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IGFA Health and Safety/Engineering Seminar

Presenter: Brian Aherne, Process Safety Manager (Pilz)Location: Maldron Hotel, Portlaoise.Date: Thursday, 25April, 2013

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ATEX Compliance A Practical Appraoch

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TopicsATEX

3

Legal Framework & Some Useful Definitions

What is the Risk from Grain, Feed & Food Dusts?

Risk Assessment

Some Factors Affecting the Risk of an Explosion

Selecting a Suitable Basis of Safety

CASE STUDY Flahavans (Co. Waterford): Atex Compliance

CASE STUDY Flahavans: Pilz Recommendations & Solutions

Conclusion & Roadmap to Atex Compliance

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TopicsATEX

4



Risk Assessment



CASE STUDY Flahavans Co. Waterford : Atex ComplianceCASE STUDY Flahavans (Co. Waterford): Atex Compliance



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ATEX Directive 94/9/EC & 99/92/ECTransposition into Irish Legislation

EU Directive 94/9/EC Work Equipment (Manufactureres/Importers 95,100a) On the approximation of laws of the member states concerning equipment

and protective systems intended for use in potentially explosiveatmospheres

Transposed into Irish legislation under S.I. No. 83 of 1999 EuropeanCommunities (Equipment and Protective Systems intended for use in PotentiallyExplosive Atmospheres) Regulations.

EU Directive 1999/92/ECWorker (Workplace/Employers - 137) On minimum requirements for improving the safety and health protection of

workers potentially at risk from explosive atmospheres

Transposed into Irish legislation under the Safety, Health & Welfare at Work(General Application Regulations 2007, SI 299) Part 8 - Reg. 167-175. explosiveatmospheres at places of work.

previously S.I. No. 258 of 2003 Safety, Health and Welfare at Work (ExplosiveAtmospheres) Regulations 2003.

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ATEXDefinition / Abreviation

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ATmosphre EXplosibleATEX is an abbreviation of the French term Atmosphere

Explosible, or Potentially Explosive Atmosphere.

This has a legal distinction from an Atmosphere Explosivewhich is an atmosphere that is immediately explosive.

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ATEXAbbreviations

EPD: Explosion Protection Document

HAC: Hazardous Area Classification

ERA: Explosion Risk Assessment

Technical Measures: Physical Engineering Controls

Organisational Measures: Policies, procedures, training,signage etc.

Basis of Safety: Selected (most suitable) control

measures (e.g. Inertion, ignitionsource prevention, pressure relief)

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ATEXHazardous Zones Definitions

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Zone Zone Criteria(frequency / duration of explosive atmosphere)

Gases Dusts

0 20Continually present or present for long periods.(>1,000hrs/annum) CONTINUOUSe.g. mechanical risk assessment must take into account all failures

including rare failures

1 21Occasionally likely to occur in normal operation. (>10hrs,

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ATEX Directive 99/92/ECOrganisational Measure (Signage)

The ATEX Directive stipulates that the required Ex Warning Signage mustbe posted at the entrance to all Hazardous Area zones.

GAR 2007, Part B of Schedule 10

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TopicsATEX

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Risk Assessment






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ATEXTypical Explosive Dusts

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ATEX PowdersLocation of Primary Explosions & Ignition Sources

Plant & Equipment impacting an explosive concentration

Bucket elevators

Storage binsHammer MillsDust transfer and collection equipment Enclosed equipment

Sources of Ignition

Mechanical e.g. overheated bearings Electrical (making/breaking contacts, arc/spark)

Other source of ignition (e.g. static)

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ATEX Directive 99/92/ECVentilation & Housekeeping

Primary Explosion can lead to secondary (more severe) explosion

For most combustible dusts, a deposit less than 1 mm deep evenly distributedover the whole floor area is sufficient, if raised into suspension, to fillcompletely a room of normal height with an explosive dust/air mixture -unlikely in a clean air-tight containment / negative pressure.

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Why do we need ATEX?Sample U.S. Statistics

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TopicsATEX

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Risk Assessment






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ATEXRisk Assessment Steps To Achieve Legal Compliance

1. Identify dust (and vapour) ATEX properties (testing may be required)

2. Hazardous Areas Classification (HAC) Assign Zones and extents on plan

and elevation drawings

3. Explosion Risk Assessment (ERA) Identify and assess all sources of ignition4. Assess Explosion risk overall

5. Assess suitable and reliable Controls Measure

6. Implement Solutions based on industry best practice (Basis of Safety)

7. Provide legally required training8. Post Atex signage

9. Regularly update, audit and review the site EPD

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ATEX Directive 99/92/EC13 potential ignition sources

1. Hot Surfaces

2. Flames and Hot Gases

3. Mechanically Generated Sparks

4. Electrical Apparatus5. Stray Electric Currents

6. Static Electricity

7. Exothermic Reactions

8. Lightning9. Radio Frequency Electromagnetic

Waves

10.Electromagnetic Waves (3x1011-

3x1015Hz)11. Ionizing Radiation

12.Ultrasonics

13.Adiabatic Compression

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ATEXAtex E.U. Non-Binding Guide (2003)

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ATEX DirectiveAtex E.U. Non-Binding Guide (2003)

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ATEX DirectiveAtex E.U. Non-Binding Guide (2003)

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TopicsATEX

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Risk Assessment






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Dust Explosion Pentagon

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Dust Explosion Pentagon 5 elements required:

1. Fuel (combustible dust cloud)

2. O23. Ignition4. Suspension (dispersion of particles in sufficient quantity and

concentration)5. Confinement (of the dust cloud)

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Dust Explosion Pentagon

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ATEX DustsCharacteristics Affecting Actual Risk

Factors impacting an explosive risk

Particle size (c. < 500 um)

Particle shape: spherical, flat or fibrous Group IIIA: Combustible Flyings Group IIIB: Non-Conductive Dust Group IIIC: Conductive Dust

Chemical properties of a dustMoisture contentCloud dispersion Powder volume resistivity Transport velocity

Air currentsDust extraction rate Fall height Physical barriers

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ATEX DustsDust Testing Characteristics

The most important characteristics to test for, (once the initial test hasconfirmed that the material is capable of forming an explosive mixture), are:

Min. Ignition Energy (MIE) mJ Pmax barg KST (ST Class) bar ms -1 Layer Ignition Temperature (LIT) CMin. Ignition Temperature (MIT Cloud) CMinimum Explosion Concentration (MEC) mg/m3 Particle size (micron)Moisture Content % Powder Volume Resistivity

Limiting O2 conc. BZ No.

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TopicsATEX

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Risk Assessment






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Basis of Safety

Basis of Safety: The basis of safety should first be explosion prevention

followed by ignition source prevention.

Control Measures: Preventive Protective - Mitigating

The basis of safety is a hierarchy of control:

1. Eliminate the possibility of the formation of an explosive dust cloud orlayer2. Ignition source prevention (e.g. ATEX equipment)3. Ignition source detection (e.g. metal/spark detection)4. Containment design pressure

5. Isolation (e.g. mechanical/chemical)6. Mitigation of effects of an explosion pressure relief design, external

venting, flameless internal venting etc.7. Spark Detection and Suppression (powder, gas, chemical inhibitor)8. Building design (e.g. pressure resisting / relieving construction)

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ATEX Directive 99/92/ECTechnical Measures Prevention & Protection

Obligations of the EMPLPOYER Art. 3:The employer shall take ORGANISATIONAL and/orTECHNICAL measures in order of priority:

to prevent the formation of explosive atmospheres, orwhere the nature of the activity does not allow that,

to avoid the ignition of explosive atmospheres, and

to mitigate the detrimental effects of an explosion soas to ensure the health and safety of workers.

Above 3 to be combined/supplemented withpropagation measures and reviewed regularly and, inany event, whenever significant changes occur.

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Basis of Safety samplesSpark Detection & Suppression

Spark Detection & Suppression

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Basis of Safety samplesExplosion Venting

Explosion Venting

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Basis of Safety samplesBlast Relief

Pressure/Blast Relieving Panels / Walls

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Basis of Safety samplesHigh Integrity & High Reliability Equipment

SIL rated equipment

High Integrity & High Reliability Equipment (LOPA & SIL Assessments

Required)

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33

ATEX SignageEquipment

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TopicsATEX

34



Risk Assessment






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ATEX Case StudyFlahavans

Case Study

Plant which has equipment spanning 4 generations was able to adopt a pro-active and practical approach to meet the requirements of ATEX

Regulations

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Explosion Protection Document completed by Pilz (2011)


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ATEX C S d

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Why Pilz? Practical approach Competence Experience of regulatory

requirements, E.U. Norms andindustry best practice

Provision of transparent andactionable route to compliance

Independently Certified


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ATEX C St d

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Pilz Atex Risk Assessment of large volume of plant and equipment


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Explosion Protection Document Findings

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Explosion Protection Document Findings HAC Example - Service Bin Silo


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Explosion Protection Document Findings ERA Example - Service Bin Silo

ATEX Case Study

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Atex Risk Assessment Prioritised Risk Areas


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ATEX Case Study

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ATEX Case StudyFlahavans EPD Pilz Findings

Executive Summary

ATEX

Regulatory Environment

Explosion Protection Document Structure


Flahavans Priority Listing

Next Steps

Compliance Strategy Phasing

Risk Associatedwith 9 Micro-Plants

ONE HIGHPRIORITY

PLANT AREA

FOUR MEDIUMPRIORITY PLANT

AREA

ATEX Case Study

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From Full Plant Risk Assessment

EPD Priority Areas

8 Green Intake Silos areas of concern for Atex upgrade.

Sweep Augers and associated Motor and Electrical Power Supply andcontrol System did not meet the required ATEX Zone 21 classification.


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ATEX Case Study

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Pilz Upgrade Project Deliverables

Electrical design and specification for the New Sweep Auger System Electrical Installation for the Sweep Auger Systems for the 8 Grain Intake

Silos Electrostatic Audit. SAT, FAT Provide a full handover package e.g:

M&E drawings

Data Sheets Electrostatic Audit

Full validation and certification of completed to ETCI Atex requirements DoCs. Provision of ATEX Training


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Overall Compliance Strategy

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Overall Compliance Strategy Flahavans

Executive Summary

ATEX

Regulatory Environment

Explosion Protection Document Structure


Flahavans Priority Listing

Next Steps

Compliance Strategy Phasing

Aims:

Full Plant-wide Compliance

Phased Strategy

3 Year Plan

Prioritised Approach

Project based with parallel implementation lines

Project Management

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Project ManagementPilz & Flahavans Project Methodology

In order to ensure this project would be executedin a systematic and professional manner, Pilzand Flahavans agreed that a structured projectmethodology consisting of seven key phases

would be followed.

User RequirementsSpecification

AssembleTeam

Front End Study(including Design)

Tendering

Process

Full DetailedDesign

Implementation

Closure & Handover

Pilz Offering as part of Equipment Upgrades

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Project Management (Risk, Sschedule, Installation, Supervision)

Full M&E Specification, Design & Analysis

e.g. re-design of ATEX rated mounting plates, couplings,

pulleys, Ingress Protection (IP), containment runs, isolation

switches, glanding etc. to suit ATEX modifications

Safety Validation

Factory Acceptance Test (FAT)

Installation & Commissioning

Site Acceptance Test (SAT)

Full ATEX Certification of all installations

g p q p pg

Topics

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pATEX

48



Risk Assessment






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Recommendation 1:

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Area: Old Oats Storage Silo Bins 1 8

Action: Replace motors with suitable ATEX rated motors

Temperature sensing on all 8 motors

Replacement of Old Oats Bins Auger Motors

Recommendation 2:

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Installation of ATEX sensors on Elevators

Area: Intake Elevator to main plant

Action: Installation of speed / alignment sensors

Installation of rotation slippage sensors

Installation of bearing temperature sensors

Recommendation 3:

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Area: Intake Elevator to main plant

Dust Extraction System in main plant

Action: Calculation of the vent panel sizes for intake elevator

Complete relief vent panel sizing calculations for 12 vents

Confirm accuracy of the relief vent panel sizing

Recommendation 4:R l f ll di i i ATEX

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Area: Various Areas

Action: Replace motors with suitable ATEX rated motors

Replacement of all medium priority non-ATEX motors

Recommendation 5:I t ll ti f ATEX

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Area: Dust Extraction Auger Conveyor

Hulls Bin Storage Auger Conveyor

Action: Installation of speed / alignment sensors

Installation of rotation slippage sensors

Installation of bearing temperature sensors

Installation of ATEX sensors on conveyors

Recommendation 6:Installation of ATEX level sensors in silos

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Area: Bran Service Bin

Sussex / Hulls Bins

Wheat /Barley Bin

Boiler Service Bin

Hull Bin Storage Hopper

Action: Install suitable ATEX rated level sensors

Installation of ATEX level sensors in silos

Recommendation 7:Installation of ATEX lighting

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Area: Bran Service Bin

Sussex / Hulls Bins

Wheat /Barley BinBoiler Service Bin

Hull Bin Storage Hopper

Storage Room

Action: Install suitable ATEX rated lighting and switches

Installation of ATEX lighting

Recommendation 8:Electrostatic Survey

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Area: Complete site

Action: Complete a site survey to assess the scope of

works for an electrostatic audit

Electrostatic Survey

Recommendation 9:Further Dust Testing

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Area: Oats dust from various areas of the site

Action: Complete dust testing on oats from various

locations

Further Dust Testing

Recommendation 10:Detailed Plant & Equipment Electrical Review

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Area: Complete site

Action: Complete a site survey to assess the scope of

equipment upgrades

Detailed Plant & Equipment Electrical Review

ATEX Case Study FlahavansUpgrade Works Green Intake Silos and Auger Control

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Upgrade Works Green Intake Silos and Auger Control

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ATEX Case Study - FlahavansUpgrade Works Green Intake Silos and Auger Control

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ATEX Case Study Flahavans


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ATEX Case Study Flahavans


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Grain Silo Auger Operating Manual

Flahavans


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Sample Component Data Sheets

65


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Sample Component Data Sheets

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ATEX Case Study - FlahavansSample Test Records, Static Audit, Ex Certification

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p

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TopicsATEX

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68



Risk Assessment






ATEX Where to Start?Seeing the wood from the trees

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Large Plants will have large amounts ofplant and equipment to be assessed.

High volume of information anddocumentation to be assessed

Large number of actions Project Management

Identify roles and responsibilities Risk Assessment Prioritisation of actions is Key

Schedule/Programme Control Maximise plant availability Minimise costs Minimise risk

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ATEX The JourneySuccess Factors

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Legislation

BestPractice

Practical &

Cost-EffectiveSolutions

Risk AssessmentCompetence

ATEX The JourneySuccess Factors

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ATEX Directive 99/92/ECCompliance Strategy

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Customer Benefits ?

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1. Pilz reputation and independence accepted by all inthe value chain

2. Competence of consultants and engineers assuredtrough audited competence scheme.

3. Integration of solution engineering with ERA4. Flexible use of Pilz resources compliments use of

available internal resouces

5. Global organisational reach with consistentinterpretation of

- Directives, Stsndards and Regulations- Country of use language capability

6. Early lifecycle involvement of experienced teams will

reduce the cost of late life-cycle remedial action

+

PNOZ,

dandpro-

yvaryfrom

equipment.

information.

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CMSE,

InduraNETp,

PAS4000,

PAScal,

PASconfig,

Pilz,

PIT,

PLID,

PMCprotego,

PMD,P

MI,

P

Primo,

PSEN,

PSS,

PVIS,

SafetyBUSp,

SafetyEYE,

SafetyNETp,

thespiritofsafetyareregistere

tectedtrademarksofPilzGmbH&Co.

KGinsomecountries.W

ewouldpointoutthatproductfeatures

may

thedetailsstatedinthis

document,dependingonthestatusat

thetimeofpublicationandthescopeofthee

Weacceptnoresponsibilityforthevalidity,accuracyandentire

tyofthetextandgraphicspresentedin

this

PleasecontactourTechnicalSupportifyouhaveanyquestion

s.

Brian Aherne

Pilz, Business & technology park, Model Farm Road,Cork, Ireland

Tel: +353 21 4346535 Email: [email protected]

Keep up-to-date on Pilzwww.pilz.com

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