Basic Elements of Explosion Basic Elements of Explosion Protection in the EU Legislative Protection in the EU Legislative

ContextContext

Dr.-Ing. Uwe KlausmeyerDr.-Ing. Uwe KlausmeyerPhysikalisch-Technische BundesanstaltPhysikalisch-Technische Bundesanstalt

Braunschweig, GermanyBraunschweig, Germany

ATEX Symposium22 – 24 Eylül 2011, Ankara, Türkiye

The ATEX RegulationThe ATEX Regulation

EU Directives of the „New Approach“ Legislative EU Directives of the „New Approach“ Legislative Framework, consisting of:Framework, consisting of:- 94/9/EC (trade of equipment, ESRs)- 94/9/EC (trade of equipment, ESRs)- 1999/92/EC (safety of workplace)- 1999/92/EC (safety of workplace)

Accident in Oppau, GermanyAccident in Oppau, Germany

Accident in Buncefield‚UK, 2005Accident in Buncefield‚UK, 2005

Buncefield, 2005Buncefield, 2005

Buncefield, 2005Buncefield, 2005

Accident at INEOS near Cologne, GermanyAccident at INEOS near Cologne, Germany17th of March, 200817th of March, 2008

Pipeline ofEthyleneis burning

Has set fire to amethylacetate tank

Explosion Explosion protectionprotection

Oxy

gen

Combustible

Ignition sourceProper Compostition

Avoid concurrence:Avoid concurrence:- Oxygen (air)!!! Inertization

- Ignition source!!! Elimination

- Combustibles (gas, vapour, dust)!!! Ventilation

- Convection

- Buoyancy

SpreadSpread of of gasesgases

Lighter than air

Heavier than air

Spread of liquids, leakagesSpread of liquids, leakages

Gas

Gasoline

Combustible liquidsCombustible liquids

5 ml gasoline is enough to produce 200 l of explosive atmosphere, which can destroy a barrel!

Formation of highly flammable vapour/ air mixture can occur when handling with even small amounts of break cleaners!

Spread of combustible dustsSpread of combustible dusts

Dust layers with a thickness of 1 mm can be enough to produce explosive atmospheres!

Critical concentration of Flammable Critical concentration of Flammable substancessubstances (safety characteristics) (safety characteristics)

Influence of concentrationInfluence of concentration

Ignition sources – EN 1127-1Ignition sources – EN 1127-1

Ignition of an explosive atmosphere can be caused by various sources:• hot surfaces• flames and hot gases• mechanically generated sparks• electrical installations• equalizing currents, cathodic corrosion protection• static electricity• lightning• electromagnetic waves (high-frequency)• optical radiation• ionising radiation• ultrasonics• adiabatic compression and shock waves• exothermal reactions

Different types of protections (safety Different types of protections (safety concepts) offered by EN/IEC standardsconcepts) offered by EN/IEC standards

Gases/Vapours Dusts

Type of protection Symbol Electricalequipment

Non-electricalequipment

Electricalequipment

Flameproof enclosure d ● ● -

Protection by enclosure tD - - ●

Enclosed break device nC ● - -

Non-incendive component nC ● - -

Pressurized apparatus p ● ● ●

Powder filling q ● - ●

Oil immersion o/k ● ● -

Increased safety e ● - -

Non-sparking nA ● - -

Constructive safety c - ● -

Encapsulation m ● - ●

Hermetically sealed device nC ● - -

Sealed/encapsulated device nC ● - -

Intrinsic safety i ● - ●

Restricted breathing enclosure nR/fr ● ● ●

Protection by control of ignition sources b - ● -

Flameproof enclosure “d”, to mitigate Flameproof enclosure “d”, to mitigate an explosion hazardan explosion hazard

Explosive gasmixture

Ignition devicepressure transducer

Special preparation:

•Max tolerances at all gaps

•Without gaskets and grease

44

1

12

33

3

5

4

4

5

6

Ignition hazards of a complex apparatus:Ignition hazards of a complex apparatus:a fork lift (electrical motor or combustion a fork lift (electrical motor or combustion

engine)engine)

Electrical apparatus

•Motor „d“, „e“•control device „d“, „e“, „i“•accumulator „e“•plug and socket „d“•lighting fixture and

control lights „d“, „e“

1

Electrical installation2• IEC/EN 60079-14

Mechanical apparatus3

•Brakes and oil hydraulic system/components

Sparks caused by metallic parts5• Coating with brass, bronze and

stainless steel

Electrostatic charge• Conductable wheels• conductable seat material• conductable housing• grounding against electrostatic charge

4

Temperature control6•Motor control device•motor•hydraulic oil/system

Engine7

7

The ATEX RegimeThe ATEX Regime

• Free Trade Directive 94/9/EC in the Internal EU Market (Essential Health and Safety Requirements – ESRs, obligations of the manufacturer)

• Worker protection (Social) Directive 1999/92/EC (obligations of the end user)

• ATEX Standing Committee

• ATEX Notified Bodies

• ATEX Consultant, CENELEC, CEN, Presumption of Conformity with ESRs

What‘s about this „mark“????What‘s about this „mark“????

Chinese Export, Confusion Everywhere ;-))))

1. Conformité Européenne (FR)2. Legal mark, NOT a quality mark like TSE, VDE, UL… IECEx3. Affixed by a manufacturer on his own responsibilty4. may be based on an EC Type Examination Certificate by an independent ATEX Notified body, in the ATEX field only for Zone 0 and Zone 1 classified areas5. installation and instruction manual!!!!! installation and instruction manual!!!!!

11.10.2001

(Low Voltage Directive 73/23/EEC)Machinery Directive 98/37/ECATEX (Explosion-proof equipment) 94/9/ECEMC Directive 89/336/EECPressure Equipment Directive 97/23/ECR&TTE-Directive 1999/5/ECToys Directive 88/378/EECPersonal Protective Equipment Directive 89/686/EECConstruction Products Directive 89/106/EECMedical Devices Directive 93/42/EEC(CE-Kennzeichnungs-Richtlinie 93/68/EEC)

Important directives of the New ApproachImportant directives of the New Approach

Relation of ATEX, CEN/CENELEC, ISO Relation of ATEX, CEN/CENELEC, ISO and IEC/IECExand IEC/IECEx

New Practice of many ATEX Notified Bodies (IECEx ExCB) New Practice of many ATEX Notified Bodies (IECEx ExCB) is to use the elements of IECEx (ExTRs, QAR) to issue a EC is to use the elements of IECEx (ExTRs, QAR) to issue a EC Type Examination Ccertificate and the QA NotificationType Examination Ccertificate and the QA Notification

ATEX Notified Bodies - Nando

IEC vs. CEN/CENELECIEC vs. CEN/CENELEC

• Dresden/Vienna Agreement on Parallel Voting of documents, stand still agreement CLC/IEC

• EN 60079-0 (former edition EN 50014 - EEx) is equivalent to IEC 60079-0 (Ex),EN/IEC 60079-1 „d“, -2 „p“, -5 „q“, -6 „o“,-7 „e“, -11 „i“, ….. , -18 „m“, -26 „Zone 0“…., -34 „QM Production“, -36, -37 (mech.)

• Plant operation: EN/IEC 60079-10-1/-2, EN/IEC 60079-14, -17, -19

Safety concepts for equipment – older Safety concepts for equipment – older versions of the standardsversions of the standards

Selection and installation of equipment in accordance to EN/IEC 60079-14

Zone Equipment category

(Directive 94/9/EG)

Safety level

0 /20

II 1 G/D

Even in the event of infrequent malfunctions

1/21

II 1 G/D oder II 2 G/D

In the event of expected malfunctions

2/22

II 1 G/D oder

II 2 G/D oder II 3 G/D

Normal operation

Temperatur Class:

Explosion Group

II A Methan, Benzine, Methanol

II B Schwefelwasserstoff II C Wasserstoff, Acetylen

Maximum surface temperature

Classification of equipment inaccordance to EN/IEC 60079-0

Explosion characteristics Methane Biogas 70 % CH4

30 % CO2

Petrol Propan

Explosion limits /air [Vol.- %] 4,4 - 17 4,4 - 14 0,6 - 8 1,7- 10,9

Ingition Temperature [0C] 595 220 - 260 450

Relative density (air = 1) 0,55 0,85 ca. 3,2 (gas) 1,55

Flashpoint [0C] < - 20 - 104

Temperaturclass T 1 T 1 T 3 T 3

Explosion group II A II A II A II A

Max. Ex.- pressure [bar] 8,1 8,5 9,4

Hazardous substance andHazardous substance andsafety characteristics (EN/IEC 60079-20)safety characteristics (EN/IEC 60079-20)

Examples of 94/9-equipment with Examples of 94/9-equipment with EC Declaration of ConformityEC Declaration of Conformity

To be installed in accordance with IEC 60079-14

Classification of equipmentClassification of equipment

Minimum duties of the manufacturerMinimum duties of the manufacturer

Electrical equipment

• Category 1/M1:- EC Type Examination Cert.- QA Notification/Annex IV

• Category 2/M2:- EC Type Examination Cert.- QA Notification/Annex VII

• Category 3:- self declaration of conformity, ATEX Notified Body not required

Mechanical equipment

• Category 1/M1:- EC Type Examination Cert.- QA Notification/Annex IV

• Category 2/M2:- self declaration of conformity- Deposit of product documentation at an ATEX Notified Body

• Category 3:- self declaration of conformity, ATEX Notified Body not required

Way to the CE markingWay to the CE marking

CE – conformity marking# andEC – declaration of conformity by the manufacturer(Annex X)

category 1, M1equipment,protective systems

category 2, M2electrical equipment,combustion engines

category 2, M2non-electricalequipment

category 3equipment

Unit verification(Annex IX)

Productionqualityassurance(Annex IV) orProductverification(Annex V)

Productqualityassurance(Annex VII)

orConformityto type(Annex VI)

ECtype-examinationcertificate(Annex III)

ECtype-examinationcertificate(Annex III)

Deposit ofdocumentation(Article 8, 1b ii)

Internalcontrol ofproduction(Annex VIII)

Internalcontrol ofproduction(Annex VIII)

all categoriesequipment,protective systems

Notified Body

ManufacturerCategory accordingarticle 8

#: not for components according Article 8, 3

EC Declarationof Conformity

01.01.2010

EC Declarationof Conformity

01.01.2010

Risk assessment acc. ATEX Directive 1999/92

•Probability and duration of a significant amount of explosive gas or dust atmosphere (Zone classification in acc. to EN/IEC 60079-10-1, -2)

•Probability and energy of ignition source

•scale of damages which might occur

The employer hasto conduct an

ignition risk assessment:

EU-Directive 1999/92/EGEU-Directive 1999/92/EGand IEC 60079-10-1and IEC 60079-10-1

Zone 0 A place in which an explosive atmosphere consisting of a mixture with air of flammable substances in the form of gas, vapour or mist is present continuously or for long periods or frequently.

Zone 1A place in which an explosive atmosphere consisting of a mixture with air or flammable substances in the form of gas, vapour or mist is likely to occur in normal operation occasionally.

Zone 2A place in which an explosive atmosphere consisting of a mixture with air of flammable substances in the form of gas, vapour or mist is not likely to occur in normal operation but, if it does occur, will persist for a short period only.

Directive 1999/92/EGDirective 1999/92/EGand IEC 60079-10-2and IEC 60079-10-2

Zone 20A place in which an explosive atmosphere in the form of a cloud of combustable dust in air is present continously, or for long periods or frequently.

Zone 21A place in which an explosive atmosphere in the form of a cloud of combustible dust in air is likely to occur in normal operation occasionally.

Zone 22A place in which an explosive atmosphere in the form of a cloud of combustible dust in air is not likely to occur in normal operation but, if itdoes occur, will persist for a short period only.

Examples for zoning hazardous areas –Examples for zoning hazardous areas –example of IEC 60079-10example of IEC 60079-10

Stirrer

Examples of 94/9-equipment with Examples of 94/9-equipment with EC Declaration of ConformityEC Declaration of Conformity

CE – EU Dir. 94/9 marked equipment is required by the user‘s directive 1999/92

Explosion protection document: description of the plant, the process, the activities and flammable material quantities

material data

results of the explosion risk assessment

Explosion protection measures

Organizational measures (training staff, …)

Directive 1999/92/EGDirective 1999/92/EG(1) Documentation(1) Documentation

Get assistance by NAMUR.de andNAMUR recommendation xyz

MaintenanceIEC 60079-17and -19

• Ensure expertise of the personell

• Training and experience must be ensured

• Prevent occurence of hazardous atmophere

• install a fire monitor if necessary

• Making sure before restarting that the explosion protection measures required for normal operation have been reactived

• clean dust deposits from installed products

Directive 1999/92/EGDirective 1999/92/EG(2) Maintenance(2) Maintenance

The ATEX Standing CommitteeThe ATEX Standing Committee

• Representatives coming from Ministries of the EU Member States, Industry Associations, ExNB Group, Standardization Bodies CENELEC and CEN, ATEX Consultant, …. the Stakeholders

• Interpretation of the Directives 94/9 and 1999/92

• Interface to other Directives, e.g. to the Machinery Directive

• Meeting once a year in Brussels

ATEX Notified Body groupATEX Notified Body group

The ATEX Notified Bodies– More than 60 ATEX Notified Bodies with similar scopes– but it is a national notificationnotification, not an accreditation in

acc. with ISO/IEC standards– requirements for notification see annex XI of the 94/9– general experience: no chance outside EU with such a

notification, ISO/IEC 17025 and ISO Guide 65 are to be applied by internationally recognized ILAC/IAF accreditation bodies like TÜRKAK