Safety seminar 2015 Excellence in Process Safety, Consequences for design, engineering, commissioning and operation

Excellence in safety is the key to address the increasing complexity of industrial production processes and the increase of rules and regulations both in Europe and internationally. Experts in the field of Safety in Design will give an overview of methodologies and programs  developed to improve process safety in the chemical industry and related sectors.

Alarm about the number of alarms; give back the overview to the operator, Remco Deerenberg, Croon

Companies more and more recognize that the alarm-load for operators has to be reduced. It is true that increasing incidents, production loss and maintenance costs can be related to alarms that were overlooked in the quantity of alarms. Conservative estimates indicate that up to 3% of all losses can be attributed to problems in the alarm management. Via the new directive IEC 62682 Alarm management is likely to become law? Checks on the proper operation of your DCS will increase, just as is happening for other standards regarding safety. Croon has experience to get the Alarm management organized as per the EEMUA directive and to reduce the alarm load. 

Remco Deerenberg (41 years of age) works as Consultant Industrial Automation at Croon Elektrotechniek; as well as Innovation Coordinator since 1st of January. He has a degree at University of Applied Sciences of Utrecht graduating in Sales Management. His areas of expertise are especially related to industrial automation. This combination makes him an outstanding candidate for combining the technical departments and sales-drive departments in such a way that they work together in an advantageous manner for Croon. Presentation file here

Cyber security engineering, Sinclair Koelemij, Honeywell

We introduced the concept of security engineering for industrial control systems. A brief introduction will discuss some major incidents that happened in the industry to show the importance of cyber security. Next we will discuss the challenges a project phases when implementing an industrial control system. Where in the project does cyber security start, where does it end and who are the stakeholders. Are there minimum requirements and standards impacting control system projects?

Sinclair Koelemij is a cyber-security professional who serves as technical leader for EMEA at Honeywell Industrial Cyber Security. He has over 35 years of control systems experience in various engineering, service, management, and consultancy roles, of which the last 14 years in cyber security for industrial control systems. Sinclair participated in the development of several cyber security standards, and has conducted many risk and security assessments in the field of critical infrastructure, he conducted both consultancy and remediation projects. Sinclair completed an M.S. education in Information Technology, a bachelor degree in Informatics, and holds several security certifications, including CISSP-ISSAP, CISM, CRISC, and the physical security certification PSP. Presentation file here

Remnant Life Assessment, Jac de Boer, Tebodin 

Invest in existing and aged assets, renew the assets or maybe relocate assets. Familiar decisions for asset owners who are incessantly faced with a more competitive world, higher safety and environmental standards and higher demands on quality and output. Remnant live assessments for these aging assets give asset owners the input to support their business case and make the proper investment evaluation. Tebodin shares the experience of executed Remnant Live Assessment projects in the Middle East and developed a step approach for Remnant Live Assessments for the European markets.

Mr. Jac de Boer has extensive experience in various facets of asset management and maintenance management. Markets in which he has experience are Oil & Gas, Energy, Utility and Offshore. Presentation file here

Safety requirements for furnace fuel handling systems, Menno van der Bij, Technip

The EN-746 standard and the new ISO-13577 standard both specify the safety requirements for combustion and fuel handling systems that are part of industrial furnaces and associated processing equipment. These standards deal with significant hazards, and events relevant to combustion and fuel handling systems.

This presentation focuses on high temperature furnaces such as steam reforming and cracking furnaces and will address differences in approach between EN 746-2 and ISO 13577; prescriptive and performance based. The differences will be demonstrated with two examples:

  • All Burner Closed test versus valve proving
  • Safety Integrity Level (SIL) classification to determine Safety Instrumented Function architecture versus predefined architecture

Menno van der Bij is Deputy Manager Electrical and Instrumentation department at Technip Benelux in The Netherlands. He joined KTI, now Technip Benelux, in 1985 as instrument designer and has been responsible for instrument design and engineering in Hydrogen, Ethylene and Gas treatment projects (onshore and offshore). He is member of ISO/TC 244 and CEN/TC 186 “Industrial furnaces and associated process equipment” standardization committees. He participates in the WIB WG functional safety and the NEN SIL-Platform. Presentation file here

Protection against explosion hazard in chemical industry, Dirk Roosendans, Total

The oil industry operates installations with important quantities of flammable substances. A particular hazard is the accidental release of a large quantity of flammable material resulting in the formation and ignition of a flammable cloud within the installation, leading to a devastating vapour cloud explosion or “VCE”. A technology is under development in TOTAL for the mitigation of VCEs based on the injection of inhibitor particles in the cloud. A number of chemicals with inhibiting properties have been tested on laboratory scale and medium scale.

Dirk Roosendans has a master degree in chemical engineering and a master degree in safety engineering and has been working 25 years in the area of process safety. He is currently conducting a PhD on vapour cloud explosion mitigation. He spent the first 10 years of his career as a risk engineer, of which 7 years with the consultancy company Det Norske Veritas (DNV). In 2002, he joined ATOFINA as Process Safety Manager at the headquarters in Brussels. In 2004, Dirk became the corporate Process Safety Manager for Total Petrochemicals and in 2007, he took the position of corporate manager for Health and Industrial Safety in the same organization. In January 2012, upon the merger of the chemicals branch and the refining branch of TOTAL, Dirk Roosendans was appointed corporate Process Safety Manager for this new entity. Presentation file here

'An integrated Project and Operations team - A Success Factor for a Safe Start Up, Prof. Geert Vercruysse, BASF

The gradual transition from a construction zone to a production plant happens during the pre commissioning and commissioning phase of a project. The presentation will show with an example how this was safely executed in the Butadiene Expansion Project at the BASF Antwerp site. A close cooperation with the construction contractors, the use of a turnaround management tool and the set up of an integrated construction and operations team were clearly three success factors for a safe start up.

Prof. Ir. Geert Vercruysse graduated in 1992 at the University of Ghent. He started his career at BASF Antwerp as a production manager for the EB/Styrene plant where he became project manager in 1998 and plant manager in 2001. As of 2004 he became plant manager at the Steamcracker, which is also located on the Antwerp site. In October 2012 he took the responsibility of the Butadiene Project as Project Manager. Since October 2010 Geert combines his professional activities with the role of guest professor in Process Safety Engineering at KU Leuven and University of Ghent. Presentation file here


Mobatec - Model-based technology, Construction and Application of Dynamic Models

By Dr. Ir. Mathieu Westerweele

Process modelling Expert and founder of Mobatec research


A chemical engineer is often asked to describe the static and/or dynamic behaviour of a physical, chemical or biological process. This information is required in the different stages of a plant life cycle like analysis, control, design, research, simulation, optimization or process operation.

To analyse the behaviour of such a process, the engineer requires a mathematical representation of the physical and chemical and/or biological phenomena taking place.

Mobatec Modeller is a software tool for developing dynamic (and steady-state) process models (based on first principles) of physical, chemical and/or biological processes of any size - from a single unit to entire processing plants. It is designed to effectively assist a model developer in building and maintaining consistent models. The tool is used to build very large dynamic process models of entire plants (resulting in more than 100.000 equations that need to be solved simultaneously). User-friendliness, functionality and good user-assistance are a prerequisite for being able to manage such large models.

During the presentation a short introduction to the basics behind the development of dynamic process models will be provided.

Presentation file here


The Antwerp-Rotterdam Rhein Ruhr Chemical Megacluster - in transition toward a Smart Specialisation

By Dr. Ludo Diels - research manager Sustainable Chemistry at the Flemish Institute for Technological Research (VITO)


Process intensification and the partial replacement of fossil based resources by biomass-based and renewable resource form the basis for the Sustainable Chemistry Development. The integration of waste (including also waste gases as CO2 and H2) and wastewater management and technologies are key in the development of a sustainable World. This also is the basis of the Sewage Plus concept, a combined waste and wastewater treatment system leading to reduced energy consumption in water treatment and production.

Presentation file here


process safety - Introduction into incident investigation

By Ir. Jan Pranger

An incident, with or without harm or damage, demonstrates that the organisation was not able to operate as planned and indicates a flaw in its management systems. Therefore, incident investigation is an important learning tool and lessons learned must be applied at operational and management levels. Jan Pranger will present an introduction into incident investigation in the context of AIChE’s Risk Based Process Safety System framework. Especially in sensitive investigations with significant implications for the organisation, credibility is achieved by a rigorous and structured approach that warrants the integrity of the facts identified and their logical connection. Further, any investigation method is based on an accident model in which human factors must be explicitly addressed. This lecture presents several investigation methods and describes to what extent the above criteria are met and for what type of incidents they can be applied.

Presentation file here


The madness of green PET drop-in versus the opportunities of its bio-PEF replacement

By Prof. Dr. Gert-Jan Gruter - Chief Technology Officer Avantium Technology

A lot of attention has been focused on developing new technologies from non-fossil based resources for providing energy and chemicals, such as monomers for plastics and other materials. Although for energy, besides biomass, also other alternatives such as solar, wind, geothermal, etc. exist, for materials the only alternative resource is biomass. In the race to bring bio-based polymers to the market, two different strategies can be observed.

On the one hand, a lot of effort is directed to produce molecules that we already use today (drop-in) such as bio-based ethylene, propylene, para-xylene (terephthalic acid) and ethylene glycol. Many of the technologies under development use carbohydrates, typically C6H12O6 as starting material. However, it can be questioned if it makes sense to produce hydrocarbons such as p-xylene (C8; no oxygen) from glucose (C6; more than half its mass oxygen).

On the other hand, does it not make more sense to develop new monomers when changing from hydrocarbon fossil fuels to carbohydrate biomass? ‘New’ monomers such as lactic acid, succinic acid, furan dicarboxylic acid and others are examples of products under development by companies that selected the alternative approach, namely to develop new materials.

In the lecture, the pro’s and con’s of ‘drop-in’ versus ‘new’ will be discussed by evaluating the options to bio-PET and its alternative bio-PEF by zooming in on economics and into technical opportunities and challenges.

Process intensification and the partial replacement of fossil based resources by biomass-based and renewable resource form the basis for the Sustainable Chemistry Development. The integration of waste (including also waste gases as CO2 and H2) and wastewater management and technologies are key in the development of a sustainable World. This also is the basis of the Sewage Plus concept, a combined waste and wastewater treatment system leading to reduced energy consumption in water treatment and production.

Presentation file here