How to Run General Purpose Analyzers in Potentially Explosive Atmospheres

(Considerations are Limited to EEx II G)

Norbert Zeug BARTEC BENKE GmbH D-21465 Reinbek

BIRA WAT Symposium Mortsel, March 16th, 2006

Legal Regulations ATEX

Harmonised General Conditions in Europe
Explosion Protection Directive 94/9/EC
(for Manufacturers)
Conformity Assessment Potential ignition source (electrical and non electrical) during normal operation, expected or rare unit malfunction:

Directive 1999/92/EC
(for Operators)
Assessment of Explosion Risk temporal behaviour of flammable components (Gas and Dust) classification of hazardous areas

Unit Groups, -categories

Zones

Basic Questions
Area Classification
Zone 1
explosive atmosphere is likely to occur in normal operation occasionally

Zone 2
explosive atmosphere is not likely to occur in normal operation but, if it does occur, will persist for a short period only

Temperature Class
T1 T2 T3 T4 T5 T6 A B (B+H2) C 450C 300C 200C 135C 100C 85C (examples: methane, ethane, ammonia, gasoline,) (examples: ethylene, ethylene oxide, hydrogen sulphide,..) hydrogen, acetylene, carbon disulphide

Explosion Sub Groups

Planning Analyser Systems

What can we do, if general purpose analysers should/must be used? Two possible approaches
Approach 1 following Directive 94/9/EC Approach 2 following Directive 1999/92/EC

Planning Analyser Systems

In both approaches we need to consider the Cause of Risk External Source
dangerous amount of an explosive atmosphere in the environment of the analyser system

Internal Source
dangerous amount of an explosive atmosphere via the introduction of the sample stream itself (flammable product to be measured)

Approach 1: Directive 94/9/EC

Approved Types of Protections: European/International Norm Description
EN 60079-0 / EN 60079-1 / EN 60079-2 / EN 60079-5 / EN 60079-6 / EN 60079-7 / EN 60079-11 / EN 60079-15 / EN 60079-18 / IEC 60079-0 IEC 60079-1 IEC 60079-2 IEC 60079-5 IEC 60079-6 IEC 60079-7 IEC 60079-11 IEC 60079-15 IEC 60079-18 general requirements flameproof enclosure d pressurized enclosure p powder filling q oil immersion o increased safety e intrinsic safety i type of protection n (category 3G) encapsulation m

Pressurized Enclosure p
EN 60079-2 valid since June 2004 EN 50016 transition period till June 1st, 2007 For current projects both norms can be used

EEx p Control Systems for Zone 1

Purge phase
Closed enclosure is purged with purge gas Automatic dilution of potentially present explosive gas mixtures to a safe level

Operation phase
Creation and monitoring of an internal overpressure Preventing the intrusion of an explosive atmosphere from outside (permanent purge or compensation for leakage losses) Switch on of all general purpose devices

Malfunction
Overpressure drops below 0.5 mbar All general purpose devices are shut down automatically

Simplified Procedure for Zone 2

Purge phase not strictly required
It is required to ensure, that no explosive atmosphere is present when the system is energised manual purge usage of gas sensors etc.

Operation phase
Identical to Zone 1

Malfunction
No automatic shut down necessary Alarming is sufficient

Analysers EEx p Packaged

Non flammable Samples:
including gas mixtures which are below LEL at any time Most simple case Analyser can be treated like any other electrical equipment Purge gas: air Overpressure sustained via leakage compensation Installation in Zone 1: EEx p control system with automatic purge phase and shut down in case of pressure loss Installation in Zone 2: according to simplified procedure

Analysers EEx p Packaged

Introduction of Flammable Samples: Examination of the Containment System This means:
Checking the internal sample path for potential leakages Checking for ICAs (Ignition-Capable Apparatus)

Flame arresters for sample gas inlet and outlet if a potential ignition source is in the gas path Two cases to be considered
a) no leakage possible
fail-safe containment

b) quantifiable amount of leakage

containment with limited leakage

Analysers EEx p Packaged

Introduction of Flammable Samples:
hazardous area

Decision Matrix (only EN 60079-2)

electronics

Limited Leakage
physical state of sample gas or liquid gas or liquid gas liquid normal operation no no yes yes malfunction case no yes yes yes A B C
STOP

measuring cell

sample lines (restricted flow)

power and data cables

Analysers EEx p Packaged

Introduction of Flammable Samples: Case A fail-safe containment
electronics hazardous area

Valid for gases and liquids Purge gas: air sufficient No permanent purge required purge gas loss compensation sufficient Installation in Zone 1 EEx p control system with automatic purge phase and shut down in case of pressure loss Installation in Zone 2 according to simplified procedure

measuring cell

sample lines (restricted flow) for instance welded connections

power and data cables

Analysers EEx p Packaged

Introduction of Flammable Samples: Case A fail-safe containment
electronics hazardous area

Overpressure of purged cabinet > sample pressure Only valid for gases Purge gas: air sufficient Purge gas loss compensation Installation in Zone 1 automatic EEx p control system precautions that overpressure of containment is 50 Pa above sample pressure at any time Installation in Zone 2 according to simplified procedure

measuring cell

sample lines (restricted flow) simple screw fittings, O-rings, etc.

power and data cables

Analysers EEx p Packaged

Introduction of Flammable Samples: Case B containment with limited leakage only during failure situation Method 1
Dilution via permanent air purge Valid for gases ICAs outside dilution zone Installation in Zone 1 automatic EEx p control system precautions that purge gas dilutes leaking gas to < 25% LEL Installation in Zone 2 according to simplified procedure same precautions as Zone 1
hazardous area

electronics measuring cell

sample lines (restricted flow) simple screw fittings, O-rings, etc.

power and data cables

Analysers EEx p Packaged

Introduction of Flammable Samples: Case B containment with limited leakage only during failure situation Method 2
Inert gas purge (N2, CO2, Ar) with loss compensation Gases and liquids
Oxygen content < 2% UEL < 80%
hazardous area

electronics measuring cell

Installation in Zone 1 automatic EEx p control system Installation in Zone 2 according to simplified procedure

sample lines (restricted flow) simple screw fittings, O-rings, etc.

power and data cables

Analysers EEx p Packaged

Introduction of Flammable Samples: Case B containment with limited leakage only during failure situation Method 3
Dilution via permanent inert gas purge (N2, CO2, Ar) Liquids and gases containing oxygen > 2% or gases with UEL > 80% Method not suitable for liquids with UEL > 80% Installation in Zone 1 automatic EEx p control system precautions that purge gas dilutes possible oxygen content to < 2% Installation in Zone 2 according to simplified procedure same precautions as Zone 1
hazardous area

electronics measuring cell

sample lines (restricted flow) simple screw fittings, O-rings, etc.

power and data cables

Analysers EEx p Packaged

Introduction of Flammable Samples:
Case C containment with limited leakage normal operation and failure situation Dilution via permanent air purge Only valid for gases Installation in Zone 1 EEx p control system with automatic purge phase precautions that purge gas dilutes leaking gas to < 25% LEL Installation in Zone 2 according to simplified procedure same precautions as Zone 1
hazardous area

electronics measuring cell

sample lines (restricted flow) simple screw fittings, O-rings, etc.

power and data cables

Required Hardware

ATEX certified EEx p Control Unit for instance control units from BARTEC Cabinet which fulfils the requirements of
EN 60079-02 EN / IEC 60079-0 IP code according to IEC 60529

APEX for Zone 1

SILAS for Zone 2

How to Comply with the Regulation

Zone 2 application
EEx p packaging is done by a supplier manufacturer declaration plus manual EEx p packaging is done by plant operator itself written risk assessment description of concept attachments to the explosion protection document manual

Zone 1 application
One-off approval for specific use done by an authorised person (e.g. TV in Germany) EEx p packaging is done by a supplier who owns a ATEX certificate for EEx p systems (BARTEC BENKE)

Please consider national and regional regulations too!

Analyser Communication

Via serial interface

PC must be located in general purpose area or explosion proofed itself Connection switched off in case of purge loss

Built-in Touch Panel PC

Example
Process Mass Spectrometer for flammable Gases
fail-safe containment solution EC-type examination certificate Universal Cabinet (TV 04ATEX2403) Ex protection type: II 2G EEx p II T4 Done by BARTEC BENKE

Example
Process FT-NIR Spectrometer for liquid Samples
Separation of electric parts from wet parts via optical fibres Based on Bruker Matrix FT-NIR spectrometer EC-type examination certificate Universal Cabinet (TV 04ATEX2403) Ex protection type: II 2G EEx p II T4 Done by BARTEC BENKE

Some Additional Considerations

General purpose analyzers are not designed for harsh environment Temperature fluctuation can cause severe problems measurement accuracy Ex climatisation could be necessary Solution: BARTEC BENKEs Compact Air Conditioning Unit ATEX certified for Zone 1 TV 97 ATEX 1224 X

Approach 2: Directive 1999/92/EC

Analyser System is not treated as an apparatus but as an installation (plant component) Applying the EN 61285 (IEC 1285) norm Process Control Safety of Analyser Houses

Safety of Analyser Houses

Consideration of internal and external sources Generation of overpressure (25 50Pa) via intake of fresh air from general purpose area (on suction intake from Zone 2 air-intake duct must be monitored with an LEL-sensor Limitation of amount of flammable media fed into the shelter 50% LEL must not exceeded in case of failure (please consult national and regional regulations too) Bypasses / fast loops must be installed outside the shelter It is recommended to install sampling systems outside too At least 5-fold air change per hour Calculation must consider amount of flammable media (rule of thumb: LEL 0.8% v/v)

Safety of Analyser Houses

Actions in case of pressure drop inside the shelter
power off of all general purpose equipment shut off flammable media feed lines outside shelter alarming required

Monitoring of leakages
Strategically located LEL-sensors Consideration of gas / vapour densities

Flammable liquid media

floor with sink and drain at the deepest point liquids with flash point above 55C need not to be considered as long as no hot surfaces are present

Entrance from Zone 0 or 1 via sluice Measures must be taken for protection against substances harmful to health (not covered in this lecture)

Safety of Analyser Houses

Assembly Example for Shelters in Zone 1
GENERAL PURPOSE AREA

ZONE 2 ZONE 1 4 1 AR General Purpose Area SSR 5 3 2

Sluice

1 Ex-Air Conditioning Unit 4 Bottle Cabinet 2 Bypass/Fast Loop 5 Analyser 3 Sampling System 6 Flash Light, Horn

LEL-Sensor AR = Analyser Room SSR = Sampling System Room

Safety of Analyser Houses

Assembly Example for Shelters in Zone 1
GENERAL PURPOSE AREA

ZONE 2 ZONE 1 4 1 AR General Purpose Area SSR 5 3 2

Sluice

1 Ex-Air Conditioning Unit 4 Bottle Cabinet 2 Bypass/Fast Loop 5 Analyser 3 Sampling System 6 Flash Light, Horn

LEL-Sensor AR = Analyser Room SSR = Sampling System Room

Safety of Analyser Houses

Assembly Example for Shelters in Zone 2
GENERAL PURPOSE AREA

ZONE 2 4 1 AR General Purpose Area SSR 6 5 3 2

1 Ex-Air Conditioning Unit 4 Bottle Cabinet 2 Bypass/Fast Loop 5 Analyser 3 Sampling System 6 Flash Light, Horn

LEL-Sensor AR = Analyser Room SSR = Sampling System Room

Safety of Analyser Houses

Assembly Example for Shelters in Zone 2
GENERAL PURPOSE AREA

ZONE 2 4 1 AR General Purpose Area SSR 6 5 3 2

1 Ex-Air Conditioning Unit 4 Bottle Cabinet 2 Bypass/Fast Loop 5 Analyser 3 Sampling System 6 Flash Light, Horn

LEL-Sensor AR = Analyser Room SSR = Sampling System Room

How to Comply with the Regulation

written risk assessment description of concept list of flash points of all flammable liquids list of explosion proofed equipment and its compliance with zone plan attachments to the explosion protection document

Thank you for your attention