Expert Mission on ATEX Implementation
Internal Market 65344
1. Introduction
2. Lesson-7: Requirements for Explosion Protection Document (EPD)
3. Lesson-8: Importance of Zone Determination for potentially
Explosive Atmospheres
4. Example Explosion Protection Document
5. Some practical examples
Turkey, Istanbul, 26 - 27 May 2014
Presented by
Jan SLIJPEN
TAIEX Experts
Expert Mission on ATEX Implementation
Internal Market 65344
Expert Mission on ATEX Implementation
Internal Market 65344
Kocaeli 3.635 km2
Konya - 40.824 km2
NL: total area: 41.526 km2
water: 7.643 km2
land: 33.883 km2
!7 million inhabtants
Expert Mission on ATEX Implementation
Internal Market 65344
Ing. Jan Slijpen
Education: Chemical Engineering
Additional: Risk Management, Occupational Safety and Health (OSH),
Process Safety (Seveso), Product Safety, Lead Auditor,
Experience:
• Chemical Industry: Environmental + Safety Engineer (5 years)
• National Government (DLI): OSH Inspector, Specialist Occupational Hygiene,
Specialist Process Safety, Team Head (10 years in total)
• International Experience (ILO, OPCW, EC, UNEP): Project Leadership (8 years)
Current Position: Project Leader Market Surveillance for Product Safety
Project leader for Process Safety
Special Task: International Trainer on OSH, Seveso, Implementation,
Market Surveillance, Process Safety
Expert Mission on ATEX Implementation
Internal Market 65344
ATEX Directives
2 Directives applicable in the EU for Explosive
Atmospheres (ATmosphéres EXplosibles):
•
ATEX 95 Economic (Product) Directive 94/9/EC,
23-03-1994
ADDRESSED at MANUFACTURER
•
ATEX 137 Social (Workplace) Directive 1999/92/EC,
16-12-1999
ADDRESSED at USER (Employer)
Expert Mission on ATEX Implementation
Internal Market 65344
Scope ATEX 95
(Product Directive)
• Requirements for Equipment for use in potentially Explosive
Atmospheres
• Focus on the elimination of trade barriers
– Free movement of goods
– Creation of level-playing field in EAA
• Applicable to all places where explosive atmospheres may
occur (ALSO inside equipment and apparatus)
• Only equipment and preventive systems that comply with and
meet the requirements of ATEX 95 may be brought to the EER
market
Expert Mission on ATEX Implementation
Internal Market 65344
Scope ATEX 137
(Workplace Directive)
Scope:
• Sets out minimum requirements for the safety and health
protection of workers potentially at risk from explosive
atmospheres in the workplace
• Basically NOT applicable inside equipment and apparatus
• OSH Framework Directive requires protection against any risk
at the workplace, so also against the consequences of an
explosion
Expert Mission on ATEX Implementation
Internal Market 65344
Aim ATEX 137
Aim and Focus:
• Protection of workers’ health and safety at work against
explosions
• Obligations are addressed at Employers
• The quantity of a flammable gas / liquid or solid determines
whether a site comes under the jurisdiction of the ATEX-137
Directive
• ATEX-137 contains broader obligations than ATEX-95
Expert Mission on ATEX Implementation
Internal Market 65344
Conditions for an EXPLOSION
Expert Mission on ATEX Implementation
Internal Market 65344
ATEX Classifications
Expert Mission on ATEX Implementation
Internal Market 65344
Places where Explosion Risks occur
Type of Industry:
• Large Companies
–
–
–
–
Petrochemical Industry: e.g. refineries
Chemical Industry
Pharmaceutical Industry
Food Industry
• Small and Medium sized Industry (SME)
–
–
–
–
–
Paint Industry
Waste Industry
Parquet laying
Wood processing Industry
Agricultural sector
In general: at many unexpected places
Risk Management System
ACT
System Check
Subject Explosive Atmospheres
HI+RA
PO
OC
LoC
Measures-oriented Supervision
CHECK
System-oriented Supervision
APP
Workplace
Workplace Check
PDCA
Deming circle
MR
PLAN
MoC
EP
IA
SP
Technical + Organisational Measures
Preventive LoDs
Repressive LoDs
Scenario
DO
Expert Mission on ATEX Implementation
Internal Market 65344
Abbrevations RMS
Control Elements Management System
APP
= Accident Prevention Policy
IH+RA = Identification Hazards + Risk Assessment
PO
= Personnel en Organization
OC
= Operational Control
MoC = Management of Change
EP
= Emergency Preparedness
SP
= Safety Performance
IA
= Internal Audits
MR
= Management Review
Explanation other Abbreviations
LoC
= Loss of Control / Loss of Containment
LoD
= Line of Defense (Specific: ATEX Control Measures)
RM Verification Process
Document review
Interviews
Workplace Inspection
Observations
Findings
Finding
Finding
Documented?
Criteria
Appropriate?
Good
Moderate
Poor
Bad
Implemented?
Assessment + Judgement
Conclusions
Follow Up: Enforcement?
RM INSPECTION VERIFICATION QUESTIONS
Documented?
Appropriate?
Main Questions
Are the correct RISKS identified?
Are the correct MEASURES implemented?
Are measures well MAINTAINED?
Is Risk Management System (RMS) appropriate
as to effectively control all activities?
Is the Prevention Policy of sufficient Quality?
Implemented?
15
Expert Mission on ATEX Implementation
Internal Market 65344
General Control Measures
EXPLOSION PREVENTION
General:
• Prevention of formation of explosive atmospheres
• Avoidance of ignition of explosive atmospheres
• Mitigation of the effects of an explosion
• All preventive + repressive measures operational
as to prevent any further propagation of explosions
• Review: All technical and organizational measures
must be reviewed regularly and in any case after
significant changes
Expert Mission on ATEX Implementation
Internal Market 65344
General Control Measures
EXPLOSION PREVENTION
General:
• Safe design: Safe design of workplaces, also in
relation to Explosion Hazards
• Safe work: Work can be performed safely at
places with explosive atmospheres
• Supervision: sufficient and effective
• Classification: Hazardous areas to be
classified and indicated
• Coordination and Cooperation
Expert Mission on ATEX Implementation
Internal Market 65344
Specific Control Measures
EXPLOSION PREVENTION
Specific:
• Safe discharge of hazardous substances
• Equipment and protective systems for use in explosive
atmospheres meets requirements of ATEX 95 (in EPD)
• Equipment requirements:
– Hazardous zone 0 of 20: category 1 equipment
– Hazardous zone 1 of 21: category 1 of 2 equipment
– Hazardous zone 2 of 22: category1, 2 of 3 equipment
Expert Mission on ATEX Implementation
Internal Market 65344
Specific Control Measures
EXPLOSION PREVENTION
SPECIFIC
• Exchange of wrong ATEX equipment be prevented
• Special protective clothing for workers in areas with
possible explosive atmospheres
• An alarm / warning system must be installed and in
operation
• After a change (MoC) and/or maintenance of equipment in
areas with explosion risks an initial check should be carried
out by qualified person before the installation is put into
operation again
Expert Mission on ATEX Implementation
Internal Market 65344
Specific Control Measures
EXPLOSION PREVENTION
Specific:
• Work Instructions: in writing
• Approval of work before start of the it:
– Work permit system must be in operation
• Equipment must be fail-safe in case of power
interruption
• Emergency and/or escape equipment provided
to workers
• Authorized persons may only switch off equipment
Expert Mission on ATEX Implementation
Internal Market 65344
EXPLOSION PROTECTION DOCUMENT (EPD)
Minimum required CONTENT:
•
•
•
•
Identification of Explosion Hazards at all workplaces
Identification of Ignition Sources at all workplaces
Assessment of Explosion Risks
Classification of Hazardous Zones
– zone 0, 1 or 2 for Gas / zone 20, 21 or 22 for Dust
• Description of design, construction, operation and maintenance of
workplaces, work equipment, process installations and warning devices
• Description of preventive and repressive control measures as to
Prevent, Eliminate or Reduce / Mitigate the (consequences of) explosion
• Description of system for cooperation and coordination of work in areas
with explosion risks, e.g. work permit system
• Way of training of workers regarding Explosive Risks
Expert Mission on ATEX Implementation
Internal Market 65344
Identification of Explosion Hazards +
Assessment of Explosion Risks (in EPD)
RISK: in general R = P x E
Other: Risk Graph / Fine & Kiney
When assessing explosion risks, take into account:
• Likelihood that explosive atmospheres will occur and their
persistence
• Likelihood that ignition sources, including electrostatic
discharges, will be present and become active and effective,
• Possible interactions between substances in use, processes
and installations
• Scale of the anticipated effects (Consequences).
Expert Mission on ATEX Implementation
Internal Market 65344
Identification of Ignition sources
Type of Ignition Sources
•
•
•
•
•
•
•
•
•
•
•
Hot surfaces
Fire and hot gasses
Mechanical sparks
Static discharges
Lightning
Radio waves
Optical radiation
Ionizing radiation
Ultrasonic noise
Shock waves, adiabatic compression
Exothermic reactions including self-ignition
Expert Mission on ATEX Implementation
Internal Market 65344
ATEX Zoning around Storage Tanks
EXAMPLES
a. Fixed Roof Storage Tank
b. Floating Roof Storage Tank
Expert Mission on ATEX Implementation
Internal Market 65344
Fixed Roof Storage Tank
Expert Mission on ATEX Implementation
Internal Market 65344
Flooting Roof Storage Tank
Expert Mission on ATEX Implementation
Example Content
Explosion Protection Document
Internal Market 65344
General part of the EPD (General Site EPD)
•
•
•
Objectives and Goals of the EPD
Definitions
Cooperation and Coordination
– Normal operations
– Maintenance
– Significant changes
•
•
•
Tasks and Responsibilities with respect to control explosive
atmospheres
Composition and Set-up of an ATEX Commission
ATEX Coordinator
– Competencies and qualifications of the ATEX Coordinator
•
•
Management of Change with respect to ATEX
Training on ATEX
Expert Mission on ATEX Implementation
Example Content
Explosion Protection Document
Internal Market 65344
Specific part of the EPD (Specific Plant EPD)
•
•
•
•
•
•
•
Description of the site, plants, installations, processes + substances
PI&D’s
Identification of hazardous substances (explosive prone substances)
Identification of ignition sources
Risk analysis: IH + RA
Classification of hazardous zones (workplaces / work areas)
Explosion Prevention + repression Measures
– Technical
– Organisational
•
ATEX Coordinator
– Competencies and qualifications of the ATEX Coordinator
•
•
Management of Change with respect to ATEX
Training on ATEX
Expert Mission on ATEX Implementation
Internal Market 65344
Explosion Control Measures
• Preventive Technical Control Measures
–
–
–
–
–
Use of less explosive prone substances, if possible
Use of other chemical and/or physical processes
Reduction in use of explosive prone substances
Avoidance of ignition sources
Application of ATEX-proof equipment (ATEX-95)
• Repressive Technical Control Measures
–
–
–
–
Explosive proof design (intrinsically safe equipment)
Explosion relief systems
Systems for suppression of explosions
Other repressive or emergency control
Expert Mission on ATEX Implementation
Internal Market 65344
Explosion Control Measures
•
Preventive + repressive Organizational Control Measures
–
–
–
–
–
–
–
–
–
–
–
ATEX Training
Inspections
Maintenance
Testing
Supervision
Marking explosion hazardous zones: warning signs
Verification control measures at start-up + after significant changes
Management of Change (MoC)
Work permit system
Emergency procedures
Learning from ATEX accidents and incidents
Expert Mission on ATEX Implementation
Internal Market 65344
Importance of Zone Determinations for
potentially Explosive Atmospheres
Importance Explosion Zones Classification
• Prevention of sever consequences like
–
–
–
–
–
•
Possible fatalities
Injuries
Interruption of production
Economic damage
Image damage
Special Attention for Zone 0
Expert Mission on ATEX Implementation
Internal Market 65344
Zone 0 Situations
Zone 0 situations
•
•
•
•
•
Inside Storage tanks on top of stored Flammable Liquids
Gas Pipelines
Pomp Pits
Flammable Vapour Return Pipelines
Vapour Recovery (Incineration) Units
Expert Mission on ATEX Implementation
Internal Market 65344
Zone 0 Situations
Zone 0 situations
• ATEX 137 NOT applicable inside apparatus?
• ATEX 137 applicable for workplaces with explosive risks
• Prevention of explosions is a general feature of workplace
conditions legislation (Framework Directive 89/391/EG)
• ATEX 95 applicable for all situations where explosive
atmospheres may occur (also inside apparatus)
Expert Mission on ATEX Implementation
Internal Market 65344
Drain System for
Flammable Liquids (Pomp Pit)
Expert Mission on ATEX Implementation
Internal Market 65344
ATEX Risk Matrix
Potential
Ignitition Source
Equipment
NOT EX Proof
Category-3
Equipment for
Zone 2
Category-2
Equipment
for zone 1 and 2
Explosive
Atmosphere
Zone 2
Improvement
Notice
Zone 1
Administrative
Fine
Zone 0
Stoppage of
Operation
Improvement
Notice
Stoppage of
Operation
Improvement
Notice
Expert Mission on ATEX Implementation
Internal Market 65344
Zone 0
Category 2 Level Switch
ATEX Matrix ?
Zone 0
LS
PLC
DCS
Petrol
LT
Expert Mission on ATEX Implementation
Internal Market 65344
Zone 1 in Tank Pit
Grinding work with Work Permit and
continious LEL measuring
ATEX Matrix ?
Tank Pit
Zone 0
Zone 1
Petrol
LEL
Measurement
Expert Mission on ATEX Implementation
Internal Market 65344
Zone 0 in Pomp Pit
Grinding work with Work Permit and
continious LEL measuring
ATEX Matrix ?
Pomp Pit
Zone 0
LEL
Measurement
Ex II 1 G EEX de IIB T5
Expert Mission on ATEX Implementation
Internal Market 65344