Technical Safety Management for INDUSTRIAL NATURAL GAS APPLICATIONS.

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Oliver Holmes
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1 Technical Safety Management for INDUSTRIAL NATURAL GAS APPLICATIONS

2 01 // TECHNICAL SAFETY MANAGEMENT TSM TSM // THE 3 PHASE PRINCIPLE Free your company from the reproach of organiza onal faults by introducing a Technical Safety Management (TMS).

The plants for the distribu on of natural gas of public supply operated by you up to the last isola on valve before the gas appliance are energy plants.

The operator is always responsible for the technical safety of these plants.

ves on products implemented by means of the German Equipment and Product Safety Act (German Product Safety Act (Produktsicherheitsgesetz, ProdSG) and the German Ordinance on Industrial Safety and

2 2 01 // TECHNICAL SAFETY MANAGEMENT TSM TSM // THE 3 PHASE PRINCIPLE Free your company from the reproach of organiza onal faults by introducing a Technical Safety Management (TMS). The procedure developed by gasexperten in order to fulfill the legal and norma ve requirements is easily and prac cally realizable. The plants for the distribu on of natural gas of public supply operated by you up to the last isola on valve before the gas appliance are energy plants. With respect to the technical requirements regarding energy plants, the na onal or country-specific standards have to be par cularly observed. The operator is always responsible for the technical safety of these plants. With respect to the safety requirements regarding supply facili es (fuel handling systems) and directly related plant components (thermal processing plants), the requirements of the relevant direc ves on products implemented by means of the German Equipment and Product Safety Act (German Product Safety Act (Produktsicherheitsgesetz, ProdSG) and the German Ordinance on Industrial Safety and Health (Betriebssicherheitsverordnung, BetrSichV) have to be observed. This may be regulated differently in the individual countries. The main task of a Technical Safety Management is to support the company s autonomous ac ons and at the same me to strengthen the competency of the technical self-administra on. Requirements regarding qualifica on and organiza on of the technical areas are formulated in such a way that they perfectly correspond to the necessary needs of the operators. The close connec on between gasexperten and standards commi ees ensures that you are always up-to-date with respect to the latest technology and the related legal and norma ve requirements. gasexperten develops customer-specific solu ons regarding regula ons on equipment or measures regarding industrial safety in order to ensure and fulfill the German Ordinance on Industrial Safety and Health. On the basis of these European rules, experts will also support German companies outside Europe. In this respect, gasexperten will be glad to support you and provide you with our technical and expert know-how. USE THE 3 PHASE PRINCIPLE AND GET YOUR TSM PLAQUE: PHASE I Technical Safety Management Safety Assessment PHASE 1: Safety Assessment PHASE 2: Qualifica on PHASE 3: Process Integra on PHASE III Process Integra on Quali ca on PHASE II

3 02 // PHASE I SAFETY ASSESSMENT PHASE I Technical Safety Management Safety Assessment SAFETY ASSESSMENT // QUICK CHECK PHASE III Process Integra on g ua Quali ca on PHASE II You ask yourself What

Have our employees of maintenance been trained sufficiently in order to safely deal with gaseous media?

ve assessment with respect to his plants and his organiza on.

on plants. Individual fields According to specifica ons, valves and assemblies will be divided into risk groups and evaluated. Assessment Please find a detailed statement in the risk assessment.

3 3 02 // PHASE I SAFETY ASSESSMENT PHASE I Technical Safety Management Safety Assessment SAFETY ASSESSMENT // QUICK CHECK PHASE III Process Integra on g ua Quali ca on PHASE II You ask yourself What is the current status of our gas infrastructure with respect to safety technology? Is there any risk at the moment? Have our employees of maintenance been trained sufficiently in order to safely deal with gaseous media? The quick check carried out by qualified and competent persons offers each operator of an opera onal gas pipeline network and of plants heated with natural gas the possibility to receive a cost-effec ve assessment with respect to his plants and his organiza on. German version: German version: German version: Overview As a result you will receive an overview in the form of a graphical representa- on regarding the situa on of your organiza on, of the produc on plants. Individual fields According to specifica ons, valves and assemblies will be divided into risk groups and evaluated. Assessment Please find a detailed statement in the risk assessment. For gasexperten, the task is not completed therea er, rather recommends possible solu ons and further measures in order to remove defects priori zed and sustainably. A safe and trouble-free opera on is the basis of a high supply security of the plant. Gas pipelines have to be in proper condi on and have to be controlled on a regular basis. Thermal processing plants have to comply with a minimum standard with respect to the safety equipment. The result of the assessment may be included in the obliga ons according to the German Occupa onal Safety and Health Act and German Ordinance on Industrial Safety and Health as working basis and safety assessment. Excerpt from the German Occupa onal Safety and Health Act (Arbeitsschutzgesetz, ArbSchG) Sec on 3 Basic Obliga ons of the Employer (1) The employer is obligated to take the necessary measures for employment protec on under considera on of the circumstances which influence the safety and health of the employees at the workplace. He has to examine the measures with respect to their effec veness and, if necessary, to adjust them to changing circumstances. In this respect, he has to strive for an improvement of safety and health protec on of the employees. TECHNICAL SAFETY MANAGEMENT

4 03 // PHASE II QUALIFICATION PHASE I Technical Safety Management Safety Assessment QUALIFICATION // QUALIFICATION OF EMPLOYEES AND PLANTS PHASE III Process Integra on Quali ca on PHASE II During

4 4 03 // PHASE II QUALIFICATION PHASE I Technical Safety Management Safety Assessment QUALIFICATION // QUALIFICATION OF EMPLOYEES AND PLANTS PHASE III Process Integra on Quali ca on PHASE II During the qualifica on, the results determined in Phase I Quick Check will be divided into two topics: Qualification of employees by means of further training at gasexperten workshops Qualification of plants by means of renovation of the industrial furnace plants / thermal processing plants as well as gas appliances. QUALIFICATION OF EMPLOYEES In the German Occupa onal Safety and Health Act and the German Ordinance on Industrial Safety and Health, the legislator requires regular trainings for the qualifica on of employees. By means of the professional seminars of gasexperten, the company complies with these requirements regarding planning construc on, maintenance and opera on of natural gas and thermal processing plants. The seminars are an element for further training of competent persons and experts who want to qualify as qualified person according to the German Ordinance on Industrial Safety and Health. Thus, the operators of industrial natural gas plants may carry out maintenance work with their own personnel. The seminars are plant-specifically geared towards the company and therefore, they are very prac ce-oriented for the individual employee. With respect to safety technology, machine builders and plant manufacturers thus keep their employees at a high level. The requirements are conveyed by means of a modular training concept. A er having visited all 4 modules, you may appoint the employee as qualified person within the meaning of the German Ordinance on Industrial Safety and Health. A erwards, the field of ac vity involves the complete supervision of the gas pressure control line including the safety system with burner. MODUL 1 // TECHNICAL SERVICE AND MAINTENANCE OF NATURAL GAS AND THERMAL PROCESSING PLANTS ON INDUSTRIAL FACTORY GROUNDS Provision of informa on concerning the structure and organiza on of gas usage of an industrial company according to legal and norma ve requirements. Informa on with respect to prac ce regarding the work on gas pipelines. Informa on with respect to the approach regarding changes on plants in the field of maintenance. Legal bases regarding the operational organization of gas usage on thermal processing plants DVGW (Deutscher Verein des Gas- und Wasserfaches e.v. - Technisch-wissenschaftlicher Verein = German Technical and Scientific Association for Gas and Water) worksheet G 1010 Requirements regarding the qualification and organization of operators of natural gas systems on factory grounds Requirements regarding industrial safety for operators of natural gas systems Technical Safety Management and the involvement in a quality management system BGR (Berufsgenossenschaftliche Regeln = German Occupational Safety Regulations) 500 Work on Gas Pipelines DIN EN Safety requirements regarding fuel handling systems Exercise regarding the dealing with essential changes Example: provision to safeguard the existing standard Par cipants Persons responsible for the technical service and maintenance departments. Employees from customer service, maintenance and opera on who work on gas pipelines, burner systems. Dura on 1 day

5 MODUL 2 // GAS PRESSURE CONTROL By means of the seminar, profound knowledge regarding the devices and components for gas pressure control is imparted.

Functions of the valves: filters, pressure regulators, safety shut-off valves and safety relief valves Examples for the selection and design of devices Theoretical exercise for determining setting

customer service, maintenance and opera- on who work on gas pipelines, burner systems.

in the daily business and with respect to assessments regarding troubleshoo ng in case of faults.

5 5 MODUL 2 // GAS PRESSURE CONTROL By means of the seminar, profound knowledge regarding the devices and components for gas pressure control is imparted. The focus is on the independent carrying out of se ng and maintenance work, the exchange of wear parts as well as the removal and avoidance of faults. Functions of the valves: filters, pressure regulators, safety shut-off valves and safety relief valves Examples for the selection and design of devices Theoretical exercise for determining setting and test values The right spare parts Practical exercises regarding start-up, setting and control of regulators and safety devices, error detection Project planning Par cipants Employees from customer service, maintenance and opera- on who work on gas pipelines, burner systems. Dura on 1 day MODUL 3 // EQUIPMENT TECHNOLOGY The par cipants learn to independently exchange gas components on the thermal processing plant und receive informa on with respect to systems of burners in the daily business and with respect to assessments regarding troubleshoo ng in case of faults. Presentation of the legal situation in case of maintenance and technical service by qualified persons Decision support in case of questions regarding the changes on machines Bases regarding DVGW TRGI (Technische Regel für Gasinstallationen = Technical Rule for Gas Installations) 2008/practical assistances Practical exercises regarding the exchange of gas appliances Par cipants Employees from customer service, maintenance and opera- on who work on gas pipelines, burner systems. Dura on 1 day MODUL 4 // BURNER SYSTEMS The par cipants learn how a burner system is planned. This leads to the assessment of a gas pressure control line on the thermal processing plant. You receive informa on with respect to burner systems and with respect to assessments regarding troubleshoo ng in case of faults. Design of functions of the valves: filters, pressure regulators, safety shut-off valves and safety relief valves Technical framework conditions such as flow, pressure losses Bm3 and Nm3, influences on control Getting to know data of burners and their setting values Workshop: Project planning of a complete gas / air ratio control line with burner and necessary settings Basic knowledge and prac cal ps for the reliable igni on of gas burners Par cipants Employees from planning, customer service, maintenance and opera on who work on or plan gas pipelines, burner systems. Dura on 1 day TECHNICAL SAFETY MANAGEMENT

6 QUALIFICATION OF PLANTS They are responsible for the various industrial furnaces (steel, aluminum, ceramics, a er-burning units etc.

now the queson is who can remove these defects. In this respect it is important to know that there is no so-called general gas approval.

With the TSM partners of our group of companies, we will safely guide you through this labyrinth and set clear interfaces with respect to the award of contracts.

DIN EN 1500 geln Flüssig gas = Technica 1-1 and -2 l Rules Liq EN ER GI EW SC HA FT SG IR TES ET Z Natural ga Gas pressu s re trol and m conea system (net suring operator), work G 493-1 and 491,

Liquid gas TRF 2010 an DIN EN 15 d 001-1 and -2 Natural ga Freely-laid s pipelines: DIN EN 1500-2 and G 61 1-1 and 4-1 and -2 Liquid gas TRF 2012 an 15001-1 an d DIN EN d -2 Natural g Liquid gas

6 6 QUALIFICATION OF PLANTS They are responsible for the various industrial furnaces (steel, aluminum, ceramics, a er-burning units etc.) By means of Phase 1 of the TSM / Security Assessment Quick Check you will receive informa on about exis ng defects on the thermal processing plant or the upstream natural gas pipeline system.now the queson is who can remove these defects. In this respect it is important to know that there is no so-called general gas approval.. Your gas infrastructure is divided into diﬀerent areas of applica on which are regulated by means of a comprehensive labyrinth of norms. With the TSM partners of our group of companies, we will safely guide you through this labyrinth and set clear interfaces with respect to the award of contracts. Natural gas Freely-laid pi pelines: DIN EN an Gas installaɵ d -2 and G 61 on: 4-1 and -2 Device connec G 60 0 Ɵon-pressure reducɵon: G Liquid gas: TR F (Technische Re Gas) 2012 an d DIN EN 1500 geln Flüssig gas = Technica 1-1 and -2 l Rules Liq EN ER GI EW SC HA FT SG IR TES ET Z Natural ga Gas pressu s re trol and m conea system (net suring operator), work G and 491, G -2, G 495 Liquid gas TRF 2012 PR OD UK TS ICH ERHEITS GE SE TZ Natural ga Undergrou s nd pipelin es DIN EN and : -2 Freely-laid pi DIN EN 15 pelines: 00 and G and -2 1 and -2 Liquid gas TRF 2010 an DIN EN 15 d and -2 Natural ga Freely-laid s pipelines: DIN EN and G and 4-1 and -2 Liquid gas TRF 2012 an an d DIN EN d -2 Natural g Liquid gas as and Thermal pr oc DIN EN 74 essing plant 6-2 Aim of this group of companies is to support you as the customer in dealing with your gas infrastructure by means of a fully developed system. You engage gasexperten to find solu ons and our TSM partners will implement the necessary tasks for you in accordance with standards. As a result, your plants will again correspond to the latest state of technology. uid

7 04 // PHASE III PROCESS INTEGRATION PHASE I Technical Safety Management Safety Assessment PROCESS INTEGRATION INTO QM SYSTEMS PHASE III Process Integra on Quali ca on PHASE II gasexperten

Management System (QM-System). EN guidelines, norms and DVGW worksheets which are published as recognized rules of technology form the basis.

Aim Joint implementation of the TSM guideline with additional integration of certifiable standard processes into the company s internal QM-System according to DIN EN ISO.

Preliminary mee ng for the clarifica on of the concrete approach with me schedule Applica on of the TSM check list Provision of cer fiable standard processes for changes on gas facili es Implementa

intranet sites, e-learning for the yearly instruc on etc.

system Risk of organizational faults of the management is minimized Confirmation to comply with the requirements of the German Ordinance on Industrial Safety and Health Cost reduction by integration

7 7 04 // PHASE III PROCESS INTEGRATION PHASE I Technical Safety Management Safety Assessment PROCESS INTEGRATION INTO QM SYSTEMS PHASE III Process Integra on Quali ca on PHASE II gasexperten implements requirements with respect to qualifica on and organiza on of the technical areas of your company according to your specific needs and transfers the result in a cer fiable Quality Management System (QM-System). EN guidelines, norms and DVGW worksheets which are published as recognized rules of technology form the basis. For this purpose, we use our special TSM approach which has proven its worth in many customer projects. Aim Joint implementation of the TSM guideline with additional integration of certifiable standard processes into the company s internal QM-System according to DIN EN ISO. Securing of a maximum legal certainty for operators of gas facilities on factory grounds in the event of damage. Preliminary mee ng for the clarifica on of the concrete approach with me schedule Applica on of the TSM check list Provision of cer fiable standard processes for changes on gas facili es Implementa on of cer fiable standard processes in exis ng QM-System or, if necessary, in exis ng Integrated Management Systems (IMS) according to DIN EN ISO Provision of dra s for appointments, manuals, intranet sites, e-learning for the yearly instruc on etc. Prepara on of the en re documenta on including the necessary internal guidelines of the company Prepara on and assistance with respect to an internal and external audit Your benefit Certifiable TSM system Risk of organizational faults of the management is minimized Confirmation to comply with the requirements of the German Ordinance on Industrial Safety and Health Cost reduction by integration into the internal QM-System of the company With respect to future changes on the gas facilities as well as on the organizational and operational structure, the level of safety remains the same You will receive a cer fiable en re documenta on. In addi on to various opera ng instruc ons, this will include the appointment as person responsible for the gas facili es as well as the appointment as qualified person according to the German Ordinance on Industrial Safety and Health and much more. Appointment as person responsible for the gas facili es. Appointment as qualified person according to the German Ordinance on Industrial Safety and Health. Opera ng instruc ons. TECHNICAL SAFETY MANAGEMENT

8 Sicherheitsmanagement STUFE I Sicherheitsbetrachtung ra on Quali zierung GET YOUR GASEXPERTEN TSM PLAQUE We will be glad to advise you on all ques ons regarding the Technical Safety Management. By phone or in a personal mee ng. STUFE II r T r info@gasexperten.com Technical changes reserved GAS_2014_020 gasexperten Bussardweg Löchgau info@gasexperten.com

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