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FLSmidth’s OK™ cement mill delivers the highest flexibility with its exclusive grinding profile. Rapid and stable transitions between products are made during operation with slag, fly ash, limestone and pozzolan by adjustments to operational parameters. OK cement mills already produce nearly every cement product around the world.
Proven reliable, consistent, and flexible the OK mill remains the choice for all cement, blended cement and slag grinding products.
For more information visit www.flsmidth.com
OK™
cement millflexibility
The OK™ vertical roller mill is manufactured by FLSmidth under licensefrom Earthtechnica Company, LTD. and Taiheiyo Cement Corporation.
FLSmidth’s OK™ cement mill delivers the highest flexibility with its exclusive grinding profile. Rapid and stable transitions between products are made during operation with slag, fly ash, limestone and pozzolan by adjustments to operational parameters. OK cement mills already produce nearly every cement product around the world.
Proven reliable, consistent, and flexible the OK mill remains the choice for all cement, blended cement and slag grinding products.
For more information visit www.flsmidth.com
OK™
cement millflexibility
The OK™ vertical roller mill is manufactured by FLSmidth under licensefrom Earthtechnica Company, LTD. and Taiheiyo Cement Corporation.
The OK™ 36 cement mill at Supremo Cimento Ltd. in Adrianópolis, Brazil, is one of the 140 OK cement mills sold globally and the 50 sold in the Americas. As the only vertical roller mill (VRM) specifically designed for cement grinding, the OK mill repeatedly demonstrates performance with the highest efficiency, reliability, and flexibility. Throughout the world the OK Mill remains the preferred cement VRM.
For further information, please contact:FLSmidth Inc.Tel +1 (610) 264-6011 / Fax +1 (610) 264-6170Website: www.flsmidth.com
CONTENTS MAY
Palladian Publications Ltd15 South Street, Farnham, Surrey GU9 7QU, ENGLAND
Tel +44 (0)1252 718999Fax +44 (0)1252 718992
Email: [email protected]: www.worldcement.com
Volume 47: Number 05
May 2016
ISSN 02636050
THIS MONTH’S COVER
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16 23WORLD CEMENT REGULARS
05 Comment
07 News
10 Keynote: Snowden told us so… but did we listen? Robert Steininger, IBM Security, gives his view on cyber security and its relevance for the cement industry.
148 Product News
152 Regional Report Infographic
REGIONAL REPORT: NORTH AMERICA
16 Coal Grinding and Firing Systems - HAZOP AnalysisJagrut Upadhyay, PEC Consulting Group LLC, USA, outlines and explains the use of the HAZOP study within coal grinding and firing systems.
23 Innovations in Online Analyser UseTom Messer, Suwannee American Cement, USA, Ronaldo Dos Santos, Votorantim Cimentos, USA and Richard Woodward, Woodward Consulting, USA, examine the role of analysers at the Suwannee American Cement plant in Branford.
FILTER MEDIA, ESPs, BAGHOUSES, CCUS
30 What a DragChris Polizzi, WL Gore & Associates, USA, addresses the benefits that can be gained by installing filter bags with the lowest possible drag.
35 Hot Gas Filtration with Catalytic NOx Removal of Industrial Exhaust GasesUlrich Schwarz, GEA Bischoff GmbH, Martin Dunkel, BWF Tec GmbH & Co. KG, and Rainer Skroch, GEA Bischoff GmbH, Germany, discuss the suitability of catalytically activated ceramic filter elements.
GENERAL INTEREST
44 A Baghouse Born AgainJoseph P. Arsenault, Ash Grove Cement, and Luis J. Castano, IAC Inc., describe how a baghouse refurbish project can go hand in hand with effective modernisations to solve specific operational challenges, injecting new life and improved performance into plant process filters.
123 Getting the Most from your Human CapitalJohn Kline and Charles Kline, Kline Consulting LLC, USA, follow up on their previous article, here with a focus on designing training events for the cement industry.
CONVEYORS, CHAINS, BUCKET ELEVATORS
51 Critical ValvesTodd Loudin, Flowrox Inc., USA, examines the advantageous usage of pinch valves in dense phase conveyor systems.
May 2016 / 3World Cement
109 141
71 8157 Cleaning Conveyor BeltsDaniel Marshall, Martin Engineering, USA, discusses the numerous considerations necessary when selecting an appropriate method of removing carryback.
65 Examining Lagging FrictionBrett DeVries, Flexco, USA, investigates how lagging optimises a conveyor’s performance.
71 Overcoming the Inherent in Feeding Coal MillsAdam Wallace, Precision Machine and Manufacturing, Inc., USA, outlines how an innovative rotary valve can help the cement industry cope with difficulties in handling raw coal, which remains an economically viable fuel.
77 Complete Conveyor SolutionsAaron Gibbs and Greg Bierie, ASGCO, USA, explore ways in which cement plants can increase production without increasing maintenance or costs.
81 Mobile Feeder-BreakersDon Hughes, Joy Global, USA, discusses the use of mobile feeder-breakers for in-pit operations.
87 A New SolutionKevin R. Peterson, Vortex, USA, outlines the development of three new diverters to handle situations where extreme abrasion is causing difficulties.
CEMS, EMISSIONS MONITORING, GAS ANALYSIS
91 PC Mact – From Rule to RealityBrad Blase and Rudi Muenster, VIM Technologies, Inc., USA, detail the challenges associated with the implementation of PC MACT.
101 Direct Reactivity Measurements by Isothermal Calorimetry in Cement Process ControlPaul Sandberg, Calmetrix, USA, details the use of isothermal calorimetry in a number of process control tasks within the cement industry.
109 Tackling the Climate ChallengeJan Theulen, HeidelbergCement, presents how the company drives forward the capture, storage and utilisation of carbon.
117 Measuring EmissionsDan Kietzer, SICK, Inc., USA, compares in-situ and extractive gas analysers and outlines the factors for consideration when choosing an emissions analyser.
PROCESS CONTROL AND AUTOMATION
129 Renewable Energy in the Cement IndustryThomas Hillig, THEnergy, Germany, presents the case for the cement industry to initiate the transition to a low carbon economy.
BURNERS, KILNS, PREHEATERS/PRECALCINERS
133 Levelling UpJosef Keuschnigg jun., PM-Technologies, Austria; Reinhard Ringdorfer, Unitherm, Austria, and Michael Janzer, CemProTec, Germany, present a case study detailing low-cost plant upgrade solutions.
141 Optimising Bypass SystemsMark Mutter and Lawrie Evans, JAMCEM Consulting, UK, detail steps to reduce the level of bypass required in the manufacturing of clinker.
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This time last year the UK marked the second annual National Women in Engineering Day (NWED). This event was established by the Women’s Engineering Society as a way of championing female engineers and encouraging more women into the profession. With the UK reportedly needing to double the number of recruits into engineering if it is to
meet demand, it makes sense to target the half of the population that’s drastically underrepresented in the industry.
Statistics show that just 7% of the engineering workforce in the UK is female. That’s the lowest figure in Europe, way behind the likes of Latvia, Bulgaria and Cyprus, which lead with nearly 30%. It’s also significantly behind the US, which sits at about 14%. And it doesn’t look like it’s improving at any great pace – at the moment, just 3.4% of engineering and manufacturing apprentices are female. There is no great tsunami of female engineers waiting to sweep across the nation and balance out the workforce.
The Women’s Engineering Society (WES) and the UK government, which set up the #notjustforboys campaign to encourage more girls into careers in STEM subjects (Science, Technology, Engineering and Mathematics), both point out that girls perform equally well if not better in
these subjects, but are simply not pursuing them through further education at the same rate that boys do. A few examples: less than 20% of Physics A Level (a British qualification taken aged 16 – 18) students are female. WES reports that this figure hasn’t changed for 25 years, which seems incredible when you consider how much ground has been broken in other areas in that time. Moving on to undergraduate qualifications, there are around 20 000 more men than women studying engineering at university. Gender stereotypes are being blamed for this imbalance, and these start young. This is compounded by a lack of women engineer role models, which is one of the issues that NWED aims to tackle, chartering social media to spread the message through inspirational case studies, messages and, of course, selfies.
Though clearly the UK is lagging behind on this issue, we are by no means alone and as a forward-thinking publication in a forward-thinking industry, we’d be remiss if we didn’t suggest that you share your own endeavours on our social media pages (and selfies, if you like). How do you encourage new recruits to your company, and what percentage of your workforce is female? Is it important to you to have a balanced workforce? We look forward to hearing from you. Please contact us at [email protected] or [email protected].
Meanwhile, I hope you enjoy this issue and wish to express my thanks to all those people who sent in their news to be included. As this is the time of year that we start thinking about next year’s editorial schedule, we would appreciate your feedback on this and all our features to make sure World Cement remains relevant to you.
Katherine Guenioui, Editor
CONTACT DETAILS SUBSCRIPTIONS
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WORLD CEMENT (ISSN No: 0263-6050, USPS No: 020-996) is published monthly by Palladian Publications, GBR and is distributed in the USA by Asendia USA, 17B S Middlesex Ave, Monroe NJ 08831.
Periodicals postage paid New Brunswick, NJ and additional mailing offices. POSTMASTER: send address changes to World Cement, 701C Ashland Ave, Folcroft PA 19032
Copyright© Palladian Publications Ltd 2016. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of the copyright owner. All views expressed in this journal are those of the respective contributors and are not necessarily the opinions of the publisher, neither do the publishers endorse any of the claims made in the articles or the advertisements.
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May 2016 / 7World Cement
CEMTEC Cement and Mining Technology GMBH received an order from Daesung Machinery Co. Ltd. (South Korea) for the supply of main process equipment for the fine grinding of flyash at 6900 cm2/g, which, according to Blaine, comprises one ball mill Ø3.0 x 7.0 m and one latest generation separator CTC-045.
Beforehand, several trials took place in the presence of the customer, in the R&D facilities of CEMTEC in Austria, where flyash products with fineness above 8500 cm2/g (Blaine) were easily obtained. The grinding plant, owned by AHA Greentech Co. Ltd as patent holder of a new technology for the use of flyash from power plants in cement production, is to be commissioned in summer 2016.
Korea CEMTEC delivers flyash grinding equipment
Through the merger of its North American operations in Canada and USA, Pruftechnik has further established its presence on the North American territory. With the new organisation, the maker of OPTALIGN and ROTALIGN has kick-started the direct distribution of their products in the USA.
The new operation enables Pruftechnik to bridge the gap between R&D, product management, international sales and production in Germany and the end user community in the United States. The ‘factory direct’ approach makes the company more customer-centric.
North America Pruftechnik reinforces footprint
Cambodia New contract for Gebr Pfeiffer
Gebr. Pfeiffer has been awarded a contract by the Chip Mong Group to supply three vertical roller mills for a new cement production line in Touk Meas, Cambodia. The order comprises an MPS 3350 BK for coal as well as an MVR 5000 R-4 for raw material and an MVR 6000 C-6 for cement grinding. The cement mill will be equipped with a MultiDrive consisting of four modules, with an installed power of 7200 kW. This drive system ensures a redundant operation of the MVR mill and achieves a high level of availability of a vertical roller mill. It was this increased availability that led to the product’s selection for this project, along with the fact that the combination allowed the customer to go for the cost-saving ‘one mill solution’.
The MultiDrive® enables grinding operation to continue not only when one grinding roller is swung out but also in case of a planned maintenance stop or unplanned outage of one of the 1800-kW gear units. This also applies in the unlikely event of a failure of an electric drive motor. The cement mill MVR 6000 C-6, which will be set up in cooperation with CITIC Heavy Industries, will be the largest vertical roller mill in the ASEAN region and mark another important milestone for Gebr. Pfeiffer. Delivery of the mills is scheduled to take place in the 1Q17.
15 – 19 May 2016
IEEE-IAS/PCA Cement Industry Technical Conference
Dallas, Texas, USA
www.cementconference.org
20 – 22 June 2016
CBCi
São Paulo, Brazil
www.7cbci.com.br
31 May – 3 June 2016
REFRA-Kolloquium 2016
Berlin, Germany
www.refra-kolloquium.com
28 – 30 June 2016
Hillhead
Buxton, UK
www.hillhead.com
12 – 13 October 20163rd Alternative Fuels Symposium
Duisburg, Landschaftspark Nord
www.lechtenberg-partner.de
29 – 30 August 2016
FICEM
Buenos Aires, Argentina
www.ficem.org
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Ohorongo Otavi Community Trust, in collaboration with the ministry of Health and Social Services, has given bursaries to three nursing students, to enable them to further pursue their studies, to the value of N$60 540.00. The hand-over took place in Windhoek on 18 April. The following students were recipients of the bursaries: Ms. Helena Kakunawe Hofeni, Mr. Henry L. Dollar, Mr. Clement K. Samati.
Independent Cement Consultants has been awarded a Queen’s award for Enterprise in the category of International Trade. This recognises its approach to business with integrity and strong year-on-year growth in international markets and represents the highest accolade for business success.Partner and director Kevin Rudd will attend a presentation award at Buckingham Palace on 14 July.
Wonder Cement Ltd. has appointed Mr. Jagdish Chandra Toshniwal as its Managing Director. Mr. Toshniwal joined Wonder Cement in 2015 as Executive Director and has led the company through the expansion of its footprint in Rajasthan and neighbouring markets. He will focus on creating a national footprint and generating a large customer base in the domestic market.
China New cooler order for Claudius Peters
At the end of 2015, the Chinese Company Quantou Group, Shandong Province, awarded a contract to Claudius Peters Projects for the delivery of a new ETA Stage cooler to increase capacity.
The cooler exchange for the production line of the Quantou group will be a milestone of combining high waste heat recovery and high efficient clinker cooling.
Claudius Peters has already sold 76 ETA coolers worldwide, although it is the first order for the Quantou Group. The ETA cooler 1076//75S has a capacity of 6500 tpd and comprises a roller crusher and a HE module. This cooler will replace a moving floor cooler from another supplier and will improve the availability and efficiency of the cement line.
Europe LEILAC consortium secures funding
The LEILAC (Low Emissions Intensity Lime and Cement) consortium has successfully secured f12 million in funding over five years from the European Commissioning Horizon 2020 Grant Programme. The consortium comprises HeidelbergCement, Cemex, Tarmac, Lhois, Amec Foster Wheeler, ECN, Imperial College, PSE, Quantis and the Carbon Trust, and is led by technology provider Calix. It aims to apply and demonstrate a breakthrough technology that will enable Europe’s cement and lime industries to reduce their carbon footprint significantly. The consortium will also contribute a further f9 million towards the project.
Calix’s Direct Separation process provides a common platform for carbon capture in both the lime and cement industries. This can help these sectors to thrive in the face of tighter international CO
2 emissions regulations,where the only options may be
to capture and store CO2 instead of emitting it into the atmosphere.
For the first three years the project will focus on the finalisation of the design of the of the demonstration plant, which will be constructed at the HeidelbergCement plant in Lixhe, Belgium, following the necessary permits being secured. The pilot unit will then undergo two years of extensive testing in a standard operational environment, at a feed capacity of 240 tpd of cement raw meal and 200 t ground limestone, over a continuous basis for several weeks.
Fundamental research on the process demands and performance will be carried out to demonstrate that the technology works sufficiently and robustly enough to be scaled up to full operational use. The product results will be shared widely with the industry at key intervals during the testing.
Takraf USA was recently selected by Birmingham, Alabama-based Vulcan Materials Company (VMC) to supply a 6000 st/h rail-mounted luffing and slewing shiploader to Calica, Mexico. This new shiploader will replace the existing shiploader, which has been in service since 1988.
Located on the Quinatana Roo coast of Mexico near Playa Del Carmen, the Calica quarry and port is one of the largest construction aggregate facilities for VMC in North America. The company is the United States’ largest producer of construction aggregates.
Mexico Takraf USA awarded shiploader contract
IN BRIEF
10 \
SNOWDEN TOLD US SO…BUT DID WE LISTEN? Robert Steininger, IBM Security, gives his view on cyber security and its relevance for the cement industry.
“Don’t plug it in!”This was the advice I had given pretty much 15 years ago at the IEEE Portland Cement conference in Vancouver in 2001 to a question I had received after my talk, namely: “Is there anything better than a firewall to protect the control system network from unauthorised access?”. Sure,
it was meant to be a bit cheeky, but at the same time, in the automation world we considered ourselves ‘safe’ as long as we were ‘left alone’. In other words, if there was no connection to other networks like the corporate office network or specifically the internet, then you could consider yourself safe. Well, unfortunately, that statement
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from then is certainly no longer valid today. But, first things first.
Is the threat real?I start off with the transliteration of a German saying which is: ‘Don’t believe any statistics that you haven’t falsified yourself.’ So, if a security guy paints a bleak picture then you should probably take the information with a grain of salt and do your own research.
A widespread misperception I often encounter is that hackers today are as they were in the movie Wargames from 1983, where a high school student pretty much accidentally hacks a military supercomputer and nearly starts a nuclear war. Don’t get me wrong, we still face individuals who attempt to hack sites and corporations out there and they can inflict damage. The recent hack of the UK based telecommunications company TalkTalk by a 15 year old boy is proof-in-point.
However, the bigger threat stems from organised cybercrime. Once a primary target has been identified, teams will be formed to accomplish that target. If plan A can’t be attained then the aim switches over to plan B or C. Budgets are allocated, tools deployed and bot-net services are rented with sufficient bandwidth as needed.
But why, you might ask yourself, would someone globally be interested in your cement plant, grinding facility, loading terminal, etc.? Industrial espionage is certainly an issue, but, short of being a research site, the production details of Portland cement are largely publicly available. So, that shouldn’t be it. And to some extent, that is the tricky part to figure out as the motives can vary. With most facilities being part of a larger organisation, corporate information in relation to planned mergers or takeovers might be of greater relevance, or potentially customer records could be the target of interest.
However, a rather new development is the deployment of ‘Ransomware’. Criminals are not so much interested in information that could be of value to them rather than to you. That information in turn is not necessarily stolen and moved off-site, but, in a rising number of incidences is encrypted in situ. Once the malware is introduced, it will almost indiscriminately start encrypting any files it can
get access to, including server-based documents and databases. As the encryption is so strong, the only way to restore access is by paying a ransom to receive the key. The only alternative is, in case you have recent and valid backups and were able to detect and neutralise the threat, to restore to a point from before the encryption took place.
And here are some of the interesting figures. PwC found in a survey that in 2014 an estimated 42.7 Mio successful IT security incidents took place. The Ponemone Institute uncovered in 2015 that on average it took 256 days before a successful hack was discovered, and, for the systems that IBM Security monitors for its customers, we register currently about 8 Mio intrusion attempts per day.
How would they get in?Sure, you have a corporate firewall and an IT Security department looking after everything,
even if they don’t talk to the process control guys, right? What we have to consider is that the sophistication of the attacks has gone up tremendously. I have to go back to the STUXNET attacks first reported in 2010. I have a background in programming the Siemens S7 and PCS 7 systems that were impacted by the malware, and what the hackers accomplished is nothing short of a miracle. Remember my earlier statement of ‘don’t plug it in’? There are different
strategies for protecting ‘crown jewels’, which refer to a corporation’s most valuable assets; of which one is a complete physical segregation of networks. In other words, introducing an ‘airgap’ where no physical connection between networks exists. We may assume that the PLCs of the Iranian nuclear enrichment sites were not connected to the Internet in the first place. And yet, the strategy deployed helped to bridge that airgap and furthermore fool the security measures built into the automation systems allowing the variable frequency drives to speed up to ultimately self-destruct some of these units. So, in order to reach these isolated units, the attackers had to think about who would be most likely to connect to these units in future. In the present day context, hackers use a process called social engineering. They use sites like LinkedIn, Xing, Twitter, Facebook and similar to find a potential contact that might have access to the information
Industrial espionage is certainly
an issue
”
May 201614 \ World Cement
within the organisation they are after. These can then be targeted with e.g. spear phishing emails that in turn, when clicked on, might be able to install malware on the user’s PC. In the case of STUXNET it is rumoured that an infected USB drive was tossed through the open window of a potential contractor. Have you ever found a USB stick and wanted to do the right thing – return it to the rightful owner that is – and thus, quickly plugged it into your PC to see if you can find a name or recognise some information? I certainly have done that.
So, what’s the solution?Within the security industry, it is pretty much the agreed view that you should consider every (affordable) system capable of being hacked. If you accept this as a starting point then you can design your security strategy around it. The threat landscape is changing so quickly that relying on static measures is no longer good enough (e.g. the airgap). However, there is also some good news. The IBM X-Force Threat Intelligence report for the 4th quarter released in November 2015 identified also a couple of measures that aren’t high tech or costly to implement, but can have a big impact on your security status. These include:
Keep systems updatedThis sounds simple enough for the corporate office, but in a control system environment it can be challenging for three reasons. The first is, it will require connectivity to the internet which has to be provided in secure form. A properly designed and configured network layout is one fairly simple answer to that problem.
The second issue is around the effort involved in updating all the computers and other network components associated with the control system. While all these updates are available from the manufacturers, the deployment of these is a different story. Especially in a live production environment there is no fast and easy way around it. My apologies, I can only speak for the Siemens system, but I am sure that other manufacturers have a similar (or even better) approach to this. When I checked last, Siemens was testing any new Microsoft bug updates for the operating system and issued a list of validated patches that could be safely deployed and would be compatible with its control system. That process caused about a month’s delay.
And the third challenge around the updates is that, in many cases, control systems are based on more stable versions of an operating system (OS) that often would be at least a version behind the one found in the office environment. I would think that you can still find many fine working control systems that are running on Windows XP, an OS that has now been abandoned for crucially needed
security updates for close to two years. For a hacker these are low-hanging fruit.
From the OS side, you will find tools that help you to at least semi automate some of the processes; and you can expect that the control system manufacturers will also become further sensitised to the issue of cyber security.
Develop security policies and educate your workforceA similar big impact was attributed to a lack of (or insufficient) security policies and general awareness. What I mean by that are things like:
On and off boarding of employeesIn cases where employees left the organisation, access IDs were not (or not in a timely manner) removed, allowing these individuals to have continued access to systems from the outside. In other cases where there might have been dismissals, some employees installed backdoors before they were made to leave the organisation from where they had continued access to sensitive information or were able to impact operations.
Shared admin accessFrom my past experience this was especially true for control system networks. In many cases the e.g. Microsoft active directory function with domain control wasn’t deployed and thus, for ease of maintenance, universal admin accounts were in use.
Sharpen user awareness for cyber securityMany security professionals believe that users are in fact the weakest link. If they are not aware of safe computing practices, an inadvertent click on the wrong link or a visit to an insecure website can completely undermine the investment you might have made in other active IT security measures.
Or, as an organisation, have you considered that you should be interested how your employee’s home network is configured? Low or no security on a private WiFi could give organised crime easier access to the company laptop of a targeted employee.
Do regular backupsIf the worst happens, keep in mind that restoring an uncompromised backup might in some cases be the quickest and least expensive route to recovery. But remember what I mentioned before. The average duration for discovering a hack is 256 days. How will your backup strategy accommodate that?
The next level of defenceSo far, this was the easy part. More advanced strategies will have to include how to keep on top of the ever-evolving threat landscape. It would go beyond the scope of this article to give in-depth descriptions or advice on a comprehensive cyber
May 2016 / 15World Cement
security strategy. I merely wanted to touch on some of the major parts and possibly leave out some that others will deem an absolute must. For that I apologise.
The firewall is dead, long live the firewallAs already mentioned, statically configured firewalls are in many cases a mere delay for a hacking attempt. More sophisticated versions that work in conjunction with an Intrusion Detection or Intrusion Detection and Prevention System (IDS/IDPS) are a step up. Especially if they are connected to a Security Information and Event Management System (SIEM).
The enemy withinA SIEM should be designed to have a ‘holistic’ look across all networked devices of the entire corporation, possibly in different locations, countries and even continents. It collects and correlates the logs of all these devices and analyses them based on rules. Perhaps a failed login attempt on a user’s laptop, followed by some strange network activity on a switch in combination with an unusual user name and password combination on a firewall in isolation might not have triggered any alarms, but the presence of all these together might indicate an unauthorised login attempt on a sensitive database server. And this will work for external hacking attempts as much as for violations carried out by one of your own employees. The system will flag such cases, and out of a flood of maybe a million events, it might highlight just one or two that should be further investigated by your dedicated cyber security team. The aforementioned report highlights that a large number of information thefts are inside jobs. How will your perimeter firewall protect you from that threat?
Your friendly hacker from next doorSo far, all if this has only been a theoretical exercise as you cannot prove that no-one has hacked your system. You can only prove that someone has hacked it if you find the evidence. In order to test all levels of defence and your internal reporting and alarm escalation, you should consider undergoing regular Penetration tests (PEN Tests). In such a scenario, a ‘friendly’ organisation undertakes a hacking attempt to find out how vulnerable your present-day configuration is. The intent is not to shut down
or damage your operation rather than to provide evidence as to how far the hacking attempt went and what the resultant consequences would have been. The detailed report will then help you to further harden your setup.
Help! We’ve been hacked!It is more than likely that one day a hacker will gain access to something they shouldn’t have gotten access to. The question is, are you prepared for such an event? The initial instinct of: ‘turn off the internet’ might firstly not be that simple and secondly in some cases not an option. Is it more important that your customers can continue to order online or that the ‘thief’ gets away with some medium-sensitive information? In the heat of the moment it is often tricky to establish facts. How do you react to the media, etc.? An emergency response plan is key along with regular reviewing of your procedures and testing
of the vulnerability of your system. In addition, referring back to the X-Force report mentioned earlier, the initial cause for an investigation in some cases reveals that a much more sophisticated attack had taken place weeks and months before. We call these onion layered attacks. Seldom will a customer have the skill set to determine in-house how this more sophisticated attack took place. In such situations you can call on Cyber Security Emergency Response Teams like the one from IBM. These are
available on an ad hoc basis but they can provide much better value on an annual subscription basis.
How are we doing or where shall we start?To my knowledge there isn’t a single solution out there that will cover all bases and can be justified from a financial point of view. In reality, every setup and situation will be different. What is right and good for one customer may not be sufficient or affordable for another. In many cases, IBM’s starting point is the ‘Ten Essential Practices’, a questionnaire-based approach that can help you to determine where you are and where you should be, and, based on that, to start developing your own strategies. Often, our customers request our Senior Cyber Security Consultants to conduct a workshop with their key personnel to get a more accurate picture of their situation and specific advice in how to address the gaps.
More advanced strategies will
have to include how to keep on top of the ever-evolving
threat landscape
COAL GRINDING AND FIRING SYSTEMS - HAZOP ANALYSIS
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A Process Hazard Analysis (PHA) is a key element of a Process Safety Management (PSM) programme. It analyses potential risks to personnel operating in an industrial
environment.A PHA is a thorough, detailed, systematic approach
to finding potential hazards in an industrial plant. It includes an analysis of the equipment, instrumentation, utilities, human actions, and external factors that could be potential hazards. In this article, we focus on potential causes and consequences of fires, explosions, release of explosive or flammable solid fuel and major spills of solid fuel – coal or petroleum coke.
One of the techniques of a PHA used to identify hazards and operability problems is the HAZOP (Hazard and Operability) study that can be performed on both a new or operating coal grinding and firing system. It is believed that the HAZOP is perhaps the most widely used methodology for identifying and mitigating hazards.
Generally in a new system, technology suppliers’ cross-functional teams carry out risk analysis of their equipment and systems and incorporate preventive measures. A HAZOP study in a new system helps in evaluating the system’s safety and identifying any unforeseen situations that could be hazardous.
A HAZOP study of an operating system has a different purpose. The objective is to identify potential deviations from the design intent and design operating parameters and accidental incidents that need to be subjected to a detailed and comprehensive evaluation, scrutiny and risk analysis.
Although the primary assumption when performing a HAZOP study of an operating system is that the
JAGRUT UPADHYAY, PEC CONSULTING GROUP LLC, US, OUTLINES AND EXPLAINS THE USE OF THE HAZOP STUDY WITHIN COAL GRINDING AND FIRING SYSTEMS.
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original process design and equipment standards are probably correct, it is an opportunity to review the design, any additional technical support needed, and operational and safety requirements.
This article describes activities and elements involved in a HAZOP study of a coal grinding and firing system.
The handling, preparation, storage, conveying and firing of pulverised coal are critical processes in a typical cement or lime plant and have inherent operating risks. There are many operational difficulties in handling and transporting raw coal in locations that face extremely low or high ambient temperatures. Under such adverse conditions, establishing effective safety measures for coal handling and transportation is necessary to ensure a trouble free and smooth plant operation.
Various qualities of coal are used as fuel. Due to the combustible properties of coal in general, safe handling is important during the entire process from
the point of receiving to firing through preparation and storage and conveying of ground fine coal.
Accidents are mainly caused by the unintended release of energy caused by fire and explosion. A HAZOP study identifies situations where such a release of energy may occur. It also identifies and estimates the potential severity of damage and recommends mitigation measures.
A HAZOP study of a typical operating coal grinding and firing system encompasses the following areas:
1. Fuel handling and storage – raw coal receiving, storage and handling.
2. Fuel preparation – raw coal grinding.
3. Fuel conveying – fine coal storage and conveying for an indirect firing system.
4. Fuel conveying – fine coal conveying for a direct firing system.
5. Kiln burner (firing system).
The purpose of a kiln burner is to optimise the combustion of fuels to release heat in the kiln ensuring ‘complete combustion’. As the kiln burner is an important and integral component of the coal grinding and firing system, it is necessary to integrate it with the grinding facility.
A PLC (Programmable Logic Control) based BMS (Burner Management System) is an effective tool to ensure the safe operation of a kiln burner. Older fuel firing systems may not have such system incorporated.
As defined in NFPA 85, ‘the BMS is a control system dedicated to combustion safety and operator assistance in the starting and stopping of fuel preparation and burning equipment and for preventing mis-operation of and damage to fuel preparation and burning equipment.’
A BMS is a safety solution for kiln burners that enables safe start, safe operation and safe shutdown in all operating conditions, including normal operating and emergency conditions, thus reducing possible errors even when the correct operating procedure is followed. It is equipped with features such as a flame detector, flame safeguard, and fail-safe mechanisms.
A BMS is a form of protection against malfunction of the fuel firing system and associated systems and against unsafe operating conditions. It performs the role of an operator’s assistant by providing status information. An additional advantage of a BMS is the increase of the burner’s efficiency, which reduces greenhouse gas emissions.
MethodologyA HAZOP study is generally performed using a comprehensive and widely used ‘What If’ methodology in the industry. The ‘What If’ analysis is a creative, brainstorming methodology to identify and evaluate the process hazards. A HAZOP study is a team exercise.
Spillage and unsafe conditions at coal mill.
Coal dust emission from fine coal bin.
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A team of 3 or 4 experts usually performs the technique. By reviewing relevant documents, process knowledge and experience, the team develops ‘What-If’ questions around all possible deviations, upset process conditions, equipment failures and potential human errors. Potential hazards, operational problems and design faults are thus identified. The team evaluates the consequences of each deviation and, depending on what safeguards are available in the present system, decides upon recommendations or actions for preventing such occurrences.
Pulverised coal presents the highest hazard and therefore the coal grinding system is given the most intense evaluation.
In an operating coal grinding plant, it is assumed that the plant and equipment have been designed and engineered properly based on legal requirements, design/engineering codes, industry standards and good engineering practices. It is also assumed that the coal grinding and firing system is operated at least at minimum design capacity.
The HAZOP Study of coal grinding and firing systems addresses the following aspects:
1. The hazards of the coal grinding and firing process.
2. Engineering and administrative controls applicable to the hazards and their interrelationships.
3. Detection methods (Hydrocarbon detectors and gas analysers) and continuous process monitoring.
4. Consequences of failure of engineering and administrative controls.
5. Human factors affecting the operation.
6. A qualitative evaluation of safety and health effects of failure of controls on employees.
7. The identification of any previous incident that had a potential for catastrophic consequences.
DocumentationThe following documents, depending on the type of the process, will be required as a basis to perform a HAZOP study:
l Lay out and G A drawings.
l Equipment lists of process areas under study.
l Process flow sheets.
l Process and instrument diagrams.
l Process control loops.
l Process and safety interlocks.
l Instrumentation and alarms.
l Gas analysers with location.
l Process variables with all limits.
l Operating procedures and work instructions for various modes of operation such as normal start-up, normal operation, normal shut down and emergency operation mode.
l Maintenance procedures and work instructions.
l Documentation on auxiliary systems such as inertisation measures and installations and hot air generator if applicable.
l Documentation on fire hydrant system.
l Documentation on kiln burner (kiln firing system) control system.
l Raw coal analysis – including Hard Grove Index, sieve analysis, ash content, volatile content and moisture content, net calorific value.
l Fine coal analysis – residual product moisture, fineness.
l Method to control bypassing the Interlocks and alarms and record of bypassing the interlocks.
l Hazardous area classification.
StaffingA HAZOP study is performed by a team consisting of process and maintenance engineers with specific knowledge of the operation and maintenance of coal grinding and firing processes. At least one member of the team must be knowledgeable in the specific process hazard analysis. Operation and maintenance engineers as well as coal mill operators participate in structured brainstorming to look for deviations from the design performance.
ResultsA HAZOP study identifies potential deviations which had not been experienced in the coal grinding and firing system.
The ultimate aim of a HAZOP study is to achieve the following:
l Ensure that the coal grinding and firing system can be started, operated and shut down safely.
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l Recommend appropriate changes to the process design or its operation that increase safety or enhance operability.
l Consider existing safety interfaces with operation software including installations such as the coal mill baghouse, fine coal storage and dosing system, fuel firing systems, inertisation systems, etc.
l Develop recommendations and actions to eliminate potential occurrences identified as risks.
A HAZOP analysis is also required whenever there have been modifications/changes to the equipment, system, operation and maintenance procedures, operating parameters, environmental conditions, and also in the case of accidents or near misses. Therefore, a HAZOP analysis also provides an opportunity to develop a system to manage changes effectively.
The HAZOP study results are used to:
l Compare basic concepts.
l Focus on important risk areas.
l Provide inputs to more comprehensive hazard analyses.
It may be noted that many plants do not have BMS incorporated in the kiln firing system as part of an original installation. Though some basic safety and operational interlocks do exist in the operating
system, they are not comparable with a foolproof control system. Therefore, a HAZOP study can help in determining the need of any additional control system for an existing plant, such as BMS, to enhance the safety of the system as well as personnel.
Results of a HAZOP analysis are also beneficial in terms of enhancing equipment safety, reliability and availability and, therefore, improve the profitability of an organisation. Participants gain a thorough understanding of the coal grinding and firing system.
ReportThe HAZOP Report is a key document concerning the safety of the plant, equipment and personnel. It is essential that the findings and such knowledgeable study are easily available for future reference in case there is a need to modify the equipment or its operating conditions.
The HAZOP Study Report provides comprehensive results compiled in specific formats and clearly lists the actions to be taken by the plant management.
Bibliography
y RAUSAND, M. ‘A presentation on Preliminary Hazard Analysis by Marvin Rausand, October 7, 2005,’ System Reliability Theory (2nd ed), (2004).
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