At Ex Explosion Guidelines
At Ex Explosion Guidelines
RISK OF EXPLOSION
Explosions can occur anywhere that combustible gases, fumes, particulate or dust are stored or transported. Under certain circumstances an explosive combination is created when exposed to air. This could result in an explosion if an ignition source exists. Typical explosive environments are found in the chemical and pharmaceutical industries, refineries, fuel storage facilities, and in painting/surface coating businesses. However, companies transporting and treating dust-creating bulk solids such as corn, animal feed or other organic products are also vulnerable. A large number of guidelines and standards ensure the minimization of explosion risks in such areas.
Creating an explosion prevention document which contains all available data and effective measureses
Labelling on a printed plate EC-type evaluation by an authorized agency if an electrical system belongs to category 1 or 2, a non-electrical system into category 1 or if it is a matter of a protective measure.
The labeling of the system according to ATEX 95 is necessary only if it vents into an explosive setting. If an explosive environment exists only inside the extraction system, labeling is not necessary. However, various system components can be affected such as fans, switchgear, engines for rotary valves, sensors and level indicators or differential pressure measuring systems.
CLASSIFICATION BY ZONES
Zones are divided into the following classifications:
Constant, long period or frequent risk Occasional risk No risk during normal operation (rarely or short-lived)
Guidelines VDI 2263-6 and BGR 104 make recommendations for zone divisions in extraction systems. The dirty air duct can be categorized as a non-explosive zone (n.e.B.) with proper operation and corresponding flow speeds (normally > 20 m/s). Since for example, subsequent to a retrofitting, dust can accumulate in many spaces, so the dirty air duct classification as zone 22 is safer.
Zone division of the installation area according to the operator's explosion protection sheet
Filter system with top mounted fan, rotary valve with open dust discharge, protective measures for the prevention of combustion.
Additional precautions for explosion protection must be taken if combustible gases or solvents are also extracted.
Ignition Temperature: temperature at which dust ignites. The maximum surface temperature may only be 2/3 of the ignition energy. For example, inside a fan motor: the lowest allowable ignition temperature = 202,5 C. Ignition temperatures are > 300 C for almost all types of dust. KST-value = speed of pressure increase = increase of the red curve pmax = maximum explosion excess pressure which would be created in a closed case.
BZ BZ 1 BZ 2 BZ 3 BZ 4 BZ 5 BZ 6
normal pressure
TIME Depending on the KST-value, the dust is divided into the following categories: Dust explosion class St 1 St 2 St 3 KSt-value in bar x m x s-1 > 0 to 200 > 200 to 300 > 300
UEG = lower explosion limit = minimum dust concentration level for the dust-air combination to become explosive. The minimum volume is usually at 30 g/m. MZE = Minimum Combustion Energy MZE > 10 mJ 3 mJ < MZE < 10 mJ MZW < 3 mJ Normal flammability
Highly flammable
Extremely flammable
Vario dust collection system with integrated motor-impeller unit, discharge into a 50-L container. Protective measures: averting ignition with a back pressure flap on the dirty air side.
PROTECTIVE PROCEDURES
Protective measures must be chosen in the following priority: 1. Prevention of an explosive environment 2. Avoidance of sources of ignition (combustion) 3. Specific explosion protection
Specific Averting sources of ignition
The ratio of inert material should be > 50 Gew-% Without specifying the dust, a weight ratio of inert material to dust of > 9:1 must be assumed. Due to the large quantities of inert material required, this process is economically feasible only with low volumes of dust.
PREVENTING COMBUSTION
Avoiding sources of ignition can be undertaken for systems at risk for explosion, even if specific protective measures are already in place. The only way explosion/combustion can be prevented is if the following conditions are met: minimal dust ignition energy is > 10 J; no mixed compounds, eg., explosive dust with sufficient volume of explosive gases/fumes; no risk of spontaneous combustion; intake of ignition sources into the filtration system must be prevented.
ATEX SYSTEMS
A basic prerequisite for an avoidance of ignition sources is the utilization of systems with the corresponding ATEX system category depending on the zone division (see page 3).
(1)
(2)
A spark detection and extinguisher system could help to achieve one protective measure in some instances
(3)
Extinguished Detected
Sparks are detected inside the duct ahead of the filter and are extinguished immediately by water spray. However, piping measuring at least 6 meters between spark detection and dosing is necessary. Extinguishing may not be reliable for larger sources of flame such as burning components. An evaluation must be made on an individual basis if additional constructive measures are required. Spark detection and flame extinguishing are common solutions for retrofitting existing systems without extensive explosion protection measures.
Below are some examples: (1) Solenoid valves in the clean air room: ATEX category 3D (2) Fans/motors in the clean air room: ATEX category 3D Terminal box in the clean gas room: ATEX category 1D (3) Level sensors in the dirty air room: ATEX category 1D Rotary valves and screw-conveyors including gear motors: ATEX category 1D Gear motors of rotary gate valves and screw-conveyors: ATEX category 3D
Reducing Potential
To avoid sparks created by electrostatic discharges, it is absolutely essential to ground conductive components inside explosive areas (bleeder resistor < 106 Ohm).
For dust which easily ignites (<10 mJ), the use of conductive filter elements is imperative.
Dust characteristics and pressure increase (KST-value) and maximum explosion excess pressure Pmax Filter dimensions Indoor/outdoor installation with possible safety zones in front of pressure release mechanisms Dust toxicity etc.
Characteristics
Low cost Also function with gases and metal dusts A variety of installation directions are possible Pressure relief indoors is not allowed Pressure relief into fire and explosion prone areas is prohibited. Practically maintenance-free (in the winter, snow must be removed manually from horizontal installations of >50 cm; small quantities of snow are not a concern.) A safety zone outside the flame range must be marked in front of the burst panels Individuals are not allowed outside the safety zone. Adjacent buildings must also be protected against explosions and flames.
Technical data on Keller's standard burst panels. Response excess pressure: 0.1 bar Effective relief surface area on each burst panel: 0.535 m2 Height: 586 x 920 mm Resistant to vacuums up to 50 mbar standard version, alternatively up to 200 mbar Allowed for KST-values to 300 bar x m/s
Characteristics
Minimal KST value: 200 bar x m/s Response excess pressure: 0.1 bar For dust with a minimum combustion energy level (MIE) > 3 mJ Safe distance: 5 m for people; 0.5 m for objects/walls Fits standard burst panels - suitable for retrofits The ratio between the relieved volume and the volume of the room must be at least 1:15 Stainless steel version available for outdoor installations Practically maintenance-free Control is included Can be used following an explosion after replacing the burst panel.
Safe distance 5 m
10
Characteristics Response excess pressure: 0.05 bar Allowed for KST-values up to 300 bar x m/s Also usable for gases/fumes Relief into zone 22 is permissible Can be used further after an explosion following an inspection Practically maintenance-free The increase of pressure in the place of installation shall be considered No flame discharge or any discharge into the workplace is allowed; however, within a marked security area of 2,5 m maintenance staff can remain during operation
Security area
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Explosion Suppression
Through explosion suppression, an explosion is prevented within 50 milliseconds by means of detection and addition of an extinguishing powder. A dynamic pressure sensor is installed in the dirty air room, and an infrared sensor is installed at the dirty air inlet (to detect slow explosions). The tanks in which the extinguishing agents are stored are controlled via the control center.
Characteristics Allowed for KST-values up to 500 bar x m/s Ideal for installation in the workplace or in the vicinity of toxic dusts Explosion decoupling possible by means of an extinguishing agent can be achieved with minimal effort, since both detection and control are readily available. Cannot be used for pure metal dust
Pressure sensor
Round filter with explosion suppression Extinguishing agent lock in the pipe
Pressure sensor
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Ideal for installation on the factory floor and where high KST-values are required.
start-up damper
Purified air
Explosion fast-closing slider Exhaust air fan Exhaust air silencer Explosion Particle protection valve measurement device Pressure sensor Pressure-tight filter system for aluminum dust explosion
Collection
Functional diagram
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Explosive Decoupling
Filtration systems with constructive explosion protection must generally be decoupled. Specific installation distances should be established. See example below for back pressure flap. Specific installation distances have to be taken into consideration - Example back pressure flap
Fan Installation distance
The ductwork between ProFlap and explosion protected housing/filter shall have the same pressure surge protection (normally at least 2 mm sheet thickness, welded).
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Disposal
Most commonly used decoupling measures:
protective measure): For rigid filter elements such as SINBRAN or filter tubes with a support frame, some flame decoupling can be assumed. The duct on the clean air side has to resist the excess explosion pressure; however, it should not collapse. An inadequately installed duct can create a hazardous situation. The ducting must be directed into a safe zone.
Disposal tank: Must be pressure resistant at the direct openings into disposal tanks.
Rotary valves (for decoupling flames and pressure): Rotary valves must be installed according to ATEX 95 (flashback and pressure surge protected).
Flap valve (for decoupling flames and pressure): Flap valves must be installed according to ATEX 95 (flashback and pressure surge protected).. Flap valve
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Standards and technical specifications EN 1127-1 Explosion protection - Basic principles and systems engineering EN 13463 Non-electrical systems in explosion endangered areas EN 14460 Explosion resistant systems EN 14491 Systems for pressure relief of dust explosions VDI 2263 Dust fires and dust explosions VDI 3673 Pressure relief of dust explosions EN 14986 Explosion protection measures at fans BGR 104 Explosion protection measures BGR 109 Guidelines to avoid the danger of dust explosions at grinding, brushing and polishing of aluminium and its alloys (former ZH 1/23) BGR 132 Guideline "static electricity" (former ZH 1/200) BGR 204 Handling with magnesium (former ZH 1/328) Noted bodies/Test institutes to detect dust characteristics/Experts: Institute for Research and Testing of the German Social Accident insurance www.bgia.de German Research Association for applied system safety and industrial medicine (FSA) Service provider and inspecting authority concerning guideline 94/9/EC www.fsa.de/ Physical-technical federal agengy (German PTB) - Explosion protection http://www.explosionsschutz.ptb.de/hp.htm?186,34 DEKRA EXAM GmbH www.bg-exam.de/ IBExU Institut fr Sicherheitstechnik GmbH - European notified body for the ATEX directive www.ibexu.de/ TV Product Service GmbH (TV=German Technical Inspection Agency) www.tuev-sued.de BAM - Federal Institute for Materials Research and Testing www.bam.de FTZU - Physical-Technical Testing Institute www.ftzu.cz FireEX Consultant, GmbH, Richard Siwek
Keller USA, Inc. 2168 Carolina Place Drive FORT MILL, SC 29708 Phone: +1 8033962000 Fax: +1 8033962905 [email protected], www.kellerusa.com
09/2012