IGFA Health and Safety/Engineering Seminar

Presenter: Location: Date:

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

ATEX Compliance A Practical Appraoch

Topics ATEX
Legal Framework & Some Useful Definitions What is the Risk from Grain, Feed & Food Dusts? Risk Assessment Some Factors Affecting the Risk of an Explosion Selecting a Suitable Basis of Safety CASE STUDY Flahavans (Co. Waterford): Atex Compliance CASE STUDY Flahavans: Pilz Recommendations & Solutions Conclusion & Roadmap to Atex Compliance

Topics ATEX
Legal Framework & Some Useful Definitions What is the Risk from Grain, Feed & Food Dusts? Risk Assessment Some Factors Affecting the Risk of an Explosion Selecting a Suitable Basis of Safety Co. Waterford : Atex CASE STUDY Flahavans (Co. Waterford): AtexCompliance Compliance CASE STUDY Flahavans: Pilz Recommendations & Solutions Conclusion & Roadmap to Atex Compliance

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

EU Directive 94/9/EC Work Equipment (Manufactureres/Importers 95,100a) On the approximation of laws of the member states concerning equipment and protective systems intended for use in potentially explosive atmospheres
Transposed into Irish legislation under S.I. No. 83 of 1999 European Communities (Equipment and Protective Systems intended for use in Potentially Explosive Atmospheres) Regulations.

EU Directive 1999/92/EC Worker (Workplace/Employers - 137) On minimum requirements for improving the safety and health protection of workers potentially at risk from explosive atmospheres
Transposed into Irish legislation under the Safety, Health & Welfare at Work (General Application Regulations 2007, SI 299) Part 8 - Reg. 167-175. explosive atmospheres at places of work. previously S.I. No. 258 of 2003 Safety, Health and Welfare at Work (Explosive Atmospheres) Regulations 2003.
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ATEX Definition / Abreviation

ATmosphre EXplosible
ATEX is an abbreviation of the French term Atmosphere Explosible, or Potentially Explosive Atmosphere. This has a legal distinction from an Atmosphere Explosive which is an atmosphere that is immediately explosive.

ATEX Abbreviations
EPD: HAC: ERA: Technical Measures: Organisational Measures: Explosion Protection Document Hazardous Area Classification Explosion Risk Assessment Physical Engineering Controls Policies, procedures, training, signage etc. Selected (most suitable) control measures (e.g. Inertion, ignition source prevention, pressure relief)

Basis of Safety:

ATEX Hazardous Zones Definitions

Zone Gases Dusts

Zone Criteria (frequency / duration of explosive atmosphere)

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Continually present or present for long periods. (>1,000hrs/annum) CONTINUOUS e.g. mechanical risk assessment must take into account all failures including rare failures Occasionally likely to occur in normal operation. (>10hrs, <1,000hrs/annum) PRIMARY e.g. mechanical risk assessment must take into account normal & expected failures Unlikely to occur in normal operation. (<10hrs/annum) SECONDARY e.g. mechanical risk assessment must take into account normal failures

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ATEX Directive 99/92/EC Organisational Measure (Signage)

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

GAR 2007, Part B of Schedule 10

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Topics ATEX
Legal Framework & Some Useful Definitions What is the Risk from Grain, Feed & Food Dusts? Risk Assessment Some Factors Affecting the Risk of an Explosion Selecting a Suitable Basis of Safety Co. Waterford : Atex CASE STUDY Flahavans (Co. Waterford): AtexCompliance Compliance CASE STUDY Flahavans: Pilz Recommendations & Solutions Conclusion & Roadmap to Atex Compliance

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ATEX Typical Explosive Dusts

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ATEX Powders Location of Primary Explosions & Ignition Sources

Plant & Equipment impacting an explosive concentration Bucket elevators Storage bins Hammer Mills Dust transfer and collection equipment Enclosed equipment Sources of Ignition Mechanical e.g. overheated bearings Electrical (making/breaking contacts, arc/spark) Other source of ignition (e.g. static)

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ATEX Directive 99/92/EC Ventilation & Housekeeping

Primary Explosion can lead to secondary (more severe) explosion For most combustible dusts, a deposit less than 1 mm deep evenly distributed over the whole floor area is sufficient, if raised into suspension, to fill completely a room of normal height with an explosive dust/air mixture unlikely in a clean air-tight containment / negative pressure.

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

Topics ATEX
Legal Framework & Some Useful Definitions What is the Risk from Grain, Feed & Food Dusts? Risk Assessment Some Factors Affecting the Risk of an Explosion Selecting a Suitable Basis of Safety Co. Waterford : Atex CASE STUDY Flahavans (Co. Waterford): AtexCompliance Compliance CASE STUDY Flahavans: Pilz Recommendations & Solutions Conclusion & Roadmap to Atex Compliance

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ATEX Risk Assessment Steps To Achieve Legal Compliance

1. Identify dust (and vapour) ATEX properties (testing may be required) 2. Hazardous Areas Classification (HAC) Assign Zones and extents on plan and elevation drawings 3. Explosion Risk Assessment (ERA) Identify and assess all sources of ignition 4. Assess Explosion risk overall 5. Assess suitable and reliable Controls Measure 6. Implement Solutions based on industry best practice (Basis of Safety) 7. Provide legally required training 8. Post Atex signage 9. Regularly update, audit and review the site EPD

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ATEX Directive 99/92/EC 13 potential ignition sources

1. 2. 3. 4. 5. 6. 7. 8. 9. Hot Surfaces Flames and Hot Gases Mechanically Generated Sparks Electrical Apparatus Stray Electric Currents Static Electricity Exothermic Reactions Lightning Radio Frequency Electromagnetic Waves 10. Electromagnetic Waves (3x10113x1015Hz) 11. Ionizing Radiation 12. Ultrasonics 13. Adiabatic Compression
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ATEX Atex E.U. Non-Binding Guide (2003)

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ATEX Directive Atex E.U. Non-Binding Guide (2003)

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ATEX Directive Atex E.U. Non-Binding Guide (2003)

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Topics ATEX
Legal Framework & Some Useful Definitions What is the Risk from Grain, Feed & Food Dusts? Risk Assessment Some Factors Affecting the Risk of an Explosion Selecting a Suitable Basis of Safety Co. Waterford : Atex CASE STUDY Flahavans (Co. Waterford): AtexCompliance Compliance CASE STUDY Flahavans: Pilz Recommendations & Solutions Conclusion & Roadmap to Atex Compliance

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Dust Explosion Pentagon

Dust Explosion Pentagon 5 elements required: 1. 2. 3. 4. Fuel (combustible dust cloud) O2 Ignition Suspension (dispersion of particles in sufficient quantity and concentration) 5. Confinement (of the dust cloud)

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Dust Explosion Pentagon

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ATEX Dusts Characteristics Affecting Actual Risk

Factors impacting an explosive risk Particle size (c. < 500 um) Particle shape: spherical, flat or fibrous Group IIIA: Combustible Flyings Group IIIB: Non-Conductive Dust Group IIIC: Conductive Dust Chemical properties of a dust Moisture content Cloud dispersion Powder volume resistivity Transport velocity Air currents Dust extraction rate Fall height Physical barriers
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ATEX Dusts Dust Testing Characteristics

The most important characteristics to test for, (once the initial test has confirmed that the material is capable of forming an explosive mixture), are: Min. Ignition Energy (MIE) mJ Pmax barg KST (ST Class) bar ms -1 Layer Ignition Temperature (LIT) C Min. Ignition Temperature (MIT Cloud) C Minimum Explosion Concentration (MEC) mg/m3 Particle size (micron) Moisture Content % Powder Volume Resistivity Limiting O2 conc. BZ No.

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Topics ATEX
Legal Framework & Some Useful Definitions What is the Risk from Grain, Feed & Food Dusts? Risk Assessment Some Factors Affecting the Risk of an Explosion Selecting a Suitable Basis of Safety Co. Waterford : Atex CASE STUDY Flahavans (Co. Waterford): AtexCompliance Compliance CASE STUDY Flahavans: Pilz Recommendations & Solutions Conclusion & Roadmap to Atex Compliance

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Basis of Safety

Basis of Safety: The basis of safety should first be explosion prevention followed by ignition source prevention. Control Measures: Preventive Protective - Mitigating The basis of safety is a hierarchy of control: 1. 2. 3. 4. 5. 6. 7. 8.
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Eliminate the possibility of the formation of an explosive dust cloud or layer Ignition source prevention (e.g. ATEX equipment) Ignition source detection (e.g. metal/spark detection) Containment design pressure Isolation (e.g. mechanical/chemical) Mitigation of effects of an explosion pressure relief design, external venting, flameless internal venting etc. Spark Detection and Suppression (powder, gas, chemical inhibitor) Building design (e.g. pressure resisting / relieving construction)

ATEX Directive 99/92/EC Technical Measures Prevention & Protection

Obligations of the EMPLPOYER Art. 3: The employer shall take ORGANISATIONAL and/or TECHNICAL measures in order of priority: to prevent the formation of explosive atmospheres, or where the nature of the activity does not allow that, to avoid the ignition of explosive atmospheres, and to mitigate the detrimental effects of an explosion so as to ensure the health and safety of workers. Above 3 to be combined/supplemented with propagation measures and reviewed regularly and, in any event, whenever significant changes occur.

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Basis of Safety samples Spark Detection & Suppression

Spark Detection & Suppression

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Basis of Safety samples Explosion Venting

Explosion Venting

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Basis of Safety samples Blast Relief

Pressure/Blast Relieving Panels / Walls

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Basis of Safety samples High Integrity & High Reliability Equipment

SIL rated equipment High Integrity & High Reliability Equipment (LOPA & SIL Assessments Required)

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ATEX Signage Equipment

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Topics ATEX
Legal Framework & Some Useful Definitions What is the Risk from Grain, Feed & Food Dusts? Risk Assessment Some Factors Affecting the Risk of an Explosion Selecting a Suitable Basis of Safety Co. Waterford : Atex CASE STUDY Flahavans (Co. Waterford): AtexCompliance Compliance CASE STUDY Flahavans: Pilz Recommendations & Solutions Conclusion & Roadmap to Atex Compliance

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ATEX Case Study Flahavans

Case Study Plant which has equipment spanning 4 generations was able to adopt a proactive and practical approach to meet the requirements of ATEX Regulations

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ATEX Case Study Flahavans

Explosion Protection Document completed by Pilz (2011)

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ATEX Case Study Flahavans

Why Pilz? Practical approach Competence Experience of regulatory requirements, E.U. Norms and industry best practice Provision of transparent and actionable route to compliance Independently Certified

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ATEX Case Study Flahavans

Pilz Atex Risk Assessment of large volume of plant and equipment

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Explosion Protection Document Findings HAC Example - Service Bin Silo

Explosion Protection Document Findings ERA Example - Service Bin Silo

ATEX Case Study Flahavans

Atex Risk Assessment Prioritised Risk Areas

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ATEX Case Study Flahavans EPD Pilz Findings

Executive Summary

ONE HIGH PRIORITY PLANT AREA

Risk Associated with 9 Micro-Plants

ATEX Regulatory Environment Explosion Protection Document Structure Explosion Protection Document Findings Flahavans Priority Listing Next Steps

FOUR MEDIUM PRIORITY PLANT AREA

Compliance Strategy Phasing

ATEX Case Study Flahavans

From Full Plant Risk Assessment EPD Priority Areas 8 Green Intake Silos areas of concern for Atex upgrade. Sweep Augers and associated Motor and Electrical Power Supply and control System did not meet the required ATEX Zone 21 classification.

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ATEX Case Study Flahavans

Pilz Upgrade Project Deliverables Electrical design and specification for the New Sweep Auger System Electrical Installation for the Sweep Auger Systems for the 8 Grain Intake Silos Electrostatic Audit. SAT, FAT Provide a full handover package e.g: M&E drawings Data Sheets Electrostatic Audit Full validation and certification of completed to ETCI Atex requirements DoCs. Provision of ATEX Training

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Overall Compliance Strategy Flahavans

Aims: Full Plant-wide Compliance Phased Strategy 3 Year Plan Prioritised Approach Project based with parallel implementation lines
Executive Summary ATEX Regulatory Environment Explosion Protection Document Structure Explosion Protection Document Findings Flahavans Priority Listing Next Steps Compliance Strategy Phasing

Project Management Pilz & Flahavans Project Methodology

User Requirements Specification

Assemble Team

In order to ensure this project would be executed in a systematic and professional manner, Pilz and Flahavans agreed that a structured project methodology consisting of seven key phases would be followed.

Front End Study (including Design)

Tendering Process

Full Detailed Design

Implementation

Closure & Handover

Pilz Offering as part of Equipment Upgrades

Project Management (Risk, Sschedule, Installation, Supervision) Full M&E Specification, Design & Analysis e.g. re-design of ATEX rated mounting plates, couplings, pulleys, Ingress Protection (IP), containment runs, isolation switches, glanding etc. to suit ATEX modifications Safety Validation Factory Acceptance Test (FAT) Installation & Commissioning Site Acceptance Test (SAT) Full ATEX Certification of all installations

Topics ATEX
Legal Framework & Some Useful Definitions What is the Risk from Grain, Feed & Food Dusts? Risk Assessment Some Factors Affecting the Risk of an Explosion Selecting a Suitable Basis of Safety Co. Waterford : Atex CASE STUDY Flahavans (Co. Waterford): AtexCompliance Compliance CASE STUDY Flahavans: Pilz Recommendations & Solutions Conclusion & Roadmap to Atex Compliance

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Overall Compliance Strategy Recommendation List

Item 1 2 3 4 5 6 Recommendation Replace the Auger motors with ATEX rated motors or move the motors external to the silo. Rotation sensing should be installed on all chain and flight elevators. Basis for sizing of current explosion flaps should be reviewed. Investigate the installation of explosion flaps on elevators. Speed sensing should be repaired where it is currently installed on elevators Motors, Instruments, Probes and other electrical equipment must be assessed and if required replaced with suitable ex-rated equipment. Consider introducing a system for preventative maintenance for all pieces of equipment subject to derogation over time. Complete further dust testing on materials from different processing stages Ensure all metal parts are earthed. An electrostatic survey is recommended to be carried out. Appropriate ATEX signage must be introduced to all areas. Housekeeping must be improved. Dust accumulations must be cleaned up with immediately. Leaks in pipe work/ equipment to be repaired.

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Recommendation 1: Replacement of Old Oats Bins Auger Motors Area: Action: Old Oats Storage Silo Bins 1 8 Replace motors with suitable ATEX rated motors Temperature sensing on all 8 motors

Recommendation 2: Installation of ATEX sensors on Elevators Area: Action: Intake Elevator to main plant Installation of speed / alignment sensors Installation of rotation slippage sensors Installation of bearing temperature sensors

Recommendation 3: Confirm accuracy of the relief vent panel sizing Area: Intake Elevator to main plant Dust Extraction System in main plant Action: Calculation of the vent panel sizes for intake elevator Complete relief vent panel sizing calculations for 12 vents

Recommendation 4: Replacement of all medium priority non-ATEX motors Area: Action: Various Areas Replace motors with suitable ATEX rated motors

Recommendation 5: Installation of ATEX sensors on conveyors Area: Dust Extraction Auger Conveyor Hulls Bin Storage Auger Conveyor Action: Installation of speed / alignment sensors Installation of rotation slippage sensors Installation of bearing temperature sensors

Recommendation 6: Installation of ATEX level sensors in silos Area: Bran Service Bin Sussex / Hulls Bins Wheat /Barley Bin Boiler Service Bin Hull Bin Storage Hopper Action: Install suitable ATEX rated level sensors

Recommendation 7: Installation of ATEX lighting Area: Bran Service Bin Sussex / Hulls Bins Wheat /Barley Bin Boiler Service Bin Hull Bin Storage Hopper Storage Room Action: Install suitable ATEX rated lighting and switches

Recommendation 8: Electrostatic Survey Area: Action: Complete site Complete a site survey to assess the scope of works for an electrostatic audit

Recommendation 9: Further Dust Testing Area: Action: Oats dust from various areas of the site Complete dust testing on oats from various locations

Recommendation 10: Detailed Plant & Equipment Electrical Review Area: Action: Complete site Complete a site survey to assess the scope of equipment upgrades

ATEX Case Study Flahavans Upgrade Works Green Intake Silos and Auger Control

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ATEX Case Study - Flahavans Upgrade Works Green Intake Silos and Auger Control

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ATEX Case Study Flahavans Upgrade Works Green Intake Silos and Auger Control

ATEX Case Study Flahavans Upgrade Works Green Intake Silos and Auger Control

ATEX Case Study Flahavans

Grain Silo Auger Operating Manual

ATEX Case Study Flahavans

Sample Component Data Sheets

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ATEX Case Study Flahavans

Sample Component Data Sheets

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ATEX Case Study - Flahavans Sample Test Records, Static Audit, Ex Certification

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Topics ATEX
Legal Framework & Some Useful Definitions What is the Risk from Grain, Feed & Food Dusts? Risk Assessment Some Factors Affecting the Risk of an Explosion Selecting a Suitable Basis of Safety Co. Waterford : Atex CASE STUDY Flahavans (Co. Waterford): AtexCompliance Compliance CASE STUDY Flahavans: Pilz Recommendations & Solutions Conclusion & Roadmap to Atex Compliance

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ATEX Where to Start? Seeing the wood from the trees

Large Plants will have large amounts of plant and equipment to be assessed. High volume of information and documentation to be assessed Large number of actions Project Management Identify roles and responsibilities Risk Assessment Prioritisation of actions is Key Schedule/Programme Control Maximise plant availability Minimise costs Minimise risk

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ATEX The Journey Success Factors

Practical & Cost-Effective Solutions

Legislation

Best Practice

Risk Assessment Competence

ATEX The Journey Success Factors

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ATEX Directive 99/92/EC Compliance Strategy

Customer Benefits ?

1. Pilz reputation and independence accepted by all in the value chain 2. Competence of consultants and engineers assured trough audited competence scheme. 3. Integration of solution engineering with ERA 4. Flexible use of Pilz resources compliments use of available internal resouces 5. Global organisational reach with consistent interpretation of
- Directives, Stsndards and Regulations - Country of use language capability

6. Early lifecycle involvement of experienced teams will reduce the cost of late life-cycle remedial action

Brian Aherne

Keep up-to-date on Pilz www.pilz.com

Pilz, Business & technology park, Model Farm Road, Cork, Ireland Tel: +353 21 4346535 Email: b.aherne@pilz.ie

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