen tremendous growth in Qatar, on top of oil & gas production, processing and real-estate, the economy has been diversified to include manufacturing, excellent academic institutions, effective government engagement, dynamic healthcare sector and a global 5 star airways. This setup begs the question why is there a ap in communication between all these HSE stakeholders, the need to provide a shared platform of dialogue and networking becomes apparent. Therefore there is a big potential for establishing a local section for the American Society of Safety Engineers in Qatar. The HSE industry has evolved and reached a recognized level of maturity in this country that the lack of such a society is urgently needed, if not required. The benefits of joining a professional society will be examined such as providing networking opportunities and online membership boards where you can post questions, read peer publications, and interact in other ways that can lead to job offers, training, and more. The requirement to having a successful professional association that combines its goals of being relevant to the industry and providing cost benefit value to its members will be discussed.

Speakers Jassim Salem Al-Malki HSE & Security SR. Manager Dolphin Energy Limited, Qatar

BIOGRAPHY: Mr. Jassim Salem Al-Malki is the Sr. Manager for Health, Safety, Environment and Security (HSE&S) at Dolphin Energy, Qatar. He oversees HSE&S requirements including risk management, environmental and social responsibilities, and monitors contractor safety performance. He also ensures compliance of management safety systems through audits and provides continued asset protection for the company’s onshore and offshore facilities. He has over 18 years experience in the oil, gas and petrochemical industries, most of which has been spent in operations and engineering, health, safety, environment and risk management. Mr. Al-Malki started his career at Qatar Petrochemical Company as a Production Engineer and then moved to the Technical Engineering Department to become Head of Process Engineering. He was then promoted to become HSES Emergency Response Manager. Early in 2011, he joined Dolphin Energy, Qatar as Sr.HSES&S Manager. He holds a degree in Chemical Engineering from the University of Qatar, a High Degree Diploma in Gas Treatment, Processing Technology from the Institute of Petroleum in France and a Master’s degree in Management and Business Administration.

Title: Process Safety Management – An HSE Foundation ABSTRACT: Despite recent advances in equipment design and control systems and the increased focus on safety and risk management, industry continues to experience major accidents. However, industry is not learning from past disasters well enough to prevent their reoccurrence because the focus is too much on occupational safety, and not enough on Process Safety. Dolphin Energy Limited (DEL) has been successful in implementing good HSE practices that reduce Total Recordable Incident Rates (TRIR) to levels favorably comparable to those of industry. As DEL gained operational experiences, it was recognized that measuring HSE performance using TRIR was not a good indication that Process Safety issues were being managed properly. Thus, the DEL Process Safety Management Strategy was implemented to serve as the foundation for HSE programs. This strategy aims to ensure that risks arising from hazardous processes are properly controlled to reduce impacts on people, property, environment, revenue, and DEL reputation. The strategy includes: 1. Making Process Safety everybody’s business as is the case for personal safety and environmental protection 2. Raising Process Safety awareness 3. Integration of Process Safety with QHSE MS 4. Process Safety Lagging and Leading Metrics reporting 5. Safety Critical System Performance Standards and Verification 6. Risk Revalidation 7. Internal and External Process Safety auditing 14

Saif Al Naimi Director, HSE Regulations and Enforcement Directorate Qatar

BIOGRAPHY: Mr. Saif S Al Naimi has graduated in Chemical Engineering from Qatar University. and joined Qatar Petroleum in 1991. Having gained well over 20 years experience, it has been a journey of challenges and Mr. Saif worked in the various capacities in QP and is presently the Director, HSE Regulations & Enforcement. Mr. Saif S Al Naimi, as Director of the HSE Regulations and Enforcement Directorate, is vested with the primary responsibilities to stipulate the Regulations and follow up to ensure that the players in the petroleum activities maintain high standards of health, environment, safety and emergency preparedness and thereby contribute in creating the greatest possible values for the society. As Director of the Regulations & Enforcement Directorate has Regulatory & Enforcement responsibility to ensure for HSE and the working environment in the petroleum activities. The appointment to the position of Director HSE regulations & Enforcement Directorate has been a journey of challenges after being graduated in Chemical Engineering from Qatar University. After graduation, he joined QP and worked in the various capacities. He became Manager, Corporate Quality & Management Systems and was responsible for managing all aspects of the Quality Management System and its development throughout the Corporation and managed all quality issues related to projects very meticulously. As the Director of HSE Regulations and Enforcement his job responsibilities include liaison with the national, regional and international institutions/organizations in relation to conventions, treaties, protocols and agreements related to HSE issues and Sustainable Development and also to develop and maintain synergies between HSE local regulations and international developments. In the field of Standardisation, Mr, Saif S Al Naimi played a major role in establishing the QP Standardisation Management System and in involving QP in the national, and international standardisation efforts which lead to the establishment of the Gulf Standards Committee for oil and gas industry, which he is chairing now as Qatar Petroleum representative and also leading one of the ISO TC 67 Working group.

Title: Safety Case Framework in Qatar’s Energy Industry; Technical HSE Framework and the Safety Case Approach ABSTRACT: The Oil and Energy Industry represents the backbone of the State of Qatar economy with needs to be regulated and managed to mitigate significant and intolerable safety risk. The role of the Health, Safety and Environment Regulations and Enforcement Directorate (hereinafter HSE DG) is to assure the stakeholders, investors and the State level that Major safety risk to the State of Qatar Energy Industry is being appropriately managed whilst not forgetting the environment and occupational health and safety risks issues. 15

Speakers The HSE Regulations and Enforcement Directorate (DG) “Technical HSE Framework” has been developed to facilitate Directorate (DG) in regulating the State of Qatar’s Petroleum and Industry sector. This Framework focuses on the significant health, safety and environmental risks that could impact at state level; hence regulatory framework is required to address the “Major Hazards Management”. A major accident at any one of Qatar’s installations is likely to entail material losses, damage to the environment, the State economy, local communities and society, while the lives and health of workers may be put at risk. The likelihood of a major accident in Qatar needs to be reduced. The Safety Case approach, which will be the driving principle behind the regulatory regimes, forms the cornerstone of the Technical HSE Framework with key outcome to build safety management capacity and the safety culture within the State of Qatar. The HSE Directorate (DG) will work with other statutory and regulatory bodies in the State of Qatar in order to increase and strengthen the requirements of the legislation. The purpose of a Safety Case is to demonstrate the safety arrangements for a designated “Installation” and how these arrangements ensure that the risk associated with the activity remains at a level that is ALARP. The benefits and value added to the State of Qatar are obvious and can be summarized as following – enhanced health, safety and environmental performance of the Oil & Gas Industry and population, shareholders and investors confidence that industries are adopting the world class HSE practices. The State of Qatar will continue to build upon its role in the regional and international community as a stabile and reliable partner in Oil and Energy Industry Sector by implementing HSE culture based on the highest international standards and best approach. The HSE (DG) Directorate will do its outmost best to contribute to this effort.

Allan Hollonds Senior Advisor (Operation Best Practice) Rasgas, Qatar

Title: Prevention is Better Than the Cure – The Longford Fire and Its Aftermath

Dr. Stephen W. Ciaraldi Senior Integrity Management Specialist Applus-Velosi LTD

BIOGRAPHY: Dr. Stephen W. Ciaraldi (Steve) joined Applus-Velosi Ltd. in 2010 following 30 years employment with Amoco and BP. During that long service, Steve worked in various asset integrity management roles including R&D, facilities engineering, inspection, corrosion and chemicals management, pipeline integrity management, engineering and maintenance, risk management and as a technical authority for process safety and asset integrity. A majority of his Amoco / BP experience was directly at major production locations including those in Norway, Egypt, Trinidad and Indonesia. Steve is currently Senior Integrity Management Specialist for Applus-Velosi, with focus on Southeast Asia operations and clients. Dr. Ciaraldi obtained Ph.D. and B.S. degrees in Metallurgical Engineering from the University of Illinois. He is active in SPE and NACE and has authored 57 publications on integrity management for oil and gas production. A majority of these involve development and implementation of comprehensive integrity strategies and their associated challenges in real world, field applications.

Title: Integrity Management Of Critical Safety Systems ABSTRACT: A main goal of process safety and asset integrity management (AIM) programs in the oil and gas industry is the prevention of major accidents. As originated in the UK safety case approach and expanded upon elsewhere, it is realized that certain process equipment systems, if they failed, could cause a major accident. These systems are often called health, safety and environment (HSE) critical systems, or critical safety systems (CSS) for short. Obviously effective maintenance and integrity management of such systems is a vital process in preventing major accidents. Identification of CSS is a critical first step, with tools such as hazard registers and decision trees often deployed to accomplish this. One goal in this process is to limit the number of CSS, so that they can truly be prioritized. Once identified, performance standards for CSS should be developed so that at any stage in their life, fitness for purpose can be assessed. Maintenance, monitoring and testing regimes can then be put into place so that fitness for purpose is maintained. Execution of these is greatly facilitated through the use of computerized maintenance management systems, which also allows rapid assessment of work progress. As such, key performance indicators (KPIs) can be defined and monitored as a means of assessing CSS status. Other considerations to be carefully managed include over-rides / dispensations, change management and verification / audit of CSS. The above aspects of CSS and common pitfalls in this management process are presented, with examples drawn from actual major production operations.

Speakers Michael (Mike) Ferrow Vice President, Health, Safety and Environment ConocoPhillips, USA

Plenary Keynote speaker BIOGRAPHY: Mike Ferrow is vice president of health, safety and environment for ConocoPhillips. Ferrow began his career as an applications and test engineer for Rolls Royce, later joining the U.K. Health and Safety Executive as an inspector. In 1980, he joined Conoco in London as a safety engineer. Following assignments in capital projects, Ferrow transferred to Aberdeen in 1989 to become manager HSE for U.K. operations. In 1996 he was named vice president of operations for Conoco Indonesia in Jakarta. Moving to Dubai in 2001, he became managing director of Conoco Middle East Technology; he later transferred to Norway as manager of HSE for the North Sea business unit. In 2009, Ferrow returned to Aberdeen as manager of HSE, engineering and technical assurance. Ferrow began his current role in Houston in May 2012. Born in Gateshead, U.K., and a graduate of the University of Nottingham, Ferrow is a chartered engineer and a fellow of the Institution of Mechanical Engineers.

Title: Process Safety for a Sustainable Future ABSTRACT: Process Safety has become one of the key terms to describe approaches for preventing major accidents in the petrochemical business. But what does being good at process safety involve? There are four main considerations: design; asset integrity; operating discipline; and the management system that binds the first three together. ConocoPhillips supports the position shared by the Center for Chemical Process Safety and others that a compelling business case exists for strong, effective leadership across all elements of process safety. Corporate responsibility, risk reduction, business flexibility, and sustained value are all desirable outcomes of well-conceived and effectively executed process safety programs with key performance indicators. To further support process safety education and training at all levels, ConocoPhillips is partnering with Texas A&M at Qatar at this symposium. ConocoPhillips also is promoting R&D to help our company better understand root causes of past process safety incidents related to technical and human performance. At ConocoPhillips, we are incorporating new ideas and efforts in all these areas. We also are binding the work together in a management system that drives collaboration, knowledge sharing and active monitoring of day-to-day activities. When we learn from history and from each other, we believe we can create a future without serious process safety incidents.

Donald C. Glaser President of Simulation Solutions INC, USA

BIOGRAPHY: Don Glaser is the president of Simulation Solutions, Inc. Don’s company has been the leader in providing PC based dynamic simulations and related programs for use in training process operators since 1980. These simulators have been used in over 230 locations in 28 countries on six continents. Don has spent his entire career developing Operator Training Simulators (OTS). His company was the first to bring dynamic simulation to the personal computer, and now is the first to market a simulator that includes a virtual reality 3D training station for outside operators, field operators and supervisors. Don has developed a successful and proven comprehensive 5 Step approach to Simulator-Based-Training called INSTO™. This immersive and collaborative approach combines traditional classroom techniques with innovative Simulator-Based-Training techniques and exercises, and that provides “Hands-On/MindsOn Training for Operators.” Don has authored many articles on training applications of dynamic simulation and has delivered numerous training courses to both Instructors and Operators. He has a BS in Chemical Engineering from Lafayette College, Easton, PA.

Title: Simulator Training for Operators and Engineers ABSTRACT: Operations jobs are complex and a staff of well-trained operators and engineers are essential for safe and efficient plant operations. This presentation describes a comprehensive methodology called INSTO™ which uses Simulators, Instructor and Student Workbooks, and innovative classroom techniques for “hands-on” and “minds-on” training of operators and engineers. The INSTO™ methodology is designed for small group instruction which allows for maximum student participation. Each student has access to their own Simulator. The learning is mostly student-driven, with the instructor playing the role of mentor and coach. Most training exercises begin with the student making a written prediction about normal plant operations or responses to an upset, followed by operating the Simulator and observing and recording the actual plant behavior, and lastly comparing and discussing their predictions to actual plant behavior. Top operators and engineers rely heavily on their own mental model of the process, especially during upsets and emergencies. The INSTO™ Simulator training methodology is designed to build and strengthen these mental models, and also help operators and engineers develop and improve their troubleshooting skills. There are two types of course assessments. The first is a comprehensive grade based on the students’ scores in all the individual exercises in each of the 5 INSTO™ elements – I/Identification, N/Normal Operations, S/Start-up and Shutdown, T/Troubleshooting, and O/Optimization. The second is a self-assessment covering 30 aspects of Plant Operations within the following 6 categories: Console Manipulation, Procedural Adherence & Compliance, Situational Awareness, Decision Taking, Communications and Cooperation. 19

Speakers Dr. Konstantinos E. Kakosimos Assistant Professor of Chemical Engineering Texas A&M University at Qatar

BIOGRAPHY: Dr. Konstantinos Kakosimos main activities are focused on the development of numerical models for environmental processes and the training for risk assessment and effects calculation. He is co-author of the book entitled “Fires, explosions, and toxic gas dispersions: Effects calculation and risk analysis” published by CRC Press and he has published more than 15 papers in international peer-reviewed journals. Dr. Konstantinos Kakosimos received his PhD on the simulation of toxic gases dispersion from the Chemical Engineering Dept. of Aristotle University of Thessaloniki in 2009. He worked as Postdoctoral Research Fellow/Assistant in the same university and as visiting Research Assistant in the National Environmental Research Institute, Aarhus University Denmark and also as a Design Engineer and Environmental Consultant for a number of private firms (Hellenic Petroleum, Titan Cement Company SA, Hellenic Gold, HYETOS GP etc). On October 2012 he has been appointed Assistant Professor of Chemical Engineering in Texas A&M University at Qatar. From 2009 to 2012 he was also an elected Vice-Chairman of the Panhellenic Association of Chemical Engineers (Department of Northern Greece).

Title: Development of Focused Training Programs And Decision Support Systems On Risk Assessment ABSTRACT: Risk Assessment is a continuous evolving practice and concept that deals with processes which significantly impact human and ecological health, economics and decisionmaking. Though risk assessment is based on a number of uncompromising principles, the methodology to apply these principles can considerably differ from processes to processes. Therefore, Risk assessment professionals, freshmen and “sidekicks” face a critical need to have sufficient, up-to-date and state-of-the-art training. This is more eminent nowadays where the staffs of agencies and corporations have to effectively and efficiently manage the risk and to safeguard environmental and public health. Unfortunately, it is not possible for them to comprehend the principles and apprehend the impacts solely by attending “customized training courses”. The new era of risk assessment training demands the development of focused training programs instead of providing trimmed and reduced versions of existing ones. This way, a number of risk experts first analyse or even setup the basis of a risk assessment study for the specific processes or group of processes. Afterwards they form the training material and guides for either face-to-face or asynchronous (e.g. eLearning) programs. Finally and if necessary a decision support system is established in order to assist stakeholders on common activities, special events etc. The presentation provides some of the important factors and stages on developing a focused training program on risk assessment and a number of specific case studies i.e. small industries, new engineers and the military. 20

Charlie King Major Projects Sales Manager Angus Fire Engineering, UK

BIOGRAPHY: Charlie holds a Diploma in Mechanical Engineering from Oxford Brookes University. He has 30 years’ experience in the Fire Industry which includes: system design and hydraulic analysis, site surveys to assist in the development of design philosophies, supporting international consultancy companies for FEED specification work, development of in-house computer software for system calculations to international standards, project management and sales activities.

Title: Design of Fire Protection Systems for LNG Facilities ABSTRACT: As LNG facilities around the world become more common and are storing/processing greater quantities of product it is essential that any fire incident can be quickly mitigated by means of Fixed Fire Protection Systems. These need to be correctly designed to bring the incident under control so the risk of injuries and plant damage is minimised. As the international standards for such Fire Protection Systems provide limited design information, Angus Fire has carried out extensive test work to establish the best methods of protecting these highly volatile hazards. The presentation will summarise the findings of the test work and provide recommendations for System Design based on these findings. The aim of the presentation is to give the audience an overview of systems and equipment that could be deployed together with the system design criteria. The presentation will also include advice on checking the integrity of existing systems. From our experience there are many LNG facilities around the world that have insufficient protection because of poor design and/or equipment selection.

Speakers Dr. Haroun Mahgerefteh Professor of Chemical Engineering University College London, UK

BIOGRAPHY: Dr. Haroun Mahgerefteh is Professor of Chemical Engineering at University College London, placed 4th in the 2010 QS World University rankings. His main research interest is in Safety and Loss Prevention in the oil and gas industries, particularly pipeline rupture safety analysis where he has recently extended this work to CO2 pipelines. He is the coordinator of EC FP7 projects, CO2PipeHaz and CO2QUEST, co-investigator in EPSRC/E.On MATTRAN and UK National Grid COOLTRANS projects. Professor Mahgerefteh is a Fellow of IChemE, and winner of IChemE Frank Lees Safety and Loss Prevention Medal in 2011. He is the author of the award winning pipeline rupture computer programme, PipeTech (http://pipetechsoftware.com), employed by UK HSE as well as major oil and gas operators such as Shell and BP for safety assessment of hydrocarbon pipelines across the globe.

Title: CO2PIPEHAZ: Quantitative Hazard Assessment for next generation CO2 pipelines ABSTRACT: As part of the Carbon Capture and Storage (CCS) chain, CO2 pipelines are considered as the main method for transporting huge amounts of captured CO2 from fossil fuel power plants for subsequent sequestration. Given that CO2 is an asphyxiant at concentrations greater than 10% v/v, the safety of CO2 pipelines is of fundamental importance and indeed pivotal to the public acceptability of CCS as a viable mean for tackling the impact of global warming. This paper presents an overview of the main findings of the recently completed European Commission FP7 CO2PipeHaz project focused on the hazard assessment of CO2 pipelines. The developments of the state-of-the-art multi-phase heterogeneous discharge and dispersion models are given special consideration given that this data forms the basis for emergency response planning and determining the minimum safe distances to populated areas. Model validations are based on both laboratory and large-scale field trials using a unique CCS facility in China involving the rupture of an especially constructed fully instrumented 250m long, 0.23m i.d pipeline containing dense phase CO2. The understanding gained based on this work is used for evaluating the adequacy of control measures in CO2 pipelines, with best practice guidelines proposed.

Dr. Sam Mannan Regents Professor And Director, Holder of T. Michael O’Connor Chair I, Mary Kay O’Connor Process Safety Center Artie McFerrin Department of Chemical Engineering Texas A&M University System BIOGRAPHY: Dr. M. Sam Mannan is Regents Professor in the Chemical Engineering Department at Texas A&M University and Director of the Mary Kay O’Connor Process Safety Center at the Texas Engineering Experiment Station. The mission of the Center is to improve safety in the chemical process industry by conducting programs and research activities that promote safety as second nature for all plant personnel in their day-to-day activities. Before joining Texas A&M University, Dr. Mannan was Vice President at RMT, Inc., a nationwide engineering services company. Dr. Mannan’s experience is wide ranging, covering process design of chemical plants and refineries, computer simulation of engineering problems, mathematical modeling, process safety, risk assessment, inherently safer design, critical infrastructure vulnerability assessment, aerosol modeling, and reactive and energetic materials assessments. He co-authored the Guidelines for Safe Process Operations and Maintenance published by the Center for Chemical Process Safety, American Institute of Chemical Engineers. He is the editor of the 3rd and 4th edition of the 3-volume authoritative reference for process safety and loss prevention, Lees’ Loss Prevention in the Process Industries. Dr. Mannan has published 167 peer-reviewed journal publications, 3 books, 7 book chapters, 183 proceedings papers, 12 major reports, and 188 technical meeting presentations. Dr. Mannan is the recipient of numerous awards and recognitions. In September 2011, the Technical University of Łódź, Poland, conferred the Doctoris Honoris Causa on Dr. Mannan. In 2012, he was awarded the Bush Excellence Award for Faculty in Public Service. Dr. Mannan received his B.S. in chemical engineering from Bangladesh University of Engineering and Technology (BUET) in Dhaka, Bangladesh in 1978, and obtained his M.S. in 1983 and Ph.D. in 1986 in chemical engineering from the University of Oklahoma.

Title: Process Safety Research Agenda for the 21st Century ABSTRACT: Process safety is an evolving field whose importance becomes evident only after tragic disasters occur. During the past decades, many primary theories and technologies have been studied, invented and applied. However, we have to continuously develop advanced methods for more complex problems that remain in science, technology and organization. To address these issues, the Mary Kay O’Connor Process Safety Center convened an unprecedented gathering of academia and researchers in October 2011, to develop the “Process Safety Research Agenda for the 21st Century.” The presentation will share the results of the deliberations where 19 areas areas were identified and prioritized in terms of a set of criteria to focus future research in Process Safety.

Speakers Dr. Tomasz Olewski Associate Research Scientist Process Safety Research Group Texas A&M University at Qatar

BIOGRAPHY: Tomasz Olewski has started his career in process safety in 2007 at the Department of Safety Engineering of Technical University of Lodz (read like Wootch), where he was a faculty member and consultant of risk assessment for numerous biggest oil and chemical plants in Poland. He has joined Texas A&M University at Qatar in 2009 to support 5 years project on LNG safety funded by the BP and greatly supported by Qatar Petroleum. He holds PhD Degree in Chemical Engineering, MSc and Engineer Degree in Environmental Engineering, and diplomas in Electrical and Automatic Engineering and Safety in Industrial Processes.

Title: Source term modelling for LNG spills on land ABSTRACT: Potentially severe consequences associated to accidental liquefied natural gas (LNG) spills have motivated a number of different studies, including experimental work, towards their prediction. Most of these studies focus on vapour dispersion, however there is limited information regarding source term of vapour formation, which includes liquid spill, pool spreading and liquid vaporization rate. Existing models of the source term utilize semi-empirical equations and are built based on non-comprehensive data derived from non-cryogenic liquid spills, like oils, which do not necessary represent cryogenic liquid spill well. There are needs of further improvements to understand physical phenomena of vapour formation from cryogenic liquid spill and to quantify the most important parameters that can affect them. The vaporization of cryogenic liquids is governed by the heat transfer phenomena including conduction, convection and thermal radiation mechanisms. The present work investigates the contribution of these different heat transfer mechanisms to the vaporization rate of cryogenic liquid through the series of small and medium-scale, well-controlled and instrumented experiments performed with liquid nitrogen (LN2). The vaporization rate of LN2 was measured and correlated to the individual contributions of conductive, convective and radiative heat transfer. The experiments on convection showed that this heat transfer mode can play a significant role in the vaporization rate of the cryogenic liquid. In these set of experiments, its contribution to total heat flux to an LN2 pool spilled on a concrete surface was measured to be as high as 30% after 10 minutes for moderate wind speed of 2-3 m.s-1. The experimental data also showed that the sidewalls of the liquid containment may play a key role in the resulting amount of convective heat transfer and indicates that walls or fences could be used as a good mitigation method. It was observed that the radiative heat absorbed by the LN2 pool during the experiment represent only 50% to 65% of the incident radiation that would reach the LN2 pool surface if no vapour was present. This is attributed to the absorption and/or reflection of the radiation by the vapour. 24

Carl H. Poldrack III, REM, CEA Safety Manager Qatar Chemical Company (Q - CHEM)

BIOGRAPHY: Carl H. Poldrack, REM, CEA, is the Safety Manager of Qatar Chemical Company (Q-Chem) with responsibility for Process Safety Management, Occupational Safety, Industrial Hygiene, Emergency Response, and Operational Excellence disciplines. Carl received his B.Sc. in Environmental Management from the University of Houston and is completing his M.Sc. in Industrial and Occupational Safety from Eastern Kentucky University. Working in the oil and petrochemical industries for 32 years, Carl has been pursuing the goal of consistent excellence in systems performance in a variety of international settings and leadership roles. As a certified auditor, Carl has led over 100 comprehensive EHSS, process safety, and operational excellence audit teams around the world and has been recognized for his efforts to build and implement effective operational excellence management systems in a variety of oil and petrochemical applications.

Title: Broadening the Safety Culture: Gaining Employee Ownership of Process Safety ABSTRACT: While personnel injury and illness rates in the petrochemical industry have shown strong positive trends over the past several years, process-related incidents and events, many of them quite significant, have continued to occur with little or no change in rates. Process safety trends such as these show that believing superb personnel safety performance is a reliable gauge of comprehensive safety performance can be a deadly mistake. In particular, process incidents reveal the need to combine strong personnel safety performance with excellent process safety management programs founded on recognized engineering principles to achieve consistent comprehensive safety performance. However, the variables posed by human interfaces with well-engineered process safety management programs have proven a difficult challenge. Removing uncertainty posed by inconsistent human behaviors remains one of the greatest opportunities for improving process safety program performance. The key to successfully meshing engineered solutions with human behaviors is getting employees engaged and involved in actively managing process safety performance. This presentation provides a case study in establishing employee involvement in and ownership of process safety efforts thereby achieving significant reductions in process safety events and increasing positive results in comprehensive safety performance.

Speakers Mhorvan Sherret Director of Matrix Risk Control LTD, UK

BIOGRAPHY: Mhorvan spent his early career as a serving Police Officer joining Grampian Police in 1976. Within the former Scottish Crime Squad, now Scottish Crime and Drugs Enforcement Agency, he held management roles in a number of operations throughout the UK. He had additional responsibility for serious crime investigation, staffing, budgeting, technology and liaison with multi disciplined organisations throughout the country. He also headed the National Covert Policing methods and Surveillance Training Unit within Crime Management Division at the Scottish Police College. He has particular experience in cross functional team building and leadership with exposure to many critical incidents which required deployment within external Crisis Management Teams to ensure damage limitation and business continuity. In the private sector he has worked for a number of organisations in the development and delivery of investigation support systems and root cause analysis. He has a widespread knowledge and practical experience of investigating work place incidents and developing performance improvement programmes. He is also an accomplished instructor with an empathetic and understanding style. In his current role he has led the development of a unique, dynamic and interactive Corporate Manslaughter training “experience” which has been highly acclaimed throughout industry. He is currently a director of Matrix Risk Control (UK) Ltd.

Title: The Time to Learn to Dance is Not the Night Before the Party ABSTRACT: Prudent companies will acknowledge the value of proper independent, unbiased incident investigations which ensure that there is maximum learning from events and opportunities taken to update their risk assessments, training programmes, systems and controls to take cognisance of them. They will take the necessary steps to assess if the organisation has considered whether attitudes, policies or accepted practice encouraged or produced tolerance of the failure. Safety Management Systems and Loss Prevention Processes are critical elements of any robust investigation. Establishing a culture that withstands the scrutiny of intrusive investigation should be standard requirements for companies that take the protection of their people seriously. Prevention is not a passive process, it is a dynamic activity. Forward thinking organisations are always thinking out of the box and considering ways in which to reduce their vulnerability. It can be as simple as black and white if an organisation invests the time in good quality proactive audits of their processes and procedures. Significant issues will emerge around which they can take positive action to prevent becoming critical incidents requiring lengthy reactive investigation. 26

Randy Stadler Chief Safety, Environment And Quality Officer Qatargas

BIOGRAPHY: Randy Stadler is responsible for managing all aspects of Safety, Environmental, Quality, and Emergency services for Qatargas Operations. This includes manned and unmanned offshore platforms, 7 LNG trains with a production capacity of 42 million tonnes per annum, terminal and berthing operations supporting a fleet of 44 purpose-built ships, transporting LNG to over 20 countries across the world and Laffan Refinery producing Kerosene, Naptha, Gas Oil and LPG. Randy Stadler has spent 28 years in the oil & Gas Industry working in Engineering, Safety, Risk Management, Environmental Management, Operations Integrity, Emergency Preparedness & Response, Health and Security. He has gained experience in: 1. Leading in Management, Supervisory and Engineering positions responsible for Safety, Health, Environmental & Security for offshore and onshore operations in Nigeria, North Sea, Germany and Qatar; Managing Safety and Health for onshore and offshore global capital construction projects 2. Managing Civil & Marine Terminal Engineering supporting Upstream and Downstream operations 3. Leading the introduction and implementation of the Corporate SHE&S Leadership Model across all ExxonMobil companies

Title: Operational Safety Challenges in the Oil & Gas Industry ABSTRACT: The oil and gas industry has traditionally focused on eliminating occupational safety hazards as the primary means to eliminate incidents. In reviewing the classic incident classification pyramid; working on the lower levels of the pyramid has not necessarily eliminated catastrophic failures or fatalities. More needed to be done to manage operational hazards in conjunction with process hazards. The goal of the Qatargas Process Safety Management program is to ensure that facilities such as LNG trains, the refinery, and offshore platforms are operated safely by fully integrating process safety and occupational safety. This is done by: 1. Determining the operating limits and setting corresponding alarms 2. Standardizing certain types of communications and planning within, across, and beyond shifts 3. Managing situational awareness 4. Enabling proactive monitoring of the process and selected equipment 5. Defining a common method for managing abnormal situations 6. The Qatargas approach will be discuss and examples of successes will be highlighted 27

Speakers Dr. Caroline Sugden Technical Lead - Human And Organisational Factors Health And Safety Laboratory, UK

BIOGRAPHY: Caroline is a Fellow of the Institute of Ergonomics and Human Factors with over 18 years experience in the field of human factors. She has worked in consultancy and for London Underground and has over 9 years experience at HSL. Caroline’s PhD research considered the impact of organisational change on safety culture within a train operating company transitioning into the safety case regime. In her technical lead role she leads work on human and organisational factors in the major hazards sector, and topics of work include: human factors issues in COMAH safety reports, human reliability assessment, and competence assurance. Recent work includes the revision of HSL’ safety climate tool, safety culture consultancy, involvement in the development of a process safety climate tool, support on the development of industry safety performance indicators and ongoing work on high reliability organisations and leadership.

Morning Cup of Explosion

Michael McDowell, Huda Hamza, Ahmed Imran Valeria Casson Moreno

Investigation of Dust Explosions

Texas A&M University at Qatar

Introduction This work was performed to observe how the ignition and combustion of dusts varies with the dust concentration. The objective was to determine the explosive characteristics and minimum explosive concentration of powder materials that go into a cup of coffee. Four different materials were tested for this experiment:  

Title: Aspiring to Organisational Reliability

Powdered Sugar Coffee Creamer



Powdered Coffee



Instant Coffee Mix “3-in-1” (mixture of the

previous three)

Equipment The Hartmann Vertical Tube apparatus can be used to Coffee Creamer

Instant Coffee Mix

determine whether a dust

flammable.

gives

qualitative indication of the severity of the explosion of a dust cloud by measuring the level of deflection of the top lid.

Powdered Sugar

Results

Powdered Coffee

Methods A standard method was used for each substance to determine the approximate range of concentration where an explosion will occur using a Hartmann Vertical Tube. Samples were weighed out in amount that would correlate to concentrations of 30, 100, 200, 500, and

Substance

Powdered Sugar Coffee

Minimum Explosive Concentration1 (g/m3)

45 600

Experimental Explosive Concentration (g/m3)

200 1000

Powdered Creamer

330

500

Instant Coffee Mix

unknown

>1000

1 Based on Literature Values

1000 g/m3 in air once dispersed. Procedure: 1) Loading of the sample into the bottom cup of the Hartmann Tube 2) Lid secured and system loaded to 7 bar. 3) Activation of the spark ignition source 4) Dispersion of the sample in the tube 5) Deactivation of the spark ignition source 6) Removal of residual powder 7) Cleaning of the tube

Pressure Relief System Design for a Multi-Purpose Vessel Using Adiabatic Calorimetry Rym Kanes, Rinchu Mathew, Abd-Allah Marmar Texas A&M University at Qatar 30% H2O2 – PHI TEC I 450

bar  dP    = 0. 5147 s  dt  max

60 40 20

300 7500

11250

15000

450

50 40 30

400

350

10 0

10000

20000

Vent Area (m2)

Vent Diameter(mm)

30% H2O2

1.699×10-2

147

MeOH in Ac2O

System

4.776×10-3

3.327×10-2

205

4.819×10-2

213

Results

H2O2 → H2O +

20% DTBP

25 20

K  dT    = 0.1201 s  dt  max

15 10

350

300 6500

10000

CH3 +(CH3CO)2O → CH3COOCH3 + CH3COOH

13500

Time(s)

0 20500

17000

Temperature

20% DTBP in Toluene

Pressure (bar)

30% H2O2

0 60000

50000

G, Flow Capacity per unit cross section area of the vent line, [Kg/m2s]. Calculated using Omega Method

MeOH in Ac2O – PHI TEC I

MeOH in Ac2O (CH3 )3COOC(CH3 )3 → C2H6 +2(CH3 )2CO

40000

Conclusion

bar  dP    = 0.4892 s  dt  max

400

30000 Time (s)

According to the results obtained, only the vapor system, MeOH in Ac2O is compatible with the given the multi-purpose vessel. These results are of course based on preliminary tests on PHI-TEC I only. Further adiabatic calorimetric tests have to be done to confirm the data produced in this project.

500

450

Pressure (bar)

Temperature (K)

K  dT    = 0.5442 s  dt  max

W, Required Relief rate [kg/s] Calculated using Leung et. al’s method. A, vent size area [m2]. Used for sizing bursting disc.

1 2

22500

bar  dP    = 0. 3114 s  dt  max

500

300

Chemical Reaction

18750

Time (s)

20% DTBP in TOLUENE – PHI TEC II

The research work was conducted to size a rupture disc for a 340L multi-purpose jacked vessel. The vessel had a flange with a diameter of 80 mm, in which the bursting disc was to be installed.

System

120 100 80

350

550

Project Objectives

Three systems were studied. Each system was classified as either gassy, hybrid or vapor using PHITEC-I and PHITEC-II adiabatic calorimeters.

140

K  dT    = 0.7027 s  dt  max

400

Pressure (bar)

Methods The specific data that were required from the calorimetric tests were the following: • The onset temperature for the exothermic runaway reaction. • The rate and quantity of heat released as the runaway reaction proceeds. • The rate and magnitude of pressure generated during the runaway reaction. These data were then to be used to calculate the required vent size and scale it up for the pilot reactor.

Temperature (K)

Abstract Exothermic reactions that undergo uncontrolled self-heating as a result of loss of cooling lead to thermal runaways. This is of concern especially during the scale up of the cooling system for a chemical vessel designed to carry on an exothermic processes. The heat produced by a reaction is proportional to the volume of the reaction mixture, while the cooling capacity is a function of surface area of the vessel. Under thermal runaway the reactor behaves as an adiabatic system. Vents are passive protective layers against the effects of thermal runaways. Different peroxide decompositions (highly exothermic reactions) were studied using adiabatic calorimetry techniques to obtain the necessary parameters outlined in the DIERS methodology for vent sizing.

Temperature (K)

ABSTRACT: Understanding safety culture is part of the journey towards improving organisational reliability. Organisation’s have responsibilities for the management of their risks, and to ensure adequate and appropriate risk mitigation. Central to the effectiveness of safety management is the concept of safety culture. This presentation covers HSL’s approach which shows the steps to becoming a successful and highly reliable organisation. The first two steps, Understand SMS and investigate safety culture, are about understanding the status quo, determining whether the processes, standards and systems are adequately designed and implemented. The assessment of safety culture will provide information that will help you to understand the efficacy of risk management and safety management systems and prioritise improvements. The next step following ‘Understanding’ would be to ‘Improve’ which could involve developing KPIs and procedures, or improving accident investigation, based on signposting from your safety culture evaluation or your SMS audits. Other steps could improve development of behavioural safety programmes to address unsafe behaviours, once organisational readiness has been determined and tactical improvements derived from the safety culture assessment have been delivered. The endpoint of this journey would be an organisation well on the road towards being labelled a ‘High Reliability Organisation’.

Pressure

Acknowledgements The authors of this poster would like to thank Dr. Luc Véchot for the opportunity and support as well as Dr. Valeria Casson Moreno for all her guidance, and support.

Presentation of a new equipment at the Process Safety Laboratory: 20 liter dust explosion sphere

Abd-Allah Marmar, Amr Al-Achi, Valeria Casson, Tomasz Olewski, and Luc Véchot Chemical Engineering Program, Texas A&M University at Qatar, PO Box 23874, Doha, Qatar

WHY DO WE NEED TO KNOW ABOUT DUST EXPLOSIONS?

RESULTS: WHAT WE CAN WE MEASURE?

Dust explosions accidents are very well known in the coal industry (Fig. 1), but not many people know that it may happen in others. As a matter of fact it occurs very often in the wood, paper and food industries (Fig. 2). One of the examples is the explosion at the Imperial Sugar company in 2008 (Fig. 2). This explosion caused 14 deaths and 38 injured, among which 14 with serious life-threatening burns.

The 20 liter dust explosion sphere is used as a standard test to determine the following important parameters for dust (and gas) explosions (Fig.3):  Maximum explosion pressure, Pmax  Maximum rate of pressure rise, (dP/dt)max  Time to maximum pressure rise, t1  Time to maximum pressure, tmax  Kst (dust deflagration index)  Lower and Upper Explosion Limits (LEL and UEL) P (bar) Pmax  dP     dt  max

Fig. 1 — Coal dust explosion Source: http://blogs.plos.org/

Fig. 2 — Imperial Sugar after an explosion Source: http://www.csb.gov/

DUST EXPLOSION SPHERE COMPONENTS

Ignition

WHAT DO WE NEED TO KNOW?  Is the material flammable/explosive?  What is the flammable concentration range?  What is the worse case scenario that can occur?  How fast does it occur?  How to predict/model the consequences?  How to prevent/mitigate them?

The dust explosion sphere is a lab-scale apparatus used for explosion severity testing. The apparatus has a hold-up capacity of 20 liters. The sphere creates high turbulence to simulate the worst case scenario. The apparatus consists of the following components:  Explosion chamber  Dispersion chamber  Ignition system  Sensor system  Vacuum system  Data acquisition system

tmax

t (ms)

Fig. 3 Typical pressure graph obtained from the 20L sphere

Kst values categorize different types of dust into one of the four dust explosion classes (according to OSHA’s classification): Dust Explosion Kst Class (bar.m/s) 0

Explosion Strength No explosion

Examples Silica

0 - 200

200 - 300

Strong

Wood & flour

> 300

Very strong

Aluminum & magnesium

Weak

Powdered milk & sugar

list of posters Texas A&M University at Qatar, Chemical Engineering Program: Process Safety Research Group Chemical Reaction Hazards and Runaway Reactions Tasmia Priyanka, Valeria Casson, Luc Véchot LNG Safety Research: Medium Scale Experiments and Simulations Mohamed Chakroun, Tomasz Olewski, Luc Véchot, Sam Mannan Presentation of a new equipment at the Process Safety Laboratory: 20 litre dust explosion sphere Abd-Allah Marmar, Amr Al-Achi, Tomasz Olewski, Luc Véchot Calorimetric techniques for Chemical reaction Hazards assessments Rizan Baig, Valeria Casson, Luc Véchot Modeling of LNG Pool Boiling on Concrete Surface Syed Quraishy, Tomasz Olewski, Luc Véchot, Sam Mannan Effect of Convection and Evaporation on Spilled Liquefied Natural Gas Waqas Nawaz, Luc Vechot, Tomasz Olewski, Sam Mannan LNG Safety - Advancing the Science and Technology Huge thanks to these people.

Organizing Committee

Graduate and Undergraduate Students from the Process Safety Engineering Course 1984 San Juanico Explosions: Story of one of the deadliest industrial disasters in history Alisha Basha, Waqas Nawas 1988: Piper Alpha Oil Rig Ablaze Syed Quraishy, Tasmia Priyanka Start Up? Think Thrice! –BP Texas City Refinery Explosion case study Shaik Afzal, Mostafa Shanin Pressure Relief System Design for a Multi-Purpose Vessel Using Adiabatic Calorimetry Rym Kanes, Rinchu Mathew, Abd-Allah Marmar Morning Cup of Explosion: Investigation of Dust Explosions Michael McDowell, Huda Hamza, Hamed Imran

Organizing Committee

Dr. Luc Véchot (Chair)

Walied Shater (Co-Chair)

Assistant Professor of Chemical Engineering Head of the Process Safety Research Group

HSE Manager – Qatar Business Unit

Amanda Field

Richard Belleza Dy

Senior Administrative Coordinator

HSE Specialist

Carol Nader

Leena Khuffash

Events Manager

Security Information Coordinator

Nizi Nazar

Khadeja Abuhaliqa

Administrative Assistant

HSE and Security Coordinator

Dr. Valeria Casson

Sandra Harthoorn

Postdoctoral Research Associate

Communications & Public Affairs Specialist

Dr. Tomasz Olewski Associate Research Scientist

Brady Creel Communications Manager