Igfa Ppt 26 0 13 Vc Pilz
Transcript of Igfa Ppt 26 0 13 Vc Pilz
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IGFA Health and Safety/Engineering Seminar
Presenter: Brian Aherne, Process Safety Manager (Pilz)Location: Maldron Hotel, Portlaoise.Date: Thursday, 25April, 2013
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ATEX Compliance A Practical Appraoch
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TopicsATEX
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Legal Framework & Some Useful Definitions
What is the Risk from Grain, Feed & Food Dusts?
Risk Assessment
Some Factors Affecting the Risk of an Explosion
Selecting a Suitable Basis of Safety
CASE STUDY Flahavans (Co. Waterford): Atex Compliance
CASE STUDY Flahavans: Pilz Recommendations & Solutions
Conclusion & Roadmap to Atex Compliance
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TopicsATEX
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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 ComplianceCASE STUDY Flahavans (Co. Waterford): Atex Compliance
CASE STUDY Flahavans: Pilz Recommendations & Solutions
Conclusion & Roadmap to Atex Compliance
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ATEX Directive 94/9/EC & 99/92/ECTransposition into Irish Legislation
EU Directive 94/9/EC Work Equipment (Manufactureres/Importers 95,100a) On the approximation of laws of the member states concerning equipment
and protective systems intended for use in potentially explosiveatmospheres
Transposed into Irish legislation under S.I. No. 83 of 1999 EuropeanCommunities (Equipment and Protective Systems intended for use in PotentiallyExplosive Atmospheres) Regulations.
EU Directive 1999/92/ECWorker (Workplace/Employers - 137) On minimum requirements for improving the safety and health protection of
workers potentially at risk from explosive atmospheres
Transposed into Irish legislation under the Safety, Health & Welfare at Work(General Application Regulations 2007, SI 299) Part 8 - Reg. 167-175. explosiveatmospheres at places of work.
previously S.I. No. 258 of 2003 Safety, Health and Welfare at Work (ExplosiveAtmospheres) Regulations 2003.
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ATEXDefinition / Abreviation
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ATmosphre EXplosibleATEX is an abbreviation of the French term Atmosphere
Explosible, or Potentially Explosive Atmosphere.
This has a legal distinction from an Atmosphere Explosivewhich is an atmosphere that is immediately explosive.
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ATEXAbbreviations
EPD: Explosion Protection Document
HAC: Hazardous Area Classification
ERA: Explosion Risk Assessment
Technical Measures: Physical Engineering Controls
Organisational Measures: Policies, procedures, training,signage etc.
Basis of Safety: Selected (most suitable) control
measures (e.g. Inertion, ignitionsource prevention, pressure relief)
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ATEXHazardous Zones Definitions
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Zone Zone Criteria(frequency / duration of explosive atmosphere)
Gases Dusts
0 20Continually present or present for long periods.(>1,000hrs/annum) CONTINUOUSe.g. mechanical risk assessment must take into account all failures
including rare failures
1 21Occasionally likely to occur in normal operation. (>10hrs,
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ATEX Directive 99/92/ECOrganisational Measure (Signage)
The ATEX Directive stipulates that the required Ex Warning Signage mustbe posted at the entrance to all Hazardous Area zones.
GAR 2007, Part B of Schedule 10
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TopicsATEX
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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 ComplianceCASE STUDY Flahavans (Co. Waterford): Atex Compliance
CASE STUDY Flahavans: Pilz Recommendations & Solutions
Conclusion & Roadmap to Atex Compliance
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ATEXTypical Explosive Dusts
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ATEX PowdersLocation of Primary Explosions & Ignition Sources
Plant & Equipment impacting an explosive concentration
Bucket elevators
Storage binsHammer MillsDust transfer and collection equipment Enclosed equipment
Sources of Ignition
Mechanical e.g. overheated bearings Electrical (making/breaking contacts, arc/spark)
Other source of ignition (e.g. static)
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ATEX Directive 99/92/ECVentilation & Housekeeping
Primary Explosion can lead to secondary (more severe) explosion
For most combustible dusts, a deposit less than 1 mm deep evenly distributedover the whole floor area is sufficient, if raised into suspension, to fillcompletely a room of normal height with an explosive dust/air mixture -unlikely in a clean air-tight containment / negative pressure.
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Why do we need ATEX?Sample U.S. Statistics
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TopicsATEX
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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 ComplianceCASE STUDY Flahavans (Co. Waterford): Atex Compliance
CASE STUDY Flahavans: Pilz Recommendations & Solutions
Conclusion & Roadmap to Atex Compliance
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ATEXRisk Assessment Steps To Achieve Legal Compliance
1. Identify dust (and vapour) ATEX properties (testing may be required)
2. Hazardous Areas Classification (HAC) Assign Zones and extents on plan
and elevation drawings
3. Explosion Risk Assessment (ERA) Identify and assess all sources of ignition4. Assess Explosion risk overall
5. Assess suitable and reliable Controls Measure
6. Implement Solutions based on industry best practice (Basis of Safety)
7. Provide legally required training8. Post Atex signage
9. Regularly update, audit and review the site EPD
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ATEX Directive 99/92/EC13 potential ignition sources
1. Hot Surfaces
2. Flames and Hot Gases
3. Mechanically Generated Sparks
4. Electrical Apparatus5. Stray Electric Currents
6. Static Electricity
7. Exothermic Reactions
8. Lightning9. Radio Frequency Electromagnetic
Waves
10.Electromagnetic Waves (3x1011-
3x1015Hz)11. Ionizing Radiation
12.Ultrasonics
13.Adiabatic Compression
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ATEXAtex E.U. Non-Binding Guide (2003)
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ATEX DirectiveAtex E.U. Non-Binding Guide (2003)
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ATEX DirectiveAtex E.U. Non-Binding Guide (2003)
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TopicsATEX
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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 ComplianceCASE STUDY Flahavans (Co. Waterford): Atex Compliance
CASE STUDY Flahavans: Pilz Recommendations & Solutions
Conclusion & Roadmap to Atex Compliance
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Dust Explosion Pentagon
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Dust Explosion Pentagon 5 elements required:
1. Fuel (combustible dust cloud)
2. O23. Ignition4. Suspension (dispersion of particles in sufficient quantity and
concentration)5. Confinement (of the dust cloud)
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Dust Explosion Pentagon
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ATEX DustsCharacteristics Affecting Actual Risk
Factors impacting an explosive risk
Particle size (c. < 500 um)
Particle shape: spherical, flat or fibrous Group IIIA: Combustible Flyings Group IIIB: Non-Conductive Dust Group IIIC: Conductive Dust
Chemical properties of a dustMoisture contentCloud dispersion Powder volume resistivity Transport velocity
Air currentsDust extraction rate Fall height Physical barriers
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ATEX DustsDust Testing Characteristics
The most important characteristics to test for, (once the initial test hasconfirmed that the material is capable of forming an explosive mixture), are:
Min. Ignition Energy (MIE) mJ Pmax barg KST (ST Class) bar ms -1 Layer Ignition Temperature (LIT) CMin. Ignition Temperature (MIT Cloud) CMinimum Explosion Concentration (MEC) mg/m3 Particle size (micron)Moisture Content % Powder Volume Resistivity
Limiting O2 conc. BZ No.
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TopicsATEX
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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 ComplianceCASE STUDY Flahavans (Co. Waterford): Atex 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. Eliminate the possibility of the formation of an explosive dust cloud orlayer2. Ignition source prevention (e.g. ATEX equipment)3. Ignition source detection (e.g. metal/spark detection)4. Containment design pressure
5. Isolation (e.g. mechanical/chemical)6. Mitigation of effects of an explosion pressure relief design, external
venting, flameless internal venting etc.7. Spark Detection and Suppression (powder, gas, chemical inhibitor)8. Building design (e.g. pressure resisting / relieving construction)
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ATEX Directive 99/92/ECTechnical Measures Prevention & Protection
Obligations of the EMPLPOYER Art. 3:The employer shall take ORGANISATIONAL and/orTECHNICAL measures in order of priority:
to prevent the formation of explosive atmospheres, orwhere the nature of the activity does not allow that,
to avoid the ignition of explosive atmospheres, and
to mitigate the detrimental effects of an explosion soas to ensure the health and safety of workers.
Above 3 to be combined/supplemented withpropagation measures and reviewed regularly and, inany event, whenever significant changes occur.
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Basis of Safety samplesSpark Detection & Suppression
Spark Detection & Suppression
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Basis of Safety samplesExplosion Venting
Explosion Venting
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Basis of Safety samplesBlast Relief
Pressure/Blast Relieving Panels / Walls
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Basis of Safety samplesHigh Integrity & High Reliability Equipment
SIL rated equipment
High Integrity & High Reliability Equipment (LOPA & SIL Assessments
Required)
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ATEX SignageEquipment
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TopicsATEX
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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 ComplianceCASE STUDY Flahavans (Co. Waterford): Atex Compliance
CASE STUDY Flahavans: Pilz Recommendations & Solutions
Conclusion & Roadmap to Atex Compliance
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ATEX Case StudyFlahavans
Case Study
Plant which has equipment spanning 4 generations was able to adopt a pro-active and practical approach to meet the requirements of ATEX
Regulations
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Explosion Protection Document completed by Pilz (2011)
ATEX Case StudyFlahavans
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ATEX C S d
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Why Pilz? Practical approach Competence Experience of regulatory
requirements, E.U. Norms andindustry best practice
Provision of transparent andactionable route to compliance
Independently Certified
ATEX Case StudyFlahavans
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ATEX C St d
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Pilz Atex Risk Assessment of large volume of plant and equipment
ATEX Case StudyFlahavans
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Explosion Protection Document Findings
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Explosion Protection Document Findings HAC Example - Service Bin Silo
Explosion Protection Document Findings
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Explosion Protection Document Findings ERA Example - Service Bin Silo
ATEX Case Study
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Atex Risk Assessment Prioritised Risk Areas
ATEX Case StudyFlahavans
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ATEX Case Study
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ATEX Case StudyFlahavans EPD Pilz Findings
Executive Summary
ATEX
Regulatory Environment
Explosion Protection Document Structure
Explosion Protection Document Findings
Flahavans Priority Listing
Next Steps
Compliance Strategy Phasing
Risk Associatedwith 9 Micro-Plants
ONE HIGHPRIORITY
PLANT AREA
FOUR MEDIUMPRIORITY PLANT
AREA
ATEX Case Study
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From Full Plant Risk Assessment
EPD Priority Areas
8 Green Intake Silos areas of concern for Atex upgrade.
Sweep Augers and associated Motor and Electrical Power Supply andcontrol System did not meet the required ATEX Zone 21 classification.
ATEX Case StudyFlahavans
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ATEX Case Study
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Pilz Upgrade Project Deliverables
Electrical design and specification for the New Sweep Auger System Electrical Installation for the Sweep Auger Systems for the 8 Grain Intake
Silos Electrostatic Audit. SAT, FAT Provide a full handover package e.g:
M&E drawings
Data Sheets Electrostatic Audit
Full validation and certification of completed to ETCI Atex requirements DoCs. Provision of ATEX Training
ATEX Case StudyFlahavans
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Overall Compliance Strategy
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Overall Compliance Strategy Flahavans
Executive Summary
ATEX
Regulatory Environment
Explosion Protection Document Structure
Explosion Protection Document Findings
Flahavans Priority Listing
Next Steps
Compliance Strategy Phasing
Aims:
Full Plant-wide Compliance
Phased Strategy
3 Year Plan
Prioritised Approach
Project based with parallel implementation lines
Project Management
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Project ManagementPilz & Flahavans Project Methodology
In order to ensure this project would be executedin a systematic and professional manner, Pilzand Flahavans agreed that a structured projectmethodology consisting of seven key phases
would be followed.
User RequirementsSpecification
AssembleTeam
Front End Study(including Design)
Tendering
Process
Full DetailedDesign
Implementation
Closure & Handover
Pilz Offering as part of Equipment Upgrades
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Project Management (Risk, Sschedule, Installation, Supervision)
Full M&E Specification, Design & Analysis
e.g. re-design of ATEX rated mounting plates, couplings,
pulleys, Ingress Protection (IP), containment runs, isolation
switches, glanding etc. to suit ATEX modifications
Safety Validation
Factory Acceptance Test (FAT)
Installation & Commissioning
Site Acceptance Test (SAT)
Full ATEX Certification of all installations
g p q p pg
Topics
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pATEX
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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 ComplianceCASE STUDY Flahavans (Co. Waterford): Atex Compliance
CASE STUDY Flahavans: Pilz Recommendations & Solutions
Conclusion & Roadmap to Atex Compliance
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Recommendation 1:
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Area: Old Oats Storage Silo Bins 1 8
Action: Replace motors with suitable ATEX rated motors
Temperature sensing on all 8 motors
Replacement of Old Oats Bins Auger Motors
Recommendation 2:
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Installation of ATEX sensors on Elevators
Area: Intake Elevator to main plant
Action: Installation of speed / alignment sensors
Installation of rotation slippage sensors
Installation of bearing temperature sensors
Recommendation 3:
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Area: Intake Elevator to main plant
Dust Extraction System in main plant
Action: Calculation of the vent panel sizes for intake elevator
Complete relief vent panel sizing calculations for 12 vents
Confirm accuracy of the relief vent panel sizing
Recommendation 4:R l f ll di i i ATEX
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Area: Various Areas
Action: Replace motors with suitable ATEX rated motors
Replacement of all medium priority non-ATEX motors
Recommendation 5:I t ll ti f ATEX
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Area: Dust Extraction Auger Conveyor
Hulls Bin Storage Auger Conveyor
Action: Installation of speed / alignment sensors
Installation of rotation slippage sensors
Installation of bearing temperature sensors
Installation of ATEX sensors on conveyors
Recommendation 6:Installation of ATEX level sensors in silos
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Area: Bran Service Bin
Sussex / Hulls Bins
Wheat /Barley Bin
Boiler Service Bin
Hull Bin Storage Hopper
Action: Install suitable ATEX rated level sensors
Installation of ATEX level sensors in silos
Recommendation 7:Installation of ATEX lighting
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Area: Bran Service Bin
Sussex / Hulls Bins
Wheat /Barley BinBoiler Service Bin
Hull Bin Storage Hopper
Storage Room
Action: Install suitable ATEX rated lighting and switches
Installation of ATEX lighting
Recommendation 8:Electrostatic Survey
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Area: Complete site
Action: Complete a site survey to assess the scope of
works for an electrostatic audit
Electrostatic Survey
Recommendation 9:Further Dust Testing
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Area: Oats dust from various areas of the site
Action: Complete dust testing on oats from various
locations
Further Dust Testing
Recommendation 10:Detailed Plant & Equipment Electrical Review
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Area: Complete site
Action: Complete a site survey to assess the scope of
equipment upgrades
Detailed Plant & Equipment Electrical Review
ATEX Case Study FlahavansUpgrade Works Green Intake Silos and Auger Control
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Upgrade Works Green Intake Silos and Auger Control
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ATEX Case Study - FlahavansUpgrade Works Green Intake Silos and Auger Control
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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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Upgrade Works Green Intake Silos and Auger Control
ATEX Case Study Flahavans
Upgrade Works Green Intake Silos and Auger Control
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Upgrade Works Green Intake Silos and Auger Control
ATEX Case StudyFlahavans
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Grain Silo Auger Operating Manual
Flahavans
ATEX Case StudyFlahavans
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Sample Component Data Sheets
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ATEX Case StudyFlahavans
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Sample Component Data Sheets
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ATEX Case Study - FlahavansSample Test Records, Static Audit, Ex Certification
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p
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TopicsATEX
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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 ComplianceCASE STUDY Flahavans (Co. Waterford): Atex Compliance
CASE STUDY Flahavans: Pilz Recommendations & Solutions
Conclusion & Roadmap to Atex Compliance
ATEX Where to Start?Seeing the wood from the trees
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Large Plants will have large amounts ofplant and equipment to be assessed.
High volume of information anddocumentation to be assessed
Large number of actions Project Management
Identify roles and responsibilities Risk Assessment Prioritisation of actions is Key
Schedule/Programme Control Maximise plant availability Minimise costs Minimise risk
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ATEX The JourneySuccess Factors
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Legislation
BestPractice
Practical &
Cost-EffectiveSolutions
Risk AssessmentCompetence
ATEX The JourneySuccess Factors
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ATEX Directive 99/92/ECCompliance Strategy
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Customer Benefits ?
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1. Pilz reputation and independence accepted by all inthe value chain
2. Competence of consultants and engineers assuredtrough audited competence scheme.
3. Integration of solution engineering with ERA4. Flexible use of Pilz resources compliments use of
available internal resouces
5. Global organisational reach with consistentinterpretation of
- Directives, Stsndards and Regulations- Country of use language capability
6. Early lifecycle involvement of experienced teams will
reduce the cost of late life-cycle remedial action
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PMCprotego,
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SafetyBUSp,
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thedetailsstatedinthis
document,dependingonthestatusat
thetimeofpublicationandthescopeofthee
Weacceptnoresponsibilityforthevalidity,accuracyandentire
tyofthetextandgraphicspresentedin
this
PleasecontactourTechnicalSupportifyouhaveanyquestion
s.
Brian Aherne
Pilz, Business & technology park, Model Farm Road,Cork, Ireland
Tel: +353 21 4346535 Email: [email protected]
Keep up-to-date on Pilzwww.pilz.com