Very Good Presentation - ATEX IchemE

Equipment Use in Explosive Atmospheres
within the Pharma, Bio and Fine Chemical

Industries
Authors
Eur Ing Keith Plumb FIChemE and Neil Graham MIChemE
Presented by
Eur Ing Keith Plumb FIChemE

We are striving to avoid this!
www.integpharma.com
Overview
• Definitions
• Can an explosive atmosphere be formed?
• Carrying out a Hazardous Area Classification
• Equipment selection
• Residual risks
• Additional measures
www.integpharma.com
Standards Used in this Presentation
1. IEC 60079-0:2009 Explosive atmospheres – Part 0:

Equipment – General Requirements
2. IEC 60079-10-1:2009 Explosive atmospheres – Part 10-1:
Classification of areas –Explosive gas atmospheres
3. IEC 60079-10-2:2009 Explosive atmospheres – Part 10-2:
Classification of areas – Combustible dust atmospheres
4. IEC 60079-14: 2008 Explosive atmospheres. Electrical
installations design, selection and erection
5. EN 1127-1:2007 (E) Explosive atmospheres. Explosion
prevention and protection. Basic concepts and methodology
6. EN 13463-1:2009 Non-electrical equipment for use in
potentially explosive atmospheres Part 1: Basic methods
and requirements
www.integpharma.com
Explosive Atmospheres
• Explosive atmosphere
− A mixture with air, under atmospheric conditions of flammable
substances in the form of gas, vapour, mist dust, fibres or flyings
which, after ignited, permits self-sustaining flame propagation.
• Atmospheric conditions
− Conditions that include variations in pressure and temperature above
and below reference levels of 101.3 kPa and 20°C, provided that the
variations have negligible effect on the explosive properties of the
flammable materials.
Note: The standards do not apply to conditions other that
atmospheric conditions.
www.integpharma.com
Relevant Substances – IEC 60079-10-1
• Flammable liquid
− A liquid capable of producing a flammable vapour under any foreseeable
operating conditions.
− Generally a liquid that is being used close to or above its flash point
• Flammable gas or vapour
− A gas or vapour which, when mixed with air will form a flammable
atmosphere.
− Gas or vapour that is close to or within the limits of the lower and upper
explosive limits.
• Flammable mist
− Droplets of liquid, dispersed in air so as to form a flammable atmosphere.
In general the droplets need to be smaller than 50 microns.
− This can apply to liquids below their flash point but the concentration of sub
50 micron droplets must be great enough to allow ignition.
www.integpharma.com
Relevant Substances – IEC 60079-10-2
• Combustible Dusts
− Finely divided solids, 500 microns or less in nominal size, which may be
suspended in air, may settle out of the atmosphere under its own weight, can
burn or glow in air and may form explosive atmospheres with air at
atmospheric pressure and normal temperatures.
• Combustible Flyings
− Solid particles, includingfibres, greater than 500 microns in nominal size,
which can be suspended in air, may settle out the atmosphere under their
own weight, can burn or glow in air, and may form explosive mixtures with
air at atmospheric pressure and normal temperatures.
• Dust Layers
− A layer of dust, which is not likely to form a dust cloud, but may ignite due to
self heating or exposure to hot surfaces or thermal flux and cause a fire
hazard or over heating of equipment. The ignited layer may also act as an
ignition source for explosive atmosphere.
www.integpharma.com
Workplace Risk Assessment
FG = Flammable Gas,
Carry Out Select appropriate
START
Hazardous Area equipment to minimise Vapour or Liquid
Classification sources of ignition CD = Combustible Dust or
No Flyings
Can process Can oxygen

Yes be changed Residual Yes be exclude
FG or CD
to eliminate risk of from the
present?
FG and/or ignition? process
CD? equipment?
No
No Yes
Yes No
Explosive atmosphere Change process to Provide system to

cannot be created eliminate FG and/or CD eliminate oxygen
Mitigate consequences
END by providing explosion
relief, suppression etc.
www.integpharma.com
Is it likely that there
will be a flammable gas,
vapour or liquid and/or
a combustible dust or
flyings present?
To check this you need

to know the properties
of the process materials
being used.
www.integpharma.com
Overview of Likelihood of Explosive
Atmosphere
• Are flammable gases, vapours or mists (FGs) and/or
combustible dusts or flyings (CDs) used or created as part
of the process?
• Can these be dispersed by some form of release, including
spillage?
• Is it credible that a mixture with air in the explosion range
can be formed?
− This is determined by flash points plus lower and upper explosive limits
for FGs and minimum explosive concentration for CDs.
• Is the sufficient material to cause injury or damage.
• See EN 1127-1 for more details
www.integpharma.com
Fire and Explosion Pentagon
Dispersion Confinement
Fuel
Oxidant
Ignition
Source
www.integpharma.com
Flammability/Combustibility
Properties
• Flammable liquids, vapours and gases (FGs)
− Flash points, lower explosive limit and upper explosive limit are
frequently available from literature, material safety data sheets etc.
• Flammable mists
− Testing and simulation will be required to find out if it conceivable that
a flammable mists can be created.
• Combustible dusts and flyings (CDs)
− Some literature information on minimum explosive concentrations is
available that is indicative but not suitable for design, e.g. BIA-Report
13/97 “Combustion and explosion characteristics of dusts”.
− Combustibility properties are highly susceptible to the dust/flyings
physical properties.
− Laboratory testing of the actual dust/flyings being used is normally
required.
www.integpharma.com
Explosion Data – Lactose
Impact of Particle Size
10000 Minimum Ignition Energy 1000
Minimum Explosive Concentration
Minimum Ignition Energy - mJ
Minimum Explosive Conc - g/m3

1000
100
100
R2 = 0.1764
R2 = 0.6926
10
10
1 1
0 50 100 150 200 250
Mean Particle Size - µm
Source: BIA-Report 13/97 Combustion and explosion characteristics of dusts
www.integpharma.com
Explosion Data – Lignite
Impact of Moisture Content
Minimum Ignition Energy - mJ 1200
1100
1000
900 R2 = 0.3329
800
700
600
500
400
300
200
5 10 15 20 25 30 35
Moisture Content % by Weight
www.integpharma.com
Minimum Explosive Concentration in
Context
• The Minimum Explosive Concentration (MEC) measures the

minimum quantity of material that must be evenly
distributed in air before the dust will explode.
• If the MEC is high then a more concentrated dust cloud
must be generated before an explosive atmosphere will be
present.
www.integpharma.com
Minimum Explosible Concentration
More Details
• Typical MEC for dusts is 30 to 60 g/m3 or greater

− A 25 watt light bulb can be just be seen through a two metre coal dust
cloud with a concentration of 40 g/m3.
− It would be difficult to read a newspaper in typical explosive dust cloud.
− It is quite difficult to create a cloud this concentrated that will last more
than a few minutes unless you are doing it as part of your process or
you have poor housekeeping.
• By way of comparison the typical
occupational exposure limit for
pharmaceutical powders is
− 1 – 10,000 g/m3 or less
− There is a 1,000 to 1,000,000 fold
difference!
www.integpharma.com
Quantity of Flammable Material
• Is a Hazardous Area Classification (HAC) required where only

small quantities of materials exists?
− A risk assessment is always required but not necessarily an HAC.
• The UK Health and Safety Executive advice suggests:
− Flammable liquids.
1. If equipment is above the 2 litre scale an HAC should be considered.
2. Above 50 litres an HAC is normally required.
− Flammable gases
1. Low pressure odorised gases with small bore pipework do not
normally need a formal HAC.
2. High pressure non-odorised gases normally require a formal HAC.
− Combustible dusts - For quantities of 25 kg or less where the only way to
create a dust cloud is to drop a bag of powder then a formal HAC
would not normally be required.
www.integpharma.com
Can the process be
changed to eliminate the
flammable gas, vapour
or liquid and/or a
combustible dust or
flyings?
www.integpharma.com
Change the Process
• The best way to approach the problem of explosive

atmospheres is to eliminate them by changing the process.
• At the small scale changing to a less hazardous material
may eliminate the need for a full Hazardous Area
Classification.
• Chemical Engineers need to be involved in the early stages
of develop to reinforce the need to eliminate FGs and/or
CDs.
• If FGs and/or CDs cannot be eliminated then their
inventories must be kept to a minimum.
www.integpharma.com
Carry Out Hazardous Area
Classification
Using
Standard
IEC 60079
Part 10-1
“Classification of areas – Explosive gas
atmospheres”
Part 10-2
“Classification of areas – Combustible
dust atmospheres”
www.integpharma.com
Hazardous Area Classification
1. Record physical properties on a data sheet.
2. Identify all of sources of release and tabulate the result.
3. Identify the grade of release.
4. Note the operating temperature and pressure and plus
level of housekeeping
5. Note the level of ventilation associated with each source of
release.
6. Identify the zone for each source of release.
7. Calculate the size of each zone.
8. Plot the zones on the plan and elevation of the equipment.
www.integpharma.com
Step 1. Record Information on Data
Sheet
• Data table for gases, vapours and liquids

− Gases, vapours and liquids data sheet
• Data sheet for dusts and flyings

− Dust and flyings data sheet
www.integpharma.com
Step 2 – Identify the Source of Hazard
• Historically standards have used 2 methods

− Generalized method; this involves making judgments about
quite large areas of plant
• e.g.. 'blanket' zone 2 inside building, 1m zone 1 around
vents, zone 0 inside vessels
− Source of hazard method; each release point is analyzed to
determine the distance at which the concentration of the
flammable falls below the LEL (by a margin).
• Hazardous area classification standards IEC 60079-10-1 and IEC
60079-10-2 use the source of hazard method
• Generalized method tended to be conservative (hence
expensive) but could fail to identify small high hazard
points such as rotating equipment glands.
www.integpharma.com
Step 2. Indentify all sources of release
and tabulate them.
• Sources of release table

− Sources of release table
www.integpharma.com
Step 3. Identify the Grade of Release
• Continuous Grade Release
− Continuous or is expected to occur frequently or for long periods
(typical ~ 1000+ hrs/annum)
− E.g. Inside processing equipment
• Primary Grade Release
− Expected to occur periodically or occasionally during normal operation
(typically~ 10 – 1000 hrs/annum)
− E.g. Loading powders or solvents into vessel without LEV
• Secondary Grade Release
− Not expected to occur in normal operation and, if it does occur, is likely
to do so only infrequently and for short period.
− Typically < 10 hr/yr and a persistence of max 1 hour
− E.g. Equipment joints or spillage
Note 1. Layers, deposits and heaps of combustible dust must be considered as any other
source which can form an explosive atmosphere.
Note 2. "Normal operation" means the situation when installations are used within their
design parameters.
www.integpharma.com
Step 4. Note operating temperature and
pressure and level of housekeeping
• Operating pressure and temperature

− Important for calculation of the size of gas or vapour zone.
• Level of Housekeeping
− Relevant to the type of dust zone and the presence of dust layers
− Three levels are defined:
1. Good – Dust layers are kept to negligible thickness irrespective of
degree of release.
2. Fair – Dust layers are not negligible but are short lived (less than one
shift)
3. Poor – Dust layers are not negligible and persist for more than one
shift.
www.integpharma.com
Step 5. Note type, degree and
availability of ventilation
• Required for calculating the size of the gas/vapour zone and
for assessing the size of a dust zone.
• Natural versus artificial – general or local
• Degree of ventilation
− High (VH) – Can reduce the concentration of a release virtually instantly.
− Medium (VM) – Can control the concentration of a release and maintain a
stable zone boundary.
− Low (VL) – Cannot control the concentration of a release nor prevent long
persistence.
• Availability of ventilation
− Good – present virtually continuously (min. 0.5 m/s for natural ventilation)
− Fair – expected to be present during normal operation
− Poor – not fair or good but discontinuities are not expected to occur for
long periods
www.integpharma.com
Step 6. Identify the Hazardous Zones
• Zone 0 for Gases and Zone 20 for Dusts

− A place in which an explosive atmosphere is present continuously, or for
long periods or frequently.
− A place in which an explosive atmosphere is likely to occur in normal
operation occasionally.
− A place in which an explosive atmosphere is not likely to occur in normal
operation but, if it does occur, will persist for a short period only.
Notes:
1. Layers, deposits and heaps of combustible dust must be considered as any
other source which can form an explosive atmosphere.
2. "Normal operation" means the situation when installations are used within
their design parameters.
www.integpharma.com
Source of Release Versus
Hazardous Zone
• Traditionally there was a simple relationship
Gas Dust
− Continuous Grade Zone 0 Zone 20
− Primary Grade Zone 1 Zone 21
− Secondary Grade Zone 2 Zone 22
• But
− Ventilation has an impact on the gas zone
− Housekeeping has an impact on the dust zone
− Consequences of an explosion also has an impact
www.integpharma.com
Impact of Ventilation on Gas Zones
Degree of Ventilation
High Medium Low
Grade of Availability of Ventilation
Release
Good Fair Poor Good Fair Poor G,F or P
Zone 0 Zone 0
Continuous NH Zone 2 Zone 1 Zone 0 Zone 0
+Zone 2 +Zone 1
Zone 1 Zone 1 Zone 1 or
Primary NH Zone 2 Zone 2 Zone 1
+Zone 2 +Zone 2 0†
Zone 1 or
Secondary NH NH Zone 2 Zone 2 Zone 2 Zone 2
0†
Notes
1. NH = Non-hazardous
2. “+” symbol indicates surrounded by
3. “†” There will be a Zone 0 if the ventilation is so weak and the release is such that in
practice an explosive gas atmosphere exists virtually continuously i.e. approaching a no
ventilation condition.
www.integpharma.com
Impact of Housekeeping on Dust
Zones
• Housekeeping has an impact on thickness and the persistence of

dust layers.
• Dust layers are important because:
− A dust layer can be raised into a cloud and acts as a source of release.
This is a particular problem when small primary explosion raises dust
and cause a much larger secondary explosion.
− Dust layers can be ignited by heat flux from equipment and act as a
source of ignition.
• Dust layers from primary and secondary grades of release can be
there continuously with poor housekeeping.
• A secondary grade release with a high deposition rate can lead to
thicker layers than a primary grade release with a lower
deposition rate if housekeeping is not adequate.
www.integpharma.com
Consequences of an Explosion
• Traditional Hazardous Area Classification does not take into

account the consequence of an explosion.
• In a true risk assessment the consequences would be taken
into account and this is now being recognised.
• Two examples of changes that could be made
− The use of Zone 1 equipment in a Zone 2 to allow this equipment to be
used even in event of a prolonged gas release.
− The use of Zone 2 equipment in Zone 1 because the amount of
flammable material available is small and the equipment is in a remote
secure location that is normally unmanned.
www.integpharma.com
Step 7.
Calculate the
Size of Each
Zone
www.integpharma.com
Step 7a – Calculate the Size of Each
Gas Zone
• The size and shape of the zone is influenced by
− mass released (total and rate)
− if a liquid is released, the fraction of the liquid flow that vaporizes
− dispersal parameters e.g. buoyancy, ventilation/wind effects
• Industrial experience was enshrined in various codes and
guidelines but these were shown to give quite widely
varying predictions1.
• The work of Cox, Lees & Ang hoped to help progress from
the empirical, experienced based methods towards more
rigorous, quantitative methods.
− 'The dispersion of leaks by ventilation is difficult to model and more
work needs to be done in this area...”
• IEC 60079-10-1 attempts to provide a rigorous,
quantitative method but fails to do so.
− “This standard is not based on any rigorous science” 2
1. See figs 3.1, 3.2, 3.3 'Classification of Hazardous Locations'; A.W. Cox, F.P. Lees, M.L. Ang
2. Pers comm. UK Health and Safety Executive
www.integpharma.com
Extracts from IEC 60079-10-1
• Section 5.4 states:

− "The extent of the zone depends on the estimated or calculated
distance over which an explosive atmosphere exists before it disperses
to a concentration in air below its lower explosive limit with an
appropriate safety factor. When assessing the area of spread of gas or
vapour before dilution to below its lower explosive limit, expert advice
should be sought“
• Section B.5.2.3 states:
− "In the open air an assessment should be made on the basis of the site
layout and site features. Estimates of Vz [hypothetical volume] should
be made based on the result of using an appropriate modeling tool e.g.
from CFD analysis"
www.integpharma.com
IEC 60079-10-1 Annex B
• Annex B outlines a method for determining the type of zone

by
– estimating the minimum ventilation rate required to prevent significant
build up of an explosive gas atmosphere
– calculating a hypothetical volume, Vz, which allows determination of the
degree of ventilation
– estimating the persistence time of the release (for transient releases)
– determining the type of zone from the degree of ventilation and the
grade of release (table B.1 in the standard)
• The method is not intended to determine the extent of the
hazardous areas (though standard is not clear on this).
www.integpharma.com
IEC 60079-10-1 Annex B Continued
• Section B.5.2.2 states:
– "The hypothetical volume Vz gives a guide as to the volume of flammable
envelope from a source of release but that envelope will not normally
equate to the volume of the hazardous area. Firstly, the shape of the
hypothetical volume is not defined and will be influenced by ventilation
conditions (see B.4.3 and B.5). The degree and availability of ventilation
and possible variations in these parameters will influence the shape of the
hypothetical volume. Secondly the position of the hypothetical volume with
respect to the release will need to be established. This will primarily
depend on the direction of ventilation with the hypothetical volume biased
in the down-wind direction. Thirdly, in some situations, account must be
taken of the possibility of varying directions of ventilation and the buoyancy
(or relative density) of the gas or vapour."
• Calculation of Vz by the method outlined in Annex B is
necessary to evaluate the type of zone but does not provide
sufficient data to delineate the zone. Vz is merely a measure
of ventilation effectiveness.
• It is important to note that work by the Health and Safety
Laboratories in the UK suggests Vz could overestimate the
volume of the hazardous area by as much as 1000 times.
www.integpharma.com
Example – Degree of Ventilation
• Release characteristics
– Flammable material: Toluene
– Molecular mass of Toluene: 92 kg/kmol
– Source of release: Failure of flange gasket
– Lower explosive limit LEL: 0.046 kg/m3 (1.2 vol%)
– Grade of release: Secondary
– Safety Factor k: 0.5 for secondary grade
– Release rate (dG/dt)max 2.8 x 10-6 kg/s
• Ventilation characteristics... (indoor situation)
– No. air changes, C: 1 per hour (2.8 x 10-4 per sec)
– Quality factor, f: 5 equates to impeded air flow
– Ambient temperature, T: 20 deg C
– Temperature coefficient (T/293 K): 1
– Building (room) size, V0: 10m x 15m x 6m = 900 m3
www.integpharma.com
Example Continued
Calculate the theoretical minimum volumetric flow rate of fresh
air to dilute the release:
(dV/dt)min = (dG/dt)max x T = 2.8 x 10-6 x 293
k x LEL 293 0.5 x 0.046 x 293
= 1.2 x 10-4 m 3/s
Evaluation of hypothetical volume Vz:
Vz = f x (dV/dt)min = 5 x 1.2 x 10-4 = 2.2 m3

C 2.8 x 10-4
Calculate the time of persistence:
t = -f/C ln((LEL x k)/X0) = -5/1 ln((1.2 x 0.5)/100)
= 25.6 hr
www.integpharma.com
Example - Conclusion
• The hypothetical volume Vz is greater than 0.1m3 but less

than the room volume V0 (900 m3).
• In this case the degree of ventilation may be considered as
medium with regard to the source of the release and area
under consideration. Therefore a secondary grade of
release would equate to Zone 2
• However the flammable atmosphere would persist therefore
the concept of Zone 2 may not be met.
www.integpharma.com
Zone Sizing
• Standard IEC 60079-10-1 does not give the zone sizing – a

very unsatisfactory situation.
• The examples given in IEC 60079-10-1 can be used to give
a judgemental zone sizing. An example is covered later.
• Standard IP15 for may be used for zone sizing as could
computation fluid dynamics.
• The Health and Safety Execute the safety agency for the UK
government has done some research into this problem and
will be issuing some guidelines in the near future.
www.integpharma.com
Step 7b. Assess the Size of Each Dust
Zone
• Zone 20
− A zone 20 is generally inside contained equipment that determine size of
the zone.
− If a Zone 20 exists outside equipment you have got a serious
housekeeping and GMP problem.
• Zone 21
− The size will depend on the dust properties and ventilation.
− Good exhaust ventilation will down grade this to a Zone 22.
− A distance of 1m from the source with a vertical extension to a solid floor
is usually adequate.
• Zone 22
− A distance of 3m from the Zone 20 or Zone 21 as appropriate, extending
down to a solid floor is usually adequate.
− Mechanical barriers such as walls may limit the extent.
− The presence of dust layers may extent the Zone 22 or turn a Zone 22
into a Zone 21
www.integpharma.com
Step 8. Plot the
Zones on the Plan
and Elevation of
the Equipment
www.integpharma.com
Gas Zoning Example
• A fixed process mixing vessel, situated indoors, being

opened regularly for operational reasons. The liquid is piped
into the vessel through all welded pipework flanged at the
vessel.
www.integpharma.com
Gas Zoning Example
Principal factors which influence the type
and extent of the zone.
• Ventilation
− Type Artificial
− Degree Low inside vessel; medium outside vessel
− Availability Fair
• Source of release Grade of Release

− Liquid surface within vessel Continuous
− The opening of the vessel Primary
− Spillage or leakage of liquid close to vessel Secondary
• Product
− Flashpoint Below process and ambient temperature.
− Vapour density Greater than air.
www.integpharma.com
Example Dimensions
Taking into account the relevant parameters, the following are typical values
which will be estimated for this particular example.
a = 1m horizontally from the source of release

b = 1m above the source of release
c = 1m horizontally
d = 2m horizontally
e = 1m above grade
d c a a c d
b
Zone 0
Zone 1
Zone 2
Process Liquid
e
www.integpharma.com
Dust Zoning Example 1
Bag emptying station with no Bag emptying station with

LEV within a building LEV
Zone 20
Zone 21
See plan views
Zone 22
www.integpharma.com
Bag Emptying Station with no LEV
Within a Building
• Zone 20
− Inside the hopper because an explosive dust/air mixture is present
frequently or even continuously.
− The size of the zone is determined by the hopper.
• Zone 21
− The open manway is a primary grade of release.
− Zone 21 exist around this manhole extending 1 m from the edge of the
manhole and extending down to the floor.
• Zone 22
− Accidental spillage of the bag could cause a dust cloud to extend beyond
the Zone 21
− Zone 22 extends 3m from the edge of the Zone 21 so in effect fills the
whole of a room
www.integpharma.com
Bag Emptying Station with LEV
• Zone 20
− Inside the hopper because an explosive dust/air mixture is present
frequently or even continuously
• Zone 21
− There is no Zone 21 in this case due to the dust extraction system
• Zone 22
− The open manhole is a secondary grade of release. There is no escape
of dust in normal circumstances because of the dust extraction system
in a well designed extraction system, any dust released will be sucked
inside. Consequently, only a Zone 22 is defined around the manhole
extending for 3m from the edge of the manhole and extending down to
the floor.
www.integpharma.com
Dust Zoning Example 2
Cyclone and filter with

clean outlet outside
building
Zone 20
Zone 21
Zone 22
www.integpharma.com
Dust Zoning Example 2 Continued
• Zone 20
− Inside the cyclone because an explosive dust/air mixture is present
frequently or even continuously.
• Zone 21
− The dirty side of the filter is a Zone 21, if only small amounts of dust enter
the filter from the cyclone in normal operation. If this is not the case, the
dirty side of the filter is Zone 20.
• Zone 22
− The filter clean side may contain a dust cloud if a filter element fails. This
zone includes the ducting.
− The Zone 22 extends around the outlet of the ducting and extends down the
ground (not shown in diagram).
− The size of the Zone 22 (in plan) around the outlet will depend on the
process and properties of the dust. The expected minimum size would be
1m and the 3m is a reasonable maximum.
www.integpharma.com
Questions on Hazardous Area Classification
www.integpharma.com
Select Appropriate
Equipment for the
Zone Identified
www.integpharma.com
Equipment Definitions
• Electrical Equipment – IEC 60079-0
− Items applied as a whole or in part for the utilization of electrical energy
including amongst others, items for generation, transmission, distribution,
storage, measurement, regulation, conversion and consumption of electrical
energy and items for telecommunications.
• Non-electrical Equipment – EN 13463-1

− Currently only applies in Europe. However, non-electrical equipment is very
relevant to pharma, bio and fine chemicals.
− Machines, apparatus, fixed or mobile devices, control components and
instrumentation thereof and detection or prevention systems, which
separately or jointly are intended for the generation, transfer, storage,
measurement, control or conversion of energy and/or the processing of
material and which are capable of causing an explosion through their own
potential sources of ignition.
− Simple apparatus with no moving parts, e.g. containers or pipes on their
own are not considered equipment.
www.integpharma.com
Sources of Ignition
• Electrical Equipment
− Assume that without protective or preventative measures, electrical
equipment will be an effective source of ignition i.e. a source of ignition
that is capable of igniting the FGs and/or CDs where they are present.
• Non-Electrical Equipment
− Analyse the potential ignition sources to see if there are any effective
ignition sources.
www.integpharma.com
Ignition Sources – Non-Electric
Equipment
1. Does the equipment have a related ignition source other
than static electricity?
− Yes - Some form of preventive or protective measures may be
required. See question 2 below.
− No – Non-electrical equipment where the only source of ignition is
static electricity is not covered by the ATEX directive. Protection
against static electricity is required – covered later.
2. Are there effective ignition sources that can ignite the
explosive atmosphere present?
− Yes – Some form of preventive or protective measures will be
required.
− No – Equipment is safe to use.
www.integpharma.com
Equipment Providing Preventive or
Protection Measures
1. Select equipment that is compliant with IEC or EN

Standards and certified to be compliant.
2. Consider if there are any residual risks.
− If residual risks exists then further preventive or protective measures
will be required. See later.
www.integpharma.com
EU ATEX Marking
0999 x II 2 G
Group II only G = Gas, vapour or
mist D = Dust or flyings
Equipment Category 1, 2 or 3
Equipment Group I or II
EU Explosive Atmospheres Symbol
Notified Body reference number
CE Mark
www.integpharma.com
IEC Marking
Gases, vapours and mists
Ex d IIB T6 Gb - 40oC<Tamb<+50oC
Certified ambient temperature
range
Explosion protection level
Temperature class reference to

ambient of -20 to +40oC unless
indicated
Gas Group
Type of protection code
Explosion protection symbol
www.integpharma.com
IEC Marking
Dust and Flyings
Ex tb IIIC T125°C Db IP66
Ingress Protection
Explosion protection level
Maximum surface temperature

reference to ambient of -20 to
+40oC unless indicated
Dust Group
Type of protection code
Explosion protection symbol
www.integpharma.com
Marking Non- Electrical Equipment –
EN 13463-1
II 2 G d IIA T4
Temperature class
Gas group
Protection concept
Group II only G = Gas, vapour or

mist D = Dust or flyings
Equipment Category 1, 2 or 3
Equipment Group I or II
Notes:
1. The “Ex” symbol is not used with non- electrical equipment
2. Dust groups IIIA, IIIB and IIIC are not used with non-electrical equipment.
3. The temperature class can be replaced by the maximum surface temperature in °C
www.integpharma.com
Electrical Equipment Groups
IEC 60079-0 EU Directive 94/9/EC IEC 60079-10-X
Explosion Equipment Equipment
Group Zones
Protection Level Group Category
Ma M1
I I NA
Mb M2
Ga 1G 0
Gb II 2G 1
Gc 3G 2
II
Da 1D 20
Db III 2D 21
Dc 3D 22
Ma, Mb, Group I, M1 and M2 apply to coal mining only

www.integpharma.com
Non - Electrical Equipment Groups
EN 13463-1 EN 60079-10-X
Equipment Group Equipment Category Zones
M1
I NA
M2
1G 0
2G 1
3G 2
II
1D 20
2D 21
3D 22
Group I, M1 and M2 apply to coal mining

www.integpharma.com
Protection Concept
Electrical Equipment
Gases, Vapours and Mists
Code Protection Concept Zone
d Flameproof 1 Dusts and Flyings
pxb/pyb 1 Code Protection Concept Zone
Pressurised
pzc 2 ta 20
q Powder Filled 1 tb Enclosure 21
tc 22
o Oil Filled 1
e Increased Safety 1 p Pressurised 21/22
ia 0
ib Intrinsic Safety 1 ia 20
ic 2 ib Intrinsic Safety 21
nA Non-sparking ic 22
nL Energy limited 2
nR Restricted breathing ma 20
nC Enclosed break mb Encapsulated 21
ma 0 mc 22
mb Encapsulation 1
mc 2
www.integpharma.com
Protection Concept Non-Electrical
Equipment
Gases, Vapours, Mists, Dusts and Flyings
Code Protection Concept Zone
fr Flow restriction 2/22
d Flameproof 1/21
c Constructional safety 1/21
Control of ignition
b 1/21
sources
p Pressurisation 1/21
k Liquid immersion 1/21
www.integpharma.com
Material Groups
Gases, Vapours and Mists1 Dusts and Flyings
IIA MIE > 0.20 mJ IIIA Combustible flyings
IIB2 MIE 0.05 – 0.20 IIIB3 Non-conductive dusts

Electrical resistivity > 103Ωm
IIC2 MIE < 0.05 IIIC4 Conductive dusts

Electrical resistivity < 103Ωm
1. Group II subdivisions are also based on maximum experimental safe gap. See IEC
60079-12 and IEC60079-20
2. Equipment marked IIB can be used for IIA and IIB gases. Equipment marked IIIC can be
used for IIA and IIB gases.
3. Equipment marked IIIB can be used for non-conductive dusts and combustible flyings.
4. Equipment marked IIIC can be used for conductive and non-conductive dusts and
combustible flyings.
www.integpharma.com
Temperature Classes
Gases and Vapours
Minimum Ignition
Temperature Class of Allowable Temperature
Temperature of Gas or
Materials in Use Classes of Equipment
Vapour °C
T1 >450 T1 – T6
T2 >300 T2 – T6
T3 >200 T3 – T6
T4 >135 T4 – T6
T5 >100 T5 – T6
T6 >85 T6
www.integpharma.com
Equipment Surface Temperature
Dusts
1. Layers
− If, the layer thickness is controlled and frequently removed before
thermal effects occur
• Hopefully the case in a GMP facility
− Then apply the rule, Tmax T5 – 75 , where:
• Tmax is maximum surface temperature of the apparatus when tested in a dust
free test method.
• T5 is the minimum ignition temperature of a 5 mm dust layer
2. Clouds
− For clouds apply the rule, Tmax 2/3 TCl, where:
• TCl is the ignition temperature of a dust cloud
For more details see IEC 60079-14
www.integpharma.com
Ingress Protection
Dust Water – Protected Against
IP5X Dust Protected IPX4 Splashing water
IP6X Dust Tight IPX5 Water Jets
IPX6 Powered Water Jets
IPX7 Temporary Immersion
IPX8 Continuous Immersion
www.integpharma.com
Equipment
Selection
Examples
www.integpharma.com
Example 1 – Ethanol Pump
• Process
− Batch transfer of the contents of a
measuring head tank to a process
Head Tank
vessel.
• Hazards Area Classification
− Inside the pump is a Zone 1 because
air can enter the pump at the start and
end of each transfer.
− Outside the pump there is small Zone 1
around the single mechanical seal
because of the small leakage across the Transfer Pump
seal face.
− Outside the pump there is a large Zone Process Reactor
2 due to the possibility of seal failure

and leakage from pipe joints.
www.integpharma.com
Ethanol Properties
Flash Point 14°C
Low Explosion Limit 3.3%
Upper Explosion Limit 24.5%
Minimum Ignition Energy 0.65 mJ
Apparatus Group IIA
Auto Ignition Temperature 363°C
Temperature Class T2
www.integpharma.com
Equipment Selected
Location Inside Pump Outside Pump
Zone 1 1 2
Electrical or Non-
Non-electrical Electrical Electrical
electrical
Category Required 2 2 2 or 3
IEC or EN Standard Ex pc IIA T2 Gb or

pc IIA† T2‡ Ex pc IIA T2 Gb
Marking Ex pc IIA T2 Gc
II 2 G or
EU ATEX Marking x II 2 G x II 2 G x II 3 G
PC = Protection Concept e.g. d, e, fr etc.

† IIB or IIC would also be acceptable
‡ T3 to T6 would also be acceptable Pump analysis in EN 13463-1
www.integpharma.com
Zone 0 Issues
• Although in this example the pump does not contain a

Zone 0, the air space in the head tank and the process
reactor would each create a Zone 0.
• LEV extract fans can frequently contain a Zone 0
• There are no non-electrical equipment protection concepts
that are suitable for Zone 0. To overcome the problem two
independent protection concepts need to be used.
• Later on we examine an alternative approach to this
problem.
www.integpharma.com
Example 2 Milling Dry Lactose
• Dry milling of lactose down stream of a fluid bed dryer

discharging into an IBC, no solvent.
• Connections
− Clamped joint on outlet from dryer
− Clamped joint on the inlet to the IBC
• Containment
− Fully contained pipe work
− Mill has a purged mechanical seals
− Located in a room with HVAC
• Cleaning
− WIP after milling
− Dismantled for full clean
www.integpharma.com
Product Properties – Dust Example
Lactose Based Dry Granules

Minimum Explosive Concentration MEC1 60 g/m3
Minimum Ignition Energy (fines)1 10 mJ
Resistivity2 1 x 1012 Ωm
Apparatus Group (Resistivity > 1 x 103 Ωm) IIIB
Minimum Ignition Temperature Layer T51 450oC
Minimum Ignition Temperature Cloud TCl1 420oC
1. BIA Report 13/97 Combustion and explosion properties of dusts

2. M. Murtomaa, E. Laine, Electrostatic measurements on lactose-glucose mixtures, J.
Electrostat. 48 (2000)
www.integpharma.com
Analysis
• Sources of Release
− MEC will be exceeded inside the mill Continuous Grade Zone 20
− No dust outside the mill unless there is
mal operation and and dust cloud Secondary Grade Zone 22
will be quickly remove by the HVAC
• Probability of the Mill acting as an ignition source
− EN 13463-1 states that single impacts between metal parts need not
considered as potential ignition sources when:
• the impact velocity is less than 1 m/s and sparking metals are avoided.
• or less than 15 m/s and less than 150 J with non-sparking metals (Cu, Zn, Sn, Pb
some brasses (CuZn) and bronze (CuSn). Standard Text
− Austenitic stainless steel is not a major sparking risk because it is not easily
oxidised. However, unless the impact speed is less than 1 m/s then there is a
potential ignition source.
− Since the is MIE low, friction and static electrical discharge are also potential
ignitions sources.
www.integpharma.com
Assessment of Risk versus MIE
MIE mJ Recommended Action1
Low sensitivity to ignition. Earth plant and equipment when ignition energy
500 is at or below this level.
100 Consider earthing personnel when energy is below this level.
25 The majority of incidents occur when MIE is below this level.
High sensitivity to ignition. Consider restrictions on high resistivity non-

10 conductors when MIE is below this level.
Extremely sensitive to ignition. Precautions should be as for flammable

1 liquids and gases when MIE is below this level.
MIE is low on the scale shown in this table so static electricity is likely to be a significant
problem.
1. J Barton, Dust Explosion Prevention and Protection – A Practical Guide, IChemE
www.integpharma.com
Surface Temperature Required
• Layer Ignition Temperature

− Tmax 450 – 75oC Tmax 375oC
• Cloud Ignition Temperature

− Tmax 2/3 x 420oC Tmax 280oC
• Select the lower temperature from above, therefore surface

temperature of equipment must be less than 280oC
www.integpharma.com
Properties of Dusts - Reminder
• The analysis in this example is based on data book

information, any actual analysis needs to be based properties
of actual material.
• Particle size and moisture content will have an an impact on
the material properties. Material tested needs to be at the
moisture content leaving the dryer and the particle size
leaving the mill.
www.integpharma.com
Equipment Selected
Location Inside Mill Outside Mill
Zone 20 22
Electrical or Non-
Non-electrical Electrical
electrical
Category Required 1 3
IEC or EN Standard
pc1/pc2† T125°C Ex pc IIIB T125°C‡ Dc IP65
Marking
EU ATEX Marking x II 1 D x II 3 D
PC = Protection Concept e.g. d, e, fr etc.

† pc1/pc2 indicates two independent methods of protection ATEX Guidelines Mill Example
‡ T125°C is a common surface temperature specification
www.integpharma.com
Zone 20 Issues
• In this lactose milling example, the mill contained a Zone

20.
• Zone 20s are common is solids handling equipment
because air is frequently present during operations.
• There are no non-electrical equipment protection concepts
that are suitable for Zone 20. To overcome the problem two
independent protection concepts need to be used.
• Later on we examine an alternative approach to this
problem.
www.integpharma.com
Questions on Equipment Selection
www.integpharma.com
Once compliant
electrical and non-
electrical
equipment has
been selected, is
there a residual
risk of explosion?
www.integpharma.com
Assessment of Residual Risks
• EN 1127-1 lists the following possible ignition sources.
− Hot surfaces, mechanical sparks, flames and hot gases, electrical
sparks, stray electrical currents and cathodic corrosion protection, static
electricity, lightning, electromagnetic waves, ionising radiation, high
frequency radiation, ultrasonics, adiabatic compression and chemical
reaction.
• Effective ignition sources - whether a possible ignition
sources becomes an effective ignition sources depends on:
1. Properties of FGs and/or CDs e.g. minimum ignition energy, and
minimum ignition temperature.
2. Energy of ignition sources.
3. When ignition source occurs, normal operation, expected malfunction or
rare malfunction.
• Scale of anticipated effect of explosion
− Inventory of FGs and/or CDs
− Maximum explosion pressure, rate of pressure rise and deflagration
constant KG or KSt.
www.integpharma.com
Sources of Ignition
From Accident Reports
Stactic Electriity
Gases Dusts Flames

8.5%
Stactic Electriity 7.9% Smoldering Nests

Hot Surfaces
22.0% Hot Surfaces 12.7%
12.0%
4.8%
Welding and Open

Flames Self-Ignition
22.0% 6.0%
Welding
4.2%
Pyrophoric Iron
Sulphide
10.0%
Unknown
17.0%
Adibatic Compression
10.0%
Mechanical
Sparks/Friction
Electrical Arc and 32.7%
Mechanical Electrical Equipment
Sparks/Friction Vehicle Ignition Sparks Other 3.2%
8.0% 8.0% 8.0% 3.0%
Fire and Explosion Incident Analysis May 2005 BIA Report 11/97
Canadian Upstream Oil and Gas Industry
www.integpharma.com
Sources of Ignition for Dust
Explosions - Percentages
Equipment Dust
Silos and Collectors Mills and Conveying Dryers Mixers Polishers Sieves and
Ignition Bunkers and Crushers Systems Classifiers
Source Separators
Mechanical Sparks and
Mechanical Heating 17.2 41.0 71.3 45.5 1.8 46.1 86.4 12.5
Smouldering Nests 30.2 10.5 0 9.1 27.8 0 0 6.3

Electrostatic Discharges 2.6 9.5 3.7 16.7 9.3 34.6 0 12.5
Fire 6.0 4.8 1.3 0 0 3.9 0 12.5
Self Ignition 2.6 6.7 3.7 4.5 16.7 0 0 6.3
Hot Surfaces 10.3 0 3.7 4.5 16.7 0 0 0
Welding and Cutting 7.8 0.9 0 3.0 1.8 3.9 0 0
Electrical Equipment 3.5 0.9 0 0 0 0 0 0
Unknown 18.1 20.9 12.5 13.6 20.4 11.7 13.6 50.0
Other 1.7 4.8 3.7 3.0 3.7 0 0 0
Reference: BIA Report 11/97
www.integpharma.com
Sources of Ignition
Analysis of Accident Report Data
• Electrical equipment is not a large problem perhaps due to

existing electrical standards.
• Mechanical friction is a problem but should be covered by
selecting compliant equipment.
• Mechanical sparks, static electricity and smouldering nests
(dusts only) are a problem.
• The major sources of ignition for dusts depend on the type
of equipment.
• Some of these sources are difficult to eliminate and maybe
there during normal operation.
• Some ignition sources such as welding need to be
controlled by procedures such as hot work permits.
www.integpharma.com
Residual Ignitions Sources
• Static sparks have sufficient energy to ignite FGs and
most CDs – see table on next slide.
− Even if Ex compliant equipment is purchased, static electricity can
still be a problem due to the process.
• Mechanical sparks from stones or tramp metal
− Where the speed is greater than 15 m/s mechanical sparks can ignite
gases and vapours plus mists, dust and flying where the minimum
ignition energy is low – typical < 10 mJ
− Where the minimum ignition temperature is low the sensitivity to
mechanical sparks is greater.
• Smouldering nests can be:
− transferred from item of equipment to other items;
− created by self heating dusts or liquid soaked in porous materials.
• Hot surfaces need to be reviewed since they may be part
of process.
www.integpharma.com
Maximum Theoretical Static Electricity
Spark Energies
Static Electricity Spark Energy (mJ) at Various Voltages
Object
10 kV 20 kV 30kV
Single Screw 0.05 0.2 0.45
100 mm Flange 0.5 2 4.5
Shovel 1 4 9
50 Litre Drum 0.5 – 5 2 – 20 4.5 - 45
Funnel 0.5 – 5 2 – 20 4.5 - 45
200 Litre Drum 5 -15 20 – 60 45 – 135
Person 5 -15 20 – 60 45 – 135
Reaction Vessels 5 – 50 20 -200 45 - 450
Road Tanker 50 200 450
Reference: R. K Eckhoff, Dust Explosions in the Process Industries, 3rd Edition, Gulf Professional Publishing
www.integpharma.com
Additional Measures to Reduce
Residual Risk
• Reduce risk of static electricity generation
− Earth/ground all equipment.
− Reduce the speed of material transfer.
− Make equipment linings conductive i.e. ≤ 109Ω surface resistance and ≥
8 mm to avoid propagation brush discharges.
− Allow time for the charge in non-conductive liquids and dusts to
dissipate
− Change the process to use conductive solvents or the relative humidity
of dust handling processes.
• Protect against stones and tramp metal.
• Investigate ways to prevent self heating.
• Review welding and hot work procedures
• Eliminate hot surfaces that are hotter than the acceptable
surface temperature for FGs and/or CDs. This may require
insulation and high levels of maintenance.
www.integpharma.com
Anticipated
consequences of
an explosion
www.integpharma.com
Explosion Consequences
• Material inventory
− A high material inventory can increase the consequences of an explosion.
− Poor housekeeping can lead dust layers forming increasing the rise of
major secondary explosion resulting from a minor primary explosion.
• Equipment connectivity
− An explosion can spread between items of equipment and turn a smaller
incident into a much larger one.
• Equipment location
− Normally manned versus normally unmanned
− Local to versus remote from occupied premises
• Explosion severity
− Maximum explosion pressure and maximum rate of pressure rise KG or KSt
Where KG or KSt= dp/dt ∛vessel volume. A high KG or KSt indicates the
likelihood of a severe explosion.
− Deflagration versus detonation. Detonations are much more severe than
deflagrations.
www.integpharma.com
Explosive Properties – Gases and Vapours
Max Explosion Pressure and KG
Maximum Explosion
(Deflagration) Pressure KG
Gas/Vapour
bar m/s
Bar g
Dimethyl Formamide 8.4 78
Ethanol 7.0 78
Hydrogen 6.8 550
Isopropanol 7.8 83
Methanol 7.5 75
Toluene 7.8 94
Source: NFPA 68 Examples not to be used for design
www.integpharma.com
Impact of Temperature and Pressure
on Maximum Explosion Pressure
• Maximum explosion pressure decreases with the

temperature at the start of the explosion.
Pmax (T) = Pmax (T0) T0/T T in degrees K
• Maximum explosion increases with the pressure at the start

of the explosion
Pmax (p) = Pmax (p0) p/p0 p in bar abs
www.integpharma.com
Explosive Properties - Dusts
Max Explosion Pressure and Kst
Substance Particle Size Moisture Max Explosion Kst
m Content % (Deflagration) Bar m/s
w/w Pressure bar g
Acetylsalicylic Acid 400 0.1 7.8 157
Lactose 70 0.1 6.7 50
Lactose 220 0.0 4.8 16
Magnesium Stearate <10 (St2)
Maize Starch 11 5.4 8.6 143
Methyl Cellulose 37 10.1 209
Sugar 17 0.4 8.5 116
Sugar 275 0.1 3.9 11
Sorbitol 52 0.2 7.2 74
Source: BIA-Report 13/97 Combustion and

explosion characteristics of dusts
Examples not to be used for design
www.integpharma.com
Explosion Data – Lactose
Impact of Particle Size
20 100
Maximum Explosion Pressure 90
KSt
Maximum Explosion Pressure - Bar
80
15
70
Kst - bar m/s

60
10 50
40
30
5
R2 = 0.4532 20
10
2
R = 0.5355
0 0
0 50 100 150 200 250
Mean Particle Size - mm
www.integpharma.com
Explosion Data – Starch
Impact of Moisture Content
20 200
Maximum Explosion Pressure 180
KSt
Maximum Explosion Pressure - Bar
160
15
R2 = 0.8999 140
Kst - bar m/s

120
10 100
80
R2 = 0.8217
60
5
40
20
0 0
0 2 4 6 8 10 12 14 16 18
Moisture Content %
www.integpharma.com
Explosion Severity
Dust explosions are classified as follows:
Dust Explosion Class Kst Characteristics

Bar.m/s
St 0 0 No explosion
St 1 1 – 199 Weak/moderate explosion
St 2 200 – 300 Strong explosion
St 3 >300 Very strong explosion
There is no agreed comparable system for gases and

vapours but KG can be used to give a indication of explosion
severity.
www.integpharma.com
Deflagration versus Detonation
• All previous references to explosions are for deflagrations
• A detonation is defined as a supersonic combustion wave – a
deflagration is subsonic.
• A detonation needs to be initiated by a high explosive or a
chemical initiator except for highly reactive gases such as
hydrogen, acetylene and carbon disulphide.
• A deflagration can change suddenly to a detonation as a
result of increased turbulence, this can occur along long pipes
or ducts.
• Detonations are more destructive than deflagrations due to
the higher maximum pressure.
• The shock wave created by a deflagration to detonation
transition is even more destructive due to the high pressures
created 50 bar g
www.integpharma.com
Residual Risk Still Unacceptable?
If the some or all of the following conditions exist:
1. All potential ignitions sources cannot be eliminated.

2. The FGs and/or CDs have low minimum ignition energies or
low minimum ignition temperature.
3. There is at least one Zone 0 or Zone 20.
4. The consequences of an explosion are high.
Then it is very likely that additional preventative or

protective measures will be required.
www.integpharma.com
Can oxygen be
O2 excluded from
the process
equipment?
www.integpharma.com
Yes, oxygen can be excluded.
• Inert Gas Blanketing – Prevents an internal explosion by

reducing the oxygen concentration
− This is the preferred approach to residual risk elimination associated
with explosion within equipment since it prevents an explosion.
− Oxygen concentration must be lowered sufficiently to prevent an
explosion – the limiting oxygen concentration is a property of the FG or
CD.
− Nitrogen or carbon dioxide are the most appropriate for pharma, bio
and fine chemicals.
− Extra precautions are required since inert gases are also asphyxiants.
www.integpharma.com
No, oxygen cannot be excluded
• In this case other protective measures are required. These

protect the equipment but do not prevent an explosion.
− Explosion suppression – uses an inert material to suppress an explosion.
Sodium bicarbonate is frequently used.
− Explosion venting – vents the explosion so the pressure
in the equipment remains low. The location of the explosion
vent is a particular problem since a large amount of burning
material is ejected. New flameless venting systems may
be useable for certain applications.
− Explosion proof – equipment is design to withstand
the max explosion pressure without deforming
− Pressure shock resistant equipment - the equipment is design to withstand
the maximum explosion pressure but some equipment deformation is
permitted.
• These measures are not suitable for high KG or KSt materials i.e.
> 200 bar m/s.
• These measures are not suitable for detonations.
www.integpharma.com
Additional Measures - Mitigate
Consequences
The previous additional measures apply to explosions within
equipment. The following measures apply to all explosions.
• Reduce the inventory of FGs and CDs.

• Change the process so that materials with lower maximum
explosion pressure, KG or KSt are used.
• Automate the process or find other ways to reduce the
number of personnel in close proximity to the process.
• Move the process to a location where there are few people.
• Provide explosion quench systems between items of
equipment to prevent the spread of explosion and to prevent a
deflagration turning into a detonation.
• Provide blast proof walls and room explosion vents – this is a
particular requirement where Kg or KSt is high and/or
detonation is likely e.g. hydrogen.
www.integpharma.com
Note on Hybrid Mixtures
• Hybrid mixtures consist of a mixture of gas or vapour and
dust.
• Hybrid mixtures are not covered by the standards.
• A hybrid mixture provides fuel from two sources and
therefore the an explosion can occur when the
concentration is below both the LEL and MEC.
• The addition of just 0.5 vol% of methane can cause the MIE
of a dust to more than halve.
• The addition of 1% methane can cause the rate of pressure
rise to double and 7% methane causes a ten times
increase.
• The best safety precaution is to change the process to

eliminate hybrid mixtures.
www.integpharma.com
Workplace Risk Assessment
FG = Flammable Gas,
Carry Out Select appropriate
START
Hazardous Area equipment to minimise Vapour or Liquid
Classification sources of ignition CD = Combustible Dust or
No Flyings
Can process Can oxygen

Yes be changed Residual Yes be exclude
FG or CD
to eliminate risk of from the
present?
FG and/or ignition? process
CD? equipment?
No
No Yes
Yes No
Explosive atmosphere Change process to Provide system to

cannot be created eliminate FG and/or CD eliminate oxygen
Mitigate consequences
END by providing explosion
relief, suppression etc.
www.integpharma.com
References
1. BIA Report 11/97 Dokumentation Staubexplosionen – Analyse und Einzelfalldarstellung
2. BIA Report 13/97 Combustion and explosion properties of dusts.
3. Fire and Explosion Incident Analysis May 2005, Canadian Upstream Oil and Gas Industry
4. M. Murtomaa, E. Laine, Electrostatic measurements on lactose-glucose mixtures, J.
Electrostat. 48 (2000)
5. IEC 60079-0:2009 Explosive atmospheres – Part 0: Equipment – General Requirements
6. IEC 60079-10-1:2009 Explosive atmospheres – Part 10-1: Classification of areas –
Explosive gas atmospheres
7. IEC 60079-10-2:2009 Explosive atmospheres – Part 10-2: Classification of areas –
Combustible dust atmospheres
8. IEC 60079-14: 2008 Explosive atmospheres. Electrical installations design, selection and
erection
9. EN 1127-1:2007 (E) Explosive atmospheres. Explosion prevention and protection. Basic
concepts and methodology
10. EN 13463-1:2009 Non-electrical equipment for use in potentially explosive atmospheres
Part 1: Basic methods and requirements
11. J. Barton, Dust Explosion Prevention and Protection – A Practical Guide, IChemE
12. R. K. Eckhoff, Dust Explosions in the Process Industries, 3rd Edition, 2003, Gulf Process
Publishing.
13. Guidelines on the application of Directive 94/9/EC, 3rd Edition, June 2009, European
Commission – Enterprise and Industry
14. A.W. Cox, F.P. Lees, M.L. Ang, 'Classification of Hazardous Locations'; IChemE
www.integpharma.com
Many thanks for listening
I will now answer further questions
www.integpharma.com

Very Good Presentation - ATEX IchemE

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Very Good Presentation - ATEX IchemE

Uploaded by

Copyright:

Available Formats

Equipment Use in Explosive Atmospheres

within the Pharma, Bio and Fine Chemical

Equipment Use in Explosive Atmospheres

Equipment Use in Explosive Atmospheres

Equipment Use in Explosive Atmospheres

1. IEC 60079-0:2009 Explosive atmospheres – Part 0:

Equipment Use in Explosive Atmospheres

Equipment Use in Explosive Atmospheres

Equipment Use in Explosive Atmospheres

Equipment Use in Explosive Atmospheres

Can process Can oxygen

Explosive atmosphere Change process to Provide system to

Equipment Use in Explosive Atmospheres

To check this you need

Equipment Use in Explosive Atmospheres

Equipment Use in Explosive Atmospheres

Equipment Use in Explosive Atmospheres

Minimum Explosive Conc - g/m3

Equipment Use in Explosive Atmospheres

Equipment Use in Explosive Atmospheres

• The Minimum Explosive Concentration (MEC) measures the

Equipment Use in Explosive Atmospheres

• Typical MEC for dusts is 30 to 60 g/m3 or greater

Equipment Use in Explosive Atmospheres

• Is a Hazardous Area Classification (HAC) required where only

Equipment Use in Explosive Atmospheres

Equipment Use in Explosive Atmospheres

• The best way to approach the problem of explosive

Equipment Use in Explosive Atmospheres

Equipment Use in Explosive Atmospheres

Equipment Use in Explosive Atmospheres

• Data table for gases, vapours and liquids

• Data sheet for dusts and flyings

Equipment Use in Explosive Atmospheres

• Historically standards have used 2 methods

Equipment Use in Explosive Atmospheres

• Sources of release table

Equipment Use in Explosive Atmospheres

Equipment Use in Explosive Atmospheres

• Operating pressure and temperature

Equipment Use in Explosive Atmospheres

Equipment Use in Explosive Atmospheres

• Zone 0 for Gases and Zone 20 for Dusts

Equipment Use in Explosive Atmospheres

Equipment Use in Explosive Atmospheres

Equipment Use in Explosive Atmospheres

• Housekeeping has an impact on thickness and the persistence of

Equipment Use in Explosive Atmospheres

• Traditional Hazardous Area Classification does not take into

Equipment Use in Explosive Atmospheres

Equipment Use in Explosive Atmospheres

Equipment Use in Explosive Atmospheres

• Section 5.4 states:

Equipment Use in Explosive Atmospheres

• Annex B outlines a method for determining the type of zone

Equipment Use in Explosive Atmospheres

Equipment Use in Explosive Atmospheres

= 1.2 x 10-4 m 3/s

Evaluation of hypothetical volume Vz:

Vz = f x (dV/dt)min = 5 x 1.2 x 10-4 = 2.2 m3

Calculate the time of persistence:

t = -f/C ln((LEL x k)/X0) = -5/1 ln((1.2 x 0.5)/100)

• The hypothetical volume Vz is greater than 0.1m3 but less