ensuring your flare system is fit for purpose

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solutions Behavioural safety ABB deliver behavioural safety support for px Biodiesel Continued support to Lotte Chemical UK ABB have supported Lotte for over 15 years Sterecycle support ABB provides professional engineering to Sterecycle in Rotherham Ensuring your flare system is fit for purpose Summer 2012 edition of the customer magazine from ABB Consulting

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Behavioural safetyABB deliver behavioural safety support for px BiodieselContinued support to Lotte Chemical UKABB have supported Lotte for over 15 yearsSterecycle supportABB provides professional engineering to Sterecycle in Rotherham

Ensuring your flare system is fit for purpose

Summer 2012 edition of the customer magazine from ABB Consulting

2 ABB solutions magazine summer 2012 www.abb.com/consulting

‘Hot topic’ update3 Ensuringyourflaresystemisfitforpurpose

Feature articles4 Behavioural safety ABB deliver behavioural safety support for px6 Continued support to Lotte Chemical UK ABB have supported Lotte for over 15 years New Risk Based Inspection + software ABB launches new RBI software8 Improving business performance ABB / CIA Conference12 Sterecycle support ABB provides professional engineering to Sterecycle

Conferences and events9 Conferences Recent conferences ABB have sponsored, exhibited at or attended10 Events / training Recent events or training courses ABB have attended

Editorial

ABB solutions summer 2012 • Customer magazine from ABB Consulting • Copyright 2012 •If you have any comments or feedback please contact Graeme Collings - [email protected] • ABB Consulting, Daresbury Park, Daresbury, Warrington, Cheshire, WA4 4BT, United Kingdom • Tel: +44 (0)1925 741111 • E-mail: [email protected] •Follow us on twitter: www.twitter.com/ABBCONSULTINGUK

Continued growth...In this edition we cover articles on flare systems, behavioural safety and engineering support to a number of companies.

ABB’s Consulting business continues to be strong in it’s major UK office locations of Teesside and Warrington, supporting both local and international companies. Also our UK regional business in Aberdeen, Grangemouth, South Wales, Yorkshire and Humberside continues to go from strength to strength.

In support of the growth of the business, ABB Consulting is recruiting experienced engineers across all disciplines, and in 2012 we will also have in-takes of 12 graduates and 6 placement students. The need to invest in our people and build competency for the long term is a key driver for the business and is our response to a question our customers often ask - “How will ABB maintain its capability into the future?”

In support of this ABB Consulting also continues to invest in the training and development of its staff to maintain and grow our technical capability.

Our global growth also continues at a pace in Houston, Singapore, Abu Dhabi and Norway.

Please enjoy our latest newsletter and we would be delighted with any feedback you may have.

Peter HuntBusiness Development DirectorABB Consulting

px Biodiesel, Immingham 04.

Sterecycle, Rotherham 12.

© Sterecycle Ltd.

© Greenergy Limited.

Lotte Chemical UK, Teesside. 06.

© Lotte Chemical UK

3 www.abb.com/consulting ABB solutions magazine summer 2012

‘Hot topic’ updates

To achieve this internally developed tools and specialist software packages such as Aspen Flare System Analyser (formally Aspen FLARENETTM) and HYSYS are used. The flare system can then be tested against potential scenarios and future adjustments can be managed in a controlled and efficient way.

The outcome of such an assessment is a risk based gap analysis which identifies and prioritises improvement areas.

The next key stage is resolution of identified issues to achieve a fit for purpose flare system.

The flare system is an essential part of the relief and depressurising mechanism associated with safe operation for many assets. It is vital that when called upon to operate, it functions as designed and does not introduce new hazards into the asset at a time of emergency.

Historically, flare systems tended to be designed and installed when the asset was constructed with particular project hazard assumptions, flaring scenarios and process conditions in mind. During the intervening years, many modifications will have been made to the process connected to the flare system.

A flare system by its nature is complex in detail and usually requires specialist analysis. It is therefore essential that the flare system is regularly reviewed to ensure that the system capacity, integrity and potential loads placed upon it still fit within the original design envelope.

Flare assessments can be undertaken to fully understand the flare systems operational integrity in accordance with the organisation’s practices

and international standards. A flare assurance assessment typically includes the following elements:

− Pressure drop evaluation − Flare capacity review − Hydrate assessment − Induced vibration predictions − Relief stream evaluation − Blowdown study

A typical process follows a 5 stage methodology that gives assurance that the flare system is fit for purpose:

A rigorous model of the flare system is often created in accordance with industry standards API 521 and 537.

Ensuring your flare system is fit for purpose

A typical flare system.

Data Gathering and Validation

Model Development

Model Validation

Relief and Blowdown Scenario Generation

Production of Gap Analysis Report

ABB Consulting’s relief and flare team can undertake studies on flare systems from review to detailed studies.

4 ABB solutions magazine summer 2012 www.abb.com/consulting

Behavioural safetyThe Immingham Biodiesel Plant is operated by px on behalf of Greenergy Limited.

The site is located in Immingham dock and is capable of producing up to 200,000 tonnes (228 million

litres) of biodiesel per year. Its sea-fed location enables effective logistics and trading with the UK and European vegetable oil and biodiesel markets as well as the wider world feedstock markets. The biodiesel produced at Immingham is sold to customers in the UK and mainland Europe. The Immingham plant was the first UK facility of its type to successfully convert from a purely virgin oil processing plant to a plant able to accept waste oils on a large scale. It is now capable of processing a variety of feedstocks including rapeseed, soy, palm, used cooking oils and tallow. The site was opened in 2006 and has had a strong safety performance since then. As part of the continuing drive to improve standards the site team, led by the px Plant Manager Rob Durkin, began a programme of measures intended to increase ownership of safety amongst the workforce and to make improvements in process safety performance. The safety initiatives included the setting up of a ‘SHE Steering Group’, comprising members from operations, engineering, administration, safety and maintenance.

The Group has subsequently put in place process safety performance indicators and a set of operational and safety KPIs. To enhance the improvement programme the SHE Steering Group commissioned ABB to complete an assessment of the sites safety performance and continuous improvement plans. ABB has subsequently completed a full safety review which included personnel interviews, job walking and statistical analysis, attending meetings and reviewing job roles. Upon completion of the study, the ABB findings, conclusion and recommendations were presented to the Biodiesel Plant staff. The recommendations included:

− Resourcing shifts such that Shift Team Leaders can manage more effectively.

− Adopting 5 S principles for the site and obtain suitable training in the discipline

− Planting training so that all teams have multi skilling

− Agree shift handover, setting to work and work completion procedures

The site teams have now begun to deliver on the recommendations and are confident that the work undertaken by ABB will deliver a class leading process, behavioural and occupational safety organisation at Immingham.

The px Biodiesel Plant, Immingham, North East Lincolnshire, UK and the px team involved in the project.

Feature articles

5 www.abb.com/consulting ABB solutions magazine summer 2012

The px Biodiesel Plant, Immingham, North East Lincolnshire, UK and the px team involved in the project.

“Dave Dyer came to our site and did a thoroughly professional job, he was conscientious, going the extra mile and we found that the recommendations were achievable and sensible. Dave Dyer quickly built a rapport with our teams that meant that everyone had belief in the recommendations.” Rob Durkin, Plant Manager, px Group.

Feature articles

Dave DyerPrincipal ConsultantABB Consulting

© Greenergy Limited.

With a history of operating strategic assets including Europe’s largest combined cycle gas turbine power plant (CCGT), and gas processing facilities accounting for approximately 6% of the UK gas consumption, the px group has gained valuable experience in minimising risk and maximising profits, in a safe, professional, and environmentally conscious manner. The px group has been involved in the operation and management of assets with a construction cost in excess of £1 billion.

6 ABB solutions magazine summer 2012 www.abb.com/consulting

Feature articles

Continued support to Lotte Chemical UKAs part of their global growth strategy, Lotte Chemical UK announced last year that they will build a new 200ktpa Polyethylene Terephthalate (PET) plant to run alongside its existing 150ktpa facility at the Wilton site. An important investment for Lotte Chemical UK, the additional production capacity will help secure the future success and sustainability of the business.

© Lotte Chemical UKLotte Chemical UK plant in Redcar, Teesside.

7 www.abb.com/consulting ABB solutions magazine summer 2012

Feature articles

ABB Consulting has supported the site for over 15 years with inspection services, project management and technical engineering support. We are currently working closely with the project team to deliver the new PET plant against a challenging budget and schedule.

ABB has particular strengths in early scoping and the front end development of projects; being very clear on the needs to fully align with Lotte’s business and strategic objectives. This is key and the integrated approach fits well with how we work in delivering engineering solutions to many of our clients.

Our engineers and technologists, many of whom have worked for operating companies, understand the priorities that customers have in the development and delivery of projects,

hence decisions made reflect long term considerations for operation.

Our strong operational heritage and understanding of asset integrity, especially around maintaining a license to operate and satisfying regulatory compliance, means customers have

access to a greater depth of operational expertise that can be applied to the project’s early development to ensure the project is right first time and fit for purpose.

From soft drinks bottles to fashion, trigger sprays to cosmetic and pharmaceutical packaging, Lotte’s PET resin and PTA intermediate are used in a wide range of polyester products throughout Europe and beyond.

ABB Consulting release enhanced RBI software to help make inspection more efficient and effective.

RBI is a well proven approach for determining the optimum inspection plan for plant equipment. It uses risk based methodology to improve efficiency and lower total costs of inspection.ABB is a leading provider of RBI, having carried out studies on over 100,000 equipment items during our 20 years experience. Our RBI+© programme has reduced risk, lowered the number of invasive inspections needed and reduced total inspection costs for our clients across the process industries.

A fundamental part of the ABB RBI+© process is a collaborative review by operating and maintenance specialists from ABB and client teams. To enhance this process, ABB developed a unique software tool; RBI+© pRIME for use on projects. The tool has now been further enhanced and is available as a web based standalone tool to enable clients to complete RBI more effectively and efficiently. So for the first time operators are able to follow ABB’s best practice themselves to achieve better results whilst using less operating team time.

Benefits of the software: − Ensures RBI is more efficient using

less operating team time to achieve better results

− Reduces total inspection costs by offering a focused approach

− Ensures an efficient and consistent approach to RBI

− The living document ensures up to date information can be accessed anywhere

− Consistent and auditable results are ensured by the in-built work flow

− A project status is easy to obtain using the progress dashboards

− Access to large, fully searchable knowledge bank of equipment history

New Risk Based Inspection + software

Phil MarshConsultantABB Consulting

The project dashboard from the RBI+ database

ABB have provided an excellent service across the Polyester Production Area Works for many years now in the SHE, Functional Engineering and Capital Projects disciplines, and during this time, strong, healthy, personal relationships have been formed.

Gary Conroy, Chief Operations Officer, Lotte Chemical UK Ltd

− Considers business consequence in addition to Health, Safety and Environment

− Configurable to comply with clients’ specific requirements and strategies

We are offering you the chance to see for yourself how RBI+© pRIME could make your inspection more efficient and effective on our demo site - www.prime-toolkit.com

For more information please contact Phil Marsh - [email protected].

8 ABB solutions magazine summer 2012 www.abb.com/consulting

The annual ABB Consulting / CIA improving business performance conference, based around short listed candidates for the ABB manufacturing and resource efficiency award attracted a fantastic audience of senior managers, process engineers and production personnel.

The conference took place at Thorpe Park, Leeds at the end of February with the keynote address given by Mark Turner, Director of the Chemicals Unite at the Department for Business, Innovation and Skills, who discussed the governments growth agenda including the advanced manufacturing growth review. Mark also outlined various funding opportunities, the largest of which is the £1 billion regional growth fund round 3 call. The chemicals unit are keen to ensure a good representation from the sector and will be happy to advise on bids.

CIA Chief Executive Steve Elliott outlined the regulatory and economic climate, highlighting some of the recent developments that are helping manufacturing businesses such as the political appetite for reducing red tape and some positive signals such as Health and Safety Executive (HSE) reduced hourly intervention rates. This was balanced by the many regulatory challenges that remain such as the still heavy regulatory burden and high energy costs.

Steve then went on to discuss industry self-help initiatives which are helping improve performance such as the responsible care verification process which has be very well received by participants and the Process Safety Management standards and training.

The technical presentations highlighted the excellent work being done right across the chemicals and pharmaceutical sectors to make the UK industry more competitive, improve the bottom line and secure jobs at the same time as improving resource efficiency and safety performance. Examples came from both large and small organisations, specialities and petrochemicals, big pharma and small pharma, but there were many common threads.

People are key to success, it is important to get the employees on board, communicate the objectives and get them involved in identifying solutions. It is important for senior managers to demonstrate commitment by “walking the talk”, getting directly involved and freeing up people’s time to work on issues. Importance of up to date, visible but simple communication tools to highlight progress and challenges. Training staff in the basic techniques of LEAN manufacture will go a long way in helping speed the process as well as demonstrating commitment.

The need for workable standardised systems and procedures bought into by all staff. “It’s not rocket science”, there

are still many relatively easy wins to fined the key us unlocking the skills of the people who work on the processes.Many of the presentations highlighted work done to either directly improve energy efficiency of processes or that improving areas such as overall equipment efficiency, yield and raw material efficiency had the added benefit of reducing energy use. This was picked up in the final presentation by Chris Stubbs of ABB who discussed the importance of human factors in energy efficiency.

A recent global survey has shown that while most companies believe energy efficiency is important, only 40% of companies have invested. Just as in other aspects of business improvement, people are the key and it is important to provide targets, training and explain the importance of what people are being asked to do. Chris rounded up by giving examples of the huge savings companies have made with a little help from consultants but largely through engaging their people.

This conference is now in its 6th year and one of the outstanding successes over this period is the willingness of speakers to share information and to host site visits to share best practice. Despite the economic challenges, industry continues to make huge progress in ensuring the UK remains a worldclass player. The 2013 conference will be held on 27th February in Manchester.

Feature articles

Improving business performance

Conference speakers (Peter Hunt, ABB, Mike Lancaster, CIA, Simon Savage, Pentagon, David Payne, FUJIFILM, David Leaver, Aesica, Catherine Smyth, Aesica, Peter Tayler, GSK, Paul Everard, ABB, Chris Stubbs, ABB, Robert Bird, Huntsman).

9 www.abb.com/consulting ABB solutions magazine summer 2012

Laza Krstin, ABB, has been awarded the prestigious ‘Donald Julius Groen prize’ by the IMechE for outstanding achievement in the field of Pressure Systems.

Process Safety ManagementLondon conference

Donald Julius Groen prizeIMechE

ABB hosted its third annual conference on ‘Process Safety Management’ in London. There were guest speakers from HSE, CIA, Huntsman, Croda, Tata, Total. The conference was well received by an audience of over 70 delegates. The next conference will held on the 22nd November 2012 in London, for further information please contact Debby Law - [email protected].

Laza Krstin, ABB, receiving his award.

Conference delegates - Peter Baker, HSE; Richard Roff, Tata Steel; Steve Leigh, Croda; Phil Scott, CIA; Ken Bell, ABB; Martyn Brown, Huntsman; Allan Greensmith, Total; Paul Everard, ABB.

Conferences and events

ABB Consulting sponsored the ‘Sustainable Technology Award’ at the IChemE awards dinner. The ceremony, attended by more than 400 of the nominees, dignitaries and guests was held in Birmingham. The host was British sitcom and sketch comedian Hugh Dennis. The winner of the ABB award was the Commonwealth Scientific and Industrial Research Organisation (CSIRO), who have developed a technology that reduces the energy needed to produce magnesium by 85%.

IChemE awards dinner Birmingham

Left: Host Hugh Dennis, Sustainable Technology Award winner CSIRO and Neil Blackhall, ABB.

Launch of integrity management 2012 Annual conferenceThis one-day conference will be held on 25th September 2012 at the Marriott Hotel, Manchester Airport. This conference will explore the key attributes of integrity management and promote sharing of the lessons learned by those that have been involved in integrity management. Delegates will learn from organisations that have taken varying approaches to integrity management. To find out more or if you are interested in speaking at the conference please contact Debby Law - [email protected] or visit: www.tinyurl.com/es-seminars

Integritymanagementconferenceflyer.

ABB Consulting were one of the main sponsors at the Energy Institute Awards dinner. ABB / ExxonMobil’s asset closure project was also nominated for the prestigious Shell Safety award. The joint project was developed to manage the engineered demolition and remediation of over 600 plus service stations throughout the UK and Ireland. The programme formed part of ExxonMobil’s asset strategy for retail outlets in response to trends in the fuel market.

Energy Institute Annual awards

From left: Andrew Reay, ABB, Simon Smith, SSE, Prof. Brian Cox OBE (guest speaker), Peter Hunt, ABB, and Grant Wood, BP.

Lu Chen, ABB, has been awarded the NEPIC young achiever award in the supply chain category. The award was presented to Lu at the NEPIC dinner at Hardwick Hall, Sedgefield by Kriss Akabusi. Lu is a graduate process engineer working in ABB Consulting’s process engineering team.

NEPIC young achiever awardSedgefield, UK

Guest speaker Kris Akabusi presenting the young achiever award to winner, Lu Chen, ABB.

10 ABB solutions magazine summer 2012 www.abb.com/consulting

Conferences and events

Chemical Business Association ABB membershipABB Consulting have become members of the Chemical Business Association (CBA). The CBA is the voice of the UK chemical supply chain. It represents a wide range of businesses - from distributors and traders to manufacturers and blenders as well as logistics and service providers. The majority of CBA members are small or medium-sized enterprises many of which are facing issues that are similar to the larger scale continuous and batch chemical companies. Working more closely with the CBA and its 130+ membership will be mutually beneficial; it will provide a platform for additional business growth for ABB whilst also helping to ensure that CBA members operate more effectively, safely and sustainably into the future.

Steve Sherwen, ABB, presented a paper entitled, ‘Introduction to the risk assessment requirements under DSEAR (2002)’ at the North East Process Industries Cluster (NEPIC) event on DSEAR: Improving Hazardous Area Management, Compliance and Competence.

NEPIC DSEAR eventTeesside, UKPEL breakfast roadshows

The annual PEL Breakfast Roadshows got into full swing in April with events at Wynyard Business Park in the North East, Daresbury Park in the North West, and the Inchyra Hotel, Grangemouth in Scotland. The three events were attended by over 100 delegates representing companies from across the UK including SABIC, Invista, Huntsman, ConocoPhillips, Fine Organics, Fujifilm, Johnson Matthey, Lotte Chemical, Lucite, Syngenta, Sembcorp, INEOS Chlor Vinyls, Mexichem, CalaChem, GSK, and MacFarlan Smith.

PEL is on the curriculum!The initiative to provide undergraduates with access to PEL for their final year projects has gathered pace. Imperial college and the university of Singapore have now joined Cambridge, Heriot Watt, and Newcastle who have already signed up to the scheme.

PEL trainingIn response to the excellent feedback received last year the physical properties masterclass and the PEL open training courses have been added to the ABB Consulting Events Calendar for 2012. www.tinyurl.com/es-courses

ProvueDB.net grows in popularityThis product has now firmly established and has received great feedback.

“We couldn’t have designed this project in France so effectively without ProvueDB.net”

“After a successful trial we are looking forward to switching to ProvueDB.net”

“With the help of ABB we have moved all our databases to ProvueDB.net and haven’t looked back since. Best move we have ever made”

CAPREThis exciting new product was launched at the PEL Breakfast Roadshows in April. CAPRE combines all the commonly used pressure relief calculations into a validated, secure, and easy-to-use Add-in for Microsoft Excel. It was received with great acclaim at each event where all the attendees received a 30 day free evaluation on a complimentary USB key.

The product is competitively priced at £500pa per copy with a special offer of “3 copies for the price of 2” saving over £400pa, valid until the end of August 2012.

If you would like to find out more about this exciting new product please do not hesitate to contact us.

For further information about PEL please visit: www.pelsoftware.com

PEL Support Services+44 (0)1925 741126

ABB Consulting have been accredited by the National Skills Academy for Process Industries (NSAPI) as official providers of training courses. NSAPI work as a link between operating companies that have a skills shortage and their providers who are able to deliver training to the required industry standard. The Academy covers the chemicals, composites, petroleum, pharmaceuticals, polymers and biotechnology sectors and their role is seen as vital within the process industries. If companies are to operate effectively and safely they need access to an appropriately trained and skilled workforce. Process safety leadership is currently one of the Academies primary areas for improvement and ABB Consulting are aligned to delivering the course for them. The PSL course is aimed at director level within organisations and will position ABB as a leader in this field.

NSAPI ABB accredited

Academy Centre for Process Safety

Brian Hudson, ABB, presented a paper at the Society of Maintenance and Reliability Professionals (SMRP) annual conference in Greensboro, USA. The paper was entitled ‘Managing integrity and reliability on ageing assets onshore / offshore’. Over 1000 people attended the conference and over 100 came to Brian’s presentation.

SMRP conferenceNorth Carolina, USA

Phil Eames, ABB, presented at the tank storage annual conference held in Coventry. Phil’s paper entitled ‘Using performance indicators to drive improvement in process safety performance’ was seen by around 150 delegates attending the conference, from companies such as ConocoPhillips, Petroplus, px and Vopak.

Tank Storage annual conferenceWest Midlands, UK

Phil Eames, ABB, presenting at the tank storage annual conference.

11 www.abb.com/consulting ABB solutions magazine summer 2012

Conferences and events

Forthcoming events for 2012Conferences Conferences are major industry forums focusing on key topic areas. Please contact us if you would be interested in presenting at any of our 2012 conferences.

Seminars Seminars are focused on industry ‘hot topics’ and include inputs from external speakers.

Forums Lunchtime and evening forums provide an update on key industry topics and share best practice.

Webinars Webinars are focused on industry ‘hot topics’ and are accessed over the web.

A full list of all the above events is available at: www.tinyurl.com/es-seminars

Technical training Training courses provide in-depth knowledge on key subjects as part of an engineer’s professional development.

A full list of training courses is available at: www.tinyurl.com/es-courses

* IChemE approved training course

All of these events are organised and delivered by ABB Consulting. For more information on:Seminars please contact - Deborah LawTel: +44 (0)1642 372029 E-Mail: [email protected] Training courses please contact - Jackie Kendall Tel: +44 (0)1642 372121 E-Mail: [email protected]

Conferences

25th September Integrity management Manchester

22nd November Process Safety Management London

4th - 5th December Shutdowns and turnarounds Manchester

Seminars

11th September Learning from Buncefield Edinburgh

27th September Human factors in practice Teesside

23rd October Asset closure Manchester

Webinars

18th September RBI - Quantitative or qualitative Internet

17th October Easy living with 61508 Internet

14th November HAZDEM - keeping demolition safe Internet

Forums

5th September Automation legacy migration - how to start Grangemouth

6th September Sustainable water use Teesside

13th September Care of rotating equipment Huddersfield

14th September Is your electrical system discriminating? Hull

20th September Alarm management - ISA 18.2 vs EEMUA 191 Aberdeen

28th September Growing old gracefully! - challenge of ageing assets Warrington

4th October Managing liabilities through the life of the environmental permit Grangemouth

5th October Pressure relief - Is your last line of defence defendable? Teesside

12th October Vent and flare system health Grimsby

18th October Improving reliability of ageing assets Huddersfield

25th October Human factors in maintenance Aberdeen

26th October Making change work Warrington

Training courses

5th - 6th September IEC 61508 / 61511 SIL determination* York

11th - 12th September Essentials of pressure systems* Edinburgh

13th September Human factors incident investigation Edinburgh

18th - 20th Sept Pressure relief* York

19th September SIL awareness for control / electrical technicians Hull

26th September An engineers guide to DSEAR Edinburgh

26th - 27th September Project management in the process industries Manchester

2nd - 4th October Alarm management* Edinburgh

8th - 12th October Hazard study leaders Manchester

10th October Mechanical legislation awareness Manchester

10th - 11th October Achieved SIL Aberdeen

16th - 17th October Area classification* Manchester

17th October Hazard study awareness* Grimsby

18th October Reliability improvement masterclass York

23rd - 24th October Design and operations of piping systems* York

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Further news

Sterecycle (Rotherham) Ltd operate their facility with a lean operational team which concentrates on the day to day running of the facility. They are however aware of their regulatory responsibilities and also strive to improve the efficiency and reliability of their operation. This requires a more extensive skill set that would not be economically viable to maintain “in-house”. To achieve their objectives they recognise that they require access to specialist functional engineers and consultants to assist them, from a well respected and competent company.

ABB Consulting has been providing Sterecycle with the support they require for more than a year, in a number of areas including, maintenance and reliability, inspection services and safety. This support has been tailored to their needs and supplied on a flexible basis. The services have been supplied to provide fit for purpose, cost-effective solutions for the organisation. This often requires the use of novel approaches that utilise the practical experience and knowledge of the engineers and consultants employed by ABB.

The services supplied have included:

Maintenance and reliability − Root Cause Analysis − Maintenance assessment − Maintenance resource review − Failure Modes and Effects Analysis − Supply of interim maintenance

resources

Safety − Hazard studies of existing plant − Hazard studies of new plant − Review of target − SIL assessments − Target SIL assessment − Achieved SIL calculations

Inspection services − Fitness for service assessment − Inspection of pressure systems

Examples of services provided include:

− Failure Modes and Effects Analysis of a new autoclave to generate a maintenance strategy with a sound engineering basis before the plant was put into operation.

− A review of Layer of Protection Analysis calculations carried out. This was carried out to ensure the calculations were robust and would stand up to scrutiny by the regulatory authorities.

Sterecycle is a waste management business focused on recycling and green energy. They have their own patented technologies that are capable of recycling and recovering up to 80% of the typical household waste stream. Sterecycle’s Rotherham plant has been operating since June 2008 and at 100,000 tonnes per year throughput was the world’s first commercial scale autoclave waste treatment facility. It was expanded in January 2012 and can currently treat 130,000 tonnes per annum of mixed waste, using 3 autoclaves.

“As a small company Sterecycle simply cannot afford to employ people with all the skills needed to optimise the plant and perform the detailed works required by the regulators. ABB allows us to pick and choose the services of highly professional engineers as and when needed with the knowledge that the works undertaken will be of the highest quality. This facility allows Sterecycle to drive forward improvements and ensure regulatory compliance.”

James Crankshaw, Engineering and Site Director, Sterecyle

Sterecycle support

Sterecycle, Rotherham, UK.

© Sterecycle