Industr ial fuel -consuming appl iances - Requi rements for appl iances appl icat ion, workplace

env i ronment, approv al and inspect ion – Draf t Israel i Standard – for publ ic rev iew

(October 2015)

0

Introduction

This Draft Isr ael i Standard SI 6464 "Industrial fuel -consuming appl iances - Requirements for

appl iances appl icat ion, workplace environment , approval and inspect ion", brough t to the

r eview of the publ ic, consists of the fi r st five chapter s (1-5) of the Isr ael i Umbrel la Standard SI

6464.

These five chapter s have been prepared by two Working Groups - 407.07 Industrial Gas-Fired

Appl iance Appl icat ions – Appl iances ; and 407.08 Industrial Gas-Fired Appl iance Appl icat ions -

Workplace Environment , in the fr amework of an extensive Natural Gas Standardizat ion project ,

in the purpose of faci l i ta t ing use of Natural Gas wi th in the Isr ael i industry wh i le ensur ing the

safety of people, plan ts and proper ty.

The final ver sion of the Umbrel la Standard wi l l incorporate six chapter s, cover ing the th ree

main aspects of the Natural Gas Standardizat ion project , as fol lows:

o Appliance appl icat ions;

o Safety of the workplace environment ;

o Inspect ion process (Fir st ver i fica t ion , main tenance and per iodic in spect ions) .

The five chapter s incorporated in th is Draft Isr ael i Standard cover the fi r st two main aspects.

Chapter 6 of the Isr ael i Umbrel la Standard, cover ing the Inspect ion process, wi l l soon be

dist r ibuted for publ ic r eview.

The Natural Gas Standardizat ion project wi l l even tual ly provide the Isr ael i economy with an

Isr ael i Standard that wi l l serve as a general envelope (Umbrel la Standard), specifying general

r equiremen ts for the conver sion of Isr ael i factor ies cur ren t ly operated by di fferen t fuels, to be

operated by Natural Gas. Alongside the Umbrel la Standard, a ser ies of in ter r ela ted individual

Isr ael i Standards (adopted r elevan t foreign standards wi th nat ional modificat ions and

addi t ions) wi l l be set .

As most of the equipmen t in Isr ael i s impor ted from ei ther Europe or the US, the Umbrel la

Standard and the in ter r ela ted individual Isr ael i Standards wi l l include two separate paths - A

European path and an Amer ican path , so that in order to comply wi th the r equiremen ts of the

Isr ael i Standards, the user would have a choice of two opt ional paths to fol low: ei ther

complying with a l l r equiremen ts of the European path , or complying with a l l those of the

Amer ican path .

Th is Draft Isr ael i Standard is the draft of the European path Umbrel la Standard. The

Amer ican path of the Umbrel la Standard wi l l be dist r ibuted for publ ic r eview in due cour se.

The final product of th is standardizat ion project can be presen ted as fol lows:

Draft SI 67600 (2015)

1

A new Gas Law is cur ren t ly being formulated by the Isr ael i Governmen t .

The new formed law wil l include r eferences to the Umbrel la Standard, wh ich wi l l gran t i t the

sta tus of a mandatory standard.

To fol low and suppor t the Law, dur ing the publ ic r eview per iod, the standardizat ion

commit tees 407.07 and 407.08 wil l hold a discussion in order to broaden the scope of the

Umbrel la Standard as to a l low i ts appl icabi l i ty a lso on cen tr a l energy cen ter s wi th in

hospi ta ls, schools, hotels, etc. (e.g, steam boi ler s, water heater s, etc. ) .

With in a second phase of the project , a fur ther scope broaden ing wil l be discussed in the

standardizat ion commit tees, in order to a lso include other r elevan t aspects e.g. appl iance

appl icat ion wi th in the commercia l sector (e.g, r estauran ts, laundr ies, ki tchen of large

inst i tut ions, etc. ) , Natural Gas piping with in the premise of the factory, etc.

Draft Israeli Standard SI 6464

October 2015

ICS CODE:

Industrial fuel-consuming appliances - Requirements for

appliances application, workplace environment, approval and inspection

This document is a proposal only

This standard was prepared by the following Expert Committees:

Expert committee 40707 – Industrial Gas-Fired Appliance Applications - Appliances, comprised of the

following members:

Ran Cohen, Reuven Godali, Amos Kamhine, Esra Levenberg (Chairman), Roi Shchori, Moshe

Weingarten, Yosef Yurborsky

Expert Committee 40708 – Industrial Gas-Fired Applications – Workplace Environment, comprised of

the following members:

Armand Abramovich, Ashi Avizemer, Ilan Cohen, Ran Cohen (Chairman), Ariel Gazit, Yosef Yurborsky

The following people also contributed to the preparation of the standard: Binyamin Budnitsky, Haim

Melamed, Boris Prokuprts, Arcady Veschinsky, Yosi Zinger.

This standard has been approved by the Technical Committee 407 – Natural Gas Systems, comprised

of the following members:

Roy Gorenshtein and Michal Philosoph coordinated the preparatory work for the standard.

Descriptors:

natural gas, installations, industrial, hazardous areas classification, risk assessment

Updating the Standard

Israeli Standards are reviewed periodically at least every five years, in order to adapt them to scientific

and technological developments. Users of Standards should ascertain that they are in possession of the

latest edition of the Standard including its Amendments.

A document appearing in the "Reshumot" (The Israeli Official Journal) as an Amendment may be a

separate Amendment, or an Amendment incorporated into the Standard.

Standard validity

An Israeli Standard including revisions takes effect from its publication date in "Reshumot".

Whether the document or parts of it are Official should be checked. An Official Standard or

Amendment (in whole or in part) takes effect 60 days following publication of the notice in the

"Reshumot", unless the notice states otherwise for the effective date.

Standards mark

A manufacturer of a product complying with the requirements of the

applicable Israeli Standards is entitled, after being licensed by the

Standards Institution of Israel, to mark it with the Standards mark:

Copyright

This Standard or any part of it may not be photocopied, copied or published by any means whatsoever,

without prior permission in writing of the Standards Institution of Israel.

Table of contents Foreword ................................................................................................... .שגיאה! הסימניה אינה מוגדרת

Introduction ............................................................................................... .שגיאה! הסימניה אינה מוגדרת

1 Scope ....................................................................................................................................... 13

2 Normative References .............................................................................................................. 15

3 Terms & Definitions ................................................................................................................. 15

4 Industrial Appliances Application (IAA)................................................................................... 25

4.1 Application Rules ............................................................................................................... 25

4.2 General Requirements for Industrial Appliances Application .............................................. 26

4.3 Specific Requirements for Complete Industrial Appliances Application (IAAs) .................. 33

4.4 Specific Requirements for Partial IAAs .............................................................................. 39

5 Workplace Environment ........................................................................................................... 45

5.1 General Requirements ........................................................................................................ 45

5.2 Requirements for a working environment impact assessment (WEIA) ................................ 46

5.3 Requirements to define EX-Zones ...................................................................................... 49

5.4 Defining of Ex-Zones ......................................................................................................... 50

5.5 Ventilation ......................................................................................................................... 52

5.6 Change management procedure .......................................................................................... 52

6 Approval and Inspection ........................................................................................................... 49

6.1 Application and approval Procedure ............................................. .שגיאה! הסימניה אינה מוגדרת

6.2 IAA selection – Appendix 1 ......................................................... יאה! הסימניה אינה מוגדרת.שג

6.3 Information required for IAA Approval – Appendix 2 .................. .שגיאה! הסימניה אינה מוגדרת

6.4 Technical Documentation (Technical File) – Appendix 4.............. .שגיאה! הסימניה אינה מוגדרת

6.5 Marking plate ............................................................................... .שגיאה! הסימניה אינה מוגדרת

6.6 Check sheets ................................................................................ .שגיאה! הסימניה אינה מוגדרת

6.7 Initial Certificate for Operation .................................................... .שגיאה! הסימניה אינה מוגדרת

6.8 Operation Permit .......................................................................... .שגיאה! הסימניה אינה מוגדרת

6.9 Test Plan for Periodic Surveillance ............................................... .שגיאה! הסימניה אינה מוגדרת

6.10 Gap Report for Operation.......................................................... .שגיאה! הסימניה אינה מוגדרת

6.11 Renewed Certificate for Operation ............................................ אינה מוגדרת.שגיאה! הסימניה

6.12 Workplace environment ............................................................ .שגיאה! הסימניה אינה מוגדרת

7 Annex (informative) ........................................................................... .שגיאה! הסימניה אינה מוגדרת

7.1 Annex I – EC-and EEC Directives ................................................ .שגיאה! הסימניה אינה מוגדרת

7.2 Annex II – Pressure equipment for fuel supply ............................. .שגיאה! הסימניה אינה מוגדרת

7.3 Annex V – ATEX ........................................................................ .שגיאה! הסימניה אינה מוגדרת

7.4 Annex VI Functional Safety ......................................................... .שגיאה! הסימניה אינה מוגדרת

7.5 Annex VII Risk assessment according ISO 31010 ........................ .שגיאה! הסימניה אינה מוגדרת

7.6 Example for ................................................................................. .שגיאה! הסימניה אינה מוגדרת

7.7 Annex VII - Additional Information for Complete IAAs ............... .שגיאה! הסימניה אינה מוגדרת

Foreword

The purpose of this standard is to allow the use of natural gas within the Israeli industry, by facilitating

the connection of industrial factories to the natural gas supply system, while ensuring the safety of

people, plant and property.

The requirements relevant to the natural gas infrastructure (The transmission system, the distribution

system and the supply system) are covered by the Israeli Standard SI 5664 (all parts). This standard

covers requirements that are relevant to the Appliances Application within the industrial premises.

The three main chapters of this standard are:

• Industrial Appliances Application

Specifying requirements relevant to each and every appliance (furnace, boiler, etc.) including

all its sub-systems and accessories, and all its supporting systems.

• Safety of the workplace environment

Specifying requirements relevant to the workplace environment of the Appliances Application

installation. Providing safety and health requirements for the employee in order to protect

against any harm situations. Applies as below: What is WPE what is the relation to the

standard and IAA, i.e. venting, wps etc.

• Inspection Process

Specifying safety requirements and other requirements relevant to the design, commissioning

and to the continuous maintenance of an Appliances Application installation.

The general framework of this standard includes requirements for the conversion of an

existing factory comprising of fuel-fired appliances (fuel such as fuel oil, gas-oil, LPG) to

operate on natural gas, requirements for dual-(or multi)-fuel-fired appliances, and

requirements that are relevant to a new factory comprising of appliances that were pre-

designed to operate on natural gas.

The overall structure and the application of this standard is divided into three chapters and visualized

in the following figures:

Introduction to the Israeli standard

This Israeli standard is based on:

(i) International ISO and IEC standards and codes

(ii) Applicable directives and regulations in Europe;

(iii) Harmonized standards to these EU directives and regulations;

(iv) Non-harmonized standards and other Reference Documents such as technical guidelines;

(v) Rules and procedures of the IECEx System, International Ex-protection certification

system for equipment, service facilities and personnel, based on IEC standards (see:

www.iecex.com )

The applicability of this standard is methodologically divided into three chapters:

(1) Appliance Applications;

(2) Workplace Environment;

(3) Approval & Inspection processes.

1 Scope This standard applies to new and converted industrial fuel-consuming appliances (hereafter; Industrial

Appliance Applications) fired by:

- Natural gas

- Biogas

- LPG

- Fuel oil (light and heavy gas oil)

This standard covers the installations and operations of a range of Appliances Application feeding:

- Steam boilers

- Hot water boilers

- Thermal oil boilers

- IThE such as:

o Metallurgical and metal working plant;

o Glass making plant;

o Ceramic manufacturing plant;

o Cement, lime and gypsum manufacturing plant;

o Chemical plant;

o Waste incineration equipment

o Hot dip industrial batch and the bath of continuous galvanizing thermo processing

equipment

o Salt bath thermo processing equipment

o Quenching equipment

- Kilns

- Furnaces

- Ovens

- CHP [need to be defined]

- others

driven by single, dual and multiple fuel burners.

At a workplace and at its environment, several different risks could occur and be a danger for

safety and health for the employees. During a systematic risk assessment all the hazards at the

working place and in the working environment shall be assessed and the risk for safety and health

of the employees can be reduced by measures.

This Standard is fully applicable for new plants. For existing plants only the new installed devices

including its integrating effect at the interfaces will be considered, as specified in the following

Chapters.

Any requirement in this standard overrules any other requirement which may contradict it.

Note:

Appliances solely driven by fuel oil are not covered by this standard.

Heating Recovery Steam Generator (HRSG) are also not covered by this standard.

Elevators or rotated machinery – are not a in the scope of this standard Issues that are under the responsibility of a Ministry other than the Ministries of Energy and

Economy (e.g, the quality of the flue gases emissions, which is under the responsibility of the

Ministry of Environmental protection), are not covered by this standard.

2 Normative References These references apply within this standard:

Israeli Standards SI 100 - Kerosene

SI 107-2 - Gas-oil: Gas-oil for heating and gas-oil for gas turbine applications

SI 116 - Fuel-oil (Mazout)

SI 1134-1 - Liquefied petroleum gas – LPG for general purposes, except automotive LPG – Chemical and

physical requirements

SI 5731 - Fatty acid methyl esters (FAME) for use in diesel engines and heating applications –

Requirements and test methods

SI 6373 - Fuels from recycled oils – Requirements and test methods

SI 12952-8 - Water-tube boilers and auxiliary installations – part 8 – Requirements for firing systems for

liquid and gaseous fuels for the boiler

SI 12953-7 - Shell boilers – part 7: Requirements for firing systems for liquid and gaseous fuels for the

boilers

SI 60079-0 Explosive Atmospheres - Part 0: Equipment - General Requirements

SI 67600 - Automatic forced draught burners for gaseous fuels

SI 74600-2 - Industrial Thermoprocessing equipment – part 2 – Safety for combustion and fuel handling

systems

Israeli Regulations and documents

- Work safety ordinance (5730-1970)

- Work inspection regulation (safety management plan), 2013 – regulatory clarifications for the

meaning of "acceptable risk" requirements

- Occupational Safety and Health Regulation

- Aerial space closure for the release of natural gas (2008)

International Standards ISO 12100 - Safety of machinery - General principles for design - Risk assessment and risk reduction

ISO 31010 - Risk management -- Risk assessment techniques

IEC 61508-1 - Functional safety of electrical/electronic/programmable electronic safety-related systems -

Part 1: General requirements

IEC 61508-2 - Functional safety of electrical/electronic/programmable electronic safety-related systems -

Part 2: Requirements for electrical/electronic/programmable electronic safety-related systems

IEC 61508-3 - Functional safety of electrical/electronic/programmable electronic safety-related systems -

Part 3: Software requirements

IEC 61508-4 - Functional safety of electrical/electronic/programmable electronic safety-related systems -

Part 4: Definitions and abbreviations

IEC 61508-5 - Functional safety of electrical/electronic/programmable electronic safety-related systems -

Part 5: Examples of methods for the determination of safety integrity levels

IEC 61508-6 - Functional safety of electrical/electronic/programmable electronic safety-related systems -

Part 6: Guidelines on the application of IEC 61508-2 and IEC 61508-3

IEC 61508-7 - Functional safety of electrical/electronic/programmable electronic safety-related systems -

Part 7: Overview of techniques and measures

IEC 61511 - Functional safety - Safety instrumented systems for the process industry sector

IEC 61882 - Hazard and operability studies (HAZOP studies)

European Standards EN 267 - Automatic forced draught burners for liquid fuels

EN 1127-1 - Explosive atmospheres - Explosion prevention and protection - Basic concepts and

methodology

EN 50495 - Safety devices required for the safe functioning of equipment with respect to explosion

risks

EN 13480-1 - Metallic industrial piping - Part 1: General

EN 13480-2 - Metallic industrial piping - Part 2: Materials

EN 13480-3 - Metallic industrial piping - Part 3: Design and calculation

EN 13480-4 - Metallic industrial piping - Part 4: Fabrication and installation

EN 13480-5 - Metallic industrial piping - Part 5: Inspection and testing

EN 13480-6 - Metallic industrial piping - Part 6: Additional requirements for buried piping

CEN/TR 13480-7 - Metallic industrial piping - Part 7: Guidance on the use of conformity assessment

procedures

EN 13480-8 - Metallic industrial piping - Part 8: Additional requirements for aluminium and

aluminium alloy piping

National Standards and documents ATEX 14/34/EU - equipment and protective systems intended for use in potentially explosive

atmospheres

ATEX 99/92/EG - Minimum requirements for improving the safety and health protection of

workers potentially at risk from explosive atmospheres

IECEx System Scheme 02 - Equipment

IECEx System Scheme 03 - Service Facilities

IECEx System Scheme 05 - Personnel

DVGW G213 - Equipment for the production of fuel gas mixtures

IGEM UP 1 - Strength testing, tightness testing and direct purging of industrial and

commercial gas installtions

3 Terms & Definitions

3.1 Acceptable Risk

A risk that has been decreased to a level that has been defined as acceptable by the employer,

considering his legal obligations and the safety policy of the workplace. The acceptance of a risk to the

organization is determined by the law and by the management policy of the organization, and is in

accordance with the acceptable levels of risks within other organizations of similar business areas and

is compared to global acceptance levels.

[Source: Work inspection regulation (safety management plan), 2013 – regulatory clarifications for the

meaning of "acceptable risk" requirements]

3.2 Accreditation Body

Organizations that issue credentials or certify third parties against official standards. The accreditation

process ensures that their certification practices are acceptable, typically meaning that they are

competent to test and certify third parties, behave ethically and employ suitable quality assurance.

In respect to this document, only the following Accreditation Bodies, are applicable:

United States Occupational Safety and Health Administration (OSHA), which designates Nationally

Recognized Testing Laboratory (NRTL)·Any Accreditation Body that is recognized and listed by The

International Laboratory Accreditation Cooperation (ILAC MRA) as ISRAC (The Israel Laboratory

Accreditation Authority).

3.3 Air/Fuel Ratio

Ratio between the mass flow of combustion air and the mass flow of the fuel.

3.4 Assessment Team to conduct a risk assessment

The examination relies on the Assessment Team from various disciplines with appropriate skills and

experience who display intuition and good judgement.

Recommended roles for team members are as follows:

• Study leader: not closely associated with the design team and the project. Trained and experienced in leading HAZOP studies. Responsible for communications between project management and the HAZOP team. Plans the study. Agrees study team composition. Ensures the study team is supplied with a design representation package. Suggests guide words and guide word – element/characteristic interpretations to be used in the study. Conducts the study. Ensures documentation of the results.

• Recorder: documents proceedings of the meetings. Documents the hazards and problem areas identified, recommendations made and any actions for follow-up. Assists the study leader in planning and administrative duties. In some cases, the study leader may carry out this role.

• Designer: explains the design and its representation. Explains how a defined deviation can occur and the corresponding system response.

• User: explains the operational context within which the element under study will operate, the operational consequences of a deviation and the extent to which deviations may be hazardous.

• Specialists: provide expertise relevant to the system and the study. May be called upon for limited participation with the role revolving amongst different individuals.

• Maintainer: maintenance staff representative.

3.5 Combustion Air

Ambient air, or mixture of ambient air with other gases such as water vapour, carbon dioxide, that is

used as oxygen supply for combustion process.

3.6 Competent Person

A person who has the permission by the law and the regulator to perform a certain kind of work.

3.7 Contractor

Is an individual, firm, corporation or company that either in person or through a representative is

engaged in and is responsible for the connection, installation, commissioning, testing, repair, or

servicing of appliances and equipment and:

• is experienced in such work and, • is familiar with all precautions required and, • has complied with all the requirements, • has the relevant licensee to make his work, under the Israeli laws.

Connection, installation, commissioning, testing, repair and servicing of gas appliance installations

shall be performed by a Contractor.

3.8 Employer

Anybody of persons corporate or unincorporate and the legal personal representative of a deceased

employer; in relation to a person who is a member of registered cooperative society, and engaged in

work carried out by that cooperative society, the cooperative society shall for the purposes of this

Ordinance be deemed to be the employer of such person, and such person shall for the said purposes

be deemed to be employed by the cooperative society, notwithstanding that he is remunerated in whole

or in part by shares in the profits of gross earnings of the cooperative society.

[Source: Work safety ordinance (5730-1970)]

3.9 End-User

An operator of the Industrial Appliances Application who is held legally responsible for the operation

(e.g. installing, operating, adjusting, maintaining, cleaning, repairing or moving machinery) of the

same to comply with any requirements of Israeli law and/or directives.

3.10 Fuel

Combustible gases or combustible liquids.

3.11 Fuel Group 1

Fuels defined as explosive, extremely flammable, highly flammable, flammable (where the maximum

allowable temperature is above flashpoint), very toxic, toxic, and/or oxidizing.

3.12 Functional Safety

Functional safety is part of the overall safety concept. Functional safety may be achieved by

instrumentation e. g. pressure transmitter, safety PLC, solenoid, actuator, valve, solenoids and others.

Depends on the system the functional safety system prevent the plant and operators against hazards.

The safety system can be triggered by different events like disoperation by human’s errors, hardware

failures and environmental changes. Functional Safety is the capability of a safety system or other

means to reduce risk, to execute the actions required for achieving or maintaining a safe state for the

process and its related equipment.

3.13 Gases

Gases: gases, liquefied gases, gases dissolved under pressure, vapors and those liquids whose vapor

pressure at the maximum allowable temperature is greater than 0,5 bar above normal atmospheric

pressure of 1,013 bar (1.013 mbar).

3.14 Gas Mixtures

A combustible mixture with the main components LPG and Air.

3.15 Industrial Appliances Application (IAA)

An industrial fuel consuming process installation using combustion air (or equivalent) and any fuel to

feed any industrial process with its defined boundary from the point of delivery of fuel downstream,

and including the manual isolating valve which is situated close upstream of the first control device of

the Industrial Appliances Application to the release point of flue gas into the atmosphere through any

given exhaust system.

3.16 Complete IAA

New installed equipment of an IAA with boundaries as defined in גיאה! מקור ההפניה לא נמצא.ש .

3.17 Partial IAA

New installed equipment of an IAA with boundaries as from the point of delivery of fuel downstream,

excluding the manual isolating valve which is situated close upstream of the first control device of the

Industrial Appliances Application to the interface of the boiler/IThE (boiler flange).

The boiler /IThE is not a part of the Partial IAA.

3.18 IThE - Industrial Thermoprocessing Equipment

Industrial fuel-consuming appliances

3.19 Machinery

• an assembly, fitted with or intended to be fitted with a drive system other than directly applied human or animal effort, consisting of linked parts or components, at least one of which moves, and which are joined

• together for a specific application, • an assembly referred to in the first indent, missing only • the components to connect it on site or to sources of energy and motion, • an assembly referred to in the first and second indents, ready to be installed and able to

function as it stands • only if mounted on a means of transport, or installed in a building or a structure, • assemblies of machinery referred to in the first, second and third indents or partly completed

machinery referred to partly completed machinery which, in order to achieve the same end, are arranged and controlled so that they function as an integral whole,

• an assembly of linked parts or components, at least one of which moves and which are joined together,

• intended for lifting loads and whose only power source is directly applied human effort

3.20 Manufacturer of Machinery

Means any natural or legal person who designs and / or manufactures machinery or partly completed

machinery and is responsible for the conformity of the machinery or the partly completed machinery

with a view to its being placed on the market, under his own name or trademark or for his own use. In

the absence of a manufacturer as defined above, any natural or legal person who places on the market

or puts into service machinery or partly completed machinery shall be considered as a manufacturer.

3.21 Ministry

The government department responsible for issuing the gas appliance installation permits, as was

established by the government.

3.22 Nominal Pressure

Nominal pressure for which the equipment is designed, as specified by the manufacturer.

3.23 Normally Use

An appliance is set to normally use when:

• It is correctly installed and regularly serviced in accordance with operating manual • Used with a normal variation in the fuel quality and a normal fluctuation in the supply

pressure • Used in accordance with its intended purpose or in a way which can be reasonably foreseen

3.24 Notified Body

Notified Bodies are governmental approved private inspection bodies, which control the conformity

assessment of manufacturer and their industrial products. The notified bodies for the manufacture of

pressure equipment (in particular fuel supply equipment).

3.25 Operator

The person(s) installing, operating, adjusting, maintaining, cleaning, repairing or moving machinery.

[Source: machinery directive]

3.26 Piping

Means piping components intended for the transport of fluids, when connected together for integration

into a pressure system. Piping includes in particular a pipe or system of pipes, tubing, fittings,

expansion joints, hoses, or other pressure-bearing components as appropriate. Heat exchangers

consisting of pipes for the purpose of cooling or heating air shall be considered as piping.

3.27 Placing on the Israeli market

Placing on the Israeli market means making available for the first time machinery or partly completed

machinery with a view to distribution or use.

3.28 Purging

Forced introduction of air or inert gas into the combustion chamber and flue passages, in order to

displace any remaining fuel/air mixture and/or products of combustion, and which takes place between

the start signal and the energizing of the ignition device.

3.29 Pressure equipment

Means a vessel, a piping, a safety accessories or any pressure accessories. Where applicable, pressure

equipment includes elements attached to pressurized parts, such as flanges, nozzles, couplings,

supports, lifting lugs, etc.

3.30 Risk Assessment

The determination of quantitative or qualitative estimate of risk related to a concrete situation and a

recognized threat (also called hazard). Quantitative risk assessment requires calculations of two

components of risk (R): the magnitude of the potential loss (L), and the probability (P) that the loss

will occur.

3.31 Safety Accessories

Means devices designed to protect pressure equipment against the allowable limits being exceeded.

Such devices include:

• devices for direct pressure limitation, such as safety valves, bursting disc safety devices, buckling rods, controlled safety pressure relief systems (CSPRS)

• limiting devices, which either activate the means for correction or provide for shutdown or shutdown and lockout, such as pressure switches or temperature switches or fluid level switches and “safety related measurement control and regulation (SRMCR)” devices.

3.32 Safety Components

A component which serves to fulfil a safety function,— which is independently placed on the

market,— the failure and/or malfunction of which endangers the safety of persons, and— which is not

necessary in order for the machinery to function, or for which normal components may be substituted

in order for the machinery to function.

3.33 Safety Instrument Function (SIF)

A function of a safety related system to reduce the risk in an application with the objective to achieve

or keep a safe state. The safety function is always related to a safety loop, not to a component or

device.

3.34 Significant changes on existing IAA

The former confirmed technical characteristics of an existing IAA remain unchanged after a matching

with a Partial IAA.

3.35 SIL

Discrete level (one out of four) for specifying the safety integrity requirements of the safety

instrumented functions to be allocated to the safety instrumented systems. Safety integritylevel 4 has

the highest level of safety integrity; safety integrity level 1 has the lowest

3.36 System

The subject of an IAA, generally includes a process, a product, an activity, a facility or a logical

system.

3.37 Technical Characteristics

Specified performance data’s belonging to any IAA which are officially documented to the entire

technical instruction or data plate of any IAA.

3.38 Third Party Certification

Third-party certification involves an independent assessment declaring that specified requirements

pertaining to a product or process have been met.

In this respect, a third-party is an accredited body which is entitled by an Accreditation Body, and

holds certification as per ISO 17025 or ISO 17020, as required for the relevant standards and the

personnel issuing the inspection, respectively. Upon definition of standards and regulations, the

Accreditation Body may allow a Third-party to provide third-party certification and testing services.

All this in order to ensure and assess compliance to the previously defined codes, but also to provide

an official certification mark or a declaration of conformity.

In respect to this document, only Third-parties, that are accredited by one of the Accreditation

Bodies (as is set in this document) and its headquarters is sited and registered in USA, EU or

Israel are applicable.

3.39 Valve, manual isolating

Manually operated valve which is upstream of all other fuel controls to that IThE and by means of

which the Fuel supply to the IThE / boiler can be manually shut off

3.40 Verification Dossier

A written document where the occurrence of an explosive atmosphere, the defined zones and the

needed measures are described.

3.41 Vessel

A housing designed and built to contain fluids under pressure including its direct attachments up to the

coupling point connecting it to other equipment. A vessel may be composed of more than one

chamber.

3.42 Workplace Environment

A systematic check about safety and health related problems at a workplace or working tasked for the

workers. The goal is, to create / construct a working environment for workers without any hazards to

safety and health during the work at the working place or the working task. The working environment

shall be safe and healthy in all tasks like construction, operation, inspection, maintenance and

housekeeping.

4 Industrial Appliances Application (IAA) This section covers the requirements for technical installations of both new and existing plants which

are to be connected to the NG (Natural Gas) grid. IAAs of new plants will be treated as Complete

IAAs, whereas IAAs of existing plants will be treated as Partial IAAs.

The General Requirements as defined in Chapter 4.2 of this Standard are mandatory requirements for

both installations new and old. Presumption of conformity is achieved when the Specific

Requirements of chapter 4.3 and 4.4 are fulfilled.

4.1 Application Rules

In order to achieve presumption of conformity all IAAs shall met the General Requirements.

In addition to this, specific requirements

• set out in Chapter 4.3 for new plants with Complete IAAs -with the interface from fuel main

valve to the exhaust gas connection- shall be fulfilled.

• set out in Chapter 4.4 for existing plants with Partial IAAs – with the interface from fuel main

valve to burner flange- shall be fulfilled

Any machinery, parts of machinery, fuel supply pressure equipment and accessories with or without

safety function within the boundaries of the Industrial Appliances Application shall in general comply

with Israeli law if compliance with such applicable law is mandatory for such equipment in question

and bear a valid CE marking of conformity regulating requirements for devices in line with the

effective EU directive/regulation applicable under the relevant framework. Such mark of conformity

shall include the related conformity declaration or assessment required to obtain such mark of

conformity.

The conformity declaration of all appliances shall:

• be accompanied by technical instructions and installation guidance intended for the installer/

operator as issued by the manufacturer

• be accompanied by instructions for use and servicing, intended for the operator /user,

• bear appropriate warning notices in compliance with the Israeli law under which the device

has been placed on the market, which must also appear on the packaging.

It is explicitly desired that machinery, parts of machinery, fuel pressure equipment appliances,

accessories with or without safety function bear correct CE indication with an entire significant (CE)

declaration of conformity.

Further proof of suitability can be:

• EC Type examination certificates such as corresponding to Pressure Equipment Directive

97/23/EC will be repealed from the 19 July 2016 by the new PED Directive 2014/68/EU, Gas

Appliance Directive 2009/142/EC, Construction Product Regulation 305/2011 , EMC

Directive 2004/108/EC Low Voltage Directive 2006/95/EC will be repealed from the 20 April

2016 by the new LVD Directive 2014/35/EU; Machinery Directive 2006/42/EC.

• Significant Type test reports according to the applicable desired normative issued by ISO EN

17025 appointed laboratory

Where the manufacturer is required to present a self-declaration of conformity, it shall be issued

according to the requirements of ISO 17050 (parts 1 and 2).

Note: EC Declaration of Conformity - The EC Declaration of Conformity must contain all relevant information to identify the Union harmonization legislation according to which it is issued, as well as the manufacturer, the authorized representative, the notified body if applicable, the product, and where appropriate a reference to harmonized standards or other technical specifications. By drawing up and signing the EC Declaration of Conformity, the manufacturer assumes responsibility for the compliance of the product. The CE marking indicates the conformity of the product with the Union legislation applying to the product and providing for CE marking. CE marking The CE marking is a key indicator (but not proof) of a product’s compliance with EU legislation and enables the free movement of products within the European market, whether they are manufactured in the EEA. By affixing the CE Marking the manufacturer declares on his sole responsibility that the product conforms to all applicable directives/regulations. Where a notified body is involved in the production control phase according to the applicable Union harmonization legislation, its identification number must follow the CE marking. The manufacturer or the authorized representative affixes the identification number if the legislation so requires, under the responsibility of the notified body.

For old appliances which comply with the requirements of older versions of applicable standards, no

grace period is allowed. The responsible person or manufacturer shall provide a gap analysis report of

the applicable new and former standard within a self-declaration. If there is no manufacturer, a third

party shall provide an approved the gap analysis.

4.2 General Requirements for Industrial Appliances Application

The Industrial Appliances Application and all machinery and devices within the boundary as defined

in chapter 1 shall be designed and built as to allow safety operation and to present no danger to

persons and properties.

Unburned fuel release

Industrial Appliances Application shall be constructed so that the fuel leakage rate is not dangerous.

Industrial Appliances Application shall be constructed so that fuel release during ignition and re-

ignition and after flame extinction is limited in order to avoid a dangerous accumulation of unburned

fuels in the appliance.

Ignition

Industrial Appliances Application shall be so constructed that, when used normally:

• ignition and re-ignition is smooth, • cross-lighting is assured.

Combustion

Industrial Appliances Application shall be so constructed that, when used normally, flame stability is

assured and combustion products do not contain unacceptable concentrations of substances harmful to

health.

Industrial Appliances Application shall be so constructed that, when used normally, there will be no

accidental release of combustion products.

Industrial Appliances Application connected to a flue for the dispersal of combustion products must be

so constructed that in abnormal draught conditions there is no release of combustion products in a

dangerous quantity into the room concerned.

Temperatures

Parts of Industrial Appliances Application which are intended to be placed in close proximity to the

floor or other surfaces must not reach temperatures which present a danger in the surrounding area.

The surface temperature of knobs and levers of appliances intended to be manipulated must not

present a danger to the user.

The surface temperatures of external parts of Industrial Appliances Application intended for industrial

use, with the exception of surfaces or parts which are associated with the transmission of heat, must

not under operating conditions present a danger to the user/operator and, for whom an appropriate

reaction time must be taken into account.

Design and construction

• Industrial Appliances Application shall be so constructed that, when used normally, no

instability, distortion, breakage or wear likely to impair their safety can occur.

• Condensation produced at the start-up and/or during use must not affect the safety of

Industrial Appliances Application.

• Industrial Appliances Application shall be so designed and constructed as to minimize the risk

of explosion in the event of a fire of external origin.

• Industrial Appliances Application shall be so constructed that water and inappropriate air

penetration into the fuel circuit does not occur.

• In the event of a normal fluctuation of auxiliary energy, Industrial Appliances Application

shall continue to operate safely.

• Abnormal fluctuation or failure of auxiliary energy or its restoration must not lead to an unsafe

situation. (Functional Safety)

• Industrial Appliances Application shall be so designed and constructed as to obviate hazards

of electrical origin. In the area in which it applies, compliance with the safety objectives in

respect of electrical hazards laid down in chapter 4.3.10

Materials

Materials must be appropriate for their intended purpose and must withstand the technical, chemical

and thermal conditions to which they will foreseeably be subjected. The properties of materials that

are important for safety must be guaranteed by the manufacturer or the supplier of the Industrial

Appliances Application.

Fittings for fuel handling systems

Fittings intended to be part of an Industrial Appliances Application shall be so designed and built as to

fulfil correctly their intended purpose when incorporated in accordance with the instructions for

installation. The instructions for installation, adjustment, operation and maintenance must be provided

with the fittings concerned.

4.2.1 Requirements for Machinery within the Industrial Appliances Application

The requirements are applicable to following products such as:

• Machinery • Safety components • Partly completed machinery

The aim is to establish health and safety requirements relating to the design and construction of

machinery.

4.2.2 Risk assessment for Industrial Appliances Application

A risk assessment for Industrial Appliances Application is generally carried out in order to determine

and minimize the health and safety levels which occur through the Industrial Appliances Application.

A so called assessment team as defined in chapter 3.4 shall conduct a risk assessment of the IAA.

By the iterative process of risk assessment and risk reduction the manufacturer or his authorized

representative shall:

• Determine the limits of the machinery / Industrial Appliances Application, which include the

intended use and any reasonably foreseeable misuse thereof;

• Identify the hazards that can be generated by the machinery / Industrial Appliances

Application and the associated hazardous situations;

• Estimate the risks, taking into account the severity of the possible injury or damage to health

and the probability of its occurrence;

• Evaluate the risks, with a view to determining whether risk reduction is required;

• Eliminate the hazards or reduce the risks associated with these hazards by application of

protective measures, in the order of priority established in section

4.2.2.1 Functional Safety devices (SIL Loops)

Any claim of functional safety for a component, subsystem or system should be independently

certified to the recognized functional safety standards IEC 61508. A certified product, like transmitter,

valve etc., can then be claimed to be Functionally Safe to a particular Safety Integrity Level in a

specific range of applications.

• The device shall provide a certificate according IEC 61508 to the customer with a test report

describing the scope and limits of performance.

• In case there is no certificate available and a self-declaration has been issued, compliance of

the device with IEC 61508 shall be confirmed by a third party which is accredited according

to the applicable desired standard issued by ISO EN 17025 appointed laboratory.

Information in detail of the required acceptance criteria are given in chapter 6.

Note:

The installation of these safety devices shall be assessed by a functional safety assessment of phase 4

of IEC 61511 (design and engineering) regarding the specified SIF and SIL. Further information about

how to perform this assessment is described in 4.3.11.

4.2.2.2 Devices for explosive atmospheres

Devices for use in potentially explosive atmospheres are divided into three groups. Devices for

Group II stand for explosive gases. Whereby Group I will be not considered because it will applicable

for coal mining and Group III for environment with dust.

4.2.3 Fuel supply Pressure Equipment

The aim is to minimize the hazards that are caused by the fuel supply pipes and the corresponding

accessories. Therefore it establishes requirements for the design and manufacture of fuel supply

equipment with a maximum allowable pressure greater than 0,5 bar.

The fuel supply equipment shall be designed, manufactured and checked, and if applicable equipped

and installed, in such a way as to ensure its safety when put into service in accordance with the

manufacturer’s instructions, or in reasonably foreseeable conditions.

In choosing the most appropriate solutions, the manufacturer shall apply the principles set out below in

the following order:

• Eliminate or reduce hazards as far as is reasonably practicable; • Apply appropriate protection measures against hazards which cannot be eliminated; • Where appropriate, inform users of residual hazards and indicate whether it is necessary to

take appropriate special measures to reduce the risks at the time of installation and/or use.

The piping and the corresponding accessories shall be designed for loadings appropriate to its intended

use and other reasonably foreseeable operating conditions. In particular, the following factors shall be

taken into account:

• Internal/external pressure, • Ambient and operational temperatures, • Static pressure and mass of contents in operating and test conditions, • Traffic, wind, earthquake loading, • Reaction forces and moments which result from the supports, attachments, piping, etc., • Corrosion and erosion, fatigue, etc.

Various loadings which can occur at the same time shall be considered, taking into account the

probability of their simultaneous occurrence. A more complete description of the essential safety

requirements is given in chapter .שגיאה! מקור ההפניה לא נמצא.

4.2.3.1 Design and construction of fuel pipework

The requirements for design and construction of fuel pipework differ for several categories depending

on the nominal size (DN) and the maximum allowable pressure (PS), meaning the corresponding risks

of the particular fuel connection part.

The conformity assessment categorization is shown in chapter .שגיאה! מקור ההפניה לא נמצא which

contents two figures, one for gaseous and one for liquid fuels,

The procedure necessary for the approval of the fuel supply equipment is depending on the conformity

assessment category.

The category 0-parts have to be designed and manufactured in accordance with the sound engineering

practice in order to ensure safe use. Whereas all parts belonging to category I or higher need the CE

marking according PED 97/23/EEC. From the 19.7.2016 this directive will be replaced by

2014/68/EC.

For categories 1 to 3 the approval procedure is described in several modules. It is always possible to

use modules from a higher but not from a lower category.

All fuel supply pipes and accessories belonging to category II or higher involves the collaboration of a

Notified Body irrespective of the used module.

In detail the modules A to H1 are described in chapter .שגיאה! מקור ההפניה לא נמצא.

Fuel pressure equipment or assemblies which are in conformity with the standards named in the

chapter Specific Requirements shall be presumed to be in conformity with these essential safety

requirements.

4.2.4 General requirements for operation in explosive atmospheres

The IECEx Schemes are listed in detail in Annex III.

Only such classified equipment can be used.

These general requirements are valid for gaseous atmospheres. Environments where dust atmospheres

may occur are not covered by the present requirement. Mechanical incidents are not considered at the

moment in the requirement.

4.2.4.1 Classification of Zones

Classification of zones shall be performed in accordance with the requirements of SI 60079-10-1.

National standards, e.g. SI 25000, or others from other countries can also be used in conjunction with

SI 60079-10-1, so that a complete set of requirements is achieved

4.2.4.2 Requirement for the IEC Ex documentation (Verification Dossier)

An explosion protection document (verification dossier) based on a “explosion risk assessment” shall

be issued for all places in which explosive atmospheres may occur.

In addition it shall contain the following information and documents:

• Area classification documents as required by SI 60079-10-1 with plans showing the classification and extent of the hazardous areas including the zoning

• Optional assessment of consequences of ignition • Where applicable gas classification in relation to the group or subgroup of the electrical

equipment • Temperature class or ignition temperature of the gas or vapour involved • External influences and ambient temperature.

In regards to the equipment, which is built into the installation, the following information has to be

included in the verification dossier:

• Manufacturer’s instructions for selection, installation and initial inspection • Documents for electrical equipment with conditions of use • Interconnection of equipment • Details of relevant calculations • Manufacturer’s / qualified person’s declaration

Consideration should be given to obtaining information for maintenance and repair to meet the

requirements of SI 60079-17 and SI 60079-19 respectively.

Considering the installation, the verification dossier has to list the following information:

• Necessary information to ensure correct installation of the equipment provided in a form which is suitable to the personnel responsible for this activity

• Documentation relating to the suitability of the equipment for the area and environment to which it will be exposed, e.g. temperature ratings, type of protection, IP rating, corrosion resistance

• The plans showing types and details of wiring systems • Records of selection criteria for cable entry systems for compliance with the requirements

for the particular type of protection • Drawings and schedules relating to circuit identification • Records of the initial inspection • Installer’s/qualified person’s declaration

• Plans for follow-up inspections

4.2.4.3 Electrical Installation in explosive atmospheres

Any installations shall comply with IEC 60079-14: Explosive atmospheres - Part 14: Electrical

Installations design, selection and erection.

Table 1 – Conversion table Zoning to EPL level versus ATEX

Zone IEC - Equipment Protection Level (EPL) ATEX Category (2014/34/EU)

0 Ga II1G

1 Ga or Gb II1G or II2G

2 Ga, Gb or Gc II1G, II2G or II3G

20 Da II1D

21 Da or Db II1D or II2D

22 Da, Db or Dc II1D, II2D or II3D

Selection of equipment

In order to select the appropriate electrical equipment for hazardous areas, the following information is

required:

• Classification of the hazardous area including the equipment protection level requirements where applicable

• Where applicable gas or vapor classification in relation to the group or subgroup of the electrical equipment

• Temperature class or ignition temperature of the gas or vapor involved • Intended application of the equipment • External influences and ambient temperature

It is recommended that the equipment protection levels (EPL) requirements are recorded on the area

classification drawing. This should also apply even if consequences have not been subjected to special

risk assessment.

4.2.5 Technical instructions for Industrial Appliances Application

For all used equipment or machinery installed within the boundaries of the Industrial Appliances

Application, technical instructions intended for the installer/ operator shall be available upon

installation, commissioning, operation and maintenance, and shall contain all the instructions for

installation, operation, adjustment and servicing required to ensure that machinery or equipment

within the boundaries of the Industrial Appliances Application is used correctly within the limits of

safe operation. In particular, the instructions must specify explicitly for each single machinery or

equipment consuming any type of fuel:

• The type of fuel which can be used including, for standard fuels, its required specifications as typically used for such fuel.

• The fuel supply pressure limits required at one specifically identifiable point within the Industrial Appliances Application including the boundaries of upper and lower limit pressure during operation under nominal load and during shut-down.

• The minimum requirements for supply with fresh air or any combustion gas either naturally aspirated or supplied by means of any peripheral device including the minimum flow of fresh air or combustion air required under maximum load.

• Appropriate technical measures to be implemented in order to avoid the formation of dangerous unburned fuel quantities or mixtures of fuel/oxidant.

• The conditions for the adequate disposal of combustion products.

The instructions for use and servicing intended for the user must contain all the information required for safe use, and must in particular draw the user's attention to any restrictions on use.

Warning notices

Each used equipment or machinery installed within the boundaries of the Industrial Appliances

Application shall bear warning notices on the appliance clearly stating the type of fuel used, the fuel

supply pressure and any restrictions on its use, as well as applicable safety labels under consideration

of the use of the machinery or equipment in conjunction with the entire Industrial Appliances

Application in line with ISO 7010 Compliance labeling, ISO Mandatory Symbols labels, ISO

Prohibition Symbols labels and ISO Warning labels.

4.2.6 Fuel Quality within the Industrial Appliances Application

Only gaseous and liquid fuels complying with the requirements of the relevant Israeli standards or

technical specifications upon which they are applicable, are allowed: SI 100, SI 107-2, SI 116,

SI 1134-1, SI 5731, SI 6373.

4.2.7 Locally produced LPG/Air mixtures

LPG/ Air mixtures shall be produced according to the technical rule given in document DVGW G 213.

The mixtures coming out of this process shall keep the minimum technical characteristics as defined

in 4.2.6.

4.3 Specific Requirements for Complete Industrial Appliances Application (IAAs)

This chapter applies to Complete IAAs which include an IThE/Steam boiler or any other industrial

fuel-consuming appliances as described in the scope of this standard and is constructed and built as

completely new.

4.3.1 Risk Assessment

A risk assessment of the Complete IAA shall be conducted by the assessment team as defined in

chapter 3.4.

The assessment team can choose one of the following standards for performing a risk assessment:

• ISO 12100 shall be applied for Complete IAA, e.g. for a dedicated burner, pump, etc. This risk

assessment is an iterative process with different possibilities for reducing the risk to an

acceptable tolerance level.

Note:

This International Standard specifies basic terminology, principles and a methodology for

achieving safety in the design of machinery/product. It specifies principles of risk

assessment and risk reduction to help designers in achieving this objective. These principles

are based on knowledge and experience of the design, use, incidents, accidents and risks

associated with machinery. Procedures are described for identifying hazards and estimating

and evaluating risks during relevant phases of the machine life cycle, and for the elimination

of hazards or the provision of sufficient risk reduction. Guidance is given on the

documentation and verification of the risk assessment and risk reduction process.

• SI 61882 shall be applied for a set/combination (system) of different devices/machinery, e.g.

double block and bleed combination, pressure transmitter, relays, PLC etc.

Note:

HAZard and OPerability Analysis (HAZOP) is a structured and systematic technique for

system examination and risk management. In particular, HAZOP is often used as a technique

for identifying potential hazards in a system and identifying operability problems likely to lead

to non-conforming products or system application. HAZOP is based on a theory that assumes

risk events are caused by deviations from design or operating intentions. Identification of such

deviations is facilitated by using sets of “guide words” as a systematic list of deviation

perspectives.

4.3.2 Fuel Pipe Connection

All fuel connections within the boundaries of the Complete IAA shall be designed and constructed in

line with the applicable standard as referenced below considering the type of fuel which is used under

nominal operating conditions.

Fuel connection and pipework shall comply with all parts of EN 13480 as far as applicable.

Burnable gases and burnable liquid fuels within the boundaries of the Complete IAA are classified in

Fuel Group 1 as defined in EN 13480-1.

If different types of fuels are used for a Complete IAA each specific installation with all fittings and

pipework shall comply with the standards applicable to the possible fuels used.

Requirements regarding the fuel pipe connection as defined in SI 74600-2 for IThE and for steam

boilers in SI 12952-8 and SI 12953-7 shall additionally applied.

Fuel pipes with a diameter greater as DN 50 shall be welded with welder certificates as defined in

EN 13480.

Threaded connections of fuel pipes up to DN 50 are permitted. In general screwed and flange

connections are required. Pipe fitting and compensators shall be suitable and proofed for the desired

fuel.

Grey cast iron threaded connections are not allowed. Only those made of malleable grey cast iron are

allowed.

Suitable and proofed stainless steel press fittings systems for the desired fuel are permitted.

Flexible hoses are only permitted close to the burner and shall connect the burner with the fixed fuel

pipe connection. The flexible hoses shall be kept short and made of steel /metal with a proof for the

desired fuel. Furthermore they shall withstand factor 1,5 x of nominal pressure.

Additional requirements for bio gases shall be considered.

Fuel connections within the boundaries of the Complete IAA shall be assessed, proven and

documented according EN 13480-5.

Alternatively strength and tightness test shall be conducted and performed in accordance with

IEGM / UP / 1 Edition 2.

4.3.3 Combustion Air Connection

The construction of the combustion air pipework shall be so designed and built as to fulfil correctly

their intended purpose. The air supply to any combustion device within the boundaries of the

Complete IAA shall be designed unrestricted. If shut-off valves are installed, these devices shall be

safely controlled. The location of the combustion air intake shall be such as to prevent entry of

exhaust.

The ventilation of the building and thereby the Complete IAA shall be such as to allow an adequate

supply of process /combustion air to reach the combustion units under all circumstances and

conditions.

All manual control devices (registers, valves, etc.) for the air shall be set in their pre-determined

positions and protected against unintentional movement.

The provided combustion air shall reach the burner(s) under all conditions and ducts shall be designed

in a manner that prevents the back-flow of furnace atmosphere.

The air flow shall be monitored:

• by pressure detectors or by flow detectors.

• Air pressure detectors shall comply with EN 1854.

• Each combustion device shall be provided with an adjustment device for the air flow.

In addition to the above stated the combustion air connection shall comply with SI 74600-2, SI 67600,

EN 267, SI 12953-7 and SI 12952-8, as it is relevant.

4.3.4 Fuel/Air ratio of Complete IAAs

Any chosen air/fuel ratio within the boundaries of the Complete IAA shall be controlled within

admissible limits. The predetermined values of the fuel/air ratio within these limits shall be stated in

the operating manual with meaningful protocols. The fuel/air ratio monitoring circuit shall be

independend of the control circuit

Pneumatic gas/air ratio controls shall comply with EN 12067-1.

Electronic gas/air ratio controls shall comply with EN 12067-2 if applicable.

Mechanical fuel/air ratio controls are permitted. The mechanical Fuel/air ratio need not to be

monitored if once during the initial adjustment limits were fixed and cannot be removed afterwards.

The design of the Fuel/air ratio control has to consider process conditions as well as fuel and

combustion air properties.

The air mass flow rate shall always be in a ratio with the fuel mass flow in order to ensure safe

ignition and that throughout the operating range, a stable and safe combustion is maintained at each

individual burner. The ratio needs not be the same value at all operational conditions.

In addition to the above stated the fuel/air ratio shall comply with SI 74600-2, SI 67600, EN 267,

SI 12953-7 and SI 12952-8.

4.3.5 Burner

4.3.5.1 Forced draught Gas Burner

Forced draught Gas Burners within the boundaries of the Complete IAA shall comply with SI 67600.

4.3.5.2 Atmospheric Gas Burner

Atmospheric Gas Burners within the boundaries of the Complete IAA can be used up to 70 kW. The

burner shall comply with the requirements of EN 297. For Atmospheric Gas Burners over 70 kW shall

follow the requirements of EN 746-2.

4.3.5.3 Burners for specific Application with liquid fuels

Burner within the boundaries of the Complete IAA for specific application shall comply with SI 267.

Any other Industrial IThE burner shall comply with SI 74600-2

The additional requirements for the alternating operation between various fuels shall be considered. In

cases of doubts an additional risk analysis for the alternating operation shall be conducted and

considered

4.3.5.4 Multi fuel burner for Complete IAA

Multi fuel burner within the boundaries of a Complete IAA shall comply with the applicable technical

standard for the fuel used.

The following standards shall apply and the type test confirmation for each fuel shall be available:

• SI 267

• SI 67600

These multi fuel burners are individually equipped for the fuel used.

The additional requirements for the alternating operation between various fuels shall be considered. In

cases of doubts an additional risk analysis for the alternating operation shall be conducted and

considered

Any other multi fuel Industrial IThE including the burner shall comply with SI 74600-2.

4.3.6 Boiler/IThE – Safety for combustion and fuel handling systems

4.3.6.1 Industrial thermoprocessing equipment

Industrial thermoprocessing equipment (IThE) within the boundaries of the Complete IAA shall

comply with SI 74600-2

4.3.6.2 Water-tube boilers

Water-tube boilers and auxiliary installations with volumes in excess of 2 liters for the generation of

steam and/or hot water at an allowable pressure greater than 0,5 bar and with a temperature in excess

of 110°C as well as auxiliary installations (other plant equipment) within the boundaries of the

Complete IAA shall comply with SI 12952-8; requirements for firing system for liquid gaseous fuels

for boiler.

4.3.6.3 Shell boilers

Shell boilers shall comply with volumes in excess of 2 liters for the generation of steam and/or hot

water at an allowable pressure greater than 0,5 bar and with a temperature in excess of 110°C as well

as auxiliary installations (other plant equipment) within the boundaries of the Complete IAA shall

comply with SI 12953-7; requirements for firing system for liquid gaseous fuels for boiler.

4.3.7 Flue Gas Evacuation

Flue Gas Evacuation connection and pipework shall comply with EN 13480 and the operation shall be

safeguarded as in SI 74600-2 for IThE, steam boiler SI 12952-8 and SI 12953-7.

The leak tightness of the flue gas evacuation connection and pipework within the boundaries of the

Complete IAA shall be proven according EN 13480-5 or alternative method Note: The

IThE/Shellboiler or any other industrial fuel-consuming appliances as described in the scope of this

standard shall be included in the leak tightness test as far as applicable.

4.3.7.1 Common chimney for several firings

If a common chimney exists the prescribed risk assessment as laid down in chapter 4.3.1 shall include

the possible hazards related to a common stack.

In general flue gas flows from several firings entering a common duct shall be constructed in such a

way that,

• during all operating conditions the chimney pressure shall variate in an acceptable tolerance

• explosive flue gas mixtures are excluded

• unacceptable backpressure to the single firings shall be prevented

• the temperature of the (common) flue gas is low enough to avoid self-ignition

• External ignition sources are prevented

• in case the flue gas ducts of each single burner are controlled with mechanical dampers, the

design and the control of each single Burner Management System, shall consider all

operational circumstances and implement controlled interlocks, if needed

4.3.8 Purging of the combustion room and the flue gas passages

The combustion chamber and the connected flue gas passes shall be of such a design as to ensure

effective purging. Prior to any firing system start-up, the combustion room and the flue gases passes

shall be effectively purged. The operating instructions of the combustion unit shall be followed.

If nothing else is defined the forced ventilation mass flow shall content the combustion room, all flue

gas passages up to entering the chimney (total volume) in such a way that the total volume is 5 times

changed prior any firing system start-up. A minimum purging time is defined with 30 s.

After any false-start, cutout during normal or abnormal situation, the above mentioned procedure shall

be repeated before any re firing start-up.

Manually operated firings shall consist as well an adequate/effective purging. This shall be ensured

with adequate timing relay.

In some special cases for IThE the purging conditions can variate from the aforesaid.

In that case SI 74600-2 shall be considered.

4.3.9 Flue gas / unburned gas Emissions of industrial premises

4.3.9.1 Flue gas Emissions

Flue gas emissions of industrial premises shall comply with the Israel clean air law.

4.3.9.2 Temporary unburned gas Emissions

Unburned gas emissions of industrial premises shall comply with

• the Israel clean air law. • the Israel procedure for the aerial space closure for the release of natural gas • the safety measures and procedures specified in IEGM / UP / 1 Edition 2.

4.3.10 Electrical Installation

Any electrical installation of industrial appliance application and its protective circuits shall be

installed and proven in accordance with Israel Electricity - Law Actual Version and its corresponding

directives .All electrical enclosures, components and cabling shall be suitable for the environment.

4.3.11 Functional Safety of Complete IAA

Functional safety of Complete industrial appliance applications shall comply with IEC 61508 for

products/ machinery and the design and engineering of a system consisting of different devices or

machinery shall comply with IEC 61511 or IEC 62061.

Note 1: Other parts of the overall safety of a system are mechanical safeguards or organization

procedures are partly considered by these standards, In most situations, safety is achieved by a number

of systems which rely on many technologies (for example mechanical, hydraulic, pneumatic,

electrical, electronic, programmable electronic). This standard also provides a framework within

which safety-related systems based on other technologies.

Note 2: The electric safety is not part of the functional safety standard.

4.4 Specific Requirements for Partial IAAs

This chapter applies for Partial IAAs, which shall be a part of an existing IThE/Steamboiler or any

other industrial fuel-consuming appliances as described in the scope of this standard.

Mainly converted IAAs from LPG/Fuel Oil to natural gas are covered by this chapter.

Generally it will be assumed, that the given Technical Characteristics of the existing

IThE/Steamboiler, or any other industrial fuel-consuming appliances as described in the scope, remain

unchanged. The new Partial IAA shall be matched to the existing IThE/Steamboiler by ensuring full

technical and safety compatibility. If the Technical Characteristics cannot be kept additional individual

measures shall be applied. These so-called Significant Changes on an existing system shall be assessed

individually by the authorities.

4.4.1 Risk Assessment

A risk assessment of the Partial IAA shall be conducted by the assessment team as defined in

chapter 3.4.

The assessment team can choose one of the following standards for performing a risk assessment:

• ISO 12100 shall be applied for Partial IAA, e.g. for a dedicated burner, pump, etc. This risk

assessment is an iterative process with different possibilities for reducing the risk to an

acceptable tolerance.

Note:

This International Standard specifies basic terminology, principles and a methodology for

achieving safety in the design of machinery/product. It specifies principles of risk

assessment and risk reduction to help designers in achieving this objective. These principles

are based on knowledge and experience of the design, use, incidents, accidents and risks

associated with machinery. Procedures are described for identifying hazards and estimating

and evaluating risks during relevant phases of the machine life cycle, and for the elimination

of hazards or the provision of sufficient risk reduction. Guidance is given on the

documentation and verification of the risk assessment and risk reduction process.

• SI 61882 shall be applied for a set/combination (system) of different devices/ machinery, e.g.

double block and bleed combination, pressure transmitter, relays, PLC etc.

Note:

HAZard and OPerability Analysis (HAZOP) is a structured and systematic technique for

system examination and risk management. In particular, HAZOP is often used as a technique

for identifying potential hazards in a system and identifying operability problems likely to lead

to non-conforming products or system application. HAZOP is based on a theory that assumes

risk events are caused by deviations from design or operating intentions. Identification of such

deviations is facilitated by using sets of “guide words” as a systematic list of deviation

perspectives.

4.4.2 Fuel Pipe Connection

All fuel connections within the boundaries of the Partial IAA shall be designed and constructed in line

with the applicable standard as referenced below considering the type of fuel which is used under

nominal operating conditions.

Fuel connection and pipework shall comply with all parts of EN 13480.

Burnable gases and burnable liquid fuels within the boundaries of the Partial IAA are classified in Fuel

Group 1 as defined in EN 13480-1.

If different types of fuels are used for a Partial IAA each specific installation with all fittings and

pipework shall comply with the standards applicable to the possible fuels used.

Requirements regarding the fuel pipe connection as defined in SI 74600-2 for IThE and for steam

boilers in SI 12952-8 and SI 12953-7 shall apply additionally.

Fuel pipes with a diameter greater as DN 50 shall be welded with welder certificates as defined in

EN 13480.

Threaded connections of fuel pipes up to DN 50 are permitted. In general screwed and flange

connections are required. Pipe fitting and compensators shall be suitable and proofed for the desired

fuel.

Grey cast iron threaded connections are not permitted.

Suitable and proofed stainless steel press fittings system for the desired fuel are permitted.

Flexible hoses are only permitted close to the burner and shall connect the burner with the fixed fuel

pipe connection. The flexible hoses shall be kept short and of made in steel /metal with a proof for the

desired fuel. Furthermore they shall withstand factor 1,5 x of nominal pressure.

Additional requirements for bio gases shall be considered.

Fuel connections within the boundaries of the Partial IAA shall be assessed, proven and documented

according EN 13480-5.

Alternatively strength and tightness test shall be conducted and performed in accordance with

IGEM / UP / 1 Edition 2.

4.4.3 Combustion Air Connection

The design of the combustion air pipework shall be so designed and built as to fulfil correctly their

intended purpose. The air supply to any combustion device within the boundaries of the Partial IAA

shall be designed unrestricted. If shut-off valves are installed, these devices shall be safely controlled.

The location of the combustion air intake shall be such as to prevent entry of exhaust.

The ventilation of the building and thereby the Partial IAA shall be such as to allow an adequate

supply of process /combustion air to reach the combustion units under all circumstances and

conditions.

All manual control devices (registers, valves, etc.) for the air shall be set in their pre-determined

positions and protected against unintentional movement.

The provided combustion air shall reach the burner(s) under all conditions and ducts shall be designed

in a manner that prevents the back-flow of furnace atmosphere.

The air flow shall be monitored:

• by pressure detectors or by flow detectors.

• Air pressure detectors shall comply with EN 1854.

• Each combustion device shall be provided with an adjustment device for the air flow.

In addition to the above stated the combustion air connection shall comply with SI 74600-2, SI 67600,

EN 267, SI 12953-7 and SI 12952-8, as it is relevant.

4.4.4 Fuel/Air Ratio of Partial IAAs

Any chosen air/fuel ratio within the boundaries of the Partial IAA shall be controlled within

admissible limits. The predetermined values of the fuel/air ratio within these limits shall be stated in

the operating manual with meaningful protocols. The fuel/air ratio monitoring circuit shall be

independend of the control circuit

Pneumatic gas/air ratio controls shall comply with EN 12067-1 or EN 12078.

Electronic gas/air ratio controls shall comply with EN 12067 2 if applicable.

Mechanical gas/air ratio controls are permitted. The mechanical as/air ratio need not to be monitored if

once during the initial adjustment limits were fixed an cannot be removed afterwards.

The design of the air/gas ratio control has to consider process conditions as well as fuel and

combustion air properties.

Defect or malfunction should effect that the system will tend towards higher excess air or proceed to

lockout if the air/gas ratio results in an unsafe condition.

The air mass flow rate shall always be in a ratio with the fuel mass flow in order to ensure safe

ignition and that throughout the operating range, a stable and safe combustion is maintained at each

individual burner. The ratio needs not be the same value at all operational conditions.

In addition to the above stated the fuel/air ratio shall comply with SI 74600-2, SI 67600, EN 267,

SI 12953-7 and SI 12952-8.

4.4.5 Burner

4.4.5.1 Forced draught Gas Burner

Forced draught Gas Burners within the boundaries of the Partial IAA shall comply with SI 67600.

4.4.5.2 Atmospheric Gas Burner

Atmospheric Gas Burners within the boundaries of the Partial IAA can be used up to 70 kW. The

burner shall comply with the requirements of EN 297. For Atmospheric Gas Burners over 70 kW shall

follow the requirements of EN 746-2.

4.4.5.3 Burners for specific Application with liquid fuels

Burner within the boundaries of the Partial IAA for specific application shall comply with SI 267

Any other Industrial thermoprocessing equipment (IThE) burner shall comply with SI 74600-2

The additional requirements for the alternating operation between various fuels shall be considered. In

cases of doubts an additional risk analysis for the alternating operation shall be conducted and

considered

4.4.5.4 Multi fuel burner

Multi fuel burner within the boundaries of the Partial IAA shall comply with the applicable technical

standard for the fuel used.

The following standards shall apply and the type test confirmation for each fuel shall be available:

• EN 267

• SI 67600

These multi fuel burners are individually equipped for the fuel used.

The additional requirements for the alternating operation between various fuels shall be considered. In

cases of doubts an additional risk analysis for the alternating operation shall be conducted and

considered

Any other multi fuel Industrial thermoprocessing equipment (IThE) including the burner shall comply

with SI 74600-2.

4.4.6 Electrical Installation

Any electrical installation of industrial appliance application and its protective circuits shall be

installed and proven in accordance with Israel Electricity Law – Last Edition and its corresponding

directives .All electrical enclosures, components and cabling shall be suitable for the environment.

4.4.7 Functional Safety of a Partial IAA

Functional safety of Complete industrial appliance applications shall comply with IEC 61508 for

products/ machinery and the design and engineering of a system consisting of different devices or

machinery shall comply with IEC 61511 or IEC 62061.

Note Other parts of the overall safety of a system are mechanical safeguards or organization

procedures are partly considered by these standards, In most situations, safety is achieved by a number

of systems which rely on many technologies (for example mechanical, hydraulic, pneumatic,

electrical, electronic, programmable electronic). This standard also provides a framework within

which safety-related systems based on other technologies.

4.4.8 Purging of the combustion room and the flue gas passages

The combustion chamber and the connected flue gas passes shall be of such a design as to ensure

effective purging. Prior to any firing system start-up, the combustion room and the flue gases passes

shall be effectively purged. The operating instructions of shall be followed.

If nothing else is defined the forced ventilation mass flow shall content the combustion room, all flue

gas passages up to entering the chimney (total volume) in such a way that the total volume is 5 times

changed prior any firing system start-up. A minimum purging time is defined with 30 s.

After any false-start, cutout during normal or abnormal situation, the above mentioned procedure shall

be repeated before any re firing start-up.

Manually operated firings shall consist as well an adequate/effective purging. This shall be ensured

with adequate timing relay.

In some special cases for IThE the purging conditions can variate from the aforesaid.

In that case SI 74600-2 shall be considered.

4.4.9 Flue gas / unburned gas Emissions of industrial premises

4.4.9.1 Flue gas Emissions

Flue gas emissions of industrial premises shall comply with the Israel clean air law.

4.4.9.2 Temporary unburned gas Emissions

Unburned gas emissions of industrial premises shall comply with

• the Israel clean air law. • the Israel procedure for the aerial space closure for the release of natural gas • the safety measures and procedures specified in IGEM / UP / 1 Edition 2.

4.4.10 Integration Requirements for Partial IAAs

As a result of the conducted risk assessment as prescribed in chapter 4.2.2, the downstream interfaces

between the Partial IAA which shall be a part of an existing IThE/Shell boiler shall be considered. The

interface is the existing manually mains valve downstream and the burner/boiler flange connection.

Any other industrial fuel-consuming appliances as described in the scope of this standard may have

other relevant interfaces and shall be treated individually against applicable requirements.

5 Workplace Environment During the planning of a new plant or new facility or a modification of an existing plant / facility,

latest upon completion before the work starts, a “Working Environment Impact Assessment” (WEIA)

has to be performed for the “complete IAA” (see chapter 4.3) or the changes done by the “partial IAA”

(see chapter 4.4) to assess the hazards of safety and Health for the workers which are caused by the

changes.

During the WEIA the influence of the existing part of a plant / facility has to be considered because

this part could have an influence to the new installed IAA. After the assessment, the employer and

operators knows the hazards of the working place or working task and shall take the necessary

measures to eliminate them.

During the WEIA process, it will be checked if the requirements for safety and health of changed part

will be fulfilled and the explosion protective study and documentation will be created of this outcome.

Also the influence of the environment has be checked during the WEIA process.

One part the WEIA analysis is to check the test certificates of the installed technical safety equipment

but not a function test.

It is not part of the WEIA analyses to check if the technical equipment will fulfill the requirements of

chapter 4. This will be done during the approval process described in chapter 5.3.

5.1 General Requirements

The goal of the WEIA is to establish a safe and healthy working environment.

If according to the WEIA performed, no unacceptable hazards/risks in the working environment have

been found, the operator can operate his plant without any changes. If the risks of some hazards are

unacceptable (see clause 5.2.2), the operator must take the appropriate measures to obtain a safe level.

The measures must comply with state of the art.

In case of a doubt with respect to the extent of the acceptance of a risk, it is required to consult

professionals with the relevant knowledge, comprehension and experience in the field of risk

assessment.

The decisions that concern the risks shall be brought to the attention of the workers.

It is recommended to act, as much as possible, towards decreasing the risk to the lowest reasonable

level that can be achieved (As Low As Reasonably Achievable principle – ALARA), or at least,

towards decreasing the risk to the lowest practical level (As Low As Reasonably Practicable principle

– ALARP). All of this, while maintaining the continuous improvement principle.

Hereby, “complete IAA” or “partial IAA” equipment are considered the same. Meaning, unsafe

“existing equipment” shall be changed or refitted to a safe level.

For every workplace and working task a WEIA shall be realized. One part of the WEIA is the “new

equipment” the other part is the “existing equipment” with his hazards to safety and health for the

workers at the work.

The working environment could be checked during the planning / Construction phase used the

checklist of hazards and method to assess the risk.

If an explosive atmosphere occurs, a special risk assessment (see chapter 5.3.2) has to perform to

define EX-Zones. This special risk assessment shall be performed during the planning phase and

immediately before operation of the equipment / plant starts.

5.2 Requirements for a working environment impact assessment (WEIA)

The general requirements for a WEIA are described in the Occupational Safety and Health Regulation.

The general way how to perform risk assessments (like the WEIA) is described in ISO 31010:2009.

At the ISO 31010:2009 no checklist with specific hazardous factors and no method to assess the risk

are defined. A checklist with hazardous factors and a risk matrix is defined in this standard.

A WEIA involves the following steps:

1. identification of hazards / compilation of a hazard catalogue,

2. identification of employees (and others) at potential risk from those hazards,

3. estimation of the risk involved,

4. considering if the risk can be eliminated by substitution,

• if not: making a judgement (T-O-P) on whether further measures to prevent or reduce the risk

need to be installed. Judgement (T-O-P) shall include the following measures, sorted

according to their importance:

o Technical measures

o Operational measures

o Personal measures

5. Behaviour related measures, especially trainings must be given to the employees

6. document hazard / risk and taken measures shall be listed in a document

7. Verify that the risk is reduced to an acceptable and a safe and healthy workplace is established

5.2.1 Identification of hazards

In order to identify the potential hazard in the working environment, the employer shall verify that an

updated version of a document that summarizes the risk assessment of safety and health (OSH) of

work environment exists (and that it includes the checklist of hazardous factors as specified in

annex פניה לא נמצא.שגיאה! מקור הה ). The employer has to verify that the recommendations of the

safety and health of work (OSH) risk assessment are being implemented.

5.2.2 Methods of Risk Assessment

Every risk at a working-place or a working task has to be assed. If the risk is too big (red or yellow),

the employer shall take measure to eliminate the risk to a minimum, an ALARP (as low as reasonably

practicable) Process could define.

In ISO 31010:2009 no specific method to assess the risk is given. The following table is a practice

example given in this standard.

ALARP stands for "as low as reasonably practicable", and is a term often used in the milieu of safety-critical and safety-involved systems. The ALARP principle is that the residual risk shall be as low as reasonably practicable.

It has particular connotations as a route to reduce risks SFAIRP (so far as is reasonably practicable) in UK Health and Safety law.

For a risk to be ALARP it must be possible to demonstrate that the cost involved in reducing the risk further would be grossly disproportionate to the benefit gained. The ALARP principle arises from the fact that infinite time, effort and money could be spent on the attempt of reducing a risk to zero. It should not be understood as simply a quantitative measure of benefit against detriment. It is more a best common practice of judgement of the balance of risk and societal benefit.

*reduction in earning capacity

The working environment could be checked during the planning / construction phase used the

checklist of hazards and method to assess the risk.

5.2.3 Aim – and arrangements hierarchy

If there is an unacceptable risk, safety and health measures must be taken. In chapter 5.2.2 is defined a

priority of measures:

The employer must follow the hierarchy when he takes measures to ensure a safe and healthy

workplace / working task.

The way has to be followed by the “employer” and will be check during the “Approval and testing

process” as described in chapter .שגיאה! מקור ההפניה לא נמצא.

5.3 Requirements to define EX-Zones

Minimum requirements for the safety and health protection of workers potentially at risk from

explosive atmospheres. “Explosive atmosphere” means a mixture with air, under atmospheric

conditions, of flammable substances in the form of gases, vapors, mists or dusts in which, after

ignition has occurred, combustion spreads to the entire unburned mixture.

The requirements to define EX-Zones are described in chapter 4.2.4.1 and 4.2.4.2.

5.3.1 Prevention of and protection against explosion

With a view to preventing, within the Occupational Safety and Health Regulation) and providing

protection against explosions, the employer shall take technical and/or organizational measures

appropriate to the nature of the operation, in order of priority and in accordance with the following

basic principles:

Ø the prevention of the formation of explosive atmospheres, or where the nature of the activity

does not allow that,

Ø the avoidance of the ignition of explosive atmospheres, and

Ø the mitigation of the detrimental effects of an explosion so as to ensure the health and safety of

workers.

These measures shall where necessary be combined and/or supplemented with measures against the

propagation of explosions and shall be reviewed regularly and, in any event, whenever significant

changes occur.

5.3.2 Explosion risk assessment– Verification dossier

During the explosion risk assessment the specific risks arising from explosive atmospheres, taking

account at least of:

Ø the likelihood that explosive atmospheres will occur and their persistence,

Ø the likelihood that ignition sources, including electrostatic discharges, will be present and

become active and effective,

Ø the installations, substances used, processes, and their possible interactions,

Ø the scale of the anticipated effects.

Explosion risks shall be assessed overall.

Places which are or can be connected via openings to places in which explosive atmospheres may

occur shall be taken into account in assessing explosion risks.

5.3.3 Verification dossier

In carrying out the obligations laid down in chapter 5.3.2, the employer shall ensure that a document,

hereinafter referred to as the ‘explosion protection document’, is drawn up and kept up to date.

The explosion protection document shall demonstrate in particular:

Ø that the explosion risks have been determined and assessed,

Ø that adequate measures will be taken to attain the aims of this Directive,

Ø those places which have been classified into zones in accordance with Annex I of 1999/92/EC

(see .שגיאה! מקור ההפניה לא נמצא),

Ø those places where the minimum requirements set out in Annex II of 1999/92/EC will apply,

Ø that the workplace and work equipment, including warning devices, are designed, operated

and maintained with due regard for safety,

Ø that in accordance with Council Directive 89/655/EEC (1), arrangements have been made for

the safe use of work equipment.

The explosion protection document shall be drawn up prior to the commencement of work and be

revised when the workplace, work equipment or organization of the work undergoes significant

changes, extensions or conversions. The employer may combine existing explosion risk assessments,

documents or other equivalent reports produced.

5.3.4 Defining of Ex-Zones

As described in chapter 4.2.4.1 and 4.2.4.2, the requirements to define Ex-Zones are defined in

IEC 60079-10-1. IEC 60079-10-1 allows the application of national standards to define Ex-Zones, e.g.

SI 25000.

Other countries have their own national standards to define Ex-Zones. In the following table some

examples from other countries are given:

Country or Region of Origin

Code or Standard Designation

Title Developing Body

Application Notes

Australia and New Zealand

AS/NZS (IEC) 60079-10-1

Explosive Atmospheres Part 10-1: Classification of areas – Explosive Gas Atmospheres

Standards Australia/ Standards New Zealand

Introduced in AS/NZS 60079-10-1 as the national Annex

Germany BRG 104 ExRL »Explosionsschutz- Regeln – Regeln für das Vermeiden der Gefahren durch explosionsfähige Atmosphäre mit Beispielsammlung« ExRL “Explosion Protection- Rules – Rules for avoiding the dangers of explosion able atmospheres with examples collection“

Germany TRBS 2152 Technischen Regeln fϋr Betriebssicherheitsverordnung Technical Rules for Plant Safety Provisions

Italy GUIDA CEI 31-35 & GUIDE CEI 31-35/A

Explosive atmospheres – Guide for classification of hazardous areas for the presence of gas in application of CEI EN 60079-10-1 (CEI 31-87)

CEI – Comitato electrotecnico Italiano CEI – Italian

Scope of this Guide is the analysis of the classification of hazardous

Country or Region of Origin

Code or Standard Designation

Title Developing Body

Application Notes

Electrotechnical Commission

areas due to the presence of flammable gases, vapours or mists, according to IEC standard 60079-10-1.

Sweden Klassning av explosionsfa rliga områden

Classification of Hazardous Areas Svensk Elstandard

Available only in Swedish

Switzerland SUVA Merkblatt Nr. 2153

Explosionsschutz Grundsätze Mindestvorschriften Zonen Explosion protection Basics Minimal requirements Zones

Schweizerische Unfallversicher-ungsanstalt

The Nether lands

NPR 7910-1 Netherlands practical guideline NPR 7910-1, Classifcation of hazardous areas with respect to explosion hazard – part 1: gas explosion hazard, based on NEN-EN-IEC 60079-10-1

Netherlands Standardisation Institute, NEN

UK IP15 Model code of safe practice for the petroleum industry, Part 15: Area Classification Code for Petroleum Installations Handling Flammable Liquids.

Energy Institute

IP15 is used as an industry standard in the petro(chem) industry in many countries

UK IGEM/SR/25

Hazardous area classification of natural gas installations.

Institution of Gas Engineers and Managers

USA API RP 505 Recommended Practice for Classification of Locations for Electrical Installations at Petroleum Facilities classified as Class I, Zone 0, Zone 1 and Zone 2.

American Petroleum Institute (API)

USA NFPA 59A Standard for the Production, Storage, and Handling of Liquefied Natural Gas.

National Fire Protection Association

USA NFPA 497 Recommended Practice for the Classification of Flammable Liquids, Gases, or Vapors and of Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas

National Fire Protection Association

5.3.5 Ventilation of Ex-Zones

The definition of Ex-Zones depends on the ventilation of the area where a dangerous explosive

atmosphere can occur. It makes a big different if you use a natural ventilation or a mechanical

ventilation. During mechanical ventilation the opening in the building, the air temperature and the

wind direction and wind speed has an influence of the efficiency of the ventilation.

The calculation of the wall openings by natural ventilation is described in IEC 60079-10-1. There are

all factors described with an influence of the ventilation.

The kind of ventilation and the right calculation of the ventilation have a great impact of the definition

of the Ex-Zones, see chapter 5.3.4.

5.4 Management of change (MOC) procedure

The plant employer shall prepare a change management procedure and will act according to it.

This procedure shall specify, among others, the instructions to guide the user with respect to the

activities needed during performing a change in the plant, including:

• Mapping all the means (expected and unexpected) that are due to be affected by the change. • Assessment of all the impacts relevant to performing the change. • Defining "stopping points" to examine and to define weather the change is needed and how

to promote it (including the relevant complementary steps), before performing it. • Validation of the relevant procedures to the activity.

6 Approval and Inspection – To be completed

7 Annex (informative) – To be completed