POTENTIALLY EXPLOSIVE ATMOSPHERES IN THE ANAEROBIC DIGESTION SECTOR

Transcription

1 7 May 2015 POTENTIALLY EXPLOSIVE ATMOSPHERES IN THE ANAEROBIC DIGESTION SECTOR IAN BARKER, FIET, C.ENG

2 AGENDA Introduction to B&V What is ATEX and DSEAR What are the Employers Duties What standards exist Managing Competency Examples of Issues Seen Conclusions 2

3 INTRODUCTION TO B&V 3

4 GLOBAL OPERATIONS 2014 Revenue Projects in countries Canada United States Mexico Honduras Ecuador Peru Bolivia Puerto Rico Brazil Russia Ireland Netherlands United Kingdom Poland Ukraine Kazakhstan Romania Mongolia Bulgaria Armenia Turkey Japan Iraq Pakistan China Egypt Saudi Nepal Arabia UAE India Taiwan Oman Thailand Vietnam Philippines Ghana Singapore Malaysia Mozambique Indonesia offices worldwide Paraguay Chile Argentina South Africa Employee owned: Australia Gray identifies countries where we have completed projects Employees

5 WE RE BUILDING A WORLD OF DIFFERENCE. TOGETHER. Founded in 1915 Global workforce of more than 10,000 Employee-owned corporation $3.0 billion in annual revenues in 2014 More than 110 offices worldwide Completed projects in more than 100 countries Black & Veatch conducts 7,000+ active projects globally at any one time 5

6 SOLVING THE WORLD S COMPLEX CHALLENGES IN EACH OF OUR MARKETS Energy Water Telecommunications Thailand United Kingdom California, USA Security Management Consulting Environmental Ukraine Kent, UK California, USA Using teamwork and collaboration we provide sustainable and reliable solutions 6

7 WHAT IS ATEX AND DSEAR? 7

8 B&V 7 May 2015 WHAT CAN GO WRONG GLASGOW A GAS EXPLOSION! 8

9 Black & Veatch 7 May 2015 WHAT IS ATEX Derived from the French title of the original directive 94/9/EC - Appareils destinés à être utilisés en ATmosphères EXplosives. ATEX 94/9/EC covers the Equipment and protective systems ATEX 99/92/EC covers the Minimum requirements for safety and health protection of workers. Also referred to as ATEX 137 NOTE ATEX 94/9/EC is being replaced by 2014/34/EU from 20th April

10 UK LEGISLATION Equipment FIRE & EXPLOSION B&V People 7 May 2015 ATEX 94/9/EC ATEX 1999/92/EC CAD 98/24/EC EPS 2001 DSEAR 2002 COSHH EXPLOSIVE ATMOSPHERES OTHER ENERGETIC EVENTS, FIRE AND EXPLOSION TOXICITY The Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres (Amended) Regulations 2001 (SI 2001 No. 3766) Dangerous Substances and Explosive Atmospheres Regulations Chemical Agents Directive (98/24/EC) 10

11 Black & Veatch 7 May 2015 DSEAR - DANGEROUS SUBSTANCES AND EXPLOSIVE ATMOSPHERES REGULATIONS 2002 Often referred to as the ATEX Workplace Regulations. UK implementation of ATEX 99/92/EC. Identifies the duties of the employer in respect of his workers. Covers workplaces where a dangerous substance is or is liable to be present at the workplace Methane Ammonia 11

12 Black & Veatch 7 May 2015 DSEAR Reg 4 Employers Duties Reg 5 Risk Assessment Reg 6 Control of Risk / Mitigation Reg 7 Requirements for places with Explosive Atmospheres Reg 8 Accidents Reg 9 Training Reg 11 Co-Ordination 12

13 WHAT ARE THE EMPLOYERS DUTIES? 13

14 Black & Veatch 7 May 2015 RISK ASSESSMENT - DOCUMENTED List hazardous substances and zones List work processes and quantities List what measures have been taken to reduce the risk Sufficient information required to show that the workplace and work processes are safe Workplace verification To be reviewed on a regular basis and after any significant changes 14

15 WHAT STANDARDS EXIST FOR THE UK? 15

16 Black & Veatch 7 May 2015 BS EN series Main Series of Explosive Atmospheres Standards Zone Classification a very conservative approach. Electrical Equipment for use in Potentially Explosive Atmospheres Electrical Installation / Inspection BS EN series Non-Electrical Equipment for use in Potentially Explosive Atmospheres IGEM SR/25 Institution of Gas Engineers & Managers Based on Health & Safety Laboratory Report 630 Area classification for secondary releases from low pressure natural gas systems Provides Zone Classification for Gas Installations 16

17 B&V 7 May 2015 AREA CLASSIFICATION Zone 0 A flammable atmosphere is CONTINUOUSLY present, or present for LONG PERIODS Zone 1 A flammable atmosphere is LIKELY to occur during normal operation Zone 2 A flammable atmosphere is NOT LIKELY to occur during normal operation but if it does its duration will be for a short time only. (Typically 6 times per year for less than 1 hour) Zones 20, 21 & 22 are the equivalents for DUST environments 17

18 B&V 7 May 2015 AREA CLASSIFICATION 18

19 MANAGING COMPETENCY? 19

20 Black & Veatch 7 May 2015 COMPETENCY CompEx Global Competency Scheme (21 UK Centres) IECEx IECEx Certification of Personnel Competence Scheme Both cover design, installation and testing of electrical and non-electrical equipment. A simple way for employers and constructors to demonstrate competency. 20

21 EXAMPLES 21

22 Black & Veatch 7 May 2015 SOME RELEVANT PROJECTS IN UK Davyhulme STW Anaerobic Digesters 12MWe Electrical Output plus all heat for the process Mogden STW Anaerobic Digesters 2 nd largest STW in the UK Serves 2.1 million people Reading STW Anaerobic Digesters 4 MWe Electrical Output First STW Commissioned under DSEAR Commissioning started 1 st July 2003 Colchester & Pyewipe AD Plants Each plant generates 2.4MWe plus all heat for the process 22

23 Davyhulme AD Contract Value: 75M Black & Veatch 18 May 2015 EPC for 91,000 tonnes of DS per year. A CHP facility consisting of five 2.4 MWe biogas fired gas engines with steam heat recovery and boilers generating in total 26 tonne/h of steam. 4no. Thermal Hydrolysis Streams; Imported cake facility; Sludge thickening & Dewatering; Modifications to existing AD tanks; Biogas holders and biogas clean-up plant; Steam plant; CHP plant (12MWe); Digested sludge storage; HV electrical infrastructure modifications. Control and Automation 12 months operation & optimisation Awards Received: International IChemE award for Innovation & Excellence in Energy; British Construction Industry (BCI) Award - Major Civil Engineering Project

24 AUDIT ISSUES 24

25 Black & Veatch 7 May 2015 TYPICAL AUDIT ISSUES No Hazardous Area Assessment No proof that the work space is safe No ATEX Certificates for equipment in the hazardous area No Hazardous Area Electrical Inspection Report No DSEAR Validation Audit Poor quality installation. Lack of Verification of overall explosion safety. Unsafe working practices. No control on working practices in zoned areas 25

26 Black & Veatch 7 May 2015 SITE ISSUES Equipment Labels Site Labels Inaccurate / Incorrect Zoning Assessments. Inadequate Zoning Drawings. Equipment not ATEX certified for Potentially Explosive Atmospheres. Hazardous Zones not labelled. Hazardous Zones not being managed. Earthing and Bonding not carried out. 26

27 ZONING ERRORS Black & Veatch 7 May 2015 Digester Over-Pressure Relief Valves Rated for 750m3/hr through 2 x 250mm dia. Pipe Resultant gas velocity is 10 m/sec up the pipe and hits a flat plate! Assessment called for a 3 metre zone 2 When IGEM SR/25 is used this becomes a 35m radius zone because of the impeded exit (flat plate across the outlet). A large part of site became zoned! 27

28 Black & Veatch 7 May 2015 IGEM SR/25 OUTLET ZONES Impeded Vent Ideal Vent 28

29 B&V 7 May 2015 SITE MANAGEMENT 29

30 B&V 7 May 2015 GOOD AND POOR DESIGN 30

31 B&V 7 May 2015 GOOD VS POOR EARTHING / BONDING 31

32 CONCLUSION 32

33 Black & Veatch 7 May 2015 WHAT SHOULD EVERY SITE HAVE? RISK ASSESSMENT RECORD Valid Hazardous Area Assessment Associated Hazardous Area Drawings Copies of all ATEX Certificates for equipment in the hazardous area DSEAR Validation Audit Regular Hazardous Area Electrical Inspection Report Work processes / procedures to manage the risks Competency checks for staff Regular reviews of documentation Regular site safety reviews 33

34 Thank you Ian Barker Black & Veatch Ltd. +44 (0) Please come and visit on Stand K11 (opposite wave/tidal seminar theatre) 34