Danny Zepeda, Rotor Optics LLC.
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Danny Zepeda, Rotor Optics LLC.
- 1. Small UAS Safety Considerations In The Petrochemical Industry Danny A. Zepeda Co-Founder of Rotor Optics LLC I&E Electrical Engineer at Valero Benicia Refinery B.S.E.E.(Emphasis in Power System) California Polytechnic State University San Luis Obispo
- 2. Presentation FAA Small UAS Rule & Regulations – The Foundation. Drones Safety Considerations in Hazardous Environments: Hazardous Materials Hazardous (Classified) Locations Electromagnetic Interference Proposed practice for sUAS Operation in the Oil and Gas Industry.
- 3. FAA Propose Small UAS Rulemaking FAA mission is to provide the safest, most efficient aerospace system in the world. www.RotorOptics.com The FAA has progressed to safely integrate sUAS into the National Air Space (NAS) in the manner that does not impose unacceptable risk to other aircrafts, people or property.
- 4. Electric Utility sUAS Standards & Practices Petrochemical, Oil & Gas sUAS Standards & Practices Emergency Response sUAS Standards & Practices FAA - BASE SUAS Rules & Regulations www.RotorOptics.com
- 5. Small UAS in the Oil & Gas Industry Can a sUAS accident/ malfunction cause a incident dangerous to human & cause a environmental impact? Additional risk should be consider when developing a small unmanned aircraft program for hazardous industries. Many benefits using a Small UAS in the Petrochemical industry can complete difficult task without risking personal is ideal. www.RotorOptics.com
- 7. All three elements of the fire triangle These elements must be present simultaneously and in specific quantities for a fire or explosion to occur. Oxygen + Fuel Ignition + = Fire www.RotorOptics.com Hazardous Material
- 8. Hazardous Material • Flammable / Combustible Liquids & Vapor (FUEL) • Vapor Concentration in Air (OXYGEN) • Ignition Source (IGNITION) www.RotorOptics.com
- 9. Hazardous Material Flammable & Combustible liquids are easily ignited with explosive force. These liquids are classified according to their flash point to indicate the danger they pose as a fire hazard. www.RotorOptics.com
- 10. Flash point is the minimum temperature a liquid gives off enough vapor to form a ignitable mixture in the air. Hazardous Material 77F FLASH POINT At 77F° vapor to form a ignitable mixture in the air 0F° 50F° 100F° www.RotorOptics.com
- 11. Hazardous Material Flammable Liquids have flash points below 100°F degrees. Combustible Liquids have flash points at or above 100°F degrees. 100°F Combustible Liquids FP>100°F Flammable Liquids FP<100°F FlashPoint Temperature Boiling Point Flammable FP<100°F Combustible FP>100°F 77°F 0°F -44°F 140°F 200°F www.RotorOptics.com
- 12. Hazardous Material Flammable Liquids have flash points below 100°F degrees. Combustible Liquids have flash points at or above 100°F degrees. 100°F FlashPoint Temperature Boiling Point 74°F 0°F -44°F 140°F 200°F CAT 1 CAT 2 CAT 3 CAT 4 100°F www.RotorOptics.com
- 13. 0% 100%50% Hazardous Material Lower Explosive Limit (LEL) and Upper Explosive Limit (UEL) LEL UEL (Too Lean) (Too Rich) % Percent Fuel in Air Flammable Range www.RotorOptics.com
- 14. Ignition Sources Open Flame Smoking Welding & Cutting Hot Surfaces Static Charge Mechanical Sparks Electrical Arcing www.RotorOptics.com
- 15. Ignition Sources from a sUAS Aircraft systems contain various mechanical and electrical components that may malfunction or overheat if not properly maintain. Overheating of circuits, electrical component or ESC can be consider ignition sources. Stripped Wire Short Circuits Aircraft Collision Overheat ESC www.RotorOptics.com
- 19. Hazardous (Classified) Location A hazardous location is a place where concentrations of flammable gases, vapors, or dusts occur. It is important to know the characteristics of all of material used, locations, potential sources of leaks and determine the extent of the Hazardous associated with each leak source. www.RotorOptics.com
- 20. Hazardous (Classified) Location The NEC is a standards for safe installation of electrical equipment in the US. The NEC is part of the National Fire Protection Association (NFPA). National Electric Code (NEC) Once the area is classified the NEC provides very specific and stringent requirements regarding the electrical equipment, associated wiring and installation in such locations. These requirements are intended to prevent electrical equipment from being an ignition source in flammable or combustible atmospheres. www.RotorOptics.com
- 21. Electrical Area Classification Drawings Classes: Class I: Liquid or Gases Class II: Dust or Fiber Class III: Flammable Fibers Divisions: Div 1: Normal Conditions Div 2: Abnormal Conditions Groups: (Class 1) A,B,C,D (Class 2) E,F,G (Class 3) No groups Determines the existence and extent of Hazardous (Classified) Location in a facility handling any of installation of electrical equipment, wiring devices and methods to prevent the ignition of flammable or explosive mixtures. www.RotorOptics.com
- 22. Hazardous (Classified) Location: Classes Class I:Flammable Liquids Gas or Vapors Class II: Combustible Dust or Fiber Class III: Ignitable Fibers & Flying's www.RotorOptics.com
- 23. Hazardous (Classified) Location: Divisions Division I: Normal Conditions Division 2: Abnormal Conditions www.RotorOptics.com
- 24. Division I: Normal Conditions Division II: Abnormal Conditions Hazardous (Classified) Location: Divisions www.RotorOptics.com
- 25. CLASS I Flammable Gas, Liquids, Vapor CLASS II Combustible Metal Dust CLASS III Fibers & Flying's E F G No Groups for Class III A Acetylene B Hydrogen C Cyclopropane Ethylene Groups and typical material types are: D Acetone, Butane, Hexane, Natural Gas, Fuel Oil Combustible Metals Carbonaceous material, including coal dust Flour, grain, wood, plastic etc. Hazardous (Classified) Location: Groups www.RotorOptics.com
- 27. Electromagnetic interference is disturbance that affects an electrical circuit due to either electromagnetic induction or electromagnetic radiation emitted from an external source. Electromagnetic Interference Operating a small unmanned aerial system is like flying a small computer. A problem for computer is electromagnetic interference (EMI) or radiation. www.RotorOptics.com
- 28. EMI caused by high voltage power lines or electric motors due to motor design can cause an affect or interference with the unmanned aircraft electrical components and radio controls. Electromagnetic Interference Electrical Components Radio Controls www.RotorOptics.com
- 29. Small UAS Safety in the Petrochemical Questions: • What safety standards & procedures should be implement to ensure safe sUAS operations in hazardous industries. • What design requirements should be applied to avoid source of ignition, radio and electromagnetic interference. • What maintenance & training programs should be developed. www.RotorOptics.com
- 30. Suggested Safety Practices Pre-Flight Plan: • Detail Job Description & Plan • Electrical Area (Classification) Drawings • Test Flight / Equipment Check List Drone Hazard Analysis(DHA) • Identify Hazards In The Area. • Gas Test/ Fly Zone/ Emergency Landings • Determine Weather & Wind Conditions Post Flight Analysis • Data Collection/ Records /Documentation • Equipment Maintenance/ Record Log • Findings and Lesson Learn www.RotorOptics.com
- 31. Small UAS Vision in Oil & Gas Contact Information: Danny A. Zepeda P:(760)473-3366 danny.zepeda@rotoroptics.com www.rotoroptics.com
Editor's Notes
- I like to first thank Patrick for giving me the opportunity to present at todays exposition. Looking at the list of speaker on the website I feel extremely honor to be apart of this program and very great full to present today because it is my actual Birthday. Let me quickly introduce myself for I am press for time. -My name is Danny Zepeda and I received my Electrical Engineering Degree Emphasis in Power systems form Cal Poly San Luis Obispo. -After graduation I was recruited by Valero Energy in Benicia Refinery and currently Electrical Engineer for the Electrical Reliability Department. I’ve also work in Utility industry with San Diego Gas & Electric and worked at San Onofre Nuclear Generating Station down in Southern California . I am heavily involved in IEEE-Industrial Application Society and also sever on the committee board for the Petroleum & Chemical Industry Conference that IAS holds every year. - I am also the cofounder Rotor Optics , a group of engineer that share a common interest in small UAS Application in various industries. The objective of my presentation is to share the potential hazards and safety consideration that should be considered when operating a SUAS in hazardous environment's like the Oil and Gas industry.
- I begin on briefly showing how the new standards and regulation developed by the FAA will become the base or foundation for other industries to develop their own specific standards and practices for their own sUAS operations. The heart of my presentation will share useful information on main hazard that an drone operator should consider: I discuss common characteristic/properties of hazardous material that should be known I then build on that hazardous material and attempt to explain how to classify hazardous locations I will discuss the electromagnetic inference and how then may effect drone systems electrical components and radio communications. I then will conclude my presentation with a few questions and share some safety practices that have been developed to start operating in hazardous locations.
- It is no secret that there is a great push to safely integrate small UAS into the Nation Air Space to unlock the benefits of increasing safety, create lasting jobs, boosting local economies, and further advance innovation and technology. As the FAA integrates small unmanned aircraft systems into the National Airspace their main concern is to avoid air collisions with other manned aircrafts and damaging properties and endangering people on the ground. Now that FAA is not responsible for additional safety concerns using SUAS application in specific industries.
- I predict that the new rules and regulation developed by the FAA will become a base/foundation for other industries to develop specific Drone Safety Standards and Practices for their own industry. For example: Drone Standards and Regulation may be developed for different industries like: Electric Utility Emergency Response Oil & Gas And any other industries that may develop drone programs.
- Now with my interest in Small Unmanned Aircraft System and my background in the Oil & Gas Industry, I hope to pave the way and develop safety practices for sUAS application in the petrochemical Industries. The benefits of using sUAS in Oil & Gas industry allows to and complete difficult task without risking any personal and making it a safer, increasing productive and can be cost effective solutions. I could have present today the various Drone application in the Oil & Gas refineries but I felt that there may have been a great amount of information that already exist. So I wanted to take step further and take a proactive approach and ask the question “ can these Drones potentially cause an incident that may in danger people or cause an environmental impact. With that being asked I believe when developing a Drone program in such similar industries, Hazards and Risk should be identified and mitigated when developing a program.
- I attempt to break these safety consideration into three sections. I will discuss Hazardous material and common properties that should be known Then I will then Segway into identifying Hazardous Classified Location. I’ll switch gears and discuss Electromagnetic Inference and how this energy may effects drone systems electrical and communication components.
- In the oil and gas industry the most common concern is the mixture of the following components. When fuel is mixed with oxidizing agent, most commonly oxygen and finding a potential ignition source which results into a fire or explosion to occur. These are the three elements of the fire triangle and when simultaneously present in certain quantities can cause fires or explosions.
- In my presentation I don’t specify specific hazardous material, instead I share common characteristics and properties of specific hazards material that I believe will be useful information when operating in chemical plants. (Fuel) I will explain and compare the difference between a flammable and combustible liquids and vapor (Oxygen) Explain the vapor concentration in Air and discuss the vapor Lower and Upper Explosive limits. (Ignition ) And I will show some exampled of common ignition sources.
- Flammable and combustible liquids are easily ignited, Each flammable and combustible liquids has a property called flashpoint which indicate the danger that this liquid pose as a fire hazard.
- The flash point of a flammable and combustible liquid is the minimum temperature where it begins to give off enough vapor to form a ignitable mixture in the air. I show a flammable liquid at a certain temperature. This flammable liquid has a flashpoint of 77 degree F, as this liquid temperature increase and surpasses the flashpoint the liquid begins to produces a vapor to form an ignitable mixture in the air. Flammable liquids themselves will not burn but as the liquid evaporates it gives off vapor that can mix with air, at the right concentration these vapors can form dangerous gases that can be set off by a small spark.
- The difference between a flammable and combustible liquid is identified by the flashpoint. All flammable liquids are less that 100 degree F and all combustible liquids are above 100 degree F. Even though Combustible liquids have higher flash points than flammable liquids, they can still pose a serious fire or explosion hazards when heated.
- These flammable and combustible liquid can be further subdivided into categories depending on the liquids flash points and boiling points.
- I’ve discussed the 1st element of the fire triangle: Fuel, in form of a flammable and combustible liquids or gases. The second element is the oxidizing agent where I will explain by using this graph. This graph represents the percentage of fuel in air.. (left) is 0% fuel in air and then gradually increase to the right to 100% fuel in air. Each gas vapor has a lower explosive limit and a upper explosive limit. This is the lowest and highest concentration percentage for a gas vapor in air to be capable of producing a flash of fire when ignited. I demonstrate a flammable liquids below its LEL limit…… When it reach it flashpoint it begins to produce vapor that mixes with air. If the concentration is below its LEL limit it is consider to be too lean to produce a flash of fire …… and vapor will not ignite. I demonstrate a flammable liquids above its UEL limit…… When the liquid reaches its flashpoint it begins to produce vapor that mixes with air…..If the concentration is above its UEL limit it is consider to be too rich to produce a flash of fire….the vapor will not ignite. Now the same liquid produced a vapor that mixes with air in between its flammable range……This gas vapor in air is now capable of producing a flash of fire when ignited….. The vapor will ignite and cause a flash of fire
- The final element to complete the fire triangle is the Ignition source. I show a few common ignition sources that may exist in the Oil & gas refineries.
- As sUAS are being integrated into the National Air Space, more and more industries will begin developing various application for their industries. These SUAS can now be potential ignition source. These unmanned aircraft systems contain various of mechanical and electrical components that may malfunction or overheat and can be cause ignition sources. For example: stripper wire, short circuits, system collisions and overheated components or electric speed controllers.
- The scenario that I will present will show my concern on operating a drone in hazardous environments. I demonstrate part of a chemical process unit where I identify locations consider to be Division 1 areas. This means potential sources ignitable gases may exist under normal conditions. This is do to frequent operations, maintenance or repairs at these locations. Every process block contains electrical equipment like lights motors heater etc. Now we are seeing more drones application to complete difficult task and will be a consider a frequently tool to be utilize. If an abnormal condition where to exist like a gas leak or large vapor release. And if this vapor is in-between its flammable range and finds a ignitions source can result to serious consequences like catastrophic fire or explosion.
- It only takes a small static charge for a accident or catastrophic event to occur. That why there are strict safety requirements implements in hazardous environments like such, It is important to operate safely and to not in danger the community people, equipment and cause harm to the environment.
- In order to prevent and minimize the likability of an incident the industry has set requirements and standards for location with significant hazards. I now Segway into the identifying these standards for hazardous (classified) locations that have been implemented by the NEC and is important to have some knowledge when operating in such industry.
- The definition of a hazardous location is a place where concentrations of flammable gases vapors or dust occur. It is important to know the characteristic of all material used these locations and any potential sources of leaks and determine the extent of the hazards associated with each leak source.
- Once the area is classified the National Electric Code provides a very specific requirements regarding the electrical equipment installed in such locations. These requirements are intended to prevent electrical equipment from being an ignition source in flammable or combustible atmospheres.
- Each refineries site has electrical area classification drawings which determines the existence and extent of hazardous (classified) locations in a facility handling any of the installation of electrical equipment to prevent the ignition of flammable gases. Each drawing provides Classes, Division and the chemical group.
- The traditional way the NEC classifies the hazardous location bases on the type and quality of ignitable material presented; Class I: Denotes areas where flammable gas, vapor, or liquid is present. (For example Petrochemical & Solvent Processing Plants, Sewage Treatment Area, Recycling Plant, Food Processing Plants etc.) Class II: Denotes areas where combustible dust is present. (These include Grain elevators, coal handling operation and various types of processing operations) Class III: Denotes areas where ignitable fibers and flying fire hazards are present. (Cotton textile operations are good example of Class III)
- In additions to classes; The NEC also identifies the condition of the Hazard of which they may exist. If a potential sources of ignitable gases exist under normal conditions due to the frequent operations, maintenance or repairs. These locations are identifies as Division 1 Area. If the hazard is presented as abnormal conditions such as a vapor released or a gas leak, these location are identified as a Division 2 Area.
- This example show the difference between the Division I and Division II locations. Division 1 are identified on this slide which demonstrate where there might be a hazard during normal operations. Division 2 location identified are area that may contain a hazard during a abnormal condition. Having this this knowledge allows the drone operator to identify where to safely operate a unmanned aircraft system.
- Most of the Electrical Area Classification Drawings will also entitle the specific groups and typical material in the locations. Groups ABC and D corresponds to Class I locations Groups EF and G corresponds to Class II locations. and there are no groups corresponding to Class III locations.
- I now switch gear and move away from hazardous material and location I begin to share my final safety concern, electro magnetic interference and how it may effect the controls and communication of a unmanned aircraft system.
- These drones are consider to be small flying computers. A problem for computer is electromagnetic interference (EMI) or radiation. Electromagnetic interference is the disturbance that affects an electrical circuit due to either electromagnetic induction or electromagnetic radiation emitted from an external source.
- Oil and Gas refineries are expose to various energies from high voltage equipment. EMI causes by high voltage power lines or electric motor can cause an effect or inference with the unmanned aircraft electrical components and radio controls. Design requirements should be set to insure that these systems will not effected or malfunctions when operated in such environments with various electrical magnetic energy. Furthermore specific radio controls should be consider to ensure constant commutation and control with the aircraft.
- This slide Identifies the various radio control that exist. Amplitude modulation (AM) should not be use due to the amplitude changes which can be effected by almost any electrical noise present. Frequency modulation (FM) changes frequency instead of amplitude but can also be effected by other present stray frequency signals. Pulse code modulation uses emended signals in the radio wave for the radio to encode digital signal. The most recently commonly used are spread spectrum which spreads the signal over a wider range of the spectrum which makes the signal to less likely to run into interference.
- Now before I conclude here are a few basic question we should ask ourselves if specific hazardous industries chooses to develop Drone programs in hazardous locations. What safety standards & procedures should be implement to ensure safe sUAS operations in Hazardous industries. What design requirements should be applied to avoid a potential source of ignition, or radio and electromagnetic interference with the systems components and communications to prevent aircraft collision or malfunctions. What maintenance & training programs should be developed to ensure that drone operator are educated and train to identify potential risk.
- Even though I’ve only scratch the surface and we are in the process of developing our own sUAS safety practices for various industries. We have developed the following: A Pre-Flight Plan which allows to detailed job description and develops a safe flight plan. This also forces the operator to pull any electrical area classification drawings to help identify hazardous locations. This is also will include a suggested test flight and equipment test check list before operation. Drone Hazard Analysis help identify any hazards in immediate area. This includes safe operating location, request gas testing, identify different fly zones, emergency landings, emergency exits, identify weather and wind conditions etc. When a flight mission is complete our post flight analysis includes the data collection for the specific applications. We will be require to fill out equipment maintenance record log to track equipment usage. We also plan to record any finding or lessons learns to help keep track and begin to find ways improve the Small Unmanned Aircraft Systems Programs.
- There are many application and benefit using drones in various industries. I hope to present two IEEE papers (Drone Application and This the topic discussed today Drone Safety Considerations) for the 2016 Petroleum & Chemical Industry Conference which will be held Philadelphia. I believe each industry should insure that this technology will be use properly and safely with the their specific industry. My vision to provide aerial service and engineering and help various industries to develop safe drone practice and come up with specific solution related unmanned aircraft systems. I have provide contact information and can reach by phone or email at danny.zepeda@rotoroptics.com or feel free to check out our website at www.rotoroptics.com. Thank you for your time and I will be available for any question. This concludes my presentation.