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Over the past few months I have sporadically been presenting a DSEAR (Dangerous Substances and Explosive Atmospheres) training course to front line operators at an English Water Company (no, not that one, or even that one…). One of the topics covered is Zoning – the demarcation of areas of sites where the likelihood of an explosive atmosphere being present is elevated. Process Safety is another, where one of the distinctions made with Occupational Safety (e.g. slips, trips and falls) is that, generally, Process Safety hazards are not readily detectable by our senses.

You should be able to see a step in front of you and hear a fork lift truck in your vicinity, but it is much more difficult to sense a Process safety hazard before any loss of containment (release of toxic or flammable fluids). Once this happens, your sense may be rapidly alerted – loud bang, almighty flash, over powering smell or taste – before you (and those around you) succumb soon thereafter.

One approach to this challenge is to promote constant vigilance for personnel in facilities where there are Process Hazards – Chronic Unease. The idea may be attractive to its proponents, but in practice probably reduces safety by significantly raising personnel base levels of stress levels resulting in chronic health issues and/or operational transgressions.

The Water Company has adopted a different approach. I would say it is more realistic, humane and effective. It has started to provide what one could call ‘sense’ aids. Examples include generating clear signage such as in the image above depicting areas of heightened explosive risk. These can help to engender appropriate levels of temporary unease (flipping our mental state from auto pilot to manual), prompting conscious thought and precaution. Another is portable dangerous substance monitors (indicating the proximity of threshold concentrations and translating this into a sound). A third is a directive to ‘take a break to reflect’ if personnel sense (6^th sense?) that something isn’t right.

Our senses are our best defence for protecting ourselves in the realm of Occupational Safety.

Wouldn’t it be great if we could harness them protect us (and our colleagues) from Process Hazards as well.

Article by Angus Keddie 

Process Safety Matters 

www.processsafetymatters.com

AG Consultancy, the SAP solutions specialists, has launched the first tool of its kind designed to overcome challenges posed by the implementation of global health and safety standards and Ex/ATEX inspections in the oil and gas industry and wider energy sector. 

The Aberdeen based business – which also has an office in London - has now unveiled the programme to companies, with North Sea operator Spirit Energy becoming the first to adopt the solution. At the 2024 SAP Customer Success Awards, Spirit won the Sustainability Hero category for use of the solution. 

‘Smart Ex’ allows businesses to undertake Ex/ATEX inspections internally within SAP without the need for third party products which can lead to difficulties and inefficiencies in managing multiple IT solutions lacking a ‘single source of truth’. The fully integrated solution is an end-to-end tool which encompasses planning, execution and analysis and covers the full life cycle of Ex/ATEX inspections.  

Deepal Ratnayaka, director SAP consultancy services at AG Consultancy, said: “For the oil and gas sector – and wider energy industry – the problems posed by the use of multiple platforms when undertaking Ex/ATEX Inspections are significant and the challenges for companies can be demanding. 

“’Smart Ex’ allows businesses access to mobile, real-time updates on a single system for more up to date insights for informed decision making by bringing together work management and inspection management needs, negating the need for two separate IT solutions.” 

The software – which is designed to be regularly updated with the latest technology including Artificial Intelligence and machine learning – manages various types of inspections including integrity inspections, compliance checks, tool calibrations and maintenance checklists. 

It complies with safety standards IEC60079, NEC500/505 and ATEX and a digital auditing trail allows for full traceability of inspections.  

Benefits include the reduction of manual, duplicate efforts in system updates, time savings technicians, better insights to operation, a ‘single source of truth’ and the demonstration of better compliance via audit trails and analytics. 

Ratnayaka added: “As Ex/ATEX Inspections are an important business process, critical to the safety of staff and ongoing operations, we believe this tool can be revolutionary for organisations that are currently grappling with how best to address the challenge with multiple IT systems.   

“As a trusted SAP Gold Partner, AG not only excels in consultancy but also innovates by developing products that enhance SAP solutions. Our extensive industry knowledge in oil and gas and energy, combined with our SAP proficiency, allows us to tailor SAP solutions to specific business needs. The successful implementation of ‘Smart Ex’ for Ex/ATEX Inspections at Spirit Energy is a prime example of our expertise.” 

AG Consultancy was set up in 2014 by co-founders Francis Rajan and Nick Champion to close a gap in the market by providing value orientated, high quality multi-specialist SAP consulting and support services combining deep expertise of the software with rich industry knowledge.  

AG Consultancy & Apps Ltd

What is the meaning of a Red Lens Ex-Tech Beacon?

A red Ex-tech beacon light is usually associated with an emergency. This is also the case with red beacon lights on most, if not all signalling devices Atex or not. Red in the history of humanity has stood for Stop/Danger. In AVS signalling, red is no different and signals emergency, a dangerous or hazardous condition and A situation which requires immediate action. Signal lights with a red Ex-Tech beacon light are suitable for signalling system failures, values that lie outside their safe limits (e.g. temperature or pressure) or if there is danger.

Absolutely, a red Ex-tech beacon light is a critical situation that would require swift action in any application and is Hazard-implying. The highest warning level is indicated by a red beacon light. When it lights up, it stands for the highest level of urgency and not to be used in general IEC 600073 guidelines 'for a general warning'.

For example, in a manufacturing facility where Pressure or Temperature has increased beyond the safe range and immediate shutdown is required due to the action of the protective devices (equipment failure).

Exceptions to this rule are two-colour or multi-colour signal systems with only one red and one green warning light.

What is the meaning of a Yellow Lens Ex-Tech Beacon?

These colours, renowned for their intense brightness, are employed to draw attention to specific situations. Yellow and amber Ex-Tech beacon lights signal an impending critical state that necessitates human monitoring or intervention. Devices featuring such lights are adept at indicating overloads or surpassing standard values, provided the duration remains within permissible limits. Required actions aim to forestall abnormal conditions and avert ensuing consequences. Yellow or amber Ex-Tech beacon lights are apt for cautioning against moderate dangers, serving as precautions and warnings. For example, in a manufacturing facility where Pressure or temperature has extended above the normal operating range however has not quite reached the unsafe range, but action within a line is imminently or currently taking place to return the operation of the facility to a safe range of conditions.

An amber Ex-tech beacon light is critical in any plant operation to ensure the safety of personnel. Where toxic and/or combustible gases, dust or liquids may be released generally through a form of a vent into the atmosphere (released by a pressure relief device such as a safety or Pressure relief valve).

What is the meaning of a Green Lens Ex-Tech Beacon?

The green colour simply denotes a safe normal state of operation or environment, requiring no immediate action. It's essential really to recognize green as just that- a safety colour, as opposed to a warning colour. Safety guidelines, which already indicate potential hazards, are more appropriately conveyed through blue signals.

Commonly, machines equipped with green Ex-Tech beacon lights signal readiness for operation or seamless functioning without any glitches. For example, a green Ex-Tech beacon light in a manufacturing facility could signify pressure or temperature in a normal range and no further action is required other than seamless operation of the facility. Many plants use a green Ex-tech signalling beacon to inform other personnel simply that the plant is in operation and not the earlier information regarding what the conditions of the plant are. However, the latter is assumed otherwise operation would be put to a hold to ensure safe operation of the equipment and ultimate safety of all personnel within the facility.

What is the meaning of a Blue Lens Ex-Tech Beacon?

What does a blue Ex-Tech beacon light signify? Most linked with emergency services, these lights should refrain from usage on the road or in areas of public access. Of course, different nations operate their emergency services with different colours. However, in the UK and Europe certainly, blue is connoted to be the colour of emergency services. Many plants or manufacturers of signalling would suggest that Blue is a common alternative to red signalling. However, the true utility of the Blue Ex-Tech beacons signifies any condition necessitating a specific action by the operator, distinct from the states represented by red, yellow, orange, and green colours. Blue can be assigned various meanings beyond these.

This is best explained using an example to distinguish the true difference. For example, emergency evacuation on board a ship, a blue light could signal to an operator to abandon the ship. In manufacturing settings, a blue LED beacon often signifies a distinction, such as prompting a conditioned response to shut down safety-critical processes like switch off the line and evacuate the premises.

What is the meaning of a Clear/White Lens Ex-Tech Beacon?

An Opaque/Clear/White Ex-Tech beacon really carries ambiguity. It is best explained by what it should not be used for. Many of our new clients replace their clear domes on their push buttons with stop or off functions. While clear Ex-Tech beacon lights have high light transmission without consuming light, they are unequivocally unsuitable for drawing attention to warn of danger despite their brightness. As discussed, there are standards which must be met, and each colour has its own tailored usages.

A more appropriate selection of colour, a client would therefore have to choose specific to the application with the information provided with this article. In a nutshell, a clear beacon light carries no distinct significance. It is employed when there's uncertainty regarding the use of red, yellow, green, or blue lights. Whether employee supervision or intervention is needed for the illumination of the clear dome must be evaluated case by case.

What is the meaning of a Purple Lens Ex-Tech Beacon?

At Ex-Tech, we are committed to delivering our customers the highest quality level of customer service. Purple plays a prolific role for our Oil and Gas Clients, especially in the UAE and USA as an alternative to red. When an Ex-Tech beacon light in the purple signal colour illuminates, individuals should promptly evacuate the area or trained personnel should take immediate necessary actions.

A more appropriate selection of colour, a client would therefore have to choose specific to the application with the information provided with this article. In a nutshell, a clear beacon light carries no distinct significance. It is employed when there's uncertainty regarding the use of red, yellow, green, or blue lights. Whether employee supervision or intervention is needed for the illumination of the clear dome must be evaluated case by case.

At Ex-tech Signalling, we are experts in manufacturing a wide range of AVS solutions for Harsh and Hazardous areas, and offer a wide range of products and solutions. Please contact us today for further information.

Phone: +44 (0)1752 333 933

E-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

Website

When Britain’s largest working siege machine returned to Warwick Castle recently to form the centrepiece of a new and daring action-packed show - The Legend of the Trebuchet - the castle needed a way to provide the correct tensioning for this monster of ancient and medieval warfare. Hearing the call to arms, Hoist & Winch duly supplied a class-leading Hadef electric winch offering 1500 Kg pulling force (safe working load) with supporting frame and foundations.

The trebuchet at Warwick Castle is an authentic recreation of one of the biggest and most deadly military machines of all time. Utilising a long rotating arm and the principles of leverage to launch projectiles from a sling, a trebuchet is essentially a huge catapult. It was powerful enough to hurl huge rocks that could breach castle walls. Sometimes it would even launch manure and dead animals into besieged castles to spread disease. It remained a common warfare weapon until the 15th century, when gunpowder and cannons came to the fore.

To showcase the power of the mighty trebuchet and bring a highly entertaining and educational spectacle to the banks of the River Avon next to Warwick Castle, a new show - The Legend of the Trebuchet - opened on 23 March. In the lead-up, Warwick Castle required the services of a high-performance electric winch to ensure reliable and repeatable tensioning of the trebuchet prior to launching its projectiles. The choice was a Hadef electric-powered wire-rope winch, delivered and installed by Hoist & Winch Ltd as part of a turnkey project.

                                                                                                                                                            Continued ……

After an initial site survey to discuss the requirements of this highly unusual application and specify the winch design features, Hoist & Winch returned to oversee a test fire of the trebuchet and measure its pulling force with a load cell and site tractor. Once complete, Hoist & Winch was in position to make a formal offer, comprising fully specified winch, mounting frame and foundation base.

At the centre of the solution is a Hadef 400 V, three-phase, 50 Hz electric winch that delivers 1500 kg pulling force from its 25 m rope length. Control is via a low-voltage radio remote with back-up plug-in pendant. Features of note include: a pressure roller for the wire rope drum; four-position top/bottom geared limit switches; a galvanised steel mounting frame for the winch; and electrical enclosures with IP66 protection rating.

Following order receipt and drawing approval, Hoist & Winch commenced on-site installation and commissioning, a process that included individual hydraulic pull tests of the resin anchor bolts for the winch frame. Test firing of the trebuchet also took place with measurement of the pulling force using a load cell for the LOLER (Lifting Operations and Lifting Equipment Regulations) certificate. Hoist & Winch also took care of customer handover training and issue of the LOLER Thorough Examination report.

Anyone interested in seeing the trebuchet in action can buy a ticket for The Legend of the Trebuchet, which runs until 4 November 2024. Built to a centuries-old design (with a little help from the latest electric winch technology), this incredible weapon takes centre stage in a show that combines thrilling live action and special effects throughout.

Visit www.hoistandwinch.co.uk for further information and to view recent case studies.

Hoist and Winch Ltd

Unit 20, 11B Arrow Business Park, Alcester Employment Park, Arden Road, Alcester, B49 6HN

Tel:  08450 171126                  

e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

web: www.hoistandwinch.co.uk

Hydrogen Safe, the hydrogen safety training specialist that acts as a conduit between industry and education, has announced the appointment of Amer Gaffar as Strategic Advisor as the company continues to expand.

As Director of Manchester Fuel Cell Innovation Centre at Manchester Metropolitan University, Amer will bring with him a wealth of expertise and industry leading knowledge to the business.

As an authority on hydrogen fuel cells, he will be responsible for writing strategy papers, thought leadership articles, and providing insight to be used in developing new partnerships and programmes, while also delivering lectures and CPD sessions for the company.

Amer comments: “Hydrogen Safe is a progressive business with big ambitions and that really appealed to me. I’ve worked in the green energy sector for over two decades now, so it made sense for me to extend my remit and use the knowledge and insight I have developed in this new role.

“There is certainly a lot going on at the company and I’m very pleased to have joined at such an exciting time. I look forward to meeting with education providers and businesses that want to put the infrastructure in place to work confidently and safely with hydrogen as we transition to more sustainable ways of working.”

CEO and Founder of Hydrogen Safe, Andy Lord, comments: “Amer is a wonderful addition to our team. His appointment reinforces our commitment to attracting industry leading expertise to the company. We know that we can continue to expand the business and become the trusted partner that our clients need us to be.

“We are very much looking forward to shaping our proposition as we set our sights on becoming the UK’s leading training provider in hydrogen safety.”

Members of Hydrogen UK; the Hydrogen Energy Association; the Hydrogen Skills Alliance; and NPTC Group of Colleges, Net Zero Skills Advisory Board, as well as being a corporate partner of the Greater Manchester Mayors Charity, Hydrogen Safe works with businesses, education providers and individuals to deliver courses that meet with their specific objectives and sustainability goals.

For more information, please visit: www.hydrogensafe.org and for regular updates follow: @Hydrogen Safe on LinkedIn.

Brixworth Engineering, manufacturer of the globally renowned Benco engine stands, has produced its largest-ever side-mounting turnover stand. Supplied to the Croydon facility of leading power transmission specialist Voith Turbo, the Benco 1050 (an upgrade to Brixworth’s standard Benco 1000 engine stand) is helping this progressive plant to inspect and service a variety of engines and transmissions.

With a load capacity of 5000 kg (at 500 mm from the mounting spindle) and a turning capacity of 10,000 Nm, the Benco 1050 supplied to Voith Turbo facilitates the manipulation of complete engines for inspection, repair or modification. Moreover, it is a mobile version featuring a motor drive to deliver rotational speed up to 4 rpm, although customers can opt for floor mounting and manual operation if preferable.

Control of the Benco 1050 at Voith Turbo is via a fixed pushbutton station, with pendant control available as an option. As a further point of note, Brixworth designed and manufactured additional mounting arms to minimise deflection throughout the loading and rotation process.

Rugged, cost-effective Benco engine stands are ideal for undertaking a whole host of new-build, repair and refurbishment operations quickly and easily. With these popular engine stands, users can rotate or horizontally and vertically manipulate engines with ease to minimise the dangers of personal injuries associated with the manual handling of heavy loads. An adjustable column facilitates working at a convenient height while maintaining access to all aspects of the operation.

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Although a comprehensive range of standard models is available, Brixworth has considerable experience in the design and manufacture of bespoke engine stands to suit individual customer requirements. The company can undertake site surveys and provide engineers to evaluate any special demands, ensuring the supply of a safe, effective and cost-competitive solution.

Developed over many years, Benco engine stands today enjoy a worldwide reputation for simplicity and reliability in the rotational handling of heavy, out-of-balance loads with the added benefit of near backlash-free movement. The stands, more than 5000 of which have been produced for use in over 20 countries, can reduce man hours by up to 50% through the elimination of non-productive handling procedures. They fully comply with all current working practices and safety regulations, and come with an extensive guarantee for complete peace-of-mind.

Further information is available on request to:

The Brixworth Engineering Co Ltd, Creaton Road, Brixworth, Northampton  NN6 9BW

Telephone: 01604 880338

e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.                  www.benco.co.uk

Numerous perks come with investing in the ruggedly tested, smartly connected ALTAIR io™ 4 Connected Gas Detector. One small feature, with big implications for how you and your team use the device, is the MSA id Tag. Every ALTAIR io 4 device comes with the MSA id digital device assignment feature, and it can help save you and your team time and effort. The key benefits to using the MSA id Tag are the fast and easy digital assigning of an ALTAIR io 4 device to a specific worker and seamless data monitoring of the device via MSA Grid cloud-based software while the worker is using it.

The flexible explosionproof heating device, type FHD, allows the uniform heating of surfaces in machinery and apparatus engineering, tank construction and the heating of enclosures for controls and analysing equipment for maintaining the function of built-in equipment at low ambient temperatures. The degree of protection of the flexible heaters is IP66.

Technical data

The flexible heaters consist of a self-adhesive silicone laminate with a built-in heating element. The clearance between the terminal box and the surface to be heated is such that the maximum surface temperature of the terminal box does not exceed 80 °C. Bolts for fixing the terminal box are welded on to the surface to be heated, so that it can be screwed firmly in position.

The contact protection of the heated surface is ensured by an 8 mm thick silicone foam that extends over the complete surface of the heater.

Stabilised version

If designed for low heating capacities, a stabilised version without temperature monitoring is possible. The parameters specified during routine testing must not be changed by the user.

Temperature-controlled version

Pt-100 resistance sensors or explosionproof capillary tube thermostats are used for the regulation and monitoring of surface temperatures with higher heating capacities. The Pt-100 resistance sensors can be fitted directly into the silicone laminate and fulfil the requirements for simple apparatus. The evaluation is carried out via the associated apparatus in the type of protection Intrinsic Safety. Electronic safety temperature limiters according to EN 14597 or SIL 3 are used for limiting the surface temperature.

www.thuba.com

Hart’s map of its international airports’ contracts has been upgraded to include its most recent one at Aruba, the island nation in the southern Caribbean Sea just north of the coast of Venezuela. 

“It is an impressive display of our global reach,” says Doug Hart, chairman and founder of Hart Door Systems. “And it underlines the value of our broad range of industrial doors enabling us to deliver solutions through our Speedor range of highspeed doors and our specialist shutters which includes our Conveyor door which is designed to integrate with third-party baggage handling systems.”

Mr Hart adds: “I think it is a fair comment to say that 24 hours a day somewhere in the World there is a Hart door in operation at an international airport. As the map shows we range from the Falklands in the south, to Vladivostok in the east, Bergen to the north, Aruba in the west and a lot between.

“This is a tremendous accolade for the entire team at Hart. Our product specialism for airports is second to none and comes from our policy to drive airport door systems development and product testing that ensures the systems produced by Hart are reliable and work as specified.

“Airport doors play a huge role in the safety and security within airports, and specialist door systems play an integral part in controlling key areas. Our doors aid the management of security and fire risks by securing zones from the public or intruders and by providing a physical barrier from attack or reducing fire spread.

“The Hart Speedor Conveyor door is designed to integrate with third-party baggage handling systems. It is supplied as a built unit with easy ‘plug and play’ installation. Hart has the airport experience to deliver the required solutions in exceptionally busy environments.

“For automated security and fire separation, individually or collectively, Hart developed operating systems to be able to consider integration of doors into the building security and management systems along with standards compliance.

“For high wind resistance Typhoon roller shutters resist wind up to 3000 pascals and high security to BRE standards SR4 Terror Screen is your answer.

“Using these systems allows zones to be secured from intruders, delivering attack, threat and fire/smoke-spread prevention as well as safety for the public. We are even contributing to an airport’s environmental strategy through the doors’ energy saving qualities.

“All in all our considerable investment in product development that conform with relevant standards across the Globe has been very worthwhile not just for us but for our many clients.”

www.hartdoors.com

Hydraulic industrial tools specialist, Enerpac, has announced a lifting system for safer excavator maintenance. Based on Enerpac SCJ-Series Cube Jacks, it enables lifting and holding of the entire cab, boom and arm, allowing the undercarriage to be safely removed.

During maintenance of the excavator’s swing drive and bearings, the undercarriage unit must be separated from the upper body cab and arm to give access to the swing motor and multiple sets of planetary gears. Until now this would have involved at least two service engineers jacking up the body and holding it on stands, a time consuming and hazardous practice. 

The Enerpac cube jack lifting system offers a safer, CE-certified, approach to removing the undercarriage. It comprises two pairs of cube jacks providing coordinated hydraulic lifting of loads up to 25T per jack to a height of 2m. Two cube jacks are positioned under a lifting beam at the rear of the excavator, while two cube jacks are located under the arm’s bucket lugs. Each pair of cube jacks is connected to a hydraulic pump to synchronously lift and lower the excavator body and arm.

“The excavator lifting system has been developed in collaboration with a leading excavator maintenance company looking for a safer CE-certified approach to removing the undercarriage. It automatically self-locks so that engineers can work safely under the raised cab without the need for secondary jack stands,” said an Enerpac spokesperson. ‘It has been well received especially for its safety, secure load holding, precision lifting and lowering and quick and easy set-up which make it attractive to users and customers alike.”

Enerpac Cube Jack
Enerpac cube jack technology is well proven in many industrial lifting applications. The SC-Series Cube Jacks use a base lifting frame and self-aligning, lightweight steel cribbing blocks to provide high-capacity and stabilised lifting–offering a safer, controlled and more efficient alternative to climbing jacks with wooden cribbing. 

Lloyds witness tested to 125% of maximum working load, the incremental cube jack lifting system is self-locking to support the load as each cribbing block is manually added or removed, instead of being held by hydraulic pressure. Once the mechanical lock engages, the lift cylinder retracts, and another cribbing block can be added or removed. 

To learn more about the Enerpac Self-Locking Cube Jack and find a local Enerpac distributor, visit www.enerpac.com.