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Basic Elements of Explosion Protection in the EU Legislative Context

Basic Elements of Explosion Protection in the EU Legislative Context. ATEX Symposium 22 – 24 Eylül 2011, Ankara, Türkiye. Dr.-Ing. Uwe Klausmeyer Physikalisch-Technische Bundesanstalt Braunschweig, Germany. The ATEX Regulation.

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Basic Elements of Explosion Protection in the EU Legislative Context

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  1. Basic Elements of Explosion Protection in the EU Legislative Context ATEX Symposium 22 – 24 Eylül 2011, Ankara, Türkiye Dr.-Ing. Uwe Klausmeyer Physikalisch-Technische Bundesanstalt Braunschweig, Germany

  2. The ATEX Regulation EU Directivesofthe „New Approach“ Legislative Framework, consistingof:- 94/9/EC (tradeofequipment, ESRs)- 1999/92/EC (safetyofworkplace)

  3. Accident in Oppau, Germany

  4. Accident in Buncefield‚UK, 2005

  5. Buncefield, 2005

  6. Buncefield, 2005

  7. Accident at INEOS near Cologne, Germany17th of March, 2008 Has set fire to amethylacetate tank Pipeline ofEthyleneis burning

  8. Explosion protection Avoid concurrence:- Oxygen (air)!!! Inertization- Ignition source!!! Elimination- Combustibles (gas, vapour, dust)!!! Ventilation

  9. Spreadofgases • Convection • Buoyancy Lighter than air Heavier than air

  10. Spread of liquids, leakages Gas Gasoline

  11. Combustible liquids 5 ml gasoline is enough to produce 200 l of explosive atmosphere, which can destroy a barrel! Formation of highly flammable vapour/ air mixture can occur when handling with even small amounts of break cleaners!

  12. Spread of combustible dusts Dust layers with a thickness of 1 mm can be enough to produce explosive atmospheres!

  13. Critical concentrationofFlammablesubstances (safetycharacteristics)

  14. Influence of concentration

  15. Ignition sources – EN 1127-1 • Ignition of an explosive atmosphere can be caused by various sources: • hot surfaces • flames and hot gases • mechanically generated sparks • electrical installations • equalizing currents, cathodic corrosion protection • static electricity • lightning • electromagnetic waves (high-frequency) • optical radiation • ionising radiation • ultrasonics • adiabatic compression and shock waves • exothermal reactions

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

  17. Flameproof enclosure “d”, to mitigate an explosion hazard • Special preparation: • Max tolerances at all gaps • Without gaskets and grease Ignition devicepressure transducer Explosive gasmixture

  18. Electrostatic charge 4 Electrical apparatus 1 • Conductable wheels • conductable seat material • conductable housing • grounding against electrostatic charge • Motor „d“, „e“ • control device „d“, „e“, „i“ • accumulator „e“ • plug and socket „d“ • lighting fixture and control lights „d“, „e“ Temperature control 6 • Motor control device • motor • hydraulic oil/system Sparks caused by metallic parts 5 • Coating with brass, bronze andstainless steel Electrical installation 2 • IEC/EN 60079-14 Engine 7 Mechanical apparatus 3 • Brakes and oil hydraulic system/components Ignition hazards of a complex apparatus:a fork lift (electrical motor or combustion engine) 4 3 4 3 7 1 3 6 2 1 5 5 4 4

  19. The ATEX Regime • Free Trade Directive 94/9/EC in the Internal EU Market (Essential Health and Safety Requirements – ESRs, obligations of the manufacturer) • Worker protection (Social) Directive 1999/92/EC (obligations of the end user) • ATEX Standing Committee • ATEX Notified Bodies • ATEX Consultant, CENELEC, CEN, Presumption of Conformity with ESRs

  20. What‘saboutthis „mark“???? Chinese Export, ConfusionEverywhere ;-)))) 1. ConformitéEuropéenne (FR) 2. Legal mark, NOT a qualitymarklikeTSE, VDE, UL… IECEx 3. Affixedby a manufacturer on hisownresponsibilty 4. maybebased on an EC Type ExaminationCertificatebyan independentATEX Notifiedbody, in the ATEX fieldonlyfor Zone 0 andZone 1 classifiedareas 5. installationandinstructionmanual!!!!!

  21. Important directives of the New Approach • (Low Voltage Directive 73/23/EEC) • Machinery Directive 98/37/EC • ATEX (Explosion-proof equipment) 94/9/EC • EMC Directive 89/336/EEC • Pressure Equipment Directive 97/23/EC • R&TTE-Directive 1999/5/EC • Toys Directive 88/378/EEC • Personal Protective Equipment Directive 89/686/EEC • Construction Products Directive 89/106/EEC • Medical Devices Directive 93/42/EEC • (CE-Kennzeichnungs-Richtlinie 93/68/EEC)

  22. Relation of ATEX, CEN/CENELEC, ISO and IEC/IECEx ATEX Notified Bodies - Nando New Practice ofmany ATEX NotifiedBodies (IECExExCB) istousetheelementsofIECEx (ExTRs, QAR) toissue a EC Type ExaminationCcertificateandthe QA Notification

  23. IEC vs. CEN/CENELEC • Dresden/Vienna Agreement on Parallel Voting of documents, stand still agreement CLC/IEC • EN 60079-0 (former edition EN 50014 - EEx) is equivalent to IEC 60079-0 (Ex),EN/IEC 60079-1 „d“, -2 „p“, -5 „q“, -6 „o“,-7 „e“, -11 „i“, ….. , -18 „m“, -26 „Zone 0“…., -34 „QM Production“, -36, -37 (mech.) • Plant operation: EN/IEC 60079-10-1/-2, EN/IEC 60079-14, -17, -19

  24. Safetyconceptsforequipment – olderversionsofthestandards

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

  26. Classification of equipment in accordance to EN/IEC 60079-0  Temperatur Class: Maximum surface temperature  Explosion Group

  27. Hazardoussubstanceandsafetycharacteristics (EN/IEC 60079-20)

  28. Examples of 94/9-equipment with EC Declaration of Conformity To be installed in accordance with IEC 60079-14

  29. Classificationofequipment

  30. Minimum dutiesofthemanufacturer Electrical equipment Mechanical equipment Category 1/M1:- EC Type Examination Cert.- QA Notification/Annex IV Category 2/M2:- self declaration of conformity- Deposit of product documentation at an ATEX Notified Body Category 3:- self declaration of conformity, ATEX Notified Body not required • Category 1/M1:- EC Type Examination Cert.- QA Notification/Annex IV • Category 2/M2:- EC Type Examination Cert.- QA Notification/Annex VII • Category 3:- self declaration of conformity, ATEX Notified Body not required

  31. Way to the CE marking EC Declaration of Conformity 01.01.2010 CE – conformity marking# and EC – declaration of conformity by the manufacturer(Annex X) #: not for components according Article 8, 3 all categories equipment, protective systems category 1, M1 equipment, protective systems category 2, M2 electrical equipment, combustion engines category 2, M2 non-electrical equipment category 3 equipment Unit verification (Annex IX) Production quality assurance (Annex IV) or Product verification (Annex V) Product quality assurance (Annex VII) or Conformity to type (Annex VI) Internal control of production (Annex VIII) Internal control of production (Annex VIII) Deposit of documentation (Article 8, 1b ii) EC type-examination certificate (Annex III) EC type-examination certificate (Annex III) Notified Body Manufacturer Category according article 8

  32. Risk assessment acc. ATEX Directive 1999/92 The employer hasto conduct anignitionrisk assessment: • Probability and duration of a significant amount of explosive gas or dust atmosphere (Zone classification in acc. to EN/IEC 60079-10-1, -2) • Probability and energy of ignition source • scale of damages which might occur

  33. EU-Directive 1999/92/EGand IEC 60079-10-1 Zone 0 A place in which an explosive atmosphere consisting of a mixture with air of flammable substances in the form of gas, vapour or mist is present continuously or for long periods or frequently. Zone 1 A place in which an explosive atmosphere consisting of a mixture with air or flammable substances in the form of gas, vapour or mist is likely to occur in normal operation occasionally. Zone 2 A place in which an explosive atmosphere consisting of a mixture with air of flammable substances in the form of gas, vapour or mist is not likely to occur in normal operation but, if it does occur, will persist for a short period only.

  34. Directive 1999/92/EGand IEC 60079-10-2 Zone 20 A place in which an explosive atmosphere in the form of a cloud of combustable dust in air is present continously, or for long periods or frequently. Zone 21 A place in which an explosive atmosphere in the form of a cloud of combustible dust in air is likely to occur in normal operation occasionally. Zone 22 A place in which an explosive atmosphere in the form of a cloud of combustible dust in air is not likely to occur in normal operation but, if it does occur, will persist for a short period only.

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

  36. Examples of 94/9-equipment with EC Declaration of Conformity CE – EU Dir. 94/9 marked equipment is required by the user‘s directive 1999/92

  37. Directive 1999/92/EG(1) Documentation • Explosion protection document: • description of the plant, the process, the activities and flammable material quantities • material data • results of the explosion risk assessment • Explosion protection measures • Organizational measures (training staff, …) Get assistance by NAMUR.de andNAMUR recommendation xyz

  38. Directive 1999/92/EG(2) Maintenance • Ensure expertise of the personell MaintenanceIEC 60079-17and -19 • Training and experience must be ensured • Prevent occurence of hazardous atmophere • install a fire monitor if necessary • Making sure before restarting that the explosion protection measures required for normal operation have been reactived • clean dust deposits from installed products

  39. The ATEX Standing Committee • Representatives coming from Ministries of the EU Member States, Industry Associations, ExNB Group, Standardization Bodies CENELEC and CEN, ATEX Consultant, …. the Stakeholders • Interpretation of the Directives 94/9 and 1999/92 • Interface to other Directives, e.g. to the Machinery Directive • Meeting once a year in Brussels

  40. ATEX Notified Body group The ATEX Notified Bodies • More than 60 ATEX Notified Bodies with similar scopes • but it is a national notification, not an accreditation in acc. with ISO/IEC standards • requirements for notification see annex XI of the 94/9 • general experience: no chance outside EU with such a notification, ISO/IEC 17025 and ISO Guide 65 are to be applied by internationally recognized ILAC/IAF accreditation bodies like TÜRKAK

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