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Workshop ATEX Preparation of Explosion Protection
Document TAIEX Expert Mission IM-63544
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
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Where do I come from? The Netherlands
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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

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ATEX Directives

• 2 Directives applicable in the EU for Explosive
  Atmospheres (ATmosphéres EXplosibles)
• ATEX 95 Economic (Product) Directive 94/9/EC,
  23-03-1994ADDRESSED at MANUFACTURER
• ATEX 137 Social (Workplace) Directive 1999/92/EC,
  16-12-1999ADDRESSED at USER (Employer)

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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

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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

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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

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Conditions for an EXPLOSION
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ATEX Classifications
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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

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Subject Explosive Atmospheres
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Abbrevations RMS
Control Elements Management System APP Accident
Prevention Policy IHRA Identification Hazards
Risk Assessment PO Personnel en
Organization OC Operational Control MoC Manage
ment of Change EP Emergency Preparedness SP Sa
fety Performance IA Internal Audits MR Managem
ent Review Explanation other Abbreviations LoC
Loss of Control / Loss of Containment LoD Line
of Defense (Specific ATEX Control Measures)
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RM Inspection Verification Questions
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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

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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

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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

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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

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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

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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

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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).

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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

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ATEX Zoning around Storage Tanks

• EXAMPLES
• Fixed Roof Storage Tank
• Floating Roof Storage Tank

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Fixed Roof Storage Tank
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Flooting Roof Storage Tank
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Example Content Explosion Protection Document

• 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

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Example Content Explosion Protection Document

• Specific part of the EPD (Specific Plant EPD)
• Description of the site, plants, installations,
  processes substances
• PIDs
• 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

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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

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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

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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

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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

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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)

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Drain System for Flammable Liquids (Pomp Pit)
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ATEX Risk Matrix
Improvement Notice
Improvement Notice
Stoppage of Operation
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Zone 0 Category 2 Level Switch ATEX Matrix ?
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Zone 0 in Pomp Pit Grinding work with Work Permit
and continious LEL measuring ATEX Matrix ?
Pomp Pit
Zone 0
Ex II 1 G EEX de IIB T5
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Thanks Questions?