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The controller is a crucial component of a cost-effective general SIL2 Safety solution. (Image source: Adobe Stock)

Emerson has launched a new PACSystems RX3i CPS400 Safety Controller, designed to enable Safety Integrity Level 2 (SIL2) strategies for infrastructure, fire and gas, burner management systems, and other emergency shutdown systems

As project automation becomes more sophisticated and data-driven, OEMs and systems integrators require more powerful hardware and software products to ensure compliance with standards and regulations for protecting workers, whether onboard a single piece of equipment or distributed throughout a much larger process.

The PACSystems Safety Controller is a compact, high-performance solution with robust security measures and a scalable architecture with 2,000 available I/O points, ideal for complex projects with evolving requirements. With a 64-megabyte memory capacity and scalable digital architecture it is able to support a diverse range of mission-critical applications. Using built-in industrial communications protocols the RX3i CPS400 controller can connect peer-to-peer and with higher level hosts, providing complete operational visibility.

As a secure-by-design solution incorporating Secure Boot and the Trusted Platform Module (TPM) standard, the new controller delivers rigorous data integrity and protection against potential threats. Safety-certified function blocks and pre-configured templates simplify overall system certification in accordance with the IEC 61511 standard.

Available in simplex or redundant controller configurations, the RX3i CPS400 controller can perform all safety data messaging with duplex communications using the black channel principle over EGD, allowing standardised and reliable connectivity with Emerson’s PACSystems VersaMax SafetyNet I/O system. The platform is IEC 61508 safety-certified, providing a capable SIL2 simplified solution to help designers build appropriate protection schemes.

Developers can configure the new controller using familiar software tools employed for programmable logic controllers (PLC), operator interfaces, and other automation elements, namely Emerson’s PAC Machine Edition development environment. As a unified tool chain with a user-friendly interface, the PAC Machine Edition suite enables users to easily create complete and integrated automation, visualisation and safety solutions.

“Adding the PACSystems RX3i CPS400 Safety Controller to our extensive portfolio of safety products, we continue to deliver tools users need to create compliant safety systems that are easily developed and integrated into sophisticated automation solutions,” said Daniel Smith, senior product manager with Emerson’s discrete automation business.

The range covers all applications from residential to industrial environments. (Image source: Adobe Stock)

Teledyne Gas & Flame Detection (Teledyne GFD) gas has launched its new MethaSense range of battery-powered methane detectors, comprising three models using cutting-edge NDIR (non-dispersive infrared) sensor technology for reliable and precise methane detection

MethaSense, designed for residential and commercial applications, is a compact, wireless natural gas detector with a range of 0-5 % volume, featuring accurate detection without false alarms, and immediate alerts through integrated audible and visual alarms. With progressive signal processing algorithms, MethaSense detects, alarms and monitors methane at concentrations as low as 10% of the lower explosive limit (LEL) for enhanced safety. Optional wireless (LoRaWAN) connectivity enables real-time gas detection visualisation, providing clear, actionable insights.

MethaSense XP is engineered for industrial environments where robust performance and reliability are essential. MethaSense XP’s rugged design and reliable detection capabilities ensure worker safety and operational continuity, especially in areas where maintenance access is limited.

It combines the same advanced NDIR sensor technology with enhanced durability and wireless communication options, including LoRaWAN, NB-IoT and Bluetooth. MethaSense XP again features audible and visual alarms, while its 10+ year battery autonomy and immunity to corrosion and saturation make the detector ideal for continuous safety monitoring in demanding conditions. With ATEX and IECEx certifications, MethaSense XP operates reliably in hazardous zones.

MethaSense Trace is a high-performance methane detector for LDAR (leak detection and repair) and utility applications, where accurate and autonomous methane monitoring is essential for regulatory compliance and environmental protection. A rugged build with IP67 ingress protection rating for outdoor use ensure uninterrupted performance in harsh conditions, reducing operational risks and maintenance costs.

With exceptional methane sensitivity, it provides 10× higher methane selectivity than previous-generation sensors, with a detection range that extends from 50 ppm to 100% volume for both low-emission environmental monitoring and high-concentration safety thresholds.

The detector delivers 24/7 methane emission monitoring, detection and quantification across large-scale industrial sites. By combining real-time sensing, cloud-based analytics and automated reporting, MethaSense Trace enables operators to detect, localise and measure methane emissions with precision. This not only helps reduce emissions but also ensures full compliance with new methane regulations.

“NDIR technology, as utilised by all three detectors in our new MethaSense series, offers high selectivity, fast response times and long-term reliability,” explained Régis Prevost, product line manager, Teledyne GFD. “Users benefit from natural gas detectors that provide a low-maintenance, cost-effective, versatile solution for continuous methane monitoring, supported by key features that include up to 10+ years of battery life, zero recalibration requirements, wireless connectivity options, and suitability for smart infrastructure and safety-critical environments.”

Larry Wilson, CEO, SafeStart

Larry Wilson, Author and CEO SafeStart, discusses his journey to integrating human factors in Middle East workplace safety

Oil Review Middle East (ORME): Larry, thank you for joining us today. To start, can you share your vision for workplace safety in the Middle East, considering the unique challenges and opportunities in this region?

Larry Wilson (LW): The vision for workplace safety in the Middle East with SafeStart goes beyond workplace safety. The Critical Error Reduction Techniques work at home, on the road, in the community and at the workplace. So, the vision, plan and end goal are that we would start with workplace safety, prove that it works in industry, and then move in to sports, schools, youth groups and drivers education, similar to what has happened in North America, Latin America, Europe and the UK.

ORME: How can companies begin transitioning from a reactive safety culture to one that embraces human factors, where safety becomes a shared responsibility between the company and its employees?

LW: Although many companies in the region are only concerned with compliance, that is not unique. Many companies all over the world are content with achieving minimum legal requirements. Small, contracting companies may not even be aware of what a safety culture is or what it means. However, there is a growing number of high-profile and, in some cases, high-risk companies or organisations in the Middle East that are pursuing or trying to achieve a positive safety culture. These are typically the kind of companies we like to work with. And there are many of these companies in the region.

ORME: Given the diversity in the Middle East, where safety culture may vary greatly from one country or industry to another, what are the main challenges companies face when implementing human factors training, and how can these be overcome?

LW: Certainly, there are challenges trying to manage safety with so many languages, different backgrounds with different safety cultures. However, it doesn’t matter where you’re from, it’s the same four states: rushing, frustration, fatigue and complacency wherever you go. So, everyone, regardless of their background can relate and buy in to the concepts. This still means you have to accommodate the multiple languages and variable literacy levels. However, we already have a number of languages translated and we are planning more for next year.

ORME: How does SafeStart’s approach differ from traditional safety programmes? Can you share examples of how SafeStart has been a game changer in fostering a more proactive and engaged safety culture, particularly in a region where safety may not yet be ingrained?

LW: SafeStart is not about rules, procedures, Personal Protective Equipment or training on specific hazards. SafeStart is about keeping those hazards in mind and in sight: on the job, off the job and when you’re at home or in the community. So, the benefit to the worker is that it works everywhere not just at the workplace. The workers also get colouring books and videos so they can teach these concepts to their kids, this becomes a huge game-changer in terms of culture.

ORME: After conducting public workshops in the Middle East, what has been your overall feeling about the acceptance and receptiveness of human factors programs in the region? Are there any particular takeaways or surprises from those interactions?

LW: There has been a very positive response from the people who attended the workshop in Dubai. They liked the additional layer of protection offered by a Human Factors approach. I think what surprised a few people was that they started using the concepts and techniques right away, when they were driving home in rush-hour traffic. (You see a lot of rushing, frustration, fatigue and complacency in only a few minutes).

ORME: SafeStart has chosen Dubai and the broader Middle East as a strategic investment. What was the rationale behind this decision, and what do you hope to accomplish by establishing a stronger presence in this region?

LW: When I first came to Dubai 14 years ago it seemed to me that some companies were more interested in looking good than actually being good. But I think that has changed significantly and now companies want to be good or, in some cases, be the best or best in class. As mentioned, there are many of these companies in the region and the number is growing, so we felt confident investing in the region.

ORME: Looking ahead, what are your dreams and aspirations for the future of workplace safety in the Middle East? How do you envision SafeStart’s role in shaping the safety culture in the years to come?

LW: As mentioned earlier, the dreams and aspirations aren’t limited to workplace safety. Only 5% of unintentional fatalities occur at work. 95% happen away from work. And here in the Gulf region things are happening quickly. So, if a program like SafeStart starts showing good results with SOE’s we might get a shot at getting SafeStart into schools also.

ORME: For organisations in the Middle East looking to enhance their safety culture, what are the top three pieces of advice you would give, and how can they begin implementing them right away?

LW: I’m not sure there are three, I think there might be more than that in terms of what you may need to do to enhance your safety culture, and it also depends on where you are now. But the traditional approach to changing safety culture focused almost solely, on the leadership group. And while they have a lot of leverage, where the top-down approach usually stalls out is at the first-line supervisors. However, if you combine a top-down and bottom-up approach it is very possible for all members or the organization to be engaged in the safety effort, which will, over time produce a positive safety culture.

ORME: Finally, beyond just the Middle East, how do you see the global evolution of workplace safety programs, and what role do you think the Middle East will play in setting new benchmarks for safety and human factors integration?

LW: I see an improvement in safety anywhere if I haven’t been there for five years or so. In general, things are getting better everywhere but that doesn’t mean that they don’t have a long way to go. In the Middle East some high-profile companies are already being used as benchmarks by other companies or by their affiliates in other regions. And I think that we will see more and more of this in the next 5-10 years. Many of these companies are already looking at adding a human factors approach to their overall safety management system.

Ambipar, a global leader in environmental solutions, and SBM Offshore, have launched a new robotic solution for cleaning cargo oil tanks on FPSOs, which brings significant safety, sustainability and efficiency benefits

This new system, utilising remotely operated robots, eliminates the need for people to enter the tanks during the cleaning activity, which has traditionally involved significant health and safety risks due to the restricted spaces, high temperatures, and presence of chemical residues.

In addition to protecting workers’ lives, the solution also reduces operational time and the environmental impact of these activities.

In a case where the technology was used, the robot removed heavy oily sludge while the onboard team monitored the process remotely, 24 hours a day, from a safe location outside the tank.

“This robotic solution marks a turning point for the offshore industry. By automating a traditionally hazardous process, we are not only enhancing safety but also boosting operational efficiency and reducing environmental impact. It's a clear demonstration of how innovation and responsibility can go hand in hand,” said Rogério Calderaro, head of Global Industrial Services at Ambipar.

Jaap-Harm Westhuis, Technology, Innovation and Product Development director at SBM Offshore, added, “We are excited to announce this agreement with Ambipar. Together, we will be at the forefront of a new revolutionary approach to deliver cutting-edge solutions to eliminate human-related risks while delivering complex tasks such as the cleaning of oil tanks on FPSOs. This collaboration will enable companies to offer much safer working conditions for their crew, whilst protecting the environment.”

The initiative aligns with both companies’ commitment to technological innovation and the transition to more sustainable operations in the oil and gas industry.

30 personnel were on board the rig.

Four people are known to have lost their lives when a jackup barge vessel operated by a subsidiary of offshore drilling service provider ADES Holding Company capsized as it was being towed to a new location in the Gulf of Suez

23 of the 30 personnel on board have been rescued, while search and rescue operations for the missing continue. The cause of the incident is not yet publicly known.

The barge was offshore the Gabal El Zeit area in the southern stretch of the Gulf of Suez, south of the Suez Canal, near the Red Sea. The incident is not thought to have affected navigation or operations in the Suez Canal.

The company has opened a full investigation to determine the cause of the incident and is working closely with local authorities and emergency services. It has confirmed that the barge and personnel were fully insured, with no material impact on finances or guidance for the 2025 fiscal year.

Egypt's Ministry of Petroleum and Mineral Resources stated that it immediately activated its emergency plan following the incident, deploying sector rescue teams in the Gulf of Suez and mobilising all maritime and aerial resources, including vessels, rescue equipment, and aircraft, to assist in the rescue of the crew and coordinate with state authorities to ensure the swift recovery of survivors.

Minister of Petroleum and Mineral Resources Karim Badawi and Minister of Labour Mohamed Gobran, accompanied by senior officials from both ministries, are reported to have travelled to the site.

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