Shell U.K.

Ltd Safety Regulations

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WORK UNDER PERMIT

ONSHORE OPERATIONS

Section 6 TOOL CONSIDERATIONS

Chapter 2 MOBILE INTERNAL COMBUSTION ENGINES
1

RANGE OF APPLICATION

This chapter covers safety in the use of mobile internal combustion engines in areas
where flammable dusts or vapours might be present. It includes diesel, petrol and gas
engines, whether used solely to drive vehicles or for other types of work.

HAZARDS

When operating an internal combustion engine in an area where flammable dusts or

vapours might be present, the particular hazards are:
Ignitions of any flammable dust or vapour which might be present in the vicinity,
caused by sparking, flame emission or auto-ignition at hot surfaces.
Over-speeding of the engine caused by flammable vapours in the air supply.
Noise, affecting personal hearing and/or the audibility of the site alarm.
Fire, resulting from liquid spills or vapour emissions during refuelling operations.
Exhaust fumes contaminating breathing air.
Vehicular impact.

PERMIT REQUIREMENTS AND RISK ASSESSMENT

Within those parts of any Company-operated site which are classified as non-hazardous
in relation to flammable atmospheres, Location Regulations may designate areas where
the normal use of motor vehicles is allowed subject to specified precautions.
A Fire Permit or equivalent is required for every other use of an internal combustion
engine within the Fire Permit Control Area of the site.
A pre-printed list of safety instructions may be attached, forming part of the Permit to
Work (See appendix 6.2.1)
RISK Medium/High WITH CONTROLS: Low

.
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4
EQUIPMENT STANDARDS
4.1

Standard Production Model Internal Combustion Engines

A standard production model internal combustion engine, when in use, must be treated
as a continuous source of ignition for any flammable atmosphere which might be present.
Depending upon the conditions of the engine, ignition might arise from:
Electrical sparks from the starter motor, its switches and solenoid.
Electrical sparks from the electric dynamo or alternator, control box, switches and
any lighting system.
Mechanical sparks from faulty fan blades.
Static electrical discharges from fan belt drives.
Sparks / electrical discharges from fan belt drives.
Flash back through the air induction system.
Excessive exhaust gas or exhaust pipe temperatures causing ignition of oil or other
materials in contact.
Overheating of the engine due to failure of the cooling system or loss of lubricating oil
pressure.
The brakes running hot.
Over-speeding of the engine due to induction of flammable gas or vapour.
Relief to atmosphere of explosions occurring in the crank cases.
Flame transmission to atmosphere by opening of the decompression ports.
Additionally in the case of a spark ignition engine, ignition might arise from external
sparks from the spark ignition system.
In order to minimise the likelihood of ignition arising from these causes:
The engine must be kept clean and free from oily deposits.
The electrical connections and wiring must be kept in good condition,
The engine must be kept well tuned, cooled and lubricated.
Any spark arrester fitted to the exhaust must be kept in good condition.

4.2

Automatic Overspeed Shutdown Devices

Devices can be added to standard production model diesel engines which, in the event of
overspeed due to contamination of the air intake by flammable vapours, will automatically
cut off the air supply or inject an extinguishing agent into the induction.
These devices can be used to avoid damage to the engine but cannot be relied upon to
shut down the engine quickly enough to avoid ignitions of any flammable atmosphere
which might envelope it.

4.3

Manual Shutdown Switches

Manual shutdown switches for stationary engines should be easily accessible and
instructions for their use should be prominently displayed on the engine.

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4.4

Diesel Engines Protected for Use in Hazardous Areas

The Engineering Equipment and Materials Users Association (EEMUA) Publication No

107 (Previously OCMA specification No MEC/1), makes recommendations for the
Protection of diesel engines for use in Zone 1 and Zone 2 Areas. Static engines are
produced to meet these recommendations but are not commonly available as mobile
models.
With reference specifically to Fork Lift Trucks, the HSE Guidance Note HS(G) 113
advises on the Protection of diesel engines for use in Hazardous Areas.
An engine may be referred to as Protected, only in relation to a specified Area
Classification Zone and a specified group of gases or vapours.

PRECAUTIONS DURING WORK

Only engines in good mechanical and electrical condition should be allowed entry to
Company-operated sites.
Spark arresters on exhausts may be specified for particular circumstances, but in poor
conditions, these can in themselves become sources of ignition from incandescent
particles and as a general rule they can give a false sense of security. Where spark
arresters are fitted provision must be made to ensure that they are kept clean and in
good condition.
The engine fuel tank must not be refilled while the engine is running.

5.1

In Areas Classified as Non-hazardous

5.1.1

Normal Use of Motor Vehicles

Location Regulations allowing the normal use of motor vehicles in areas of the site
classified as non-hazardous in relation to flammable atmospheres must provide for:
Drivers to be made aware of the limits of access for their vehicles on site.
Vehicle Engines not to be left running unattended within the site
Vehicle entry to be stopped in an emergency
5.1.2

Other Uses of Internal Combustion Engines

The Fire Permit or equivalent necessary for any other use of an internal combustion
engine in any part of the Fire Permit Control Area classified as non-hazardous in relation
to flammable atmospheres should provide for:
Frequent operational checks on the condition of the engine when running.
Immediate shutdown of the engine in the event of any contamination of the
atmosphere by flammable materials. (This might entail the fitting of an automatic
overspeed shutdown device for any engine to be left in a remote area).

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5.2

In Areas Classified as Hazardous

5.2.1

Protected Diesel Engines

Diesel engines meeting fully the recommendations of EEMUA 107 and HSG 113 as
appropriate for the Zone concerned, may be considered for use during normal operations
in areas classified as hazardous in relation to flammable atmospheres. Exceptional care
is necessary, however, to ensure that such engines continue to meet the necessary
standards and unless this can be guaranteed, they should be treated as Non-protected
internal combustion engines.
The use of Protected diesel engines during normal operations in Zone 1 areas may be
contemplated only if there is no reasonably practicable alternative.
5.2.2

Internal Combustion Engines other than Protected Diesel Engines

An internal combustion engine meeting the general standards required for entry into a
Company site but less than fully protected, may be used in an area classified as
hazardous in relation to flammable atmospheres only if provisions are made to keep the
area effectively non-hazardous for the period of use of the engine.
The Fire Permit or equivalent for the use of a Non-protected or an incompletely Protected
diesel engine must provide for:
Reduction of the likelihood of release of flammable gases and vapours in the area
throughout their period of engine operations.
In a Zone 1 area this condition will entail cessation of normal operations and gas
freeing of the area.
In a Zone 2 area this condition might be achieved by restriction of normal
operations.
Monitoring of the atmosphere in the vicinity of the engine, particularly upwind, for the
presence of flammable gases and vapours (this might entail frequent or
continuous gas testing).
Stopping the engine without delay in the event of an incursion of flammable gases or
vapours.
The engine not to be left unattended whilst running.

5.3

Noise Safeguards

Alternative warning arrangements should be made if the noise from the work is likely to
mask existing alarm signals.

PERSONAL PROTECTIVE EQUIPMENT

Personal protective equipment must be worn in accordance with generally applicable

Location Regulations or legal requirement as appropriate.
Hearing protection might be necessary for work close to internal combustion engines.

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7
COMPETENCE AND TRAINING
The person directly in charge of an internal combustion engine on a Company-operated
site must be aware of the geographical constraints to its movement.
All persons concerned with work in which a mobile internal combustion engine is in use
should know how to stop the engine in an emergency. The person directly in charge of an
engine operating in a Hazardous Area should be capable of assessing the general
mechanical and electrical condition of the engine and its ancillary equipment and of
deciding when its condition is such that its operation should be discontinued for safety
reasons.

REFERENCES

8.1

Health and Safety Executive Guidance

HSG 113. Lift trucks in potentially flammable atmospheres 1996.

8.2

Industry

EEMUA 107 Recommendations for the Protection of Diesel Engines Operating in

Hazardous Areas

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APPENDIX 6.2.1
TYPICAL SAFETY DATA SHEET
This forms part of Permit to Work No: __________________ Date:______________
SAFETY INSTRUCTIONS FOR WORK ENTAILING MOBILE INTERNAL COMBUSTION
ENGINES
These Instructions are additional to those specified on the accompanying Permit to
Work.
1. The engine must be in good condition both mechanically and electrically.
2. Personal protective equipment must be worn as indicated on the accompanying
Permit to Work.
3. The engine must be stopped immediately:
1. At any sign of over-speeding.
2. At any sign of overheating.
3. On any signal specified by the Permit to Work.
4. The fuel tank of the engine must not be refilled while the engine is running.
5. The engine must be fitted with ancillary equipment as specified on the accompanying
Permit to Work.
6. The engine must be stationed as indicated on the accompanying Permit to Work.
7. Safety Signs and barriers must be erected as indicated on the accompanying Permit
to Work.
8. The engine must not be left running without an attendant nearby.
9. The attendant must be fully trained in the operation of the engine and fully aware of
the site Safety Regulations regarding its use.
10. A portable dry powder or carbon dioxide fire extinguisher must be provided in the
vicinity of the engine.
Signature:______________ Position Held:_____________ Date:___________

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