Professional Documents
Culture Documents
Dust
Explosion Protection
Content
1. General .................................................................................................................................................1
1.1 Explosion triangle...............................................................................................................................2
1.2 Efficiency triangle ...............................................................................................................................3
1.3 Guideline 94/9/EG (ATEX 95) Guideline 1999/92/EG (ATEX 137) ................................................4
2. Protection concepts..........................................................................................................................14
2.1 Primary explosion protection............................................................................................................14
2.2 Suppression .....................................................................................................................................16
2.3 Explosions pressure release............................................................................................................18
3. Explosion disengagement................................................................................................................19
4. Reimelt Rules for the prevention of dust explosions ...................................................................20
5. Design recommendations for individual aggregates ....................................................................21
6. Photos showing dust explosions ....................................................................................................29
7. References .........................................................................................................................................31
1. General
Production and processing methods which create organic or chemical dusts are often closely tied to fire
and explosion hazards. The knowledge that dust can cause explosions has been known for more than
200 years. The first dust explosion which was defined as one happened on the 14th December 1785 according to records of the Turin academy of sciences in a flour storage facility in Turin/Italy.
In Germany for instance, every year approx. 350 to 400 explosions are counted, approx. 1 to 2 incidents
per day. The cause for this rapid increase is certainly related to an increasing humanization of the workplace and the corresponding clean-air measures.
The companies providing social insurance against occupational accidents and federal environmental
agencies ensure that work areas are equipped with suitable exhaust systems, this also inevitably increases the quantity of dust collection in filters and associated equipment.
In addition, the share of fines has strongly increased due to high-speed machinery and automated conveying systems.
Especially the volume of fine dust drastically increases the
risk of explosions. With the reduced dust particle size, the
surface area, hence, the impact of the explosion rises exponentially.
The disastrous effects of dust explosions can be considerably reduced or entirely prevented by primary explosion
protection measures as well as by protective measures
regarding the design.
Fig. 1:
Feed mill in Belgium
Destroyed by a dust explosion in 1994
Fuel
Oxygen
Fig. 2: Explosion triangle
Availability
Safety
Fig. 3: Efficiency triangle
article 95 (94/9/EG)
guideline with basic demands on safe
products
EC-guidelines
e.g.
guideline for machines
EC-guidelines
as
frame guideline safety at work
as used in Germany
ATEX 137
The guideline 99/92/EG came into force on 01st
January 2003.
Material and workplace which are already in use
have a transitional period of 3 years and must
correspond to the guideline on 30th June 2006.
Result:
As guarantee for improvement of health care and the safety of employees which can be exposed to the
dangers caused by an explosive atmosphere the employer has the juridical responsibility.
ADVICE: The zone division proposals are based on the assumption that the material to be treated is a customary wheat or rye flour.
zone division
referring to ATEX
137
effective 01.07.03
no
no
no
no
no
no
10
21
10
20
11
21
11
21
no
no
no
no
11
no
11
no
11
22
10
20
10
20
10
20
10
20
system part
remarks
system part
zone division
referring to
ATEX 137
Devices and system parts which are operated with low pressure. 1-14.7 psi or under
1 bar.
no
no
no
no
11
22
10
20
10
20
no
no
11
22
10
20
10
21
10
20
10
20
10
21 (20)
10
20
10
20
10
21
11
20
remarks
There is no oxydation mean such as oxygen
if the devices and systems parts are process
depending operated under vacuum during
the main process time. Contact an expert if
necessary!
There is no oxydation means such as oxygen if the devices and systems parts are
process depending operated under vacuum
during the main process time. Contact an
expert if necessary!
Explosive atmosphere is not often probable
because of the low peripheral speed.
Explosive atmosphere is probable because
of the high peripheral speed. Consider
ignition source.
Explosive atmosphere is always probable
because of the upstream fluidising bed.
There is no dust release around open
places as low pressure process, dust exhausts existing. Clean regularly.
Dust deposits are possible. Also small dust
deposits are removed. Zone 22 in the area
of 1 m around the outflow position to the
floor.
Explosive atmosphere is always probable
during the feeding process because of the
existing fluidising bed.
Explosive atmosphere is sometimes probable during the feeding process..
Explosive atmosphere is always probable.
Avoiding of effective ignition sources is not
possible as a rule. Contact an expert!
Explosive atmosphere is always probable.
Explosive atmosphere is only probable
during start and shutdown processes if
these processes are only effected sometimes according to the operation duration.
Explosive atmosphere is always probable
during the mixing and discharge process
because of the existing fluidising bed.
Explosive atmosphere is always probable
during the mixing process.
Explosive atmosphere is only sometimes
probable during the mixing process because
of the high filling level.
Explosive atmosphere is probable during
sifting process.
zone division
referring to
ATEX 137
Interior of sifters
11
21
11
22
11
22
11
22
system part
remarks
Explosive atmosphere is only sometimes
probable during the sifting.
Explosive atmosphere is rarely probable
during discharge (before each filling and
during discharge of the upstream hopper
etc.)
Explosive atmosphere is rarely probable
during discharge (before each filling and
during discharge of the upstream hopper
etc.)
Explosive atmosphere is rarely probable
during discharge (before each filling and
during discharge of the upstream hopper
etc.)
1.3.2.5 Further information for the introduction of the guideline ATEX 137.
Systems put into operation before 01st July 2003 can be operated until the 30st June 2006.
Important:
Systems which correspond to the minimum regulations BetrSichV attachement 4A and which are operated safely can be operated safely also after the 30st July 2003! (e.g. Reimelt systems which were put into
operation after 12/1996 but which are used according to the regulations!)
If new systems are installed or put into operation after the 1st July 2003 only ATEX authorized devices
can be used. The zone division must be executed according to the new zone division concept.
1.3.3 Demand on the construction and use of devices for the determined use in areas in danger of
explosion (ATEX 95)
Devices are machines, equipment, stationary or moveable installations, control and equipment parts as
well as warning and preventive systems which by themselves or in combination produce or transfer,
store, measure, control, transform or consume energies or which are designated to work material and
which have their own potential ignition sources and therefore can cause an explosion.
group II
(explosive atmosphere of gas/air or dust/air mixtures, mist or vapors)
category 1
G
(gas)
(zone 0)
D
(dust)
(zone 20)
category 2
G
(gas)
(zone 1)
D
(dust)
(zone 21)
category 3
G
(gas)
(zone 2)
D
(dust)
(zone 22)
10
Category 2 - devices:
Devices of this category must guarantee the necessary high level of safety also if repeatedly faults of the
device or other faults occur.
Documentation must be deposited at a named authority!
Category 3 - devices:
The devices of category 3 meet the necessary level of safety, if foreseeable probable ignition sources
which can occur during normal operation will be avoided.
Self-certification without involvement of a named authority!
1.3.5 Classification proposal of devices in categories according to ATEX 95
device or aggregate
device according to
ATEX 95
yes
no
category 2
Jet-Filter
category 3
The machine is designed according to the proposal from
IVSS. It must be checked if temperatures arise which can
serve as ignition sources caused by shaft glands or by
defective bearings.
The machine is designed according to the proposal from
IVSS. It must be checked if temperatures arise which can
serve as ignition sources caused by shaft glands or by
defective bearings. In addition the electrical installation in
the dust leading area of the machine could become
ignition source. This must be checked.
The machine is not designed according to the proposal of
the IVSS. Because of the material combination stainless
steel beater and stainless steel sifter basket , ignition
danger is arising caused by the peripheral speed of the
paddles ( > 1 m/s). There is danger of ignition.
The conveying screw is designed according to the
proposal of the IVSS. It must be checked if temperatures
arise which can serve as ignition sources caused by shaft
glands or by defective bearings
There is danger of ignition because of the peripheral
speed of the screw shaft.
Rotary discharge valves are used as a protection element
(as decoupling factor) and are therefore automatically
subject to ATEX95! Existing certificates which are
subject to Ex-RL must be rewritten!
Diverter valves are not subject to ATEX 95 as they have
no ignition source in the dust leading areas.!
Diverter valves could be used as protection element (as
decoupling, analogue to the rotary discharge valves) and
are therefore automatically subject to ATEX 95! It could
be useful to have such valves in the program. Check!
These devices are not subject to ATEX 95, as they have
no ignition source in the dust leading area.
Fluidising beds are not subject to ATEX 95, as they have
no ignitions source in the dust leading area. Attention!
Electrostatics must be considered!
There is danger of ignition because of the peripheral
speed of the lump breakers. It must also be checked if
temperatures arise which can serve as ignition sources
caused by shaft glands or by defective bearings
These agitators are designed according to the proposal of
the IVSS. It must be checked if temperatures arise which
can serve as ignition sources caused by shaft glands or
by defective bearings
There is danger of ignition because of the peripheral
speed and/or high driving power of the agitators. It must
be checked if temperatures arise which can serve as
ignition sources caused by shaft glands or by defective
bearings.
Jet-Filters are not subject to ATEX 95 as they have no
ignition source in the dust leading area.
Attention! Electrostatics must be considered!
11
device or aggregate
device according to
ATEX 95
yes
Kategorie 2
Kategorie 3
no
Special advice
This proposal only describes the dust leading area of a device. If the device is put in a dust leading environment or the customer defines the position of the device as Ex-Zone (e.g. zone 22), so the above
mentioned assessment must be executed again under this point of view. If necessary motors,
switches, sensors, actors and initiators must be chosen again referring to the zone (e.g. zone 22 category 3 devices).
1.3.6 Temporary regulation of ATEX 95
Devices and protection systems which correspond to the regulations valid on 23rd March 1994 may be put
into operation until the 30st June 2003.
The authorities which care about the evaluation of the conformity of the equipment which has been put
into operation before 1st July 2003 must take into account the results of the already executed examinations and controls which are subject to the regulation (valid on 23rd March 1994) about electrical systems
which are located in hazardous rooms.
1.3.7 Necessary coordination between system operator and system designer
The system operator must define the Ex-zone based on the zone definition. ATEX 137!
Based on the zone definition by the systems operator the system designer must define/select the devices
(machines, protection systems a.s.o.) ATEX 95!
12
device group
II
demands
1
redundant
protective
measures
categories
2
simple
protective
measures
gas-Ex-zones
zone 0
zone 1
zone 2
dust-Ex-zones
zone 20
zone 21
zone 22
3
safe during normal
operation
Internet:
http://www.europa.eu.int/comm/enterprise/atex/guide/guide_de.pdf
http://www.bgn.de/Fachartikel/Akzente06_01/Bindend/Atex.html
http://www.de.osha.eu.int/legislation/verord/GSGV-11.html
etc.
VDMA:
Positionspapier zu ATEX
DIN EN-Normen: DIN EN 1050 / DIN EN 1127-1 / DIN EN 13463-1 / DIN EN 13463-5 / etc.
VDI-Richtlinien:
Suppliers:
13
2. Protection concepts
To meet these requirements, several protection concepts are available:
Prevention of ignition sources as primary explosion protection measures
Suppression systems
Explosion pressure relief as protection for man and machine through design measures
Hot Surfaces
Maximum ambient temperature =
outside temperature on hot summer days
Minimum glow temperature
=
e.g. 450 C (explosion characteristics)
Minimum ignition temperature =
e.g. 370 C (explosion characteristics)
2/3 * ignition temperature
=
246 C
Glow temperature - 75 C
=
375 C according to VDI 2263
2/3 x ignition temperature - 75 C must not be reached at any point in the system.
Electrical equipment in zone 11 type of protection IP 54
Electrical equipment in zone 10 to include type examination certificate plus observation of the relevant
regulations for zone 11.
Conveying air temperature system related <120 C. Dust layers are prevented through operational measures as far as possible in accordance with VDI Guideline 2262 Dust control at the workplace. Please
inform our customers about this important point.
Shut-down procedures initiated by the control system will not increase surface temperatures.
Due to operational measures, welding and cutting operations are not executed, unless the permissibility
of such operations has been examined in detail first.
14
Electrical Apparatus
Electrical apparatus are designed according to VDE 0165/9.83, Part Z. Operational measures ensure that
the proper state function is regularly monitored.
Electrical Compensation Circuits
Equipotential bonding is designed in compliance with VDE 0165/9.83.
Static Electricity
According to ZH 1/200 Guideline for the Prevention of the Danger of Ignition caused by Electrostatic
Charges, all conductive parts are grounded to prevent spark discharges. Based on experience, brush
discharges will not ignite dust/air mixtures. Lightening-like discharges in silos are not to be expected according to VDI 2263.
Lightning
High-voltage protection equipment is to be provided by the customer in accordance with the general provisions governing the protection of equipment against high voltage/lightening, especially the paragraph on
explosion hazardous operational areas and storage areas.
Electromagnetic waves 104 Hz to 3.1012 Hz
N/A
Electromagnetic waves 3.1011 Hz to 3.1015 Hz
N/A
Ionizing radiation
N/A
Ultrasound
N/A
Chemical reactions
N/A
Should the concept of Prevention of Effective Ignition Sources not be sufficient, design measures are
required which we will now review in more detail.
Since inertisation is usually a very expensive and complex protective measure, it shall not be
discussed in detail.
15
2.2 Suppression
Explosion suppression utilizes a recognition system which detects an explosion in the early stages and
interrupts its propagation through the rapid dispersion of an extinguishing medium (powder or water). The
extinguishing medium is dispersed in the equipment to be protected via several high-pressure extinguishers.
Once the extinguishers have been activated, they must be refilled by the service personnel. The entire
system, including the connected pipelines, must be cleaned before production can be started up again.
This means downtimes and, therefore, loss of production, because explosion protection is not effective
anymore until the suppression system is ready for operation again.
The advantage of explosion suppression systems is that they can also be used for dust explosions with
toxic dusts and independently from the place where the equipment to be protected is located. Furthermore, the equipment must only be designed for a maximum gauge pressure of 1 bar (VDI 2263). Therefore, this protective measure is also well suited for existing systems which were not designed for higher
pressures!
Fig. 4: Rate of pressure rise in the course of an explosion with/without suppression in a vessel (optimum
concentration)
16
Explosion suppression systems (Fig. 2) consist of a sensor unit which registers a starting explosion, pressurized extinguishers and a control/monitoring unit. Via this control/monitoring unit, the valves of the extinguishers are activated when the sensor unit registers a starting explosion and the extinguishing medium is dispersed in the vessel.
Control unit
Sensors
Extinguishers
Alarm
Activation of
shut-off
Emergency shutdown of the
system
The contents of the extinguisher is discharged into the equipment to be protected in as short a time as
possible (Fig. 3) and evenly distributed. By this action, the explosion flames will be extinguished and the
max. explosion pressure to be expected in the area of Pmax = 7 to 10 bar will be reduced to Pred 1 bar
(see Fig. 1).
Ignition
Sensor
registers
starting
explosion
Start of
suppression
Suppression
Suppression
End of suppression
17
The quench pipe allows the explosion pressure to be released into the room with no spreading of dust or
flames. Burnt and unburnt particles are retained by the integrated dust filter, thus avoiding an explosion.
Systems can be protected without complex and expensive exhaust ducts. Thus, system parts may be set
up to meet optimum process criteria. With the quench pipe, the required relief area is much smaller than
the required area for using an exhaust duct.
18
3. Explosion disengagement
In all applications where dust explosion hazardous vessels and equipment in systems are connected via
pipes, there is the risk of propagation of a dust explosion through these pipes to other locations.
During this propagation of an explosion, turbulence, displacement and supercharging effects could either
cause excessive explosion pressures or even detonations. To prevent the propagation of an explosion
through connecting pipes, it may make sense to separate specific system parts from the effects of a possible explosion by using suitable devices, i.e. explosion disengagement.
The use of such disengagement equipment is always required in the following cases:
When the unprotected system section which could be, for example, depressurized must be safely
separated from the protected section of the system where effective ignition sources and, thus, explosions must be anticipated.
or
When vessels are connected through longer pipes so that flame jet ignition or high pressure peaks
must be anticipated. This is especially problematic, if a large vessel releases pressure into a small
one, or when a vessel with a higher pressure resistance is connected to vessels of smaller pressure
resistance.
Depending on the area of application, system parts can be separated by using e.g. rotary valves, suppression barriers, rapid action valves or diverters.
To establish the connection between above described measures and reality, the following pages list the
measures recommended by REIMELT for application with its systems.
19
20
21
5.2 For indoor silo systems (< 25m3 volume each silo) or other large units if pressure relief
Fig.:8
22
The probability that explosive dust/air mixtures occur depends on the applied conveying method, e.g. dilute-phase conveying, strand conveying, slug conveying.
With continuous pneumatic conveying systems, the protective measure Prevention of Effective
Ignition Sources is generally considered to be sufficient.
When applying the concept of Prevention of Effective Ignition Sources, it must be ensured that
no hazardous electrostatic discharge processes occur, e.g. by using conductive materials
and by grounding conductive components,
pressure generators, e.g. fans, are located in areas without product (clean-air side),
the temperature of the conveying air shall not create ignition hazards,
(The characteristic values selfignition temperature and ignition temperature should be considered in particular. Since the minimum ignition energy is temperature dependent, a high
conveying air temperature can be an additional ignition hazard.)
no hazardous friction and impact processes are created by impurities carried along by the
conveying system,
(In general, friction and impact generated sparks do not pose an ignition hazard. This is especially applicable if the minimum ignition energy of the conveyed dust is >10 mJ).
no effective ignition sources can enter continuous pneumatic conveying equipment.
(Experience shows that in many cases there is no immediate danger of igniting explosive
dust/air mixtures through glowing particle nests inside continuous pneumatic conveying systems. However, the possibility of ignition sources entering and transferring via the equipment
should be considered.)
In most conveying phases, continuous pneumatic conveying equipment has a very low dust
explosion risk. In particular, this can be attributed to the reduced probability of occurrence of
explosive dust/air mixtures and the increased minimum ignition energy through turbulence.
23
With oscillating conveyors, the generation of explosive dust/air mixtures is usually not anticipated.
In general, only electrostatic charges may present effective ignition sources.
Hazardous electrostatic discharge processes must therefore be prevented. This is ensured, for
instance, by using conductive materials and grounding all conductive parts.
.
The occurrence of explosive dust/air mixtures inside screw conveyors cannot be excluded.
Possible ignition sources in particular are:
hot surfaces through friction and grinding processes,
increase in temperature due to blockage of product,
electrostatic discharge processes. The occurrence of effective ignition sources increases as
the circumferential speed increases.
Possible protective measures to prevent effective ignition sources are as follows:
reduce circumferential speed, (based on experience, no hazardous friction or grinding processes are to be expected if the circumferential speed is 1 m/s.)
avoid indoor storage
prevent impurities from entering the equipment
prevent dangerous blockage of product, e.g. through overload protection, stop valves
avoid dangerous electrostatic charges, e.g. by using conductive materials and grounding all
conductive parts.
High-speed mills, such as pin mills, hammer mills, impact grinding mills, must always be considered to be possible ignition sources. Therefore, suitable protective measures (inertisation,
design measures) against dust explosions as well as their propagation must be applied inside
the mill as well as in the upstream and downstream equipment.
In any case, impurities should be prevented from entering the equipment to minimize the risk of
ignition.
Only in special exceptional cases can the measure of Prevention of Effective Ignition Sources
be applied (e.g. if minimum ignition energy and ignition temperature of the processed dust are
extremely high).
24
Exemplary design of a high-speed mill (schematic representation) for fluidizable products protected through explosion pressure relief devices
dust control
Exhaust pipe; alternative: quench pipe
Filter socks on
filter cages
Rotary valve
Mill
Rupture disk
Mill bunker
Rotary valve
Air
Product
Explosion pressure release
Fig.:9
25
Contrary to rotary sifters without interior moving components, mechanically generated sparks
and hot surfaces must be particularly considered when using sifters with interior moving components.
With slow-moving components inside (v 1 m x s-1) and small motor sizes (HP 4 kW), experience shows that there is no danger of ignition to be expected.
Fig.:10
With higher speed components inside and/or larger drive sizes, explosion protection through
design measures or inertisation may be omitted in the following cases:
If design measures prevent effective ignition through mechanical sparks and hot surfaces,
e.g. by selecting suitable material combinations, such as screen structure made of plastic
(REIMELT standard).
If the distance between the moving parts is large enough to prevent impurities that may have
entered the equipment from initiating dangerous friction processes. By using impurities separators (e.g. prescreen), the size of the entering impurities can be limited.
26
5.8 Mixer
Due to process engineering technology generally used with mixers, e.g. design features or high
filling levels, the occurrence of explosive dust/air mixtures is frequently limited. If this is the case, mixers can be safely operated by applying measures of Prevention of Effective Ignition
Sources. Otherwise, further measures must be applied (e.g. inertisation or explosion protection
through design measures).
5.9
Contrary to mixers without moving components inside (item 8.1), mechanically generated
sparks and hot surfaces must be considered for mixers with interior moving components.
With slow-speed interior components (v 1 m x s-1) and lower driving capacities (w 4 kW), experience shows that there is no danger of ignition to be expected.
With higher speed components inside and/or higher driving capacities, explosion protection
through design measures or inertisation may be omitted in the following cases:
If the high filling level ( 70%) limits the occurrence of explosive dust/air mixtures.
If the mixing velocity is reduced (circumferential speed 1 m x s-1) during the filling and discharge process, and so-called choppers or disintegrators are not used.
If there is sufficient distance between the parts moving against each other so that they do not
touch under any circumstances, no matter what the operating mode.
If hot surfaces which could become effective ignition sources can be prevented through impurities separators.
27
If no products are used which, under the anticipated operating conditions, such as thermal
and mechanical wear, tend towards selfignition.
If dangerous product caking is prevented by design measures or, if applicable, by appropriate cleaning methods.
28
29
This publication should make it possible to design state-of-the-art systems that are safe with
respect to dust explosions. Should you have any further questions, please do not hesitate to
contact the experts at REIMELT any time.
Rdermark, den 16.03.1998
7. References
Bia-Report 11/97.
VDI-Bericht 1717.
ZH1/200.
Reimelt-Werknormen.
31
Stand 23.05.2003
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