2024 - JOIFF Catalyst Q4

ABOUT JOIFF

JOIFF, the International Organisation for Industrial Emergency Services Management is a not-for-profit organisation dedicated to developing the knowledge, skills and understanding of personnel who work in and/or who are required to provide emergency response to incidents In Industry, primarily High Hazard Industry, with the aim of ensuring That risks in Industry are mitigated and managed safely.

The 4 pillars of JOIFF aiming to support its Membership in preventing and/or mitigating hazardous incidents in Industry are: Shared Learning – improving risk awareness amongst JOIFF Members; Accredited Training – enhancing operational preparedness in emergency response and crisis management;

Technical Advisory Group – raising the quality of safety standards in the working environment of High Hazard Industry and Professional Affiliation – networking and access to professionals who have similar challenges in their work through Conferences and other events and the prestige of being a member of a globally recognised organisation of emergency response.

Full Members of JOIFF are organisations which are high hazard industries and/or have nominated personnel as emergency responders/hazard management team members who provide cover to such organisations. Commercial Members of JOIFF are organisations that provide goods and services to organisations in the High Hazard Industry.

JOIFF welcomes enquiries for Membershipplease contact the JOIFF Secretariat for more information.

JOIFF CLG is registered in Ireland. Registration number 362542. Address as secretariat.

JOIFF is the registered Business Name of JOIFF CLG.

ABOUT THE CATALYST

The Catalyst is the Official magazine of JOIFF, The International Organisation for Industrial Emergency Services Management. The Catalyst is published Quarterly – in January, April, July & October each year. The JOIFF Catalyst magazine is distributed to all JOIFF members and member organisations worldwide. The Catalyst magazine is published by ENM Media on Behalf of JOIFF.

Publisher & Advertising Sales:

Paul Budgen

Tel: + 44 (0) 1305 831 768

Email: pbudgen@edicogroup.net

Design & Production: Christelle Sakr

Tel: +44 (0) 1305 831 768

Email: christelle@edicogroup.net

Message from JOIFF Chairman

Dear JOIFF members and readers of the Catalyst.

Since the last edition of The Catalyst in July, there continues to be many challenges that face us all.

Can I emphasise right from the start that we can gather strength, support, and ideas from each other, we are all stronger together - these ideals are very much in line with JOIFF’s core values. Please take every opportunity to reach out if you need to and contribute where you can, be it any Shared Learning and experiences from all aspects within our industry, be it high hazard industrial, pharmaceutical, marine and aviation as examples.

We would welcome any response from subject matter experts regarding wildfires, this is a particular aspect in training and emergency response that JOIFF is keen to develop as a common standard in the future.

Developing the theme of Shared Learning and Events, I was honoured to be able to chair the latest JOIFF Shared Learning event held at the National Maritime Training College of Ireland, in Cork which brought together subject matter experts to deliver papers on a variety of topical issues. It was great to welcome over 65 attendees taking part over the two days. This included several new member organisations as we develop our local JOIFF network within Ireland, as you will see in the New Members section of this edition of The Catalyst. I am happy to report that the event was a great success, and I extend my personal thanks to all those who attended the event and to the exhibitors who helped with sponsorship and finally to the Management and staff of the National Maritime College of Ireland who hosted the event.

We are keen to build on success and to develop the concept of hosting more regional Shared Learning events.

During this month, I had the pleasure of visiting one of our accredited training providers, the Tüpras Izmir Refinery in Turkey. I also represented JOIFF at a fire symposium in Izmir, all with the aim of widening the outreach of the JOIFF community - please look out for more events in the near future. While attending the Tüpras site, it was my pleasure to witness certificates being presented to successful candidates completing the JOIFF Diploma and the JOIFF Technician programmes.

I hope you find this edition of the Catalyst informative and interesting.

If you would like to contribute an article for a future edition or have any thoughts on subjects that you would like to see covered, then please let us know.

Kevin Deveson

MJOIFF, GIFireE

Chairman of JOIFF

Email: kevin@joiff.com

Please visit www.joiff.com

ROLL OF HONOR

Post-nominal qualifications of a person provide recognition as a professional, demonstrating commitment to professional standards, integrity, ethics and continuous professional development.

During Q3 2024, the following persons were awarded JOIFF post-nominal qualifications:

JOIFF DIPLOMA

The following persons in the Emergency Response Team of Turkish Petroleum Refineries Corporation (Tüpras) successfully completed the programme and were awarded the post nominals Dip.JOIFF:

Murat Agbuga • Dip.JOIFF

FF Equipment Readiness Specialist

Turkish Petroleum Refineries Corporation, Izmir Refinery, Türkiye

Murat has been working at Tüpraş İzmir Refinery since 2006. He has worked as a Technician, Inspector, Shift Supervisor and currently he works as an FF Equipment Readiness Specialist at Emergency Response Department. On receiving the JOIFF Diploma, Murat said:

“I have attended many trainings on different subjects before, but I did not have to do such a comprehensiveanddetailedstudyforaspecialization.JOIFFDiplomaProgramrevealedmany research and training needs and provided me with a lot of new information in the process. While doing research, I had a very useful training process in terms of both completing my deficiencies and finding new ideas. I had the opportunity to repeat many experiences that we knew but did not reinforce during the preparation process. I would like to thank my companyandallmymanagerswhosupportedmyparticipationinthisDiplomaprogramand provided me with information and opportunities. I think it is a training that increases self-confidence in determining emergency prevention methods and intervention strategies in the management of all emergencies and provides many benefits in technical and practical terms. I recommend the training to all my friends.”

Eren Akdeniz • Dip.JOIFF

Technical Safety Senior Engineer

Turkish Petroleum Refineries Corporation, Izmit Refinery, Türkiye

Eren graduated from the Mechanical Engineering undergraduate program in 2015 and received his master's degree in occupational safety. After working as a consultant in the field of occupational safety for about 6 years, he worked as a technical safety chief in a leading company in the casting industry for 2 years. In 2023, he started working as Technical Safety Chief at TUPRAS Izmit Refinery Fire Department. His main duties include management of emergency response teams in the refinery, availability and efficiency of emergency equipment and purchase of new equipment, fire risk assessment, development of fire protection strategies and working on fire protection systems projects.

After receiving his JOIFF Diploma, Eren expressed his feelings in the following words: “Although challenging, it has been an enriching process, this program has given me the opportunity to review my knowledge and research in depth. Asanengineer, I can say that dealing with emergencies is based on continuous improvement. It has always made me proud to take part in new projects and to be a member of such a team, and it is an honor for me to receive the internationally recognized JOIFF Diploma. I would like to thankmyDirectorErkanMODOĞLUandmyManagerAytuğAYHANfortheirexperienceand support during my participation in this diploma program”

Mehmet Aköz • Dip.JOIFF

Fire Fighting Specialist

Turkish Petroleum Refineries Corporation, Kirikkale Refinery, Türkiye

Mehmet joined the Tüpraş family in 2007 and continues to work as a firefighting specialist in the firefighting unit. He has never worked in a job related to fire and emergency before. He observed that TÜPRAŞ is a school and a workplace full of experience where people can fully educate and train themselves in this regard. He would also like to thank his managers who trained him in this regard and provided him with the opportunity. On receiving the JOIFF Diploma, Mehmet said:

“Ihaveattendedmanytrainingsbefore,butIhaveneverneededtodosuchacomprehensive and detailed study for a specialization. The JOIFF Diploma Program posed many research and educational needs and enabled me to gain a lot of new knowledge in the process.

Duringthepreparationprocess,Ihadtheopportunitytorepeatmanyofmyexperiencesthat weknewbutdidnotreinforcemuch.Iwouldliketothankmycompanyandallmymanagers who supported my participation in this Diploma program and provided information and opportunities.

I think it is a training that provides many benefits in terms of technique and practice, increasing self-confidence in determining emergency prevention methods and intervention strategies in the management of all emergencies.”

Abdurrahim Baran • Dip.JOIFF

Technical Safety Shift Supervisor

Turkish Petroleum Refineries Inc., Batman Refinery, Turkey

Abdurrahim Baran obtained two degrees from the Refinery Petro Chemistry Department and the Occupational Health and Safety Department. His initial work experience commenced on 25 July 2007 at the Tüpraş Batman Refinery where he currently serves as Technical Safety Shift Supervisor. His role entails the prevention and response to emergency incidents, including firefighting, gas leaks, environmental spills and process safety.

Abdurrahim, who successfully completed the JOIFF Diploma programme, was awarded a certificate in recognition of his achievement. On receiving the JOIFF Diploma, Abdurrahim said:

“Over the course of my 18-year tenure at Tüpraş Batman Refinery, I have participated in numerous training programs. However, none of these have been as comprehensive as the JOIFF Diploma Program, nor have they provided me with the same level of professional development. The JOIFF Diploma Programme enabled us to identify deficiencies in our approach and implement the necessary corrections. In this way, I was afforded the chance to enhance my technical knowledge further.

During the preparation process, I was afforded the opportunity to revisit and reinforce a number of experiences that we had previously encountered. I proposed to my superiors that other members of our team should also undertake the JOIFF Diploma Programme. I would like to express my gratitude to my company and all my managers who supported my participation in this programme and provided me with the opportunity to enhance my skills.

Those who complete this training will develop in technical and practical terms and will be able to manage emergency prevention in the management of all emergency situations.”

Bilal Bidakli

• Dip.JOIFF

Technical Safety Shift Supervisor

Turkish Petroleum Refineries Corporation, Kirikkale Refinery, Türkiye

Bilal started his career at Tüpraş Kırıkkale Refinery in 2013. After working as a Technical Safety Officer between 2013-2016 and Technical Safety Inspector between 2016-2019, he now works as Technical Safety Shift Supervisor.

During these periods, he has participated in many incidents on Emergency and Fire Fighting and these incidents has given him great experience. In 2021, he successfully graduated from Anadolu University Emergency and Disaster Management Department. In 2023, he enrolled in the Dip.JOIFF program and successfully completed it within one year. On receiving the JOIFF Diploma, Bilal said:

“First of all, I am very happy to be part of such an instructive program and to be part of the team that completed this program in Türkiye. Although the scope of the program, which includes nearly seven hundred cases covering emergency response processes, was intimidating at first, it was a very exciting, enjoyable and instructive experience for me to research each element and try to interpret each case specifically.

The JOIFF program has contributed a lot in terms of improving my competence in fire, rescue, emergency management, etc. In addition, thanks to this program, I gained many different perspectives and had the opportunity to apply these perspectives in my business life.

In this way, I aim to create safer and faster response strategies at Tüpraş.”

Onur Camkiran

• Dip.JOIFF

Fire Protection Senior Engineer

Turkish Petroleum Refineries Corporation, Izmir Refinery, Turkey

Onur is a mechatronics engineer. After graduating from university in 2015, he started working as a project engineer in fire extinguishing systems at an engineering company. He contributed to facility safety by providing installation and consultancy on fire detection and extinguishing systems for many facilities.

He started his career at Tüpraş in 2019. He worked as a Technical Safety Engineer and Technical Safety Chief at Tüpraş Company, respectively. Currently, he continues as a Fire Protection Senior Engineer in Emergency Response Management.

His main jobs are following up on ongoing fire projects, providing opinions on projects, creating new projects, determining unit needs and creating project and purchasing requests, following up on new technologies and experiencing them at the refinery. On being awarded the JOIFF Diploma, Onur said:

“I think we have taken one more step forward with this program, which is both challenging and educational in the field of firefighting.

Thanks to this program, I have improved myself a lot in the field of emergency response. I gained many perspectives to response in emergencies. So, I am very happy to receive this internationally valid certificate from the JOIFF Organization.

I would like to thank all my managers and colleagues who contributed to me obtaining this certificate. I am looking forward to starting the JOIFF Technician program.”

Esat Barış Kömürcü • Dip.JOIFF

Technical Safety Shift Supervisor

Turkish Petroleum Refineries Corporation, Izmir Refinery, Türkiye

Barış completed the Industrial Electronics Associate Degree Program in 2003 and holds an additional Associate Degree in Occupational Health and Safety.

Since 2006, he has been an integral part of the Fire Department at Tüpraş Izmir Refinery, currently serving as the Refinery Fire Department Shift Supervisor.

With over 18 years of experience, Barış has developed expertise in emergency response, intervention operations, equipment readiness, occupational health and safety practices, and resolving environmental and technical safety issues.

Upon receiving the prestigious JOIFF Diploma, Barış reflected on the achievement:

"This program has been instrumental in enhancing my professional knowledge and skills.

The learning experience was incredibly rewarding, and I am eager to apply my expertise to train the next generation of emergency response teams.

By doing so, I hope to make a significant contribution to our organization.”

Olcay Özdemir • Dip.JOIFF

Turkish Petroleum Refineries Corporation, Izmir Refinery, Turkey

Olcay started his career as a technical safety officer at Tüpraş Technical Safety Directorate in 1998. In 2007/2008, in order to improve his professional knowledge, he graduated from Kocaeli University, Fire Fighting High School with an associate degree.

In 2009, he received a certificate of success by participating in ship fire intervention trainings from the Naval Command. After different levels over the years, he has continued his professional life as a Fire Fighting Specialist since 2014.

On receiving the JOIFF Diploma, Olcay said:

“In the 1999 Marmara earthquake-induced Tüpraş fire, although I was a new firefighter, I gained a lot of experience and participated in the interventions from the beginning to the end. In my 26 years of professional life, I participated in various internal and external industrial facility fire intervention operations.

I think that I have taken my professional knowledge to the next level with the information I have received and acquired by participating in the Joiff Diploma program.

I gained additional new information and perspectives with the program. I have taken it into my goals to successfully complete the next stage of the program by participating in the JOIFF Technician part of the program.

I would like to thank all my managers who encouraged and supported me to participate in the Joiff diploma program.”

Hayati Öztürk • Dip.JOIFF

Fire Fighting Lead

Turkish Petroleum Refineries Corporation, Izmit Refinery, Türkiye

In 1990, Hayati started his career as a Technical Safety Technician at Petkim Petrochemical Plant Yarımca followed with the job roles of Technical Safety Inspector, Shift Supervisor, Technical

Safety Specialist and finally Fire Fighting Chief at Tüpraş Izmit refinery as of 2023. During his tenure, he participated in both industrial fires and external fires outside the refinery from time to time. The turning point in his working life was the 1999 earthquake, which affected our refinery and a large-scale fire occurred.

In 2011, he graduated from Kocaeli University Department of Firefighting and Fire Safety and in 2015 he graduated from Sakarya University Department of Occupational Health and Safety. On receiving the JOIFF Diploma, Hayati said:

“Thefactthatdifferentunitsworkatdifferenttemperaturesandpressuresandtherisksare different from each other has helped me gain experience in fighting industrial fires.

The JOIFF Diploma program provided me with new knowledge about the application of some equipment and methods that we do not use in refineries in general. I thank everyone who supported the program.”

Serdar Şahin • Dip.JOIFF

Technical Safety Specialist

Turkish Petroleum Refineries Corporation, Izmit Refinery, Turkey

Serdar has been an employee of Tüpraş İzmit Refinery Fire Fighting Department since 2000. He is currently working as Technical Safety Specialist.

His main duties include Emergency Management, Fire Protection and Fire Fighting, Industrial Fire Trainings for refinery and external company employees.

On behalf of the refinery, he participates in workshops for the preparation of training contents in the Fire Fighting and Civil Defence Department of the local university. He is a graduate of the Occupational Health and Safety Department of the same university and is a Class A Occupational Health and Safety Specialist. On receiving the JOIFF Diploma, Serdar said:

“The refinery is a hazardous environment where flammable and combustible liquids and gases are processed with equipment and lines operating at high temperature and pressure. It is of great importance to react quickly to emergency situations in the refinery before the incident grows, to quickly determine and implement the correct intervention strategies without risking process and occupational safety. For this, we keep ourselves ready by continuous training and drills.

I gained a lot of new information during the preparation and research I did during the JOIFF Diplomaprogramme.Thisprogrammegavemenewperspectives.WhatIhavelearnt has been very useful to me and I believe that I will contribute to the development of my teammates by sharing my knowledge with them.

I would like to thank my company and my managers for guiding me to this programme.”

Bilal Yigit • Dip.JOIFF

Fire

Fighting Specialist

Turkish Petroleum Refineries Corporation, Batman Refinery, Türkiye

Bilal graduated from the department of business administration and from the emergency and disaster management department and electronic technology departments and he is a occupational safety specialist in the field of occupational health and safety. He has been working at TÜPRAŞ Batman Refinery since 2011 on Fire Hazards, Toxic Gas Dispersion, Oil Spill, Process Safety, etc. He works particularly for prevention and intervention in all possible emergency situations.

When Bilal received his JOIFF Diploma, said, "I have participated in many trainings before, but I have never needed to do such a comprehensive and detailed study for a specialty. The JOIFF Diploma Program has led to many research and educational needs and has enabled me to acquire a lot of new knowledge in the process. During the preparation process, I had the opportunity to repeat many of my experiences that we know about,butIdidnotconsolidatemuch.Iwouldliketothankmycompanyandallmymanagers who supported my participation in this Diploma program, provided information and opportunities. I think it is an education that provides many benefits in terms of technique and practice, increases self-confidence in determining emergency prevention methods and response strategies.”

JOIFF TECHNICIAN

The following persons in the Emergency Response Team of Turkish Petroleum Refineries Corporation (Tüpras) successfully completed the programme and were awarded the post nominals Tech.JOIFF:

Aytug Ayhan • Tech.JOIFF

Emergency Response Manager

Turkish Petroleum Refineries Corporation, Izmit Refinery, Türkiye

Aytug graduated with a from BSc in Mechanical Engineering at Technical University in 2015. He started his career as a Technical Safety Engineer in 2015 at TUPRAS Turkey's largest and Europe's one of the largest companies in the oil & gas industry.

After working as a Technical Safety Supervisor and Superintendent between 2019 and 2024, he has been working as Emergency Response Manager since 2024 at TUPRAS. His main responsibility is to coordinate emergency response teams by managing emergency response operations and to take part in Crisis Center processes. He is also responsible for the development of the competence of emergency response teams, increasing the availability and efficiency of emergency response equipment, and fire protection systems of the refinery.

On being awarded the JOIFF Technician, Aytug said:

“AftercompletingtheDiplomaprogramlastyear,preparingfortheTechnicianprogramwith highmotivationwasaveryinstructivejourneyforme.Thespecificsubjectsinthetechnician program were quite informative and goal oriented.

Successfully completing the Technician program was an important step for my career and personal development.

I am excited to share my knowledge and experiences with my teammates. I am eagerly looking forward to completing the Leadership Program.”

Burak Çankaya • Tech.JOIFF

Fire Fighting Lead

Turkish Petroleum Refineries Corporation, Kırıkkale Refinery, Türkiye

After starting his career as a firefighter in the city fire department in 2004, Burak continued to work as a fire chief and training coordinator until 2009. During this time, he had the opportunity to respond to hundreds of fires and rescue incidents and gained serious experience in urban firefighting and rescue activities. In 2011, he started to work as a rescue team leader in Tüpraş İzmit RUP refinery construction works and took part in the first response of many technical rescue incidents during the construction phase till 2013. Between 2013 and 2016, he increased his experience by working as a fire and rescue coordinator in the construction of the Socar Star refinery. Since 2016 he is a Fire and Rescue Chief at Tüpraş Kırıkkale refinery in Turkey. As Fire and Rescue Chief, he has gained valuable experience by participating in risk assessments related to specific cases of HSE, fire and rescue, having role in emergency management, incident control and response. He is an expert who has IRATA and SPRAT L3 Rope Access certifications and has competence in rescue with technical rope. He also continues to work as a mountain search and rescue instructor, which he started in 2004, in Turkey's most experienced search and rescue organizations. He successfully completed JOIFF Technician programme that he started in 2024, within a year and on being awarded the JOIFF Technician, Burak said:

“Firstly,Iamveryhappytobeapartofsuchaninstructiveprogramandtobeamongthefirst teamtocompletethisprograminTurkey.Althoughthescopeoftheprogram,whichincludes nearlysevenhundredcasescoveringemergencyresponseprocesses,intimidatedmeatfirst; it was very exciting, enjoyable, and instructive experience for me to research each element and try to comment on each case exclusively. The contribution of the JOIFF program to me is huge in terms of improving my competence in fire, rescue, emergency management, etc. Moreover, thanks to this programme I gained many different perspectives and had the opportunity to apply these perspectives to my professional life. In this way, I aim to create safer and faster response strategies in Tüpraş.”

Serdar Oğhan • Tech.JOIFF

Fire Protection Lead Engineer

Turkish Petroleum Refineries Corporation, Batman Refinery, Türkiye

Serdar Oğhan obtained his Bachelor's degree in Environmental Engineering from the Department of Environmental Engineering and subsequently completed a Master's degree in Occupational Health and Safety Specialisation. His initial work experience was in the construction sector between 2014 and 2018.

Since 2018, he has been employed at the Tüpraş Batman Refinery, where he currently serves as Fire Protection Lead Engineer. He is responsible for the management and prevention of potential emergency situations, including fire hazards, toxic gas hazards, and environmental spills. He is responsible for the management of the Emergency Response team.

Upon receiving the JOIFF Technician designation, Serdar stated, "Isuccessfullycompletedthe diplomaprogrammelastyear.The JOIFF programmes foster a sense of responsibility to pursue self-improvement in various domains. The JOIFF Technician programme requires one to either refresh or learn new information on numerous subjects, including chemistry, refinery risks, and hydraulic calculations.

I aspire to advance my knowledge by participating in the leadership programme next year."

Enis

Sarıçiçek

• Tech.JOIFF

FF Equipment Readiness Specialist

Turkish Petroleum Refineries Corporation, Kırıkkale Refinery, Türkiye

Enis started his career in 2008 at Tüpraş Kırıkkale Refinery. In the 17 years he worked there in and progressed his career as he was assigned to higher positions. Over the years, he has taken part in and intervened in many on-site and off-site fires. Especially due to the location of our facility, it is present in factories such as Mechanical Chemistry Institution, Arms Factory, Steel Factory, Ammunition Factory, Gunpowder Factory and Chemical Factories around and in the city.

Throughout his professional life, he considered himself competent when he thought about the fires and emergencies he participated in.

On being awarded the JOIFF Technician, Enis said: “When I started taking the JOIFF training program and the units started to progress, I realizedthatIstillhadalottolearn,andIembracedmoretrainingbypayingmoreattention to education.

This training opened my horizons more, provided me with many benefits in feeding from different sources and working with my teammates. The JOIFF TECHNICIAN program is really more technical, a developer program with more information, I am happy to receive this certificate.

IwouldliketothankmyChiefEngineerMr.HayatiNİHANforhissupportformetoreceive this training and the JOIFF management who provided the training”.

Ercenk Ulucam • Tech.JOIFF

Emergency Response Manager

Turkish Petroleum Refineries Corporation, Izmir Refinery, Türkiye

Ercenk graduated with a BSc in Mechanical Engineering in 2015.

After working for a company that produces fasteners for about 2 years, he started to work as a Technical Safety Engineer at the TUPRAS Izmir Refinery Fire Department in 2017. He is currently working as an Emergency Response Manager at TUPRAS Izmir Refinery.

His main jobs are the management of the emergency response teams at the refinery, the availability and efficiency of emergency equipment and the purchase of new equipment, the assessment of fire risk, the development of fire protection strategies, and the working on fire protection systems projects.

On being awarded the JOIFF Technician, Ercenk said “Lastyear,Isuccessfullycompletedthe JOIFF Diploma program.

This year, thanks to the JOIFF Technician program, I had the opportunity to repeat the logic of hydraulic calculations and the processes of refineries and petrochemical plants. This refreshed my knowledge.

I am very pleased to have participated in this program and to receive the internationally recognized JOIFF Technician. My new goal is to participate in the JOIFF Leadership program and complete it successfully..”

The following members of the Emergency Response Team of Tüpras, Turkey also successfully completed the JOIFF Technician programme:

Murat Hamzaçelebioğlu • Tech. JOIFF

MESSAGE FROM RENATO LOPEZ

Dip.JOIFF, Tech.JOIFF, JOIFF.ERTL, JOIFF ERO

Renato Lopez

Dip.JOIFF, Tech.JOIFF, JOIFF.ERTL, JOIFF ERO

Renato is currently Security and Fire Safety Officer in the United Nations MONUSCO Peacekeeping Operations Security Section in the Democratic Republic of the Congo. In November 2021, he registered to work on the JOIFF Diploma programme and on 30th April 2024, he had successfully completed the JOIFF Diploma, JOIFF Technician, JOIFF Team Leader and JOIFF Officer programmes. JOIFF received an email from Renato last month and Catalyst readers may be interested in what he had to say.

I hope this letter finds you well. I am writing to inform you that I have recently returned from a much-needed vacation, feelingrefreshedandre-energized.Duringmytimeaway,Ihadtheopportunitytoreflectonmyprofessionaljourneyandthe milestones I have achieved.

IamparticularlyexcitedtosharethatIhavereceivedmyJOIFFcertificates.Thiscertificationisasignificantaccomplishment for me, as it represents my commitment to maintaining the highest standards of safety and emergency response within the industry.TheJOIFFcertificationisrecognizedgloballyasabenchmarkforexcellenceinfiresafetyandemergencyresponse, underscoring the critical importance of rigorous training and preparedness in our field.

The training and knowledge I have gained through this certification will undoubtedly enhance my ability to contribute effectively to our team and ensure a safer working environment for all. The JOIFF certification equips professionals with advanced skills and best practices that are essential for mitigating risks and managing emergencies efficiently. This achievementnotonlyreflectsmydedicationtoprofessionaldevelopmentbutalsoalignswithourorganization’scommitment to safety and excellence.

I am eager to apply the skills and insights I have acquired through the JOIFF certification to our ongoing projects and initiatives. I believe that this achievement will not only benefit my personal and professional growth but also positively impact our organization’s safety protocols and emergency preparedness.

I thank JOIFF again for the opportunity. The Directors of JOIFF extend congratulations to all those in the JOIFF Roll of Honour.

NEW JOIFF MEMBERS

During July, August and September 2024, the JOIFF Board of Directors were pleased to welcome the following new Members:

Argos Fire and Safety • Cork, Ireland

represented by Karen Corcoran O’Hare, Fire & Safety Consultant, Dave Cowhig, Technical Specialist and Tony Corcoran, Managing Director. Argos Fire and Safety is an Irish owned company with 42 years of knowledge and expertise in the distribution and maintenance of fire safety and rescue products with a nationwide service. They provide a service of supply, install, inspect and maintain portable fire extinguishers and training in their use, related fire and rescue equipment including hose reels, medical tents, pneumatic rescue equipment, fire pumps etc. Argos also operate a firefighting foam laboratory for analysis, and performance testing.

Arsham Imen International, (AICO Intl.) • Istanbul, Turkey and Arsham Imen International • Tehran, Iran

represented by Hani Nikoomaram, Vice President and Mohammad Dehbozorgi, Managing Director. AICO Intl. is a leading consulting / engineering / training service provider with around two decades of experience in the fields of safety & health, fire-fighting and risk to a wide range of industries, including oil & gas, petrochemical, etc. Their services are based on the process of design implementation, evaluation, review ad improvement in all areas of safety, health environment quality and fire protection.

Clare County Fire and Rescue Service • Ireland

represented by Aidan Kelly, Chief Fire Officer and Tom Burke, Senior Assistant Chief Fire Officer. Clare County Fire and Rescue Service provides response to firefighting and rescue, technical fire prevention services, building control, community fire safety and major emergency planning. The operational fire service in Clare is a retained fire service, i.e. fire fighters carry a pager and are expected to report to the fire station within five minutes and go mobile to the incident - as is the norm for rural counties in Ireland. The station officers report to a senior assistant Chief Fire Officer who is a professional technically qualified officer. At least one senior fire officer is rostered on-call each week to assist in the handling of emergency incidents.

Khormor LPG Plant • Kurdistan Region of Iraq

represented by the Khormor HSE Manager, Khormor Crisis Management and Emergency Response Coordinator, Khormor Fire Chief and Khormor Plant Manager. The Khormor Plant is the biggest private sector upstream gas operation in Iraq and has been operational since the Khormor gas field commenced production in October 2008. Pearl Petroleum is the owner and operator of the integrated gas treatment and liquified petroleum gas extraction facility, along with the Khor Mor gas field.

PlantQuest • Waterford, Ireland

represented by Ger Carton, Director, Crebhan Hughes, Operations Manager and Tom Day, R&D. PlantQuest provide asset location and facility visualisation tools to industry - pharma, med device, chemical etc. Used by emergency response teams, PlantQuest aids in the visualisation of fire system and safety systems, helping first responders to locate and efficiently navigate to any alarm within the facility. With signal free functionality, a navigation rules engine, and custom logic specific to the facility built in, facilities have been able to eradicate all double-knock/unnecessary full and partial evacuations helping to improve business continuity.

Tipperary County Fire and Rescue Service • Ireland

represented by Dave Carroll, Chief Fire Officer. Tipperary Fire and Rescue Service maintains round the clock emergency cover to protect life and property. There are twelve fire stations based throughout the County. The fire fighters based at these stations undergo continuous training to ensure that the service provided is of the highest possible standard. In addition, fire officers are available to give fire safety advice and to ensure that standards are properly maintained to ensure public safety. On average this Fire and Rescue Service attends over 1500 incidents per year and the headquarters offices administer all items relating to the operational fire service, fire safety, building control, emergency planning and petroleum licensing.

Venture Gulf Safety and Security Training Centre • Doha, Qatar

represented by Sami Suleiman, Training Centre Manager, Ritesh Nair, Head Sales and Business and Mayukh Pahari, Training Coordinator. VGSSTC was established in 1996, to cater to the growing demand of quality and cost effective occupational training services that emerged in the State of Qatar. Since then, VGSSTC has become an industry leader in the occupational health and safety field for the past 3 decades. VGSSTC aims to provide quality Health and Safety training competency based training for their clients, with their skills, knowledge and experience to ensure that all trainees are not just trained to meet the requirements of the Health and Safety at Work but are also trained to the highest of standards that VGSSTC set themselves.

Waterous Company • Minnesota, United States of America

represented by Stephen Washington, Sales Manager Europe, Middle East and Africa, Gregg Ceske, Director of Sales and Marketing and Barry Coe, Sales Manager Asia Pacific. Waterous, was founded in 1886 and constructed the first gasoline-engine-driven fire pump. From 1886 to 1929, they built entire apparatus and since 1929, they have focused on building the highest quality, best performing pumps in the industry. As they continued to grow, Waterous invested in the latest machinery and software that will continue to increase the quality and efficiencies of their pumps now and into the future. Waterous also manufacture and sell a variety of different products to meet the customers needs such as hydrants, valves and pumps for the fire industry including vehicle mounted pumps and foam systems pumps

Membership certificates being presented in the Hydra Suite in the HQ Fire station of Tipperary County Council, Ireland. The Hydra Suite is used for training in both simulating and debriefing critical incidents

Left to right: Tom Burke, Senior Assistant Chief Fire Officer, Clare County Fire and Rescue, Alec Feldman, JOIFF Director, Dave Carroll, Chief Fire Officer, Tipperary County Fire and Rescue.

The Directors look forward to the involvement of our new and existing Members in the continuing development of JOIFF.

NEW JOIFF MEMBER

INTRODUCTION

PLANTQUEST

Enhancing Site Safety and Reducing Alarm Response Times

PlantQuest digitizes large industrial facilities, enabling customers to transform their emergency response operations with an intelligent asset mapping and visualization platform. By combining and layering multiple data sources, PlantQuest empowers workers to make data-driven decisions, locate and route to assets and alarms more efficiently, reduce emergency response times, and retain critical site knowledge. The platform integrates seamlessly with existing safety systems and is designed for deployment across all types of facilities—from legacy brownfield sites to cutting-edge greenfield developments.

Efficient alarm response is crucial for maintaining workplace safety and business continuity. Delays in responding to alarms can escalate emergencies, trigger unnecessary evacuations, and disrupt production. PlantQuest mitigates these risks by digitizing site fire system drawings and presenting them in a Google Maps-like interface for emergency responders. You can learn more here.

Case Study Overview – Tier 1 Pharma Site

We have not had a single unnecessary evacuation since adopting PlantQuest over three years ago.

In September 2021, PlantQuest was deployed at a brownfield pharmaceutical facility in Leinster, Ireland, originally built in 1992. With over 800 employees operating across 1,500 rooms and 12 buildings, the facility runs 24/7, making emergency response a complex challenge.

Prior to PlantQuest's implementation, the site experienced two to three unnecessary evacuations per month, resulting in significant downtime due to delays in locating alarms.

PlantQuest’s solution tackled these issues by digitizing more than 150 fire layout drawings and implementing a platform that functions as “Google Maps” for the facility. The system maps and tracks over 6,000 fire-related devices and 2,000 EHS assets, allowing the Emergency Response Team (ERT) to respond more efficiently and effectively.

Since PlantQuest’s deployment, the facility has achieved the following:

73% Reduction in Alarm Response Time: No alarm now takes more than 12 minutes to locate and address.

Zero Unnecessary Evacuations: The facility, which previously averaged 2 to 3 evacuations per month due to false alarms, has experienced none since PlantQuest was introduced.

Improved Business Continuity: The reduction in response times and unnecessary evacuations has allowed for uninterrupted operations, minimizing costly downtime.

To learn more, visit www.plantquest.com or contact us at info@plantquest.com

On the 3rd and 4th of September 2024, JOIFF hosted the JOIFF Regional Shared

Learning Summit, in collaboration with the NMCI Training Services in Cork, Ireland.

With the Transition to Fluorine Free foam now a fact for the majority of the Global High hazard Industry due to Environmental legislation and Supply Chain concerns.

The JOIFF International Foam Summit 2024 aims to provide provide clarity on all aspects on the process of Foam Transition.

The Challenges of Transition to SFFF • Proportioning & Hardware • Foam Transition End User • Case Studies • Standards & Testing • Decontamination • Performance of SFFF • Regulatory Updates from all major markets

In addition to the Conference presentations from Subject Matter Experts from around the world, we will also be providing a platform for suppliers to meet and discuss the transition to SFFF.

The JOIFF International Foam Summit 2024 also provides a unique opportunity to meet, discuss and learn from Peers and Foam Transition Experts in person.

If you are involved with foam transition now or are involved in programmes to transition to SFFF in the next few years, this is a must-attend event to get the facts and meet the experts.

REGISTRATION IS NOW OPEN

Meet JOIFF

THE INTERNATIONAL FIRE SYMPOSIUM AND EXHIBITION 2024

Izmir, Turkey

JOIFF Directors Gerry Johnson, Kevin Deveson and Mark Feldman manned the JOIFF stand at the International Fire Symposium and Exhibition 2024 in Izmir Turkey on 3rd and 4th of October 2024. The event was organised by TMMOB Chamber of Mechanical Engineers, Izmir Branch, in cooperation with Izmir Metropolitan Municipality Fire Brigade, Department and Chamber of Mechanical Engineers and a number of engineering organisations. Kevin Deveson, JOIFF Chairman, was guest Seaker at the Symposium and he gave a Keynote presentation about JOIFF which was very well received.

SUCCESSFUL

JOIFF Accreditation Audits

During Q3 2024, successful JOIFF accreditation audits were carried out for:

Ricardo AEA National Chemical Emergency Centre (NCEC)• United Kingdom

NCEC being presented with a JOIFF certificate of reaccreditation

Ed Sullivan, Head of Chemical and Response Training, Gerry Johnson, JOIF Auditor

Tüpras Izmir Refinery • Izmir, Turkey

being presented with a JOIFF certificate of re-accreditation

Gerry Johnson, JOIFF Director, Süleyman Ersin Özen, Senior Principal Emergency Response Specialist

News from JOIFF Accredited Training Providers

FULCRUM CONSULTANTS

JOIFF-accredited eLearning programmes delivered digitally all over the world.

In the world of industrial safety and emergency response, rigorous training must underpin every action taken. Fulcrum Consultants offers a range of JOIFF-accredited eLearning

programmes which enable industrial emergency-response personnel to develop competencies and achieve an internationallyrecognised qualification in their own workplace. For over 20 years, these JOIFF-accredited programmes have been providing knowledge and skills to responders in organisations of all sizes and all over the world.

Training wherever and whenever it is required

Each programme is delivered directly to each student’s computer and/or mobile device. The focus is on developing competence through a range of methods including reports case studies, practical exercises, pictures, witness statements etc.

The student can work on elements in any order and at their own pace – a huge benefit for organisations that work shift patterns or at multiple locations.

New recruits and seasoned professionals

Whether personnel are new recruits or seasoned professionals, each programme offers a tailored learning path at the appropriate level of training. The student’s work on each unit is reviewed by an assessor with the relevant background, competence and experience, before the work is externally verified.

The programmes

The JOIFF Diploma (Dip. JOIFF) programme deals with key skills in industrial emergency responders across 24 different units. The JOIFF Technician (Tech. JOIFF) programme is a pathway for industrial emergency responders to further develop technical knowledge and skills.

The JOIFF Leadership programme is available at two levels, Emergency Response Team Leader (JOIFF.ERTL) to develop the skills needed for a Team Leader in emergency response and Emergency Response Officer (JOIFF.ERO) to develop the skills needed for effective management of emergency response teams.

The JOIFF Responder to Hazardous Materials Incidents (JOIFF.HMR) programme provides the basic knowledge and skills required by an emergency responder who attends chemical emergencies.

For further information, visit www. fulcrumconsultants.com or email info@fulcrum-consultants.com

top performance when needed!

AR 3/3

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Industrial Disasters

CAN THEY BE PREVENTED?

The Catalyst researches and provides reports on some of the major industrial incidents that have taken place in past years in the hope that people will learn from the mistakes of others so that future incidents and subsequent unnecessary losses can be prevented.

24TH JULY 2021: ACETIC ACID AND METHYL IODIDE RELEASE

Background

LyondellBassell is a plastics, chemicals and refining Company that owns and operates facilities in 32 Countries. The Company’s LA Porte Texas facility is the World’s 3rd largest producer of acetic acid, a flavour enhancer and food preservative. Acetic acid is a corrosive liquid that can cause severe skin burns and eye damage upon exposure.

On 24th July 2021, an operations technician discovered a small leak on methanol piping upstream of the unit’s

acetic acid reactor. The actuator was being removed so that the valve could be used as an energy isolation device for a pipe spool repair job. To isolate the affected pipe section, company personnel decided to close the plug valve located between the leaking pipe and the nearby acetic acid reactor. LyondellBassell used a 3rd party contractor for general, mechanical and maintenance services. The contractor had a night crew available to remove the actuator but LyondellBassell did not have a procedure detailing how to remove the actuator and neither

LyondellBassell nor the contractor had trained the contract personnel on how to remove the actuator.

Prior to this event, there were a number of incidents when chemical industry workers inadvertently removed pressure-retaining components from a plug valve installed in pressurised service while attempting to remove an actuator. Each of these incidents resulted in fatalities or serious injury. Little or no learning from these tragedies that could have prevented this tragedy was acted upon.

Photo credit: Allen Nunnally Trial Lawyers

The Incident

On the evening of 27th July a foreman and 2 pipe fitters began working to remove the actuator from the plug valve. In doing so, they inadvertently removed pressure retaining fasteners that were holding the valve cover in place.

Not recognising that they had compromised the integrity of the valve, the team began to remove the actuator and the associated equipment including a coupler but the coupler was stuck on the valve stem and could not be easily slid off.

The workers decided to use a tool to attempt to forcibly remove the coupler. The combination of forces from the tool and the process fluid pressure inside the plug valve caused the compromised valve to fail. The unfastened valve cover and plug forcibly ejected from the valve body the entire contents of the acetic acid reactor, roughly 164,000 lbs. of hot acetic acid mixture.

The Casualties

2 workers were fatally injured from chemical burns and inhalation of the release. A 3rd worker was seriously injured and 29 others sought medical treatment. LyondellBasell’s property damage resulting from the incident, including loss of use, was estimated to be $40 million.

The Cause

The US Chemical Safety Board launched an investigation and found 2 safety issues contributed to the severity of the incident - the inadvertent removal of pressure-retaining components from a plug valve in pressurised service and the lack of training for the workers conducting the work. LyondellBassell and the contractor had considered the actuator removal to be a simple task and they failed to provide the contracting crew with a written procedure and allowed work to be done without oversight because of the perceived simplicity of the actuator

Summary

removal. Neither LyondellBassell nor the contractor trained the crews on the steps necessary to safely remove the actuator.

The Lessons Learnt

Develop procedures for properly removing actuating equipment from plug valves.

Ensure that contractors are competent, adequately trained and qualified to perform work.

Ensure that hazardous energy is controlled when performing such procedures.

Require that risk assessments for process safety are conducted before the actuating equipment removal work is authorised.

Ensure that sufficient procedures and safeguards are in place to prevent worker exposure to process fluid.

Re-design plug valves so that it is very difficult to accidentally remove pressure retaining components.

Clearly label pressure retaining components on existing plug valves.

29TH JANUARY 2020: OIL AND GAS BLOWOUT

The Wendland well in Burleson County, Texas, which was operated by Chesapeake Operating, experienced a “Blowout” which resulted in oil and gas escaping from the well, and within seconds, an ignition source resulted in a flash fire in the vicinity of the well.

The Incident

At about 15.00 hrs on 29th January 2020, contract workers were in the process of installing a new tubing

head to the top casing flange when the well began releasing oil and gas through a safety valve and casing valves as part of a workover operation. Shortly after the blowout began, the hydrocarbon ignited, engulfing the area around the well in flames.

Emergency Response

Local volunteer Fire Departments, Texas Department of Public Safety, and others responded to the incident. At around 17:20 hrs., first responders began moving toward the well to search for

a missing employee. Just before 6:00 p.m., the missing employee was found deceased near the well. At around 19.00 hrs., Chesapeake reported dry gas exiting the well, slight flow of oil exiting the casing valves, and no fluids leaving the area of the wellhead.

At 20:00 hrs the Fire Departments reported the fire was controlled with very little flow from the well. Response personnel conducted clean-up efforts and at 14:30 hrs. on 31st January 2020, the response crew reported the well was successfully shut in.

The Casualties

Three workers suffered fatal burn injuries from the fire and other workers suffered serious burns. The fire destroyed the workover rig and several nearby vehicles, resulting in an estimated $1 million in property damage in addition to the fatalities and serious injuries.

The Cause

There was insufficient industry guidance on well control for wells in an underpressurised reservoir. The absence of regulations governing onshore oil and gas operations also contributed to the incident.

The Lessons Learnt

Amongst some of the issues for needed improvement listed by the US Chemical Safety Board following their investigation of the incident are: Prepare well planning procedures from industry guidance including gathering well information, analysing the information to predict potential hazards, and formulating contingency plans to address these hazards. Industry guidance should provide reliable methods for well control for completed

wells in underpressurised reservoirs. Industry guidance should require hazard assessments when locating ignition sources and atmospheric monitors near potentially flammable atmospheres.

OSHA (US Occupational Safety and Health Administration) should include onshore well drilling and well servicing operations in the agency’s Process Safety management (PSM) standard or alternatively develop a Federal standard to address these operations.

API (American Petroleum Institute) should publish guidance specifically for well control methods for completed wells in underpressurised reservoirs.

Companies should include industry standards relating to workover well control planning in their operating procedures.

The Operator of the well and its contractors did not implement effective well control measures, so proper steps were not taken to ensure the appropriate level of safety during well servicing operations. Ineffective ignition source management contributed to the fire. The Operator did not adequately review the past history of the Wendland 1-H well, which would have indicated previous well control issues. Could any of these incidents have been prevented ? What do you think ?

Photo credit: CSB

Photo credit: CSB

COMING SOON!

PREORDER NOW

Guidance

Use of firefighting foam in high-risk industries

Use of re ghting foam in high-risk industries

We are thrilled to announce that at the JOIFF International Foam Summit 2024 , taking place in London on November 12 and 13, we will be presenting the new guidance: Use of re ghting foam in high-risk industries.

Would you like to be among the rst to receive this guide?

Pre-order now!

Send an email to info@h2k.nl and receive the guidance after the Foam Summit.

Don’t miss out!

Stay tuned for more details and updates.

Use of firefighting foam in the high-risk industries

by Jochem van de Graaff, Peter de Roos and Raymond Bras

The use of foam is associated with extinguishing fires. In the high-risk industry, that is an important function, but besides extinguishing fires, there are three other typical scenarios where foam is used. In a new guide, H2K and the Unified Fire Brigade Rotterdam (GB) present a quadrant model for the use of foam in the high-risk industry.

Introduction

In the transition from fluorinecontaining to fluorine-free foam, much attention is paid to the extinguishing capacities of the new foam concentrates. Extinguishing fires is an important function of firefighting foam. When zooming in on the typical incident scenarios in the high-risk industry, it becomes clear that extinguishing fires is only one of four tactics of incident management. Besides extinguishing (combatting), controlling fires, covering hazardous substances, and consolidating a foam blanket are common incident management tactics in which foam is used as well.

Two factors play a key role in the deployment of foam in high-risk industry incidents. One factor is whether the loss of containment (LOC) has been stopped or not, and the other is whether a fire has broken out.

These factors determine how foam deployment should be approached technically and tactically, what role the foam plays, and what foam properties are desired.

Factor 1: Whether the LOC has been stopped

An LOC from a process installation leads to undesirable effects. The scope and severity of these effects depend on the substance properties, process conditions, and the involved quantities of substances. The process operators will try to stop or limit the LOC as quickly as possible. The (company) fire brigade will intervene to minimize the effects of the LOC as much as possible. This prevents further escalation and gives the process operators time to take the appropriate actions.

As long as a leakage continues, depending on the situation, a choice can be made to let the product burn

in a controlled manner.

To stabilize a situation, control over the LOC is necessary, after which the fire brigade can adjust its actions accordingly.

Factor 2: Fire or no fire

When extinguishing fire with foam, the application rate is a crucial factor. In the case of fire, a part of the foam is destroyed by the heat. This must be compensated by applying more foam. Incidents where fire is involved tend to escalate quickly.

Covering non-burning pools requires a much lower application rate and the technical approach differs from that with fire.

Figure 1 Schematic representation of a process with a few examples of LOC’s

Incident scenarios and

tactics

There are four typical incident scenarios where foam is applied. These are determined by whether the LOC has been stopped and whether there is a fire. This results in four quadrants of different incident management tactics:

1. Controlling the fire

As long as burning liquids are flowing, it is impossible to quickly and completely cover them with foam. Due to the large amount of energy present in scenarios in the high-risk industry, the capacity for complete fire suppression is often insufficient. The fire brigade focuses on preventing escalation and limiting heating of the (most) threatened parts of the installation and objects by cooling or partially extinguishing the fire with foam.

2. Combatting the fire

Once the LOC is stopped, the fire brigade can extinguish the fire. The surface of the fire is known, and the fire brigade can develop a final apporach. Extinguishing the fire is done by quickly achieving a 90% knock-down, followed by a dynamic effort to extinguish the remaining 10% of the fire completely.

3. Covering a (non-burning) pool

Covering a (non-burning) but still flowing pool requires a specific approach. Similar to controlling a fire, there may be a need to minimize the effects as much as possible.

1 = insignificant2 = little important3 = moderate important4 = important5 = very important

a. Cooling: not relevant, but if the goal is to (partly) cover the fire: the minimum prescribed expansion ratio

b. The minimum prescribed expansion ratio

c.

At this moment, application rates are only prescribed for extinguishing (combat). Using this application rate for controlling, covering, and consolidating is not appropriate. However, there are no standardized methods to determine an application rate for controlling, covering, and consolidating.

Table 1 Overview of different foam properties in different tactics

4. Consolidating the foam blanket

Maintaining a foam blanket over a long period (consolidation) is only possible

if there is control over the LOC. This approach differs from all other incident types due to its long-term nature and the focus on achieving vapor suppression with minimal foam use.

Figure 2 Quadrant model use of foam in high-risk industry

Foam Properties in the Different Quadrants

Foam Use in Different Incident Types

Traditionally, the focus in foam use has been on extinguishing fires.

For that, the foam must flow well, have cooling capacity, and be somewhat vapor tight. Foam is evaluated based on these factors using standard tests.

However, for other types of incidents, this focus can differ.

For example, in consolidation, during a long-term operation without fire, the foam doesn't need to flow quickly. Instead, optimal foam should remain vapor-tight for as long as possible (long drainage time).

Table 1 provides an overview of the different types of tactics and the importance of various factors that define the properties of the foam.

p.deroos@h2k.nl

Both in preparing for incidents and training, as well as in real incidents, insufficient attention is often paid to the desired properties of foam in different scenarios.

For example, in the consolidation phase, foam may be used as if extinguishing a fire. In such cases, insufficient attention is given to optimizing the vapor-tightness of the foam blanket by adjusting the expansion ratio or possibly the proportioning rate.

Another example is using foam below the prescribed application rate to control the effects of a fire as much as possible.

Conclusion

The guide is written to provide a framework for people and organizations

This article was presented to you by:

Jochem van de Graaff

j.vandegraaff@h2k.nl

involved in incident response in the high-risk industry to increase the effectiveness of foam use.

This may require inventing new techniques, tactics, and working methods or further developing existing ones.

The lack of standards for controlling, covering, and consolidating that clarify the quality of foam for these functions is currently a gap. All of this requires much research and testing.

We are happy to engage in discussions with people and parties who would like to exchange thoughts on this matter.

You can request a copy of our new guide via info@h2k.nl or info@gez-brandweer.nl. It will be sent after the presentation of the guide at the JOIFF Foam Summit, November 12th and 13th.

Raymond Bras

r.bras@gez-brandweer.nl

Peter de Roos

Going Wireless

by André Tomlinson

In this instalment, we are looking at a selection of remote controlled response appliances.

Rise of the Machines

Robotics is one of the tech sectors that has seen exponential growth in sophistication and design over the last two decades. Fire Services have a glut of choices today with options ranging from firefighting platforms to rescue, reconnaissance and elevated water streams. Services at present can mix and match from a range of features and capabilities. To locomote current robots can be propelled by tracks, wheels and even quadruped legs. On the working end, robots are fitted with water and foam monitors, spray bars, CAFS, hydraulic turbines, ventilation fans,

elevated booms and platforms, grapples, dozer blades, articulated grab arms and winches, to name a few. Firefighting media choices include water (volume and spray mist), semi-aspirated or expanded foam and dry chemical in either bulk or triple-medium applications. On the tech side they can be fitted with LED spot and perimeter lights, fixed or gimbal mounted HD-CCTV and thermal imaging cameras as well as multi-gas and radiation detection. Payloads can vary from a few 100 kilograms up to several tons. Some manufacturers also offer Ex rated models which is of

special importance for scouting robots.

Covering all models out in the wild is the subject of a book. The following examples have been picked due to one or more unique features.

Typically firefighting robots are

Robots at work at a factory fire in China where hazardous materials was present (Source: Shandong Guaxing Intelligent)

The Fire Ox has all the elements of a brushfire appliance (Source: Lockheed Martin).

dependent on external sources to feed monitors, turbines or spray bars. Lockheed Martin has bucked the system with their Fire Ox robot. Primarily designed for the wildfire sector the Fire Ox is fitted with a pump, water tank, hose bed, equipment compartments, a monitor, spray-bar and a LIDAR sensor, to name a few features. The Fire Ox is not only remote controlled but can be made autonomous by programming it to follow a specific course or it can follow a person walking in front of it.

The Thermite range of firefighting robots by Howe & Howe out of the United States offers a wide range of products that have a strong reputation in the market and has seen wide use. An option of interest is the addition of a CAFS system to the robot’s payload.

When it comes to flow robots are limited by the number and capacity of supply lines. Flows normally top out at approximately 4,800 l/min with a few exceptions. One of these is the RXRM180D by Shanghai GrumMan out of China that flows up to 10,800 l/min of water and foam producing reaches of 105 m at a speed of 4.5 km/h. This

performance makes it ideal for the petrochemical, oil and gas sector where fire events frequently demand higher flows. Though larger than its typical peer, the RXR-M180D is not just useful for fires in the open but can also enter inaccessible processes and navigate under pipe racks while delivering high volume flow.

The adage “death by a thousand cuts” thoroughly applies to the utilisation of smaller robots in swarms. In a mass demonstration held in China on September 2016, the concept of using the multiple robots to swarm a process fire was effectively demonstrated. Several Shangdong Guaxing Intelligent CX-RXR-MC80BD robots flowing

4,800 l/min of water and foam each managed the whole event knocking down ground fires, performing exposure protection and entering the process area to access the hard to reach interior of the process that’s normally shielded from conventional master streams.

A number of firefighting robotic products have facilities to elevate master streams or turbines. Some are single booms providing approximately 2-meters of elevation with light streams. There are a couple of robots with multi-knuckle booms on the market that exceeds the 2-meter ceiling. One example is the RXR-M60L also out of the Shandong Guaxing Intelligent stable. Based on a boom-lift chassis the vehicle has a 4-kunckle boom with a vertical reach of 15-meters and forward reach of 3-meters flowing 3,600 l/min at the tip giving it a reach of 65-meters. Due to its small footprint, the RXR-M60L is capable of entering structures like high-bay warehouses and provide and angle-of-attack that’s not possible from ground based streams. The unit can also enter process areas to reach enclosed areas inaccessible to conventional appliances. The RXR-M60L is water

The Howe & Howe Thermite with CAFS option (Source: Howe & Howe).

The RXR-M180D high-volume robot. Note that the nozzle can be swapped out for an adjustable pattern type (Source: Mingguang Haomiao Vehicles).

and foam capable.

Taking elevated master streams on robotic platforms to the next level is Mingguang Haomiao Vehicles’ RXRM150D-JP25 articulated boom tower. With a vertical reach of 25-meters and forward reach of 11-meters, the 2-knuckle boom can reach up and over most obstructions delivering 10,000 l/min of water or foam at the tip. The tip is also fitted with a HD-CCTV and thermal imaging camera. The crawler has its own monitor and can flow 1,200 l/min of water. The RXR-M150D-JP25 can be considered a “hybrid robot” as it is fitted with a cab that can be manned or remotely controlled from up to 150-meters. The vehicle is fitted with a self-defence water deluge as protection when exposed to high levels of radiant heat.

The T-Rex of the firefighting robot universe is undoubtedly the RXRMQ20D-PC18 of Mingguang Haomiao Vehicles. This is a multi-purpose robot as it can be used in both the industrial fire and Urban Search and Rescue environments. The vehicle is based on an excavator with swap-out attachments at the tip. The vehicle is fitted with a 2 m3 dry chemical skid that can produce up to 20,000 m3 of dry chemical application. Water and foam is fed from outside sources. The booms have a vertical reach of 18-meters and a horizontal reach of 15-meters. The hydraulic attachments includes a 4,800 l/min monitor, jackhammer, shears, grapple and, of specific interest to the petrochemical, oil and gas sector, a 100 mm core drill that can penetrate 10 mm of steel plate under a minute

allowing dry chemical or water/foam to applied into voids, roof spaces, furnaces and similar confined areas. The RXRMQ20D-PC18 is a hybrid robot as well as it is fitted with a cab for manned operation or can and remotely controlled. This vehicule is also fitted with a selfdefence water deluge system.

Bird’s Eye View

As in the case of robots, fire services are spoiled for choice when it comes to Unmanned Aerial Vehicles (UAV),

commonly referred to as Drones.

The most common drone in service is the observation drone that provides incident managers with an “eye in the sky” improving their situational awareness and supporting dynamic incident assessments. In this category there are literally dozens of options to choose from. Typically these drones are fitted with high definition cameras and, depending on the specification of the drone, can offer extended time over target.

The RXR-M150D-JP25 water/foam tower (Source: Mingguang Haomiao Vehicles).

The RXR-MQ20D-PC18 penetrating a tank shell with its core drill attachment (Source: Mingguang Haomiao Vehicles).

Several robots of different sizes acting as a swarm during a tank farm exercise (Source: Shandong Guaxing Intelligent Company).

The RXR-M60L elevated master stream robot (Source: Shangdong Guaxing Intelligent).

The next step up in the “eye in the sky” category are drones with high definition television plus thermal imaging. This provides incident managers with the facility to check hot spots, fire location and night vision, amongst others. Features can be stepped up by adding a LIDAR to the payload for those instances where 3D rendering of the scene is required.

As technology improves many instrument manufacturers have evolved their technologies to compact sizes that can comfortably fit on drones. These includes motion detection, gas detection through both PID sensors and infrared imaging, flame detection and radiation detection, to name but a few technologies.

Drones have become more challenging to put in service. The days of “have drone will fly” has been curtailed by most governments. Operating drones today requires certified drone pilots and operators licenses with restrictions to where and how drones can be deployed. The Photokite provides a handy compromise. This drone is tethered to a base station that does not require piloting or operating licenses. It has a 45-meter ceiling and limited lateral movement providing incident

managers with a command view of the incident though from relatively fixed perspective. Unlike conventional drones that’s mission time is restricted by battery levels, the Photokite can stay aloft for 24-hours onwards as its power is fed through the tether cable.

Firefighting wise drones are yet to come of age. This is largely attributed to their limited payloads. Valiant efforts have been made to harness dry chemical, water and foam on drones. Dry chemical extinguisher devices in various shapes and sizes have been experimented with

including launchers, exploding balls and automatic-style pendant extinguishers. Water and foam attempts have been made by tethering drones to high-pressure pumps and water/ foam reservoirs on the ground. In all instances drone’s firefighting capacity have to date been limited through either capability of the extinguishing agents or restrictions in range and freedom of movement.

One attempt to up the firefighting ante has come from Chinese drone innovators eHang. Their 216F autonomous aerial firefighting vehicle has a 100-litre premixed foam tank that is discharged at high-pressure through a protruding nozzle. It also carries six launchers that can shoot ABC dry powder projectiles. A laser range finder and HD TV camera

The Sniffer4D V2 provides live monitoring of up to 9 gasses (Source: YouTube).

Left: The Autel EVO MX4T is one example of drones that provide HD TV, thermal imaging, and GPS on one platform (Source: Autel). Right: An example of the imagery that thermal imaging can provide during nighttime operations (Source: DroneDJ).

The Photokite tethered from a command vehicle staying aloft for 24-plus hours (Source: Photokite).

is provided. Time on mission is limited to 21 minutes and needs 120 minutes to turn around. With a footprint of 7.33 x 5.6-meters and a height of 2.2-meters the 216F is unfortunately a large beast that doesn’t fit snugly into a car boot. The 216F is also not a pure UAV in that it can be manned.

The IGNIS drone by Drone Amplified goes to the opposite extreme. The IGNIS is used for aerial ignition of backburns during wildland fires. The drone is fitted with a compartment containing 450 ignition spheres that can be deployed at a rate of 120 spheres per minute. IGNIS pin-injects the spheres with a precise amount of antifreeze (ethylene glycol) that start burning after hitting the ground. The IGNIS can follow GPSguided patterns that can be remotely uploaded. The drone is fitted with a thermal imaging camera.

Wildfires place heavy emphasis on aerial surveillance. This is normally performed by spotter aircraft, either light fixed wings or helicopters. Spotters have weather and night time flight restrictions and can be limited by heavy smoke conditions. That has perked this sector’s interest fixed wing UAV’s that can fulfil its duties in all weather and smoke conditions. UAV’s can operate over the horizon with speeds of up to 80 km/h and mission times of 8+ hours.

They are packed with surveillance equipment including amongst others HD TV, Thermal Imaging, mapping and LIDAR. UAV’s can also be launched from vehicles negating the need for air or heliports that plague traditional spotter aircraft.

Finally, drones come in all shapes and sizes. Some can be carried in carry cases, vehicle compartments or the boots of cars. Larger drones are not as easy to manage. There is also the issue of turning them around in quick time with freshly charged batteries and being able to distribute the signal feed beamed out by the drone. Enters dedicated drone support vehicles. These vehicles don’t just carry the drone and backup batteries but also monitors flight metrics and the streaming signals from the drones. It can also distribute signals over wireless networks to incident managers and command vehicles.

Flippers and Snorkel

Serving the fire services on and above terra firma there’s no reason why remote controlled vehicles should not follow us into the water. Remotely Operated

Underwater Vehicles (ROV) have been serving the marine, research as well as oil and gas sectors for decades. ROV solutions to aid in search and rescue missions have fairly recently become available to the emergency services sector. Using cameras and dual sonar (echo-location) ROV’s can be used to search for drowning victims and, using a grapple arm, can assist in victim recovery. Search and Rescue ROV’s are available in portable packages requiring no sophisticated equipment to mobilise, launch, operate and recover.

The next instalment of this series will be looking at devices and systems that project firefighting media.

The EHang 216F AAV (Source: EHang).

POG and Special Risks Advisor to Bristol Fire Engineering

André Tomlinson

This article was presented to you by:

The IGNIS aerial ignition drone (Source: NE Manufacturing Alliance).

A fixed wing UAV preparing for launch (Source: UAV Navigation).

A fixed wing UAV preparing for launch (Source: UAV Navigation).

The PIVOT is one example of the new generation of mini ROV’s available to the Search and Recovery sector (Source: Deep Trekker).

THE SWEDISH ORIGINAL

WATER DRIVEN PUMP PROPORTIONERS FOR FIRE FIGHTING

FIREMIKS For Industrial and Sprinkler Firefighting

Piston pumps (-PP) are well suited for systems with wide flow range, for example sprinkler systems and Gear pumps (-GP) are particularly suited for working in deluge installations and with large flow monitors.

FIREMIKS Mobile unit for Fire Brigades

With a FIREMIKS the firefighters get a flexible resource, easy to adapt to different firefighting situations. FIREMIKS works within a wide pressure and flow range giving a precise and steady dosing rate.

EASYTOINSTALLEASYTOOPERATEEASYTOTEST

COMPACT DOSING SYSTEM, NO NEED FOR PRESSURE TANK OR ADDITIONAL ENERGY SUPPLY.

RELIABLE MECHANICAL PROPORTIONER, DRIVEN BY THE WATER FLOW ONLY, NO NEED FOR PRESSURE BALANCING OR CALIBRATION

ECONOMICAL AND ENVIRONMENTALLY BENEFICIAL TESTING WITH A DOSING RETURN VALVE AND TWO SEPARATE FLOW METERS

FIREMIKS - Proportioners for SFFF

PER AREDAL DISCUSSES THE CHALLENGES AND SOLUTIONS FOR PROPORTIONING SFFF

by Per Aredal

Could you give an overview of who you are and the history and heritage behind FIREMIKS?

Originally founded in 1979 as a Swedish family-based business - Firemiks AB is operated by the third generation, together with strong industrial partners. Throughout the years, our focus has been to develop, manufacture and distribute our own line of water driven volumetric pump proportioning systems worldwide. Our work method is to have the possibility to produce custom solutions to the individual needs of each client project, while also delivering regular models in accordance with strict international standards.

Can you explain how FIREMIKS foam proportioners work, especially in terms of adjusting to different foam viscosities?

The proportioning of the FIREMIKS is based on the principle of positive displacement for both the water motor that is driven by the extinguishing water flow and the concentrate pump

that is driven by the water motor and which injects the concentrate into the extinguishing water flow. In this manner, the dosing relation is established by the volumetric relation of the water motor and the concentrate pump. This dosing relation is not affected much by viscosity, up to a limit of course as is detailed in the units’ performance data. The concentrate pump is connected to an atmospheric concentrate tank with gravity feed to the dosing pump. Solely the extinguishing water is required to power the whole dosing system.

What are the technological innovations in FIREMIKS systems that accommodate the varying viscosities of firefighting foams?

The volumetric water motor design was conceived by us in the late seventies, and it is very compact for the flow it can take. On a typical 3% unit, the water motor will take roughly 30x the volume of the concentrate pump, yet it is barely bigger. Since the start we have

constantly refined its design for better performance and reliability. Like all pump design, it is all about the details and the execution. Important is also our flexibility to adapt the design and sizing, so we can quickly match the water motor up correctly with a wide variety of high-end concentrate pumps, each of which also has its specifics to take into account.

Could you give us an overview on the models that FIREMIKS offers?

We have a diverse range of models catering to various flow sizes and proportioning requirements. Our smallest model has a max flow of 180 lpm and the largest single model a capacity of 10000 lpm flow. To achieve larger flows, up to 20000 lpm, we offer parallel installed FIREMIKS, on a base skid or mounted as” double-deckers”.

Our three standard models are: 12000 lpm (2 x 6000 lpm), 16000 lpm (2 x 8000 lpm) and 20000 lpm (2 x 10000 lpm).For fixed proportioning we offer 1% and 3% as standard. We may also supply units with special dosing rates, for example 0,1%, 0,3% 0,5%, 2%, 2,75% and 6%, on customer’s request. Models with selectable proportioning are available with 0,3-0,6-1% and 1-23% (For selected flow sizes 0,5-1-3%).

Is it difficult to ensure accurate foam proportioning across a range of different viscosities?

this means that as long as one follows the specified min and max flow of the data sheet, FIREMIKS accommodates changes in viscosity in a wide flow- and pressure range. There is no need for pressure balancing or calibration, nor is it possible without physically changing the unit. The FM approval which we have achieved (Standard: 5130 - May 2021) for eight of our 3% models, in three flow sizes: 1800, 2400 and 4000 lpm, verifies that the FM-approved FIREMIKS units are giving correct dosing rate and handling concentrates from 1 cP up to high viscosity concentrates (6422 cP at 20 degree C and shear rate 5 1/s).

What challenges does FIREMIKS, and the wider industry, face when transitioning from AFFF to SFFF in terms of viscosity handling?

are often non-Newtonian in their nature, accurately and reliably calculating the flow behavior is much harder. On devices that need calibration, the dosing might work in a specific set of circumstances, but as soon as one variable changes, it could fall out of calibration. Then it is much better to rely on a system that by design can accommodate a wide viscosity range, like FIREMIKS.

In what ways does the design of FIREMIKS proportioners, such as piston and gear pumps, cater to different foam viscosities?

FM approval is nominating our system “Variable Viscosity Pump Proportioner”,

Regulatory bodies are driving the shift from PFAS-containing concentrates to SFFF concentrates, prompting a reassessment of many proportioning systems for compatibility. Various manufacturers offer SFFF foams with a wide range of viscosities, including very high-viscosity concentrates. To select an appropriate proportioner, understanding the concentrate's properties — whether it falls within a viscosity range of 1 cP to around 5-6000 cP (measured using a Brookfield Viscometer Spindle #4 at 30 rpm) — or if it's classified as very high viscosity is crucial. In the past engineers have relied on being to calculate the flow of concentrate, but with these new SFFF concentrates that

FIREMIKS stands out by offering two types of dosing pumps — Piston and Gear pumps —alongside a robust multivane motor based on over 35 years of market experience. When working with clients, apart from considering flows and pressures, we prioritize understanding

the concentrate type and viscosity, a quite complicated subject, before recommending the suitable pump type and accompanying installation advice.

As mentioned our models equipped with Piston pumps are classified as ““Variable Viscosity Pump Proportioner” in FM approval terminology. They maintain precise dosing rates within approved tolerances across a broad viscosity spectrum, from low viscosity to around 5-6000 cP (dependent on variables like temperature, concentrate type, and brand). Important to know is that all Piston pumps systems on the market have a limit upwards on handling viscosity concentrates, due to the Piston pump reciprocating principle; for each revolution, the plunger sucks concentrate and then presses it out and the concentrate goes from zero to full speed twice per revolution. If the static viscosity is too high with non-Newtonian concentrates, the concentrate might not flow smoothly and therefore the correct dosing rate may not be achieved.

Typically, our Piston pump models excel in systems with low start-up flows relative to the maximum flow rate, ideal for applications like sprinkler systems, providing versatility across a wide flow range.

Water motor-driven pump proportioners equipped with Gear pumps are wellsuited for handling high and veryhigh viscosity concentrates. We have successfully tested Gear pump models using Fluorine-free foams with a viscosity of up to 8,040 cP (Brookfield Viscometer Spindle #4 at 30 rpm). Gear pumps excel with high-viscosity fluids

due to their counter-rotating gears that create a consistent, non-agitating flow, ensuring effective sealing with such fluids.

Our Gear pump models are particularly efficient in applications operating at the higher end of the maximum flow rate, such as deluge and large fire monitor systems.

Are there any efficiency negatives in the transition to SFFF?

For all systems dealing with higher viscosity concentrates, ensuring adequate foam supply pipe diameter, good gravity feed, and minimizing concentrate line lengths are crucial. Our datasheets specify recommendations, and we're available for more tailored guidance for your project.

How does the "Variable viscosity pump proportioner" designation by FM Approval impact the functionality and reliability of FIREMIKS systems?

The term refers to that these units are approved for a wide range of viscosities, compared to other proportioners which often are limited to a specific viscosity, Within the approved flow and pressure range specified in each models Data sheet, the dosing remains within the approved dosing tolerances stated in the standards (for example 3,0-3,9%)

This gives the advantage that there is no need for recalibrating the FIREMIKS proportioner at any future changes of concentrate/viscosity, this is often needed with for example bladder tanks, creating added crucial down-time for this replacement/recalibration.

Can you explain the significance of the Dosing/ Return valve (DRV)?

All units can be supplied with a Dosing/ Return valve (DRV) as an option. In the Return setting the concentrate is pumped back to the tank during a test giving substantial cost saving on

concentrate and also on the no need for cleaning up and destruction of dispersed foam, an important environmental and economic benefit. The respective water and concentrate flows should be measured with two independent flow meters to calculate accurate dosing rate.

If requested we may offer a complete Dosing rate test system that follows the guidance of EN 13565-1, NFPA11 and FM 5130.

How does FIREMIKS address the calibration and maintenance challenges associated with varying foam viscosities?

The unit is factory calibrated and does not need additional calibration. One should test the system annually to ensure proper function as is required by most standards.

Looking towards the future, how is FIREMIKS preparing for further advancements in firefighting foam technology? What trends or challenges do you see?

The current shift in the market from AFFF (Aqueous Film Forming Foam) to SFFF (Synthetic Fluorine-Free Foam)

concentrates, which we expect will last for at least another 10 years, poses challenges for both existing and new foam systems. It will create a demand in upgrading many existing systems. We see also more interest in lower dosing rates as 1% and even lower for example 0,3, 0,5% etc. Also, the challenges to create good system capable of extinguishing Li-Ion batteries in an effective way is a major challenge for the whole fire-fighting industry. Firemiks AB is well-prepared in this process to further develop our system if necessary to meet different concentrates requirements.

Per Aredal

International Sales Director at Firemiks AB with +30 years of experience of producing and delivering water driven volumetric proportioners world-wide.

+46-76-139 70 34

per.aredal@firemiks.com

This article was presented to you by: www.firemiks.com

Emergency Response and the associated competencies

by Steve Watkins

A question an organisation often asks is whether their responders are competent to deal safely with the incidents that they could be faced with? A company has a responsibility to not only show that they have the resources and personnel to deal with a credible scenario associated in their business but also that they can do that safely. Personnel at all levels should have the necessary training and demonstrate competence in dealing with these situations.

As we delve into this subject, I want to challenge a common assumption that emergency response training is sufficiently covered by generic standards and job performance requirements, such as those outlined by the NFPA. While these standards provide a crucial foundation, there is a pressing need to go beyond the basics to ensure that our response efforts are truly effective, efficient, and safe.

Let’s begin by acknowledging the importance of the NFPA Job Performance Requirements. These standards offer a robust foundation for emergency response, outlining essential skills and knowledge. However, these guidelines are often seen by trainers as generic. They provide a broad overview but may not encompass the specific nuances of

every unique situation. Relying solely on these standards can lead to a dangerous gap between theoretical knowledge and practical, real-world application. For example, Fire teams may have certain knowledge and skills, but lack understanding when applied in a real world situation.

Generic training sessions are a common approach, but they frequently lack the realism necessary for effective preparation. Consider this: if your training only includes standard fire drills or basic hazard responses, what happens when you encounter an unusual or complex incident that does not match your training drills? Can you adapt?

This lack of preparedness can result in slower, less effective responses, increasing the risk of escalation. Applying the elementary skills to a changing situation when focus must also be placed on the dynamic environment can be challenging. Furthermore when incidents are not managed in their entirety, they can lead to severe consequences, including greater risks to responders and significant financial and reputational damage to the company.

So, how do we bridge these gaps? To resolve incidents effectively and prevent them from escalating, it is imperative to focus training on the following key areas:

Realistic scenario planning; Targeted skill development; Strategic training investments.

Firstly, realistic scenario planning is essential. Generic training scenarios may not accurately reflect the specific challenges your organization might face. For example, a pump seal fire could be a regular occurrence and training on a simple simulator prop would suffice 9 times out of 10. However, what if the access is difficult, exposure to other equipment or to personnel is high. These unique conditions require tailored scenarios that reflect real-world risks and operational environments.

By investing time and resources into developing scenarios that mirror potential real-life incidents, you prepare your responders for the specific challenges they might encounter. Training is often perceived expensive and does not contributing to the

profitability of the business. But there is an old saying “If you think training is expensive, then try an incident”

Design realistic, tailored scenarios that reflect the specific risks and operational contexts of your organization, moving beyond generic, one-size-fits-all drills. Develop training exercises that closely simulate the actual threats and conditions your team may face. What is most likely to go wrong and are there critical steps that need to be taken to prevent escalation. Work with the facility process operations team to design a scenario which fits in with their dilemmas.

For instance, a liquid pool fire needs the correct firefighting foam application techniques but when this has to be

done whilst cooling critical equipment with water, then conflicting actions can arise. By creating exercises that replicate the exact challenges faced in your environment, your teams have an improved understanding of the situation and are better prepared to adapt to meet the scenario demands.

Secondly, targeted skill development is crucial. Competencies defined by standards like the NFPA are a starting point, but they must be adapted to address the particular demands of your organization's emergency scenarios. This means identifying and honing the specific skills that will be required in various situations. Tailoring skills training to these specific needs ensures that responders are not just familiar with broad concepts, but are adept in the precise competencies required for their roles and the realities of their job.

While NFPA standards outline core competencies “Job Performance Criteria”, responders must also develop specialized skills relevant to their operational context. This includes:

Technical Skills: For example, understanding the intricacies of specific products, procedure and protocols;

Decision-Making Skills: Training should enhance the ability to make quick, informed decisions under pressure. Simulations can help responders practice these critical decision-making moments. Often the decision makers are often excluded during routine training;

Team Coordination: Effective response often relies on seamless teamwork. Training should emphasize communication and coordination

strategies tailored to your specific team structure and incident types.

Finally, investing in strategic training is key. Companies must allocate time, money and resources to continuously improve their emergency response training programs. This involves updating scenarios, reflecting the change in risks and incorporating lessons learned from past incidents and near-misses. To achieve these goals, companies need to strategically invest in their training programs. This involves:

Utilizing Training Simulation tools : Train on realistic simulators that mimic the incident. Talk to training providers if you don’t have your own training facility about your needs. For example if liquid firefighting of polar products is a major risk, can you train with real polar liquids and Alcohol Resistant Foams? Without this Live Fire training experience the necessary knowledge and skills cannot be applied in the correct setting;

Regularly Updating Training Protocols: Continuously incorporate lessons learned from real incidents and near-misses to keep training relevant and effective. Identify the hazards, the most effective strategy, tactical deployment to manage the incident that brings in risk mitigation measures for safe operations;

Engaging Experts and Consultants: Collaborate with industry experts to develop and refine training scenarios and protocols. A well designed training scenario should cover the skills required but also the time pressures, decision making and interoperability with other departments.

In summary, while generic emergency

response competencies are valuable, they should not be seen as a comprehensive solution. By focusing on realistic scenario planning, targeted skill development, and strategic training investments, we can enhance our preparedness and response capabilities. This approach not only mitigates the risks associated with emergencies but also minimizes financial and reputational losses for our organizations.

Beyond the specifics of training, it’s also important to foster a culture of preparedness within your organization. This means encouraging ongoing learning, promoting a proactive attitude towards emergency management, and recognizing the importance of both individual and collective readiness.

Let us commit to going beyond the basics and ensure our responders are equipped not just to meet standards, but to excel in real-world situations. Together, we can build a safer, more resilient future.

This article was presented to you by:

Steve Watkins

Consultant Training RelyOn Fire Academy

Responsible use of C6 Fluorine Chemistry and to providing its products to firefighting foam manufacturers.

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C6 Foam Concentrates are required for critical uses and major fire events.

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Reminder of Best Practice:

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Why Regular Reviews of Industrial High Hazard Emergency Response Plans Are Non-Negotiable?

ENSURING SAFETY, MITIGATING RISKS, AND KEEPING YOUR OPERATIONS RESILIENT

In the dynamic world of industrial operations, high-risk hazards are a reality that every facility must be prepared for. Whether it's a chemical spill, a fire outbreak, or an explosion, the consequences of these emergencies can be catastrophic, not only for the people working on site but also for the surrounding communities and the environment. This is why having an Industrial High Hazard Emergency Response Plan (IHHRP) is a legal and moral obligation for facilities handling dangerous substances and processes.

But having a plan is just the beginning. To ensure these plans remain effective, they must be regularly reviewed, updated, and adapted to the evolving landscape of industrial operations. Here’s why periodic reviews of Industrial High Hazard Emergency Response Plans are essential for every industrial facility.

Adapting to Changing Operational Environments

Industries are constantly evolving. Facilities expand, processes are upgraded, and new technologies and materials are introduced. These changes can significantly impact the risks present in a facility and, consequently, the measures needed to respond to emergencies.

Imagine a plant that upgrades its production line, introducing new machinery and chemicals to streamline its operations. If the emergency response plan doesn’t account for the potential hazards associated with these new elements, it becomes obsolete, exposing the facility to heightened risks. Regular reviews ensure that the plan remains relevant and tailored to the

current operational environment.

Keeping Up with Regulatory Compliance

Regulations governing high-hazard industrial facilities are constantly updated to reflect the latest safety

standards, technological advancements, and learnings from past incidents. Authorities like the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) may introduce new guidelines that require adjustments to existing emergency response plans.

By conducting regular reviews, facilities can stay compliant with evolving regulations, avoiding potential legal consequences and penalties. This not only keeps the organization aligned with industry best practices but also ensures that the workforce and surrounding communities are protected according to the latest safety standards.

Addressing Personnel Changes and Training Needs

Industrial facilities often experience changes in personnel, from frontline operators to emergency response team members and management. New staff members may not be as familiar with the existing emergency procedures as their predecessors, and they might require updated training.

Regular reviews of the Industrial High Hazard Emergency Response Plan allow facilities to identify and address these training gaps. They ensure that every team member knows their role during an emergency and that emergency drills are conducted with up-to-date information. The plan can also be adjusted to account for shifts in personnel or organizational structure, ensuring continuity in emergency response.

Incorporating Lessons Learned from Real Incidents and Drills

Emergency response plans are not theoretical documents; they are practical, actionable strategies meant to protect people, assets, and the environment during high-risk situations. The most valuable insights into their Sources:

effectiveness often come from realworld incidents or simulated emergency drills.

When an emergency occurs, or when a drill reveals a gap in the response plan, it’s crucial to act on those findings. Regular reviews allow facilities to incorporate lessons learned, ensuring that the same mistakes aren’t repeated and that the plan evolves based on practical experiences.

Enhancing Coordination with External Emergency Responders

High-hazard emergencies often require coordination with external emergency services, such as fire departments, hazardous materials (HAZMAT) teams, and medical responders. Over time, these external teams may also undergo changes in personnel, procedures, and equipment.

By reviewing the IHHRP regularly, facilities can strengthen their partnerships with these external responders, ensuring that everyone is on the same page. Joint drills, updated contact lists, and aligned procedures between internal and external teams can make the difference between a swift, efficient response and a chaotic, delayed one.

Adapting to Environmental and Community Changes

The environment and communities surrounding an industrial facility are not static; they change over time. New residential developments, changes in traffic patterns, or environmental

shifts like the construction of nearby waterways or wildlife habitats can all affect the scope and impact of potential emergencies.

Regular reviews of the emergency response plan help account for these changes, ensuring that the facility is prepared for different scenarios. For instance, an evacuation route that was once viable might no longer be practical due to new construction. Updating the plan ensures that all possible contingencies are covered.

An Ongoing Commitment to Safety and Resilience

An Industrial High Hazard Emergency Response Plan is more than just a document—it’s a lifeline that can save lives, minimize environmental impact, and protect a facility's reputation and financial stability. However, for it to serve its purpose effectively, it must be regularly reviewed and updated.

By making these reviews a priority, industrial facilities demonstrate their commitment to safety, operational resilience, and compliance. It’s an investment that pays off not only in terms of regulatory adherence but also in creating a culture of safety that values preparedness and proactive risk management.

So, the next time you look at your Industrial High Hazard Emergency Response Plan, ask yourself: is it current, comprehensive, and reflective of your facility’s present reality? If not, it’s time for a review—because in the world of high-hazard industries, preparation isn’t just important; it’s essential.

Certificate ensures quality and prevents health damage and environmental violations in PFAS cleaning

by David Pronk and Kees Kappetijn

"Workplace accidents, health damage, and environmental violations at tank cleaning companies." In September 2024, the Dutch newspaper NRC reported on issues in the world of tank cleaning. Tank cleaning is necessary not only for tanks containing hazardous substances but also for tanks with foam-forming agents. The world is in the midst of a foam transition: the current fluorine-containing firefighting foam is being replaced by a new, fluorine-free variant. Preventing contamination of the new fluorine-free foam with residual PFAS is crucial. This can be achieved through high-quality cleaning. Delivering quality and preventing health and environmental damage are key objectives of the cleaning process. These objectives are now secured in an assessment guideline. This guideline has been developed in the Netherlands, with support from industry, service providers, and regulators, but is applicable worldwide.

Assessment Guideline

Until recently, there was no certification for cleaning processes involving PFAScontaining firefighting systems. But that has changed. A project group consisting of cleaning organisations, the chemical industry, fire brigades, environmental agencies, laboratories, and waste processors came together to develop a quality framework for cleaning processes. This quality framework is completed with a certificate and is known as an assessment guideline (BRL). A BRL is developed by the market, accepted by the authorities, and assessed by an independent certification body. For the BRL PFAS cleaning, Kiwa is the organisation that oversees the cleaners who work according to the BRL.

The BRL sets the framework but does not prescribe the cleaning process. The market can decide how to flush, how often to flush, and what products to use. The cleaner, therefore, determines the cleaning process. The BRL provides guidelines for the cleaning process to

achieve the goal: a safe, risk-resistant, cost-effective, and high-quality cleaning process.

"A safe, risk-resistant, costeffective, and high-quality cleaning process."

Foam Transition

The foam transition is necessary because fluorine-containing firefighting foam has been used for decades. Industrial companies have large quantities of firefighting foam stored in stationary firefighting systems and vehicles. For public fire services, the foam is mainly stored in foam firefighting vehicles and tank trucks. For several years now, it has been evident that the poly- and perfluoroalkyl substances (PFAS) in this firefighting foam have very detrimental long-term effects on humans and the environment. Its use is now nearing an end. Industrial companies and fire services are rightly transitioning to new foam.

There are several reasons why a foam transition must be carried out carefully. Firstly, to prevent PFAS from entering the environment—and human bodies. PFAS break down very slowly, if at all, and are difficult to remove. The substances spread quickly and easily, accumulating in plants, animals, and humans. PFAS are toxic, so this accumulation is harmful.

Secondly, careful execution is essential because the European Union is introducing a total ban on the sale and use of fluorine-containing firefighting foam. The European Chemicals Agency (ECHA) has set a limit of 1,000 parts per billion (ppb) of PFAS in firefighting foam (and for some specific substances, the limit is even stricter). Fluorinecontaining foam will soon be banned. The authorities will oversee the careful execution of this foam transition.

A careful foam transition presents several challenges. Fluorine-containing

foam cannot simply be replaced with fluorine-free foam on a given day. In many cases, the fluorine-containing foam has been stored in foam tanks for many years. This means that the foam tank, and possibly other parts of the firefighting system, are contaminated with PFAS. PFAS not only accumulate in plants, animals, and humans but also in firefighting systems. Depending on the material of the tank/pipes, it is difficult to remove.

When fluorine-free foam is stored in the system, "old" PFAS will eventually be released from the system. These PFAS will mix with the new foam, resulting in the fluorine-free foam no longer being fluorine-free and, therefore, unusable. The foam transition would then need to be repeated.

Cleaning

You only want to carry out the foam transition once. Besides selecting and purchasing a new foam concentrate, suitable for different scenarios and substances, parts of the firefighting system may need to be adjusted or replaced. The old foam must be disposed of, and changes must be documented in reports such as fire brigade reports, operational plans, and fire analyses. All of this should be done in consultation with the authorities and the insurance company.

Thus, the foam transition must be executed with care to prevent residual PFAS from contaminating the new fluorine-free foam. This is achievable by cleaning the firefighting system. An adequate cleaning process can remove residual PFAS. The market has developed various cleaning processes, offered by different companies. Some

use (heated) water, while others use water and a cleaning agent.

As a customer, you want to know which cleaning process works, and whether it is safe and effective. You do not want to use a process that leads to scattered PFAS, causing environmental or health issues. There is therefore a need for guaranteed quality. In a quality system, quality is demonstrated by a certificate. A certificate that works in a free market is therefore necessary.

Assessment Guideline

The certificate sets the framework for the cleaning process, which is not limited to just cleaning. The entire cleaning process consists of four parts, each with its own guidelines. These are:

1. Scope and initial data;

2. Cleaning and execution;

3. Sampling and analysis; 4. Waste and disposal.

Firstly, the scope and initial data are framed. It is important to determine which parts of the firefighting system will be cleaned. This can involve the entire system or just the tank, for example, when the system has hardly been used and the foam has not left the tank. The objective must also be set: which limit values will be used, and which laws and regulations must be met? The BRL aligns with the limit values set by ECHA and does not include independent values.

Secondly, guidelines are set for the cleaning process, mainly focusing on environmental and health regulations, such as the use of personal protective equipment. The setup of the cleaning process itself is not standardised; different processes are possible.

Customers can decide whether to use a high-quality, long-term cleaning process or a faster, perhaps more efficient, one. But in all cases, the process must be safe and effective.

Thirdly, guidelines are set for sampling and analysis. To determine and demonstrate that the PFAS limit values have been met, samples must be taken. Environmental and health regulations for sampling have also been established, along with knowledge requirements for the operating personnel, and guidelines for the packaging, shipping, and analysis of the samples.

Finally, guidelines are set for the storage, disposal, processing, and documentation of waste. The goal is for cleaners to demonstrate that waste does not enter the environment but is stored, transported, and processed by recognised companies. To demonstrate this, a record of the waste should be kept. This is important because processing capacity is very limited. There are only a few processors, all located abroad. Waste, such as rinse water, will always need to be stored for some time before it can be transported and processed. Cleaning companies must handle this carefully and ensure that these activities are covered by the company's permits.

Safety, Quality, and Cost Efficiency

If a cleaning company operates within the set guidelines, it can be certified by an independent certification organisation after an inspection. A new inspection is conducted each year. In this way, cleaners can demonstrate that they have established a safe and effective cleaning process. The authorities, such as the Inspectorate for the Environment and Transport and environmental agencies, can refer to certified cleaners when cleaning is included in permits or decisions.

The result is that companies can be confident that PFAS have been responsibly removed, transported, and

processed from firefighting systems. The new fluorine-free foam will not be contaminated with PFAS, ensuring it remains fluorine-free. This means that the foam transition only needs to be carried out once and is executed as cost-effectively as possible. Whether there will be no contamination from residual PFAS over time will need to be determined by further research. However, using the BRL guarantees a professional work process, with no requirement for repetition. Finally, the BRL ensures that PFAS are properly removed from firefighting systems, protecting both people and the environment.

This article was presented to you by: www.kappetijn.eu

Consultant at Kappetijn Safety Specialists

Consultant at Kappetijn Safety Specialists Kees Kappetijn www.kappetijn.eu

David Pronk

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Potential Fire Scenarios and Emergencies at LPG Facilities

by Onur Özutku

LPG is an essential part of modern life and a readily accessible energy source that enhances people's comfort. This energy source is widely used worldwide. To meet the demand for LPG, numerous facilities have been established and are operating globally. However, due to differences in national safety regulations and codes, not all of these facilities are safe and efficient. As a result, there are still many unsafe LPG facilities around the world. If LPG filling facilities are not properly designed and operated in line with safety standards, they can pose severe risks of fire or explosion. This article offers guidance on various aspects of LPG, including facility design, equipment selection, emergency management, and lessons from past incidents.

1. Design and Operational Considerations for LPG Facilities.

Liquefied petroleum gas, commonly known as LPG, is a mixture of light hydrocarbon compounds, primarily propane and butane. Although nontoxic, LPG is highly flammable, making it essential for LPG terminals to be carefully designed to mitigate any hazards associated with its physical properties. LPG is produced in oil refineries or extracted from natural gas wells. It is colorless and odorless but highly explosive and flammable

when not properly contained.

LPG is a simple fuel that is relatively easy to source and more affordable than many other fossil fuels. It mainly consists of propane and butane, which are chemically similar but differ slightly, particularly in their boiling points. The boiling point of a substance is the temperature at which its vapor pressure equals the surrounding pressure, causing the liquid to change into vapor.

The boiling point of propane is -44°C, while the boiling point of butane is -1°C. The boiling temperature determines the

vapor pressure, which plays a significant role in storage conditions. At ambient temperature, vapor pressure typically ranges from 4 to 11 bar, depending on the propane ratio in the LPG mixture. As the propane ratio increases, the vapor pressure rises, as propane’s lower boiling temperature directly impacts vapor pressure. These pressures are manageable for operational teams.

LPG is an essential energy source for modern life. However, society faces two critical challenges in energy management: cost and environmental impact. The most pressing

Figure 1 Burning Cooking Gas and Autogas

environmental concerns are global warming and greenhouse gas emissions, with many nations vigorously combating greenhouse gases. This struggle is often described as a battle—an intense and costly endeavor that humanity must win to prevent further environmental harm. LPG contributes positively to this effort; it is an environmentally friendly fuel, releasing only carbon dioxide and water vapor when burned. LPG is also readily available, efficient, and easier to store than LNG or CNG, with lower storage and operational costs.

Like LNG and CNG, LPG operations involve hazardous processes, so storage and handling must adhere to stringent safety standards. Despite its many advantages, if operational teams lack the necessary knowledge and experience, LPG can pose serious risks, as past facility accidents demonstrate. Therefore, thorough training for employees and adherence to regulatory standards in facility design are essential.

Due to the potential hazards associated with LPG, all plant operations must be conducted with extreme care, following universal safety standards. LPG terminals are built for loading, unloading, storing, and distributing LPG. Given the high-risk nature of these operations, proper safety measures and planning are vital for successful facility operations. LPG facilities are inherently hazardous, making it critical that their design and layout follow strict regulations.

For these reasons, certain key design principles must be considered:

1. Safe and Efficient Design: LPG

facilities must be designed with both safety and area efficiency in mind. For instance, truck loading bays should be structured to minimize the risk of a tanker colliding with LPG pipes. Sufficient space should be provided for trucks to enter easily, with road designs that eliminate the need for reverse maneuvers near vulnerable pipelines.

2. Safe Distances from Ignition Sources: Safe distances should be maintained between loading bays and any ignition sources to reduce fire or explosion risks in case of leakage or spillage.

3. Compliance with Local Regulations: Local regulations and fire protection standards (such as NFPA 58) outline minimum distances critical to safe design.

4. Positioning Relative to Wind Direction: It is advisable to position loading bays away from the prevailing wind direction toward permanent ignition sources. This prevents LPG vapors from reaching ignition sources in the event of a leak, reducing the risk

5. Grounding of Loading Racks: Vehicles on public roads and locomotives on railways pose potential ignition risks for LPG. Loading racks should be grounded to prevent static electricity and stray currents.

6. Remote Emergency Shutdown for LPG Flow: In the event of an LPG leak or spill, there should be a way to immediately stop LPG flow in the loading bay. However, operators may not always be able to reach emergency valves or stop buttons. Remote shut-off options should be available, and emergency stop buttons should be located in accessible and sufficient locations.

7. Proximity of Emergency Stop Buttons: Emergency stop buttons should be positioned close enough to loading bays so that operators can reach them quickly via designated escape routes.

8. Leak Detection and System Shut-off: Leak detection systems should automatically shut down LPG pumps and compressors, cutting off

of Figure: Study on the characteristic of boiling expansion process of superheated LPG and its vapor cloud explosion. (https://www.sciencedirect.com/science/article/abs/pii/ S0950423022001073)

Figure 2 LPG Release Behavior

Source

LPG flow when a gas leak is detected from tanks or pipelines. Detector placement should consider prevailing wind directions and potential leakage points, such as pump seals and flanges.

9. Fire Protection Equipment: Fire protection systems should be designed according to the most critical fire scenarios. Facilities should have water spray systems and fixed monitors for diluting small leaks, along with portable and wheeled dry powder extinguishers for managing minor fires.

10. Loading Equipment Standards:

For loading zones, use loading arms and flexible hoses suitable for LPG’s chemical properties, pressure, and temperature. Additionally, hoses or arms should be equipped with safety features like breakable couplings and isolation kits.

2. Industrial Accidents in LPG Terminals and Facilities

Despite extensive experience in the LPG industry, accidents still occur. LPG is a well-established and crucial component of the global oil and gas industry, involving a wide range of stakeholders worldwide. Incident histories underscore the potential for severe accidents, which can have cascading effects on nearby businesses and residential areas.

Over the years, the LPG industry has made significant strides in enhancing safety protocols and reducing the risk of incidents. Numerous standards, codes, and Directives related to pressure equipment and explosive atmospheres

apply to LPG tank design, installation, and operations. Although the risks associated with LPG operations are largely known, they may sometimes be overlooked or underestimated by operators. Therefore, all risks must be carefully identified, and designs and equipment selections should align with those risks.

2.1. The Largest LPG Tragedy in History

On November 19, 1984, a catastrophic fire and series of explosions occurred at an LPG storage and distribution terminal in San Juan, Mexico City, Mexico. During loading operations, a pipeline burst, leading to a vapor cloud explosion. This explosion and subsequent fires triggered a BLEVE (boiling liquid expanding vapor explosion) of two small spherical tanks within five minutes.

A fireball 600 meters in diameter formed at ground level, with tank fragments thrown up to 600 meters away. Additionally, twelve flaming rocket-like fragments, each weighing 20 tons from cylindrical tanks, traveled distances between 1 and 1,200 meters. Tragically, the incident resulted in over 500 fatalities, 7,000 injuries, and the evacuation of 39,000 residents. Approximately 4,000 rescue workers were involved in the response operations.

The exact cause of the accident remains uncertain due to extensive facility damage and a lack of eyewitness accounts. Potential contributing factors may have included overfilling or excessive pressure in one of the storage tanks or pipelines.

Many factors contributed to the disaster, including terminal design flaws (such as inadequate tank spacing, ineffective gas detection, and lack of passive fire protection systems), destruction of fire-fighting systems due to explosions, poor maintenance of safety equipment, and the proximity of densely populated areas to the terminal.

One critical factor may have been the overfilling of one or more tanks over the weekend. Prior to the disaster, booster pumps in the pipeline feeding the tanks had been replaced, resulting in higher discharge pressures. This information is crucial to understanding the accident. Booster pumps create pressure between the supply tank and the distribution tank, subjecting the pipeline to both the static pressure from the suction tank and the discharge pressure generated by the pump. These combined pressures can lead to overpressure. Without adequately sized safety valves, combined with potential corrosion or erosion in the pipeline, overpressure could easily result in leaks or ruptures. Therefore, studies such as Management of Change (MOC) and Hazard and Operability Analysis (HAZOP) are essential to evaluate safety risks in new modifications or changes.

2.2. Primary Precautions to Prevent LPG Accidents

Storage Tank and Pipe Design:

Pressure storage vessels and pipelines must be designed to meet appropriate standards and to maintain their structural integrity throughout their operational life. This involves meticulously defining specifications, including operating

pressure, temperature, and materials selection. Tank and pipeline design are foundational aspects for terminals. From welding to flange assembly, all pipework must be carried out by expert teams. For fire safety, gaskets used in flanges should be fire-resistant and meet the appropriate pressure class requirements.

Tank and Unit

Spacing:

The placement and arrangement of tanks are critical to safeguarding personnel and surrounding communities. Proper ventilation is essential to disperse flammable vapors quickly following any leak or accidental release. Additionally, flammable atmospheres must be kept away from potential ignition sources both during routine operations and in the event of accidental releases.

Pressure Relief Valve Selection:

Pressure relief valves must be precisely designed to release excess pressure if operational limits in tanks or pipelines are exceeded. Their design should account for scenarios including thermal expansion, fire risks, and potential overflow conditions in pipelines. Proper installation in the correct locations and conditions is equally important.

Pressure relief valves are essential in LPG terminals to prevent overpressurization of vessels and other equipment by releasing excess pressure when necessary. These valves manage the release of gas, vapor, liquid, or steam, thereby protecting plant personnel and equipment. Failure to release excess pressure can result in equipment damage, product loss, and costly shutdowns. Available in various sizes and configurations, pressure relief valves allow pressurized liquids or gases to escape, ensuring the system does not exceed safe operating limits. They automatically activate when pressure exceeds set limits, restoring tanks or pipelines to safe operating levels.

The most common type of safety valve used in LPG terminals is the springloaded safety valve. This valve features a

spring attached to an adjustment screw, allowing operators to fine-tune the spring force by adjusting the screw. The spring connects to a disc via a spindle, with the disc positioned to block the entry point where liquid would flow into the valve under excessive pressure. When the system pressure force is lower than the spring force, the disc remains stationary, maintaining normal operating conditions. When the pressure equals the spring force, the disc starts to move, allowing LPG from the tank or pipeline to enter the valve and exit the system to relieve excess pressure.

Emergency Shut-off Measures:

In situations where LPG is at risk of release or fire, shut-off valves should be deployed to stop the flow, thus preventing further release. All inlet and outlet connections on LPG tanks must have emergency

Figure 3 LPG Pemex Disaster

Figure 4 LPG Plant Topside View

shut-off valves located as close to the tank as possible. These emergency valves can be installed inside the tank (operable manually or automatically via remote hydraulic pressure).

Emergency shut-off valves on external LPG pipelines should be capable of automatic or remote control closure. These valves are essential for safety during loading and unloading operations for tankers or ships. Emergency shut-off options should include:

a. Manual shutdown b. Manual activation from an accessible emergency location c. Automatic shutdown in case of LPG release d. Automatic shutdown triggered by thermal (fire) activation.

Process Monitoring: Continuous monitoring of operational data in

terminals is critical for ensuring process safety and operational continuity. Terminals must be equipped to track and relay data on pressure, temperature, and tank levels accurately to operators. Depending on the specific operation, other key parameters such as pump flow rates, motor voltages, and currents should also be monitored.

Process monitoring plays a crucial role in enhancing the safety and sustainability of LPG operations by minimizing risks and their impacts on workers and the environment. A simple rule to remember is: You cannot manage processes that you cannot monitor. If you cannot see or track them, you are not safe..

Detection Systems: Gas, flame, or heat detectors should be installed in LPG

facilities to alert personnel and activate emergency equipment in the event of potential hazards, such as leaks, spills, or fires. These systems serve as vigilant guardians, continuously monitoring the facility. Depending on the design, they may activate alarms or trigger automatic emergency responses. For instance, when an LPG leak is detected, the tanker loading operation is automatically halted (the LPG pump must stop), and the emergency shut-off valves for LPG are closed.

The installation of gas detectors is essential for detecting LPG leaks. Several parameters must be considered during this process, including the location of tanks in terminals, flange connections, pump seals, flexible hoses, prevailing wind directions, and low-lying areas. Therefore, the layout

Figure 5 LPG tank and Pressure Safety Valves

Figure 6 Process Monitoring

of detectors should be designed by experienced professionals based on a thorough risk assessment.

Writing Operating Procedures:

Procedures and instructions serve as critical guides for the operation of LPG terminals. When developing these guides, it is important to encompass all processes related to the storage, distribution, and handling of LPG, particularly during loading, unloading, and maintenance activities at the terminal. Well-defined procedures help prevent operators from taking unnecessary risks and reduce confusion, thereby enhancing overall safety.

When preparing procedures and instructions, it is essential to reference risk assessments, equipment manuals, and relevant LPG standards and codes. Ultimately, these documents should describe technical methods in terms that terminal employees can easily understand. In short, they should provide a clear, straightforward, and detailed series of texts that offer accurate and reliable guidance to staff.

3. Emergency in LPG Facilities

To prevent the emergence of risk situations in LPG storage operations, it is crucial to thoroughly discuss all processes and develop comprehensive emergency action plans.

Operations involving product transfer (whether tank-to-tank, tank-to-truck, or tank-to-vessel), water removal from tanks, LPG sampling for quality control, commissioning and decommissioning

Figure 7 LPG Leak Dedection

Figure 8 Standart Operationg Procedure

Figure 9 Emergency in LPG Plant

Figure 10 Unignited Liquid LPG Leak From Tank

of tanks, and venting non-condensable gases such as nitrogen can all lead to undesirable LPG releases if not executed properly. Even with primary protection layers in place to mitigate such risks, emergency situations can still arise.

Utilizing written emergency procedures at each terminal for every potential emergency and training stakeholders on these procedures prior to an incident can significantly reduce the negative impact on terminal personnel and nearby facilities.

Pre-emergency planning involves a careful analysis of each contingency under non-stressful conditions and helps assess the adequacy of the current organization, personnel, and equipment. Terminal management should take all necessary actions based on these assessments. Evaluating an emergency plan through training and drills is a crucial aspect of pre-emergency planning.

The greatest concern associated with LPG operations is the accidental release of LPG into the atmosphere. Whether these releases are ignited or not, key considerations in emergency planning should address the following questions:

a. What steps should be taken to stop the release and leaks?

b. What measures should be implemented to disperse the LPG vapor cloud and minimize exposure to employees, the terminal, or the public?

3.1. LPG Leakage

LPG vessels, tankers, and pipelines are pressurized, and a leak can cause the

pressure inside the tank to drop rapidly. This pressure drop may lead to some of the liquid vaporizing (turning into gas), which is considered a two-phase flow. If the ambient temperature is warm, the discharge is likely to consist entirely of LPG vapor. However, some of the discharged LPG may remain liquid, depending on the storage pressure and ambient temperature, causing the liquid to accumulate near the discharge point.

The higher the internal pressure in the storage or transport vessel, the faster the LPG will escape and the farther it can travel. When LPG stored under tank pressure leaks, it can cause a rapid pressure loss, resulting in a significant drop in the temperature of the liquid. The temperature of liquid LPG leaking from the tank may be below its boiling point, which can cause the liquid to spread instead of vaporizing.

Atmospheric conditions play a major role in the behavior of released LPG. For example, if it is windy, the LPG will be carried by the wind. Ambient temperature also significantly influences the situation; in hot weather, LPG tends to vaporize and form a vapor cloud. Conversely, in very cold conditions or when the ambient temperature is below the boiling point, the released LPG is more likely to remain in liquid form. In this scenario, attention should be paid to the ground slope, as liquid LPG will flow toward lower ground, much like water.

Unignited LPG Leak:

It should never be assumed that wind direction and speed will remain constant during gas or vapor release events; therefore, it is prudent to

always assume that ignition may occur.

Following the risk assessment, the first action for personnel is to dilute the gas cloud to its Lower Flammable Limit (LFL) or disperse the gas at the leak location. Water cannons can be utilized to monitor and dilute gas concentration effectively.

Ignited LPG Leaks:

In the event of an LPG fire, the first priority should be to assess the possibility of cutting off the source of the leak. The second concern is to keep any nearby open equipment as cool as possible using water streams or fog screens. While small LPG fires can be extinguished with dry powder extinguishers, there is currently no known method or extinguishing agent effective against fires involving large volumes of LPG vapor. Such fires cannot be blanketed effectively.

Considerations for Containment and Dilution: Water Curtains and Monitors:

Consider using water curtains to prevent LPG from migrating into undesired areas. You can also dilute LPG gas concentration using water monitors equipped with fog nozzles, which help disperse LPG vapor effectively.

Equipment Choice:

Fixed water curtains or water monitors are the preferred equipment during LPG leaks. Understanding the specific conditions, such as the location of the leak and prevailing wind patterns, is crucial for achieving optimal results with this equipment.

Response Strategy for Unignited Gas or Vapor Releases:

The exact response strategy for an unignited gas or vapor release incident will depend on the size and type of the release, as well as wind direction. The overall strategy should always consider the following actions:

- Cease Hot Work: Stop all hot work and ongoing operations. Activate Emergency Shutdown: Implement emergency shutdown procedures, stopping and abandoning vehicles and machinery in the terminal or affected area.

- Evacuate Non-Essential Personnel: Ensure the evacuation of all non-essential personnel. Isolate the Release Source: If feasible, isolate the source of the release. If isolation cannot be achieved safely and practically (e.g., by closing valves), utilize emergency shut-off valves only.

- Assess the Gas/Vapor Cloud: Evaluate the extent of the gas/ vapor cloud, its movement direction, and areas that may be impacted. Identify Potential Ignition Sources: Determine potential ignition sources that could ignite the gas and take necessary precautions.

- Close Nearby Roads: If a road is in proximity, close it to traffic. Notify Authorities: Inform neighboring organizations and emergency authorities about the situation.

- Monitor Drain Systems: Be aware that gas can enter terminal or facility storm drain systems, potentially moving to distant locations.

- Watch for Low Elevations: Keep an eye on low-lying areas and dips where gas can accumulate. Deploy Water Curtains and Sprays: Utilize water curtains and sprays

for gas dilution and dispersion. Atmospheric Monitoring: Use portable gas detectors to monitor the atmosphere and determine distances at which gas clouds could form explosive atmospheres.

Best Practices for Fire Water Application:

The optimal method for applying fire water for gas/vapor dilution or dispersion is to approach the release source safely, if possible. Set the tracer nozzles to a wide-angle spray to help reduce gas concentration and facilitate rapid dispersion.

When LPG tanks are exposed to heat, the rising temperature of the liquid inside leads to its evaporation, which in turn increases the internal pressure within the tank. Most tanks are equipped with Pressure Safety Valves (PSVs) designed to limit this pressure. The timing of these safety valves opening to protect the tank depends on two primary factors: the amount of heat acting on the tank and the total volume of liquid contained within it.

The main function of pressure relief valves is to prevent tank rupture due to overpressure. However, if the temperature of the tank walls exceeds a critical threshold—typically considered to be above 300°C—there is a significant risk that the tank may rupture, potentially resulting in a Boiling Liquid Expanding Vapor Explosion (BLEVE).

3.2. Emergency Procedures for LPG Terminals

To ensure terminal safety, it is crucial to identify potential emergency events and scenarios, which should be addressed in written emergency procedures. Emergency response plans must be created for each identified scenario. Below are key scenarios to consider:

Fires: Fires can occur in various forms depending on their size and type. They can range from small, easily controlled fires that cause minor damage to large, difficult-to-control fires that result in significant losses.

Key Considerations for Fire Scenarios:

Small Fires: These fires may originate from equipment malfunctions, minor leaks, or other localized issues. They can often be extinguished with portable extinguishers, such as dry powder or foam extinguishers. Operators should be trained in the proper use of these extinguishing agents and should have them readily available.

Large Fires: Large fires may arise from significant leaks or other major incidents, potentially resulting in extensive damage to the facility and surrounding areas. These fires often require specialized firefighting strategies, including: Water Deluge Systems: Implementing fixed water spray systems to cool surrounding equipment and dilute flammable vapors. Emergency Response Teams: Activating trained emergency response teams equipped to handle major fire incidents.

Response Plan: Develop clear procedures for responding

to fires, including evacuation plans, communication protocols, and firefighting strategies. Regular drills and training should be conducted to ensure all personnel are familiar with these procedures.

Preventive Measures: Conduct regular inspections of fire safety equipment and emergency systems. Maintain clear access to fire extinguishers and emergency exits.

Pressure Relief and BLEVE Prevention

When tanks are exposed to heat, the increased temperature of the LPG liquid inside causes it to evaporate, resulting in an increase in internal pressure. Most tanks are equipped with a Pressure Safety Valve (PSV) designed to limit this pressure.

Key Points on Pressure Relief:

Function of Pressure Relief Valves:

The primary purpose of pressure relief valves is to prevent tank rupture due to overpressure.

Critical Temperatures: If the tank walls exceed a critical temperature (generally considered to be above 300°C), there is a risk of rupture, leading to a Boiling Liquid Expanding Vapor Explosion (BLEVE).

Factors Affecting PSV Operation:

The effectiveness and response time of the PSV in protecting the tank depend on:

The amount of heat acting on the tank. The total volume of liquid within the

Figure 11 İgnited LPG

Figure 12 LPG Fire Models

Figure 13 Explosion Effect

Figure 14 Shrapnel Effect

Figure 15 Fire Ball

tank.

Fires in LPG facilities usually result from leaks, with their severity influenced by various factors, including:

a. Leak Rate: The speed of the leak.

b. Total Leakage Volume: The overall amount released.

c. Location of the Leak: Height above ground affects dispersion and ignition.

d. Leakage Phase: Whether the leak involves liquid or gas. Due to the vast range of potential leak sizes, extensive research is necessary to establish realistic scenarios based on past incidents. Effective fire planning should categorize leak sizes as small, medium, and large, with the worst-case scenario typically being a tank explosion.

Boiling Liquid Expanding Vapor Explosion

A Boiling Liquid Expanding Vapor Explosion (BLEVE) occurs when a liquid in a vessel exceeds its boiling point at atmospheric pressure, causing the vessel to rupture. This can happen when fire affects points above the liquid level, weakening the tank structure. BLEVE incidents can also result from mechanical damage, such as traffic accidents.

When a BLEVE occurs, debris can be propelled hundreds of meters, and escaping gas may ignite, forming a fireball. Typically, BLEVEs happen when vessels are 50% to 75% full. The vaporization energy can launch fragments up to 800 meters, with fatalities recorded as far as 244 meters away. The time from flame contact to BLEVE can vary, but uninsulated tanks may BLEVE within minutes without water cooling.

Preparation is Key: There is little time to

react during an emergency; all protective measures must be in place beforehand.

Results of BLEVE

An explosion generates an expanding spherical heat and pressure wave. The effects can be categorized into four groups:

a. Explosion Pressure Wave Effect:

A tank explosion rapidly releases LPG, creating a pressure front responsible for injuries and damage. In outdoor BLEVE scenarios, pressures of 30-40 mbar can break windows and knock individuals down at distances of four fireball.

b. Shrapnel Effect:

When tanks rupture from pressure waves, they fragment into pieces known as shrapnel or missiles, which can be ejected over long distances. The range of these projectiles depends on the tank's size, fill level, liquid temperature, and orientation.

c. Thermal Effect:

Combustion explosions release significant energy, heating gases and ambient air to high temperatures. This heat can ignite nearby flammable materials, leading to secondary fires that exacerbate injuries and damage. Determining whether the fire or explosion occurred first can be challenging. The thermal damage varies based on the type of explosive fuel and the duration of high temperatures. Explosive detonations produce intense heat for a short duration, while deflagration explosions have lower temperatures but last longer. Fireballs may appear during or after an explosion, potentially igniting fires far from the blast center.

d. Seismic Effect:

The blast pressure wave can generate localized ground shaking as it expands,

potentially damaging structures, underground pipelines, and tanks. While minor for small explosions, seismic effects can lead to significant damage in larger incidents.

Overfilling of Tanks

Overfilling occurs when the liquid in an LPG tank exceeds operational levels, leading to overpressure and the release of LPG through safety valves. Causes include operator error, equipment failure, or inadequate transfer control.

To mitigate these risks, it is essential to verify that the product is directed to the correct storage tank during transfers. Key parameters—such as flow rate, vapor pressure, and temperatures—should be monitored closely. Implementing clear labeling of pipes and valves can prevent accidents, as misrouted product can lead to overfilling.

Standard Operating Procedures must be meticulously prepared and strictly adhered to by all personnel. Key questions to consider for safe operations include:

Are high-level gauges installed to alert operators of impending overfill conditions? Can the flow be shut off safely, or could rapidly closing the valves cause surges or overpressure in the transfer line? Are there sufficient shutoff and isolation valves to quickly stop or adjust the flow? What measures are in place to prevent overpressure when the flow is halted? During tank filling, it is good practice to conduct periodic level checks to ensure that the filling process aligns with expected quantities. Maintaining a Pumping Log encourages operators to frequently monitor local or remote gauge readings.

Figure 17 Ice Prevent Valve Closing

Figure 16 Tank Level Settings Based on Response Time in a Two-stage Detector System (API 2350)

While high-level alarms or shutdown valves may be part of overfill prevention systems, they should be considered emergency measures rather than routine control mechanisms for filling operations.

Overpressure of Tanks

LPG storage tanks may exceed their operational pressure under certain undesirable conditions, leading to LPG discharge through safety valves. Identifying the conditions that can trigger overpressure is crucial, and preventive measures should be implemented in advance. The activation of safety valves should be viewed as a last line of defense.

Safety Valve Activation

If a safety valve opens due to high pressure, consider:

- What caused the high pressure?

- Is there non-condensable substances, like nitrogen?

- Can LPG be safely discharged?

- Is the liquid LPG level too high?

- Did the LPG arrive cold?

- Is thermal expansion increasing pressure?

- Can pressure be reduced by pumping LPG or cooling the tank?

- Are safety valve settings correct?

- Has there been cross-contamination with higher vapor pressure liquids?

- Is the pressure increase due to fire?

Tailor emergency response plans to these conditions.

Removing Water from Tanks and Pipelines

Dewatering LPG tanks poses risks, especially freezing. Key points include:

Ensure at least two accessible valves for the drain line. The discharge point should be safely away from the tank. Assess operator exposure to LPG during draining. Improper drainage can lead to severe incidents.

Figure 18 Pressure Safet Valve Discharge

The discharge point should be safely away from the tank. Assess operator exposure to LPG during draining.

Improper drainage can lead to severe incidents.

Flange Leakage and Pipe or Hose Failure

For unmanageable LPG leaks:

- Evacuate Personnel: Move employees to safety.

- Water Injection: Use water to displace LPG and convert the leak into a water leak, ensuring the pump pressure exceeds the LPG vapor pressure.

- Check Valves: Use check valves in water injection lines to prevent LPG contamination.

Water injection can control leakage and help extinguish fires, serving as a

barrier against BLEVE (Boiling Liquid Expanding Vapor Explosion).

LPG Transfer Pump Failure and LPG Release

LPG pumps and compressors are critical and should be maintained regularly. Key considerations include:

Proper sealing element selection. Regular ATEX inspections for safety compliance.

The use of a double seal system in LPG pumps is crucial. This system allows for the detection of leaks in the first sealing element without releasing LPG into the environment. Additionally, monitoring vibration, bearing temperature, and sealing integrity of this equipment is essential for ensuring safe operations.

Onur Özutku

Mech Engg; Masters in heat transfer and fluid mechanics, Mustafa Kemal University

I was born in Ankara,Turkey in 1987, I have been living in Turkey/ Hatay for many years. I graduated from Akdeniz University in 2010 as a Mechanical Engineer, and in 2012 I completed my master's degree in heat transfer & fluid mechanics at Mustafa Kemal University. I have been working as amechanicalengineerinthesector for13years.Iworkedinthefieldof production and manufacturing for the first 3 years of my profession, and then for 2 years, I worked in project-based maintenance-repair and capacity increase works in Oil&LPG terminals. I have been working at Milangaz for the last 8 years. I have been working as LPG Operations Engineer for 5 years and as LPG Terminal Manager for 3 years.

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Figure 19 Jet Fire from Flange

Figure 20 LPG Pump Failure

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