ATEX Awareness
ATmosphere Explosible
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Introduction
Explosive atmospheres can be
caused by flammable gases, mists
or vapours or by combustible dusts.
If there is enough of the substance,
mixed with air, then all it needs is a
source of ignition to cause an
explosion.
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What is an explosive atmosphere?
An explosive atmosphere is defined
as a mixture of dangerous
substances with air, under
atmospheric conditions, in the form
of gases, vapours, mist or dust in
which, after ignition has occurred,
combustion spreads to the entire
unburned mixture.
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Where can explosive atmospheres be found?
Many workplaces may contain, or
have activities that produce,
explosive or potentially explosive
atmospheres.
Examples include places where
work activities create or release
flammable gases or vapours, such
as vehicle paint spraying, or in
workplaces handling fine organic
dusts such as grain flour or wood.
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Dangers of Dust Explosion in Flour Mills
Dust explosions can cause
catastrophic loss of life,
injuries, and destruction
of facilities and company
assets.
Grain elevator explosion and fire
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What is ATEX?
ATEX is an abbreviation for "ATmosphere EXplosible". It is the name commonly given to
the two European Directives for controlling explosive atmospheres:
1) Directive 2014/34/EU (also known as 'ATEX 114' or 'the ATEX Equipment Directive')
on the approximation of the laws of Members States concerning equipment and
protective systems intended for use in potentially explosive atmospheres.
2) Directive 99/92/EC (also known as 'ATEX 137' or the 'ATEX Workplace Directive') on
minimum requirements for improving the health and safety protection of workers
potentially at risk from explosive atmospheres.
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What is the sufficient level of safety for equipment
to be used in potentially explosive atmospheres
according to the ATEX Product Directive?
The level of safety of equipment is dependent on the likelihood of a flammable atmosphere
arising. The higher the likelihood of a flammable atmosphere being present the stronger the
demands that need to be put on equipment when operating in such a place.
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Kst, the dust deflagration
index, measures the relative
explosion severity compared
to other dusts. The larger
the value for Kst, the more
severe the explosion.
Kst provides the best “single
number” estimate of the
anticipated behavior of a
dust deflagration.
Hazardous Areas Classification
Zone 20: An area in which an Ζone 22: An area in which an
explosive atmosphere of flammable explosive atmosphere of flammable
Zone 21: An area in which
dusts, is notanlikely to occur in
dusts, is presentexplosive
continuously or for
atmosphere of flammable
long periods or frequently normal operation but, if it does
dusts, is likely tooccur,
occurwill
in normal
persist for a short period
operation occasionally.
only.
Zone classification and equipment
Equipment Category 1 (1 G or D) EPL a
Ignition sources must be avoided:
Zone 0 or 20
• During operation without malfunctions, normal operation
• During expected malfunctions
• During rare malfunctions in operation
Equipment Category 2 (2 G or D) EPL b
Zone 1 or 21 Ignition sources shall be avoided:
• During operation without malfunctions, normal operation
• During expected malfunctions
Equipment Category 3 (3 G or D) EPL c
Zone 2 or 22 Ignition sources shall be avoided:
• During operation without malfunctions, normal operation
How is ATEX information displayed?
How is ATEX information displayed?
Why equipment and protective • ATEX approval and/or certification is a requirement to ensure that equipment and protective systems
are suitable for their intended use within designated areas containing potentially explosive
systems intended for use in atmospheres.
explosive atmospheres must be • Depending on the equipment category, which depends on the applicable hazardous zone for the
ATEX approved or certified? intended use, the approval or certification process typically involves a Notified Body who can assess
the conformity of the product and a third-party organization with a certified testing facility to test the
product.
A significant segment of
combustible dust incidents
occur at food industry:
• sugar mill and refinery plants,
• confectionery works,
• bread-baking plants,
• mill houses,
• food production lines, the
ingredients of which are flour, sugar,
coffee, tea, rice, grits, spices, milk
powder, starch, malt, etc.
• During the processing particles of bulk materials are dispersed in the air and
create a dust-air mixture with explosive concentrations of combustible dust.
• The occurrence of an ignition source near such an explosive mixture results in
an explosion that can have a devastating effect on equipment and pose a
health hazard to employees.
Main technological processes associated with the hazard of potentially
explosive environment occurrence
Why dust explosions
occur ?
The dust pentagon
Prevention of dust
explosions
Risk assessment:
‒ identify hazards, risks and controls.
Eliminate dusts at source:
‒ Example, pastes rather than
powders.
Inerting:
‒ nitrogen blankets.
Dust extraction:
‒ minimise fugitive releases.
Control of ignition sources:
‒ zoned areas.
• Explosion protection of dust-
collection systems
• Solution for production safety in
the event of an explosion of the
venting filter by reducing the
pressure of the explosion inside
the filter and isolating the
explosion from adjacent
equipment.
• Explosion protection of
pneumatic transport systems
• Systems for production safety
and explosion prevention in
adjacent pieces of equipment
using an HRD barrier or a
GATEX quick-acting slide
valve.
Explosion protection of vessels
and silos
• Explosion protection solution for
bunkers, silos and other vessels
by pressure venting and explosion
suppression, as well as protection
of related equipment by explosion
isolation.
• Explosion Protection
Documents (EPD)
• An expert explosion safety
audit of your production for
compliance with ATEX
standards and industry
standards.
ATEX Study Review 2017-2022
• Inspection and review of all Grand Mills Areas
• Ship Unloaders
• New Silos & Old Silos (wheat cleaning, handling and storage)
• Flour Mills A, B, C, D
• Flour Storage Bins and Packaging equipment
• New Feed, Old Feed
• CNG installation for boilers
• Diesel & Petrol Storage Tanks
• The review was based on
• the 2017 ATEX Study,
• the extent of recommendations’ implementation
• the extent of any modifications regarding the main production machinery
• the increased utilization of Indian wheat which is a dustier material.
• the introduction of CNG as a new fuel for Steam Boilers
Main Improvements that were identified
Implementation of Machinery Safety and Lock Out – Tag Out Procedure
Main Improvements that were identified
Good Levels of Housekeeping at certain areas
Main Improvements that were identified
Temperature monitoring installed at old silos Chain Conveyors
8.1.1.1. Cyclones and hoppers Zone Classification: Zone 20
• Mechanically generated sparks - Impact of
foreign metallic item on equipment
• Static electricity - Charge accumulation on
equipment moving parts and casing
Existing Protective Measures
There is a magnet installed before the roller
mills in order to remove any foreign metal
objects.
3. Moderate-Serious injury off
Consequence Probability 2. Possible
site injury
RISK FACTOR 6 MEDIUM
Suggested Measures
➢ Visual inspection in the equipment should be made regularly in order to identify any
loose bolts that could enter the circuit (i.e. Screws or bolts missing).
➢ The equipment, pipelines and their flanges shall be properly bonded and grounded with
the use of appropriate materials. Measurements of the effectiveness of equipotential
bonding system shall be conducted annually.
Explosion Risk Assessment after the implementation of measures
3. Moderate-Serious injury off
Consequence Probability 1. Rare
site injury
RISK FACTOR 3 LOW
5.1.1. Area surrounding the equipment installed in Zone Classification: Zone 21
the ship unloaders Ignition sources
• Hot surface - Development of
high temperature on the surface
of electrical equipment (e.g.
motors, etc)
• Electrical equipment - Spark
generation from non -ATEX
certified electrical equipment
• Static electricity - Spark due to
charge accumulation on
equipment
3. Moderate-Serious injury off
Consequence Probability 3. Likely
site injury
RISK FACTOR 9 HIGH
Suggested Measures
➢ In order for the areas under consideration not to be classified as Zone 21 hazardous areas,
openings in equipment shall be properly sealed to prevent fugitive dust emissions. Filters
dedusting the chain conveyors shall not be in operation until openings are properly
sealed.
Explosion Risk Assessment after the implementation of measures
3. Moderate-Serious injury off
Consequence Probability 1. Rare
site injury
RISK FACTOR 3 LOW
8.1.1.1. Area surrounding the Zone Classification: Zone 21
hammermill Ignition sources
• Hot surface - Development of high
temperature on the surface of electrical
equipment (e.g. motors, etc)
• Electrical equipment - Spark generation from
non -ATEX certified electrical equipment
• Hot surface - Development of high
temperature due to friction of equipment
moving parts
• Mechanically generated sparks - Spark
generation due to impact of moving parts
• Static electricity - Charge accumulation on
insulated conductive parts of equipment
Consequence 4. Major-Single Fatality Probability 4. Often
RISK FACTOR 16 EXTREME
Suggested Measures
➢ In order for the area under consideration not to be classified as Zone 21 hazardous area,
openings in equipment shall be properly sealed to prevent fugitive dust emissions.
Moreover, an appropriate housekeeping schedule shall be implemented in order to
achieve thickness of dust deposits below 0.8 mm.
Explosion Risk Assessment after the implementation of measures
Consequence 1. Insignificant-Near miss Probability 1. Rare
RISK FACTOR 1 LOW
Main Drawbacks identified
New projects and replacement of existing equipment with no ATEX consideration
Main Drawbacks identified
New projects and replacement of existing equipment with no ATEX consideration
Main Drawbacks identified
Insufficient design and improper operation of newly installed equipment
Main Drawbacks identified
Insufficient design and improper operation of newly installed equipment
5.1.1. Main Product Receiving Bag Zone Classification: Zone 20
Filters (Crude side) Ignition sources
• Static electricity - Spark due to charge
accumulation on insulated conductive parts
of equipment and filter cloths.
• Exothermic reaction - Oxidation of grain
dust depositions inside filters leading to
smouldering fire or suction of smouldering
nest from the ship. Risk of CO explosion.
• Electronic equipment - Spark generation
from non -ATEX certified electronic
equipment
Existing Protective Measures
Explosion vents are installed on the filters for
safe explosion venting.
A potential explosion created by smouldering
of grain is only possible if the deposit is left
for a long period of time without any
disturbance.
5. Catastrophic - Multiple
Consequence Probability 3. Likely
fatality
RISK FACTOR 15 EXTREME
Suggested Measures
➢ Maintenance of explosion vents shall be done according to manufacturer specifications,
in order to ensure the level of explosion protection provided by this type of equipment.
➢ The equipment, pipelines and their flanges shall be properly bonded and grounded with
the use of appropriate materials. Measurements of the effectiveness of equipotential
bonding system shall be conducted annually.
➢ In a future replacement filter cloths with antistatic properties shall be installed.
Main points from ProAct Review
• Implementation of recommendations of 2017 study dealt only with extreme risks.
• The new study will most probably require additional technical measures due to Indian
wheat.
• The key personnel in most departments is new and the knowledge on dust explosion
hazards and the identified hazards of the previous study, is limited
• New projects and replacement of existing equipment do not take into consideration the
explosion hazards.
After the Revised Study
• Training on Explosion Hazards and Involvement of all departments’ engineers in explosion
prevention and protection
✓Production – operation
✓Maintenance
✓New projects development and Procurement
• Preparation of an SOP for the Hazard Identification, design, selection and erection of new
projects and equipment within hazardous areas
The requirements for electrical equipment for
hazardous locations are multi-layered:
National and international determinations,
guidelines and standards must be complied
with to achieve the highest possible level of
safety.
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