ATEX & GASES, VAPOURS AND

DUSTS EXPLOSIONS

TEKFEN NOVEMBER 2013

Chem. Eng. Tiziano Crippa
[email protected]

2013 Dekra The Global Experts in Explosion & Process Safety

Who is Dekra Industrial?

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INTRODUCTION

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EU Legislation

In the EU Directives exist for industry handling

flammable atmospheres for:
Equipment
Machinery Directive 2006/42/EC
ATEX Products Directive 94/9/EC
Health & Safety in the Workplace
Framework Directive 89/391/EEC
Chemical Agents Directive 98/24/EC
ATEX worker protection Directive1999/92/EC

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 ATEX 95 vs. ATEX 137
European CE legislative
framework
New approach
Directive 94/9/EC Directive 1999/92/EC
ATEX 95 ATEX 137

Free trade of equipment Safe working environment

ATEX
ATtmosphere
AT
EX
EXplosible
EX

Slide 5 2011 DEKRA The Global Experts in Explosion & Process Safety
ATEX Directive 1999/92/EC (ATEX 137)
- Employers Obligations
On minimum requirements for improving the safety and health protection of
workers potentially at risk from explosive atmospheres

Employer shall take ORGANIZATIONAL 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
mitigate the detrimental effects of an explosion so as to
ensure the health and safety of workers
Where necessary measures shall be combined and / or
supplemented to prevent the propagation of explosions

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ATEX Directive 1999/92/EC
- Explosion Risk Assessment Special Requirements

Where explosive atmospheres may occur:

- hazardous area classification is required so hazardous and non-
hazardous areas are identified
- hazardous areas must be divided into appropriate Zones depending
how often flammable atmosphere will be present
- in hazardous areas special equipment must be used
- hazardous areas must be marked
- the overall explosion safety must be verified
- appropriate work clothing must be provided
These requirements do not apply where other hazardous
conditions not related to flammable atmospheres may occur

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ATEX Directive 1999/92/EC
- Explosion Protection Document
Mandatory, to demonstrate:
explosion risks DETERMINED & ASSESSED
adequate measures taken to attain aims of Directive
hazardous areas classified into zones
places where requirements of Directive apply (signs displayed)
workplace & work equipment designed, operated & maintained
with due regard for safety
arrangements made for safe use of equipment

Must be prepared before start of work and be revised as

necessary

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 STEPS TO ATEX CONFORMITY

Flammability Corrective
data Conformity measures:
replacement
equipment reconditioning
inspection certifications

Layout of Explosion
classified

H.A.C.
areas Protection
+
Technical and
signs
organizational
Document
Risk analysis measures:
procedures
Process data protection/
prevention
+ visits against explosions
+ standards training

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THEORY OF EXPLOSIONS

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EXPLOSIONS

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FIRE OR EXPLOSION ?

In a fire the fuel and oxidant are separate

In an explosion fuel and oxidant are mixed

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FIRE
Fire Triangle

Oxidant

Combustible Ignition
source

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CONDITIONS FOR EXPLOSION

Oxidant

Mixing Confinement

Fuel Ignition source

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DUST EXPLOSION

Mixture Comburent

Particle size, Closed space

humidity

Combustible Ignition
source

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DATA For LIQUIDS & GASES

Flash point
Auto-ignition
Temperature
Explosion limits
Minimum Ignition
Energy (MIE)
Minimum Igniting
Current (MIC)
Maximum Experimental
Safe Gap (MESG)
Vapour Density

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FLASH POINT
The lowest liquid
temperature at which the
vapour pressure above a
liquid is sufficient to be
ignited

Only a flash is produced

Sustained burning occurs at

(higher) fire point

Is the material flammable and

At the flash point the vapour
therefore under ATEX
pressure is about equal to
Regulations?
the LEL

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 EXPLOSION LIMITS
Fuel - air mixtures are only
flammable within the
flammable range

Although the substance is

classed as Flammable can
we operate outside the
flammable range?

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FLAMMABILITY LIMITS (vol.%)

In air In oxygen

LEL UEL LEL UEL

Hydrogen 4.0 75.0 4.0 95.0

Methane 5.0 15.0 5.1 61.0

Propane 2.1 9.5 2.4 57.0

Ethylene 2.7 36.0 2.9 80.0

Carbon monoxide 12.5 74.0 16.7 93.5

Toluene 1.2 7.1 - -

Methanol 6.0 36.0 - -

Ethanol 3.3 19.0 - -

IPA 2.0 12.7 - -

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 MINIMUM IGNITION ENERGY

MIE is smallest electrical spark

that can ignite the optimum
mixture of fuel and air

Spark is generated using a

capacitor discharge

Spark details are important

- for dusts two methods
- for electrostatics pure capacitive
discharge is relevant

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AUTOIGNITION TEMPERATURE

The AIT is the lowest

temperature at which a fuel (gas,
vapour) - air mixture ignites
spontaneously

Determined using various

standards
- flask volumes 200 - 500 ml

Flask material can influence the

results
Maximum Surface
Temperature for Electrical
Equipment (T rating)

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 TEMPERATURE CLASS

Maximum surface temperature

of equipment
T1 450 C

T2 300 C

T3 200 C

T4 135 C

T5 100 C

T6 85 C

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Minimum Igniting Current (MIC) and
Maximum Experimental Safe Gap (MESG)
Related to MIE, used to group gases in Gas Groups

MIC is determined by breaking a circuit

- circuit parameters (R, C, I) influence result
- used for intrinsically safe electrical equipment
- spark/arc cannot ignite the mixture

MESG is determined with standard flange gaps

- used for flame proof equipment
- flame from gap cannot ignite external mixture

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GAS GROUP

Indicates sensitivity to ignition (based on MIC) and ability

for propagation through gaps (based on MESG)

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VAPOUR DENSITY

Not a flammability
parameter

Values relative to air

Shows whether a gas

will
- fall Identify where the greatest
- rise
- diffuse hazard lies!
- layer

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Tests for ATEX Risk Assessment

Flashpoint determine if material is flammable at

operating temperatures.

Auto-Ignition Temperature (AIT) determine if self

ignition can occur from hot surfaces (see equipment
selection).

Flammable Range determine whether operation is

within flammability limits.

Note: Also consider vapour density

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Tests for Equipment Selection

Auto-Ignition Temperature (AIT) for the maximum surface

temperature of electrical equipment.

Minimum Igniting Current (MIC) or/and Maximum

Experimental Safe Gap (MESG) for Gas Group.

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Substances

Flammable liquids and gas

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 FLAMMABILITY OF DUSTS

Flammable or Not

Ignition Sensitivity

Explosion Protection &

Prevention

Thermal Instability

Fire Risk

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 Group A/B Classification

Can only be measured

Test usually based on
vertical tube
In UK:
- Group A = flammable
- Group B = non-flammable
- for T > 110 C furnace test
needed before a Group B can
be confirmed
Group B powders may burn
or be thermally unstable
Is a material flammable and hence
covered by ATEX?

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FLAMMABLE DUSTS

Agricultural
- corn, milk powder, sugar
Carbonaceous
- coal, peat, activated charcoal
Chemical
- adipic acid, sulfur, anthraquinone
Pharmaceutical
- aspirin, paracetamol, ibuprofen
Metal
- aluminium, iron, zinc

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IGNITION SENSITIVITY
(Avoidance of Ignition Sources)

Minimum Ignition Energy

(MIE)

Minimum Ignition Temperature

(MIT)

Layer Ignition Temperature

(LIT)

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MINIMUM IGNITION ENERGY

MIE is smallest electrical spark that

can ignite the optimum mixture of fuel
and air

Spark is generated using a capacitor

discharge

Spark details are important

- for dusts two methods
- for electrostatics pure capacitive
discharge is relevant

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MINIMUM IGNITION ENERGY EXAMPLES
GASES:
GASES In air In oxygen
DUSTS: (mJ) (mJ)
- PVC 1500 mJ Hydrogen 0.016 0.0012
- wheat flour 40 mJ
- sugar 30 mJ Methane 0.21 0.0027
- aluminium 10 mJ
- stearates 2-4 mJ Ethane 0.24 0.0019
Tested with capacitive circuit for
static assessments SOLVENT
VAPOURS
Examples are for specific Acetone 1.15
samples
Methanol 0.14

Carbon Disulphide 0.009

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 MINIMUM IGNITION TEMPERATURE

MIT is AIT for dusts

Sets maximum surface

temperature for
electrical equipment

Needs to be considered
alongside LIT where
appropriate

Godbert-Greenwald
furnace is internationally
standardised

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LAYER IGNITION TEMPERATURE

Normally determined for 5 mm

thick layer of dust

Really a thermal stability

parameter, but used with MIT

Usually lower than MIT

Depends on the layer thickness

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 EXPLOSION SEVERITY

20 Litre sphere is standard test vessel for dusts, compatible

with the 1 m3 vessel

20 Litre sphere is standard test

vessel for dusts, compatible with
the 1 m3 vessel
Turbulence level simulates
severe plant conditions
For gases tests can be carried
out in smaller vessels (> 5 litre),
using quiescent mixtures
Measures Pmax and dP/dT

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EXPLOSION INDICES

Dusts Vapours/gases
Kst Kg
Flour 87 Methane 55
Starch 150 Propane 75
Aspirin 217 Toluene 56
Pigments 286 Methanol 66
Aluminium 650 Hydrogen 550

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REMOVE THE OXIDANT

Air is 21 % oxygen

Reduce the oxygen concentration to

below the LOC

Safety factors must be applied

Two main procedures

- pressure swing inerting
- flow through inerting

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 LIMITING OXYGEN CONCENTRATION
(LOC)

Uses 20 litre sphere for dusts

Uses 5 litre sphere for gases/vapours

Values depend on inert used

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 FIRES IN DUST LAYERS

Depending on burning characteristics, a local ignition

may propagate throughout the plant beyond barriers
such as rotary valves

Burning Behaviour designates 1 of 6 classes

Flammability of Solids (Fire Train) burning rate test

defines whether a material is classed as Highly
Flammable

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STATIC ELECTRICITY

Mentioned explicitly in ATEX as one

of the ignition sources to be
controlled

Static electricity is generated

wherever movement takes place

Static electricity is often intrinsic to

the intended process

Specialised topic

2003, Chilworth Technology

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ELECTROSTATIC DATA

Minimum Ignition Energy

(MIE)

Liquid Conductivity

Volume & Surface

Resistivity

Charge Relaxation Time

Chargeability

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LIQUID CONDUCTIVITY

Liquids can be insulation

- conductive
( > 1000 pS/m) outer electrode
acetone
alcohol
- semi-conductive
- insulating
( < 50 pS/m) inner electrode
xylene
heptane

Can charge build up

especially during powder /
liquid mixing

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 RESISTIVITY / CONDUCTIVITY

For solids both volume and

surface resistivity can be
important

For powders the volume Volume

resistivity must often be Resistivity/Conductivity

complemented by the charge

relaxation

Powder chargeability is often

Surface
needed to make a complete Resistivity/Conductivity
assessment

Is the material conductive (electrical equipment)?

Is the material insulating (charge potential)?

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Tests for ATEX Risk Assessments

Minimum Ignition Energy (MIE) assess sensitivity to

ignition from electrostatic discharges.

Minimum Ignition Temperature (MIT) assess ignition

from hot surfaces (dust cloud) (See equipment selection)

Layer Ignition Temperature (LIT) assess ignition from

hot surfaces (powder layer) (See equipment selection)

20 litre sphere determine explosion severity

characteristics

Limiting Oxygen Concentration (LOC) define safe limits

for inerting systems
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Tests for ATEX Risk Assessments

Burning Behaviour assess the Fire Risk potential or

rapid flame propagation.

Thermal stability assess the risk of ignition during

drying or storage. Tests must be selected for the
specific dryer and storage condition.

Powder Volume Resistivity, Charge Relaxation Time

& Chargeability assess electrostatic charging
potential

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Tests for Equipment Selection

Minimum Ignition Temperature (MIT) & Layer Ignition

Temperature (LIT) to define maximum temperature of
enclosure for electrical equipment.

Powder Volume Resistivity to determine whether a

material is conductive and an electrical hazard.

20 litre sphere to determine whether pressure relief

panels are suitably sized, suppressions systems are
designed correctly and whether a vessel can contain
an explosion.

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HAZARDOUS AREA CLASSIFICATION

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European norms HAC

EN 60079-10-1:2009-03 Classification of areas

Explosive gas atmospheres

EN 60079-10-2:2009-08 Classification of areas

Combustible dust atmospheres

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Philosophy of
Hazardous Area Classification

Area classification assesses the probability of flammable

atmospheres occurring inside of plant, the workplace, and
elsewhere

Once the probability is established, ignition sources can be

prevented

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Steps in Area Classification

Area classification DOES:

Identify points of release
Area classification does NOT:
Take account of the
Estimate extent and duration
consequences of ignition
of flammable atmosphere

Allocate grades and sizes Assess the conformity of

to hazardous areas equipment present in
hazardous areas

Specify the correct types of

equipment
(electrical/mechanical) to use

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 Other technical standards
API Recommended Practice 505 Recommended practice for
Classification of Locations for Electrical Installations at Petroleum
Facilities Classified as Class I, Zone 0, Zone 1, and Zone 2

NFPA 654: Standard for the Prevention of Fire and Dust Explosions from
the Manufacturing, Processing, and Handling of Combustible Particulate
Solids

NFPA 497: Recommended Practice for the Classification of Flammable

Liquids, Gases, or Vapors and of Hazardous (Classified) Locations for
Electrical Installations in Chemical Process Areas

NFPA 499: Recommended Practice for the Classification of Combustible

Dusts and of Hazardous (Classified) Locations for Electrical Installations
in Chemical Process Areas
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What is area classification?

Area classification is a method of

analysing and classifying the
environment where explosive
gas/vapours and dust atmospheres
may occur so as to facilitate the
proper selection and installation of
equipment to be used safely in that
environment.
The classification also takes into
account the ignition characteristics of
the gas or vapour such as ignition
energy (gas group) and ignition
temperature (temperature class).

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Sources of release

The basic elements for establishing the hazardous zone types are the
identification of the source of release and the determination of the
grade of release.
Each item of process equipment (for example, tank, pump, pipeline,
vessel, valve etc.) should be considered as a potential source of
release of flammable material. If the item cannot foreseeably contain
flammable material, it will clearly not give rise to a hazardous area
around it. The same will apply if the item contains a flammable
material but cannot release it into the atmosphere (for example, an all-
welded pipeline is not considered to be a source of release).

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Emission sources list file (first half)

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Emission sources list file (second half)

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Type of zone

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 of 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.

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Type of zone
SOURCE
Zones are recognized as: OF EMISSION

- zone 0
- zone 1 TYPE
- zone 2 OF EMISSION

- non-hazardous area
NORMAL FAILURE
CONTINUOUS
OPERATIONS ERROR
A continuous grade of release
normally leads to a zone 0, a primary
grade to zone 1 and a secondary ZONE 0 ZONE 1 ZONE 2
grade to zone 2

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Sources giving a continuous grade of release

The surface of a flammable liquid in a fixed roof tank, with a

permanent vent to the atmosphere.
The surface of a flammable liquid which is open to the atmosphere
continuously or for long periods.

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Sources giving a primary grade of release

Seals of pumps, compressors or valves if release of

flammable material during normal operation is expected.
Water drainage points on vessels which contain
flammable liquids, which may release flammable
material into the atmosphere while draining off water
during normal operation.
Sample points which are expected to release flammable
material into the atmosphere during normal operation.
Relief valves, vents and other openings which are
expected to release flammable material into the
atmosphere during normal operation.

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Sources giving a secondary grade of release

Seals of pumps, compressors and valves where release of flammable

material during normal operation of the equipment is not expected.
Flanges, connections and pipe fittings, where release of flammable
material is not expected during normal operation.
Sample points which are not expected to release flammable material
during normal operation.
Relief valves, vents and other openings which are not expected to
release flammable material into the atmosphere during normal
operation.

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Release rate of gas or vapour

The greater the release rate, the larger the extent of the zone.
The release rate depends itself on other parameters:
Geometry of the source of release
Release velocity
Concentration
Volatility of a flammable liquid
Liquid temperature

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Source of release: open surface of liquid

In most cases, the liquid temperature will be below the boiling point and
the vapour release rate will depend principally on the following
parameters:
liquid temperature;
vapour pressure of the liquid at its surface temperature;
dimensions of the evaporation surface;
ventilation and air movement.

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Source of release: instantaneous evaporation
of a liquid (i.e. from a jet or spray)

Since the discharged liquid vaporizes virtually

instantaneously, the vapour release rate is equal to the
liquid flow rate and this depends on the following
parameters:
liquid pressure;
geometry of the source of release.
Where the liquid is not instantaneously vaporized, the
situation is complex because droplets, liquid jets and
pools may create separate sources of release.

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Source of release: leakage of a gas mixture

The gas release rate is affected by the following

parameters:
pressure within the equipment which contains the
gas;
molecular mass;
geometry of the source of release;
concentration of flammable gas in the released
mixture.

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Ventilation (1)

With increased ventilation, the extent of the zone will normally be

reduced. Obstacles which impede the ventilation may increase the
extent of the zone. On the other hand, some obstacles, for example,
dykes, walls or ceilings, may limit the extent.

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Ventilation (2)

Gas or vapour released into the atmosphere can be diluted by

dispersion or diffusion into the air until its concentration is below the
lower explosive limit. Suitable ventilation rates can also avoid
persistence of an explosive gas atmosphere thus influencing the type
of zone.
Ventilation can be accomplished by the movement of air due to the
wind and/or by temperature gradients or by artificial means such as
fans. So two main types of ventilation are thus recognized:
a) natural ventilation;
b) artificial ventilation, general or local.

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Artificial ventilation

The air movement required for ventilation is provided by artificial

means, for example, fans or extractors.
With the use of artificial ventilation it is possible to achieve:
reduction in the type and/or extent of zones;
shortening of the time of persistence of an explosive gas atmosphere;
prevention of the generation of an explosive gas atmosphere.

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Hypothetical volume Vz

The hypothetical volume Vz represents the volume over which the

mean concentration of flammable gas or vapour will typically be either
0,25 or 0,5 times the LEL, depending on the value of a safety factor, k.
This means that, at the extremities of the hypothetical volume
estimated, the concentration of gas or vapour would be significantly
below the LEL, i.e. the volume where the concentration is above the
LEL would be less than Vz.

The calculation of Vz is only intended to assist in assessing the degree

of the ventilation. The hypothetical volume is not directly related to the
size of the hazardous area.

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Determine the hypothetical volume Vz (1)

it is necessary to first establish the theoretical minimum ventilation flow

rate of fresh air to dilute a given release of flammable material to the
required concentration below the lower explosive limit:

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Determine the hypothetical volume Vz (2)

Where:
f is the efficiency of the ventilation in terms of its effectiveness in diluting
the explosive gas atmosphere, with f ranging from f = 1 (ideal situation)
to, typically f = 5 (impeded air flow).
C is the number of fresh air changes per unit time (s-1)

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Degree of ventilation

The following three degrees of ventilation are recognized:

High ventilation (VH)

Medium ventilation (VM)

Low ventilation (VL)

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Estimation of degree of ventilation

Initial estimations would suggest that a continuous grade of release

leads to a zone 0, a primary grade to zone 1 and a secondary grade to
zone 2; however, this is not always the case because of the effect of
ventilation.

The volume Vz can be used to provide a means of rating the

ventilation as high, medium or low for each grade of release.

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Ventilation Calculations
(EN 60079-10-1, Appendix B)

Vz < 0.1 m3 - High ventilation

Vz > V0 - Low ventilation
0.1 m3 < Vz < V0 - Medium ventilation
0.1 m3 < Vz << V0 - Hazardous areas based on Vz

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Negligible volume

If the explosive volume Vz is less than 100 liters, the possible

damages caused by an explosion of such a volume of solvent are
negligible (estimated damage distance less than 2 m). The statements
of Section B.5.3.2 of EN 60079 to define the degree of ventilation as
high are therefore verified and, if the availability of ventilation is good,
it is possible to consider it as a ZONE NE, not hazardous area.

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Availability of ventilation

The availability of ventilation has an influence on the presence or

formation of an explosive gas atmosphere. Thus the availability (as
well as the degree) of ventilation needs to be taken into consideration
when determining the type of zone.
Three levels of availability of the ventilation should be considered:
good: ventilation is present virtually continuously;
fair: ventilation is expected to be present during normal operation.
Discontinuities are permitted provided they occur infrequently and for
short periods;
poor: ventilation which does not meet the standard of fair or good, but
discontinuities are not expected to occur for long periods.

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Influence of independent ventilation on type of
zone

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Influence of independent ventilation on type of
zone (2)

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 Italian guidelines CEI 31-35

Costruzioni elettriche per atmosfere potenzialmente

esplosive per la presenza di gas.
Guida allapplicazione della norma EN 60079-10

Electrical apparatus for explosive atmospheres

Guide for classification of hazardous areas

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EN 60079-10 and Italian guidelines CEI 31-35

Flow rate calculation + Ventilation calculation

(EN-60079-10 and CEI 31-35) (CEI 31-35)

Determine Vz and dz
(EN-60079-10 and CEI 31-35) (CEI 31-35)

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Vz calculation

Flow rate calculations

Ventilation calculations

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Ventilation calculations

Outdoor environment w w is the wind velocity (0.5

C= m/s in open air)
L0
DSE is the max value of
L0 = 2 d z + DSE emission source dimensions

Indoor environment artificial ventilation

natural ventilation

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Ventilation in indoor environment

Artificial ventilation C=Q/V

due to external wind

Natural ventilation
due to stack effect

case 1 case 2 case 3

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Flow rate calculations

Cases:

Evaporation flow rate from vessel

Evaporation flow rate from pool

Evaporation flow rate from pool pool area not know

Single phase gas emission

Single phase gas emission saturated mixture

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dz calculations
Extent of zone: distance in any direction from the source of release to
the point where the gas/air mixture has been diluted by air to a value
below the lower explosive limit
4 formulas:

Outdoor Indoor

0.55 0.55
Gas emission (low 42300 Qg f
d z =


42300 Qg f
d z =

kz
M k LEL % vol w M k LEL % vol w
velocity) dz dz

Turbolent flow gas (

d z = 16,5 P 10 )
5 0 ,5
M 0, 4 k LEL %vol
dz
1

A
0,5
(
d z = 16,5 P 10 5 )
0 ,5
M 0, 4 dz
1
k LEL %vol
A kz
0,5

100 100
emission

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Explosive atmosphere shape

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Explosive atmosphere shape

Flanges Liquid pool

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Explosive atmosphere shape
If flow velocity is less than 10 m/s: cylindrical shape

If flow velocity is higher than 10 m/s: cylindrical or conical

- If pressure is higher than 3 bar angle of 60
- If pressure is lower than 3 bar angle of 90

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Explosive atmosphere shape

Evaporation from vessels

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Explosive atmosphere shape

Other cases

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Drawings and Report

Show Zones on site plan

Side / plan views Zone 0
All data, assumptions, example,
calculations used in report not on
drawings Zone 1
Severity, heights, and shapes of
zones to be mentioned in report
Other relevant information
Zone 2

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Layout example

E.1607.80'
CONTROL
PANEL

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HAC Methodology - DUST

2012 DEKRA The Global Experts in Explosion & Process Safety

Grade of Release

Continuous grade
continuously, or for long periods, or frequently
Primary grade
periodically or occasionally in normal operation
Secondary grade
not in normal operation. Only infrequently and for short periods

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Assign Zone number

Zone definition: An area in which an explosive atmosphere in

the form of combustible dust in air is
Zone 20
. present continuously or for long periods or frequently
Zone 21
. likely to occur in normal operation occasionally
Zone 22
. not likely to occur in normal operation but, if it does, will
persist for a short period only
Note: Normal operation includes expected abnormal, but not
catastrophic events

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Examples ZONE 20

Examples of locations that may give rise to zone 20:

locations inside the dust containment;
hoppers, silos, cyclones and filters, etc;
dust transport systems, except some parts of belt and
chain conveyors, etc;
blenders, mills, dryers, bagging equipment, etc.

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Examples ZONE 21

Examples of locations that may give rise to zone 21:

areas outside dust containment and in the immediate vicinity of access
doors subject to frequent removal or opening for operation purposes
when internal explosive dust atmospheres are present;
areas outside dust containment in the proximity of filling and emptying
points, feed belts, sampling points, truck dump stations, belt dump
over points, etc. where no measures are employed to prevent the
formation of explosive dust atmospheres;
areas outside dust containment where dust accumulates and where,
due to process operations, the dust layer is likely to be disturbed and
form explosive dust atmospheres;
areas inside dust containment where explosive dust clouds are likely to
occur (but neither continuously, nor for long periods, nor frequently),
e.g. silos (if filled and/or emptied only occasionally) and the dirty side
of filters, if large self-cleaning intervals exist.

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Examples ZONE 22
Examples of locations that may give rise to zone 22:
outlets from bag filter vents which, in the event of a malfunction, can emit
explosive dust atmospheres;
locations near equipment opened at infrequent intervals or locations near
equipment, that from experience can easily form leaks where dust is
blown out, for example, pneumatic equipment or flexible connections that
can become damaged, etc;
storage of bags containing dusty products. Failure of bags can occur
during handling, causing dust emission;
areas that are normally classified as zone 21 can fall into zone 22 when
measures, including exhaust ventilation, are employed to prevent the
formation of explosive dust atmospheres. The measures should be
carried out in the vicinity of (bag) filling and emptying points, feed belts,
sampling points, truck dump stations and belt dump over points, etc;
areas where controllable dust layers are formed that are likely to be
disturbed and create explosive dust atmospheres. Only if the layer is
removed by cleaning before hazardous dust atmospheres can be formed,
is the area designated non-hazardous. This is the major purpose of good
house keeping.
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Dust layer hazard

Dust layers are emission points

Three risks are presented by dust layers:

1) A primary explosion within a building may raise dust layers into
clouds and cause secondary explosions more damaging than the
primary event. Dust layers should always be controlled to reduce this
risk.
2) Dust layers may be ignited by the heat flux from equipment on
which the layer rests, which may be a slow process.
3) A dust layer may be raised into a cloud, ignite and cause an
explosion.

These risks depend on the properties of the dust and the thickness of
layers, which is influenced by the nature of the housekeeping. The
likelihood of a layer causing a fire can be controlled by the correct
selection of equipment and effective housekeeping.

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Levels of housekeeping

Good: Dust layers are kept to negligible thickness, or are non-existent,

irrespective of the grade of release. In this case, the risk of the
occurrence of explosive dust clouds from layers and the risk of fire due
to layers has been removed.
Fair: Dust layers are not negligible but are short-lived (less than one
shift). The dust is removed before any fire can start.
Poor: Dust layers are not negligible and persist for more than one
shift. The fire risk may be significant, and this should be controlled by
selecting equipment according to IEC 60079-14.

Poor housekeeping combined with conditions that can create a dust

cloud from a layer should be prevented. Any conditions that can create
a dust cloud (for example, someone entering the room) shall be
considered in the hazardous area classification.

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Extents of Zones

NOT calculable!
Affected by
- working methods
- ventilation
- housekeeping
- maintenance
- plant structure and layout

dust deposits are sources of release

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Zone Extent
EN 60079-10-2:2009-08
Zone 20 Zone 22
- inside dust handling equipment - 3 m from the source (with a
vertical downwards extension to
the ground or to the level of a
Zone 21 solid floor) or where the spread
- inside some equipment of dust is limited by mechanical
- 1 m from the source (with a structures (walls, etc.), their
vertical downwards extension to surfaces can be taken as the
the ground or to the level of a boundary of the zone
solid floor) or where the spread - 3 m around a non-confined Zone
of dust is limited by mechanical 21 located inside
structures (walls, etc.), their - Around dust layers
surfaces can be taken as the
boundary of the zone
Practical considerations can make
it necessary to classify a whole
area as Zone 21 or 22

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Drawings and Report

Show Zones on site plan

Zone 20
Side / plan views
All data, assumptions,
example, calculations used in
report not on drawings Zone 21
Severity, heights, and shapes
of zones mentioned in report
Other relevant information Zone 22

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Signs for Hazardous Areas

ATEX requires hazardous

areas to be marked with
special sign at points of entry

This must be done where

necessary

Signs provide information for

personnel and contractors,
visitors etc. that special Sign indicating a place where
precautions are necessary explosive atmospheres may occur

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Summary - Area Classification Procedure

WHERE CAN
Find potential sources of IT
release GET OUT?

Identify the duration

(grade of release)
Consider ventilation HOW OFTEN?

Assign zone numbers

Estimate zone size MOST OF A LOT OF
RARELY
Report, Drawings THE TIME THE TIME

Mark zones - EX signs

CONTINUOUS PRIMARY SECONDARY

(ZONE 20) (ZONE 21) (ZONE 22)

2012 DEKRA The Global Experts in Explosion & Process Safety

REFINERY - TYPICALS
EMISSION SOURCES TYPICALS
Columns, reactors, heat exchangers: flanges, PSV, Vents, etc.
Sampling points
Pumps
Compressors
Pipelines/Drainage pit
Floating roof storage tanks /Fixed roof storage tank
Pressure storage tank
Car and rail tanker (Liquefied or compressed gas or cryogenic liquid)
Car and rail tanker (liquids, closed & open circuit)
Marine terminal
Sulphur (liquid and dust) sources: pit, conveyors, loading, etc.
Below ground level areas
Separator and sewer
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TYPICAL:compressor

Identified emission sources: Requested data:

- Flange (gaseous release) - Substance, pressure, hole size

(see tables from 1 to 4)
- Mechanical seal (gaseous release) - Substance, pressure, hole size
(see tables from 5 to 8)

Assumptions for flanges: flange hole size 0.25 mm2, spreading pool
reaches steady state dimensions because response time is very long
Assumptions for mechanical seal: seal hole size 5 mm2

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TYPICAL:compressor

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TYPICAL: fixed roof storage tank

Identified emission sources:

- Flange (liquid release)

- Vent (continuous, primary and

secondary)

Assumptions:/

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TYPICAL: floating roof storage tank

Identified emission sources:

- Flange (liquid release)

- Emissions from guide poles legs

Assumptions:/

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TYPICAL: floating roof storage tank

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TYPICAL: floating roof storage tank

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TYPICAL: pipelines

Identified emission sources: Requested data:

- Flange (liquid release) - Substance, pressure, hole size

(see tables from 1 to 5)

- Flange (gaseous release) - Substance, pressure, hole size

(see tables from 6 to 8)

Assumptions for flanges: flange hole size 0.25 mm2, spreading pool
reaches steady state dimensions because response time is very long

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TYPICAL: pipelines

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TYPICAL: pipelines

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TYPICAL: pressure storage tank

Identified emission sources: Requested data:

- Flange (gaseous release) - Substance (LPG), pressure,

hole size (see table 1)
- Safety devices - Substance, pressure, DN
(specific calculations)

Assumptions : the only substance that is stored inside this kind of tank is
LPG, flange hole size 0.25 mm2
Assumptions for safety devices (not connected to the flare or treatment):
flow rate is not that one caused by external fire but because of leaks

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TYPICAL: pressure storage tank

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TYPICAL: pressure storage tank

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TYPICAL: pump

Identified emission sources: Requested data:

- Flange (liquid release) - Substance, pressure, hole size (see

tables from 1 to 5) + specific
calculations (see tables from 9 to 11)
- Flange (gaseous release) - Substance, pressure, hole size (see
tables from 6 to 8)
- Single mechanical seal or - Substance, fugitive emission (see table
12)
- Packing seal - Substance, pressure, shaft diameter
(specific calculations)
Assumptions for flanges: flange hole size 0.25 mm2, spreading pool reaches steady
state dimensions because response time is very long
Assumptions for seal: if double mechanical seal, not classified; if single mechanical,
breaking of a seal due to chipping or rifling not to incorrect installation; considered
loss 10 times the maximum expected in normal operating conditions as a structural
issue; if packing seal, hole of 0.1 mm around the shaft
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TYPICAL: pump

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TYPICAL: pump

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TYPICAL: sampling

Identified emission sources: Requested data:

- Sampling point - Substance, sampling duration

time (see tables from 1 to 4)

Assumptions : sampling 2 liters in 1 minute

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TYPICAL: sampling

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TYPICAL: sampling

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TYPICAL: sulphur unit

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TYPICAL: sulphur unit

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HOPPER CHARGE

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SILOS DISCHARGE TO TRUCK

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TYPICAL DESIGN OF EMISSION
COLLECTING SYSTEMS

Emission
treatment
system

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WORKSHOP GASOLINE TANK FARM

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WHY SPEAKING ABOUT EXPLOSIONS IN
DUCT COLLECTING SYSTEMS?

Accident happens:

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WOOD INDUSTRY

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EXPLOSION PROTECTION DOCUMENT

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 RISK ASSESMENT

HAZARDOUS AREA CLASSIFICATION IS NOT ENOUGH

EMPLOYER SHOULD ASSESS EXPLOSION RISK IN THE
CLASSIFIED AREAS TAKING INTO ACCOUNT
- likelyhood of presence of flammable atmosphere (HAC)
- likelyhood of presence of effective ignition sources
- magnitude of explosion
- protective measures

N.B. Whats RISK

assessment?
-
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 RISK

Risk: its the product of the likelyhood that a potential danger happens with a
certain magnitude

Magnitude

Low Mid High

High
Likelyhood

Risk:
Mid High
Medium
Low Low

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LIKELYHOOD OF IGNITION SOURCES

Assess the likelyhood that ignition

sources, including static electricity, may
be present and effective.

In all the classified areas (internal and external

to equipment)

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DIFFERENT IGNITION SOURCES - UNI EN 1127-1

Hot surface Electromagnetic waves from 3*1011

Hz to 3*1015 Hz
Flames and hot gases and
particles Ionizing radiation
Mechanical sparks Ultrasound
Electrical equipment Adiabatic compression and shock
waves
Stray currents
Exothermic reaction
Static electricity
Combustione di uno strato di polveri
Electromagnetic waves (RF) from o di altro materiale combustibile
104 Hz to 3*1012 Hz
Lightning

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EQUIPMENT COMPLIANCE

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RISK ASSESSMENT FOR A
CLASSIFIED AREA

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CONFORMITY OF EQUIPMENT

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Choice of equipment depending on zones

Select equipment to be used in ATEX zones in accordance

with directive 94/9/EC :

Zone 0 : II1G Zone 20 : II1D

Zone 1 : II2G Zone 21 : II2D

Zone 2 : II3G Zone 22 : II3D

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 Example
Therefore the equipment intended for use in an explosive
atmosphere must have a category:

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1st classifying : Gas groups
groups

Indicates sensitivity to ignition (based on MIC) and ability

for propagation through gaps (based on MESG)

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1st classifying : Gas groups
groups
Therefore the equipment intended for use in an explosive
atmosphere affix a group or a subdivision:
II, IIA, IIB or IIC

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AUTOIGNITION TEMPERATURE

The AIT is the lowest

temperature at which a fuel (gas,
vapour) - air mixture ignites
spontaneously

Determined using various

standards

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2nd classifying : Temperature classes

Therefore the equipment intended for use in an explosive

atmosphere is classified from T1 to T6 depending on the
maximum surface temperature that they generate

For example, an equipment with a maximum surface temperature is about 105 C will be classified T4.
The user will have to verify if T4 (135C) <AIT
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2nd classifying : Temperature classes

Temperature class

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Marking
Marking / Directive 94/9/EC
94/9/EC

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Marking / Standards (electrical apparatus - Gas)

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