ATEX explosion

approved
InSitu Oxygen
Analysers
Fred Gumprecht
M.D. ENOTEC GmbH
For the safe use of analyser systems in areas with
explosion hazards, it is important to not only rely
on the ATEX certificate.
It is also important to realise where potential
ignition sources are formed and that the equipment
be ATEX tested under conditions similar to the
expected process conditions.
In the following presentation we will focus on InSitu
type analysers with heated sensors which are a
potential ignition risk.
ATEX explosion approved InSitu
analyser at work.
The film has shown that the measurement
of true flue gas values contribute to a safe
combustion process.
We will now focus on essential gas hazard area
related safety requirements for an InSitu
analyser itsself.
ATEX approved probes for dust hazard areas
are not dealt with here as they do require a
different test and certification process.
Fast flue gas response
Ignition protection for all gas conditions at the
probe
Essential safety related
requirements:
Safety relevant components are easily inspected for
functionality
Foreseeable process conditions must be considered for
ATEX certification
Fast flue gas response
Fast flue gas response
An OXITEC probe needs about 30 seconds in normal flue gas velocity.
The green line shows the required flue gas response for safe
combustion control
An example of a different probe construction principle
which causes a slow flue gas response
Test gas flow to a small sensor volume suggests fast
response
Flue gas slowly displaces the test gas volume
through two barriers, the probe filter and the flame
arrestor
Fast flue gas response
The sensor response to the flue gas composition is important for safe combustion control.
The blue line shows a fast test gas response but an extremely slow
flue gas response.
Fast flue gas response
Ignition protection for all
gas conditions at the
probe
Important! All types of oxide ceramic sensors are electrically heated
to 700C - 800C and present a potential ignition so urce!
CO
e
Sensor O
2
Sensor
T3 = Temperature class
surface temperature
below 200C
IIC = Explosion group (safe gap)
hydrogen / acetylene
Equipment category
1 = qualified for zone 0, 1 and 2
2 = qualified for zone 1 and 2
3 = qualified for zone 2
Kind of atmosphere
G = gas
D = dust
II d IIC T3
Device group
I = mining
II = others
2 G EEx
Corresponds to the European Ex-Standards
(EN-50...)
d = Flameproof enclosure
explosion only inside the enclosure
COMTEC

KEX6001
Ignition protection for all gas
conditions at the probe
ENOTEC probe - ATEX approved for all gas conditions
Hot corrosive flue duct Ambient air
Duct wall
Regular inspection of
safety relevant
components
Hot Corrosive Flue Gas Ambient Air
Duct Wall
Pressure tested 37 Bar
Hottest Surface area 200C (T3)
Visible filter & flame arrestor
Corrosion resistant material
Redundant probe thermocouple for failsafe probe
heater controller
Regular inspection of safety
relevant components
Easy disassembling for inspection purposes
Certified construction
Certified material
Certified production
Filter & flame
arrestor
Test gas port
Terminal box
ATEX approved ENOTEC construction principle
Mounting
flange
Zirconia cell Heater
Surface temperature 450C (T1)
Certified for two temperatures
T1 and T6?
Only 1 probe thermocouple
No failsafe probe heater controller
Non visible flame arrestors
Less corrosion resistant materials
Disassembling problematic
Toxic materials used
Reference air probe volume included for
flame proof tests?
Certified production and testing?
Typical construction principle found on the world market
Regular inspection of safety
relevant components
Hot Corrosive Flue Gas
Ambient Air
Foreseeable process
conditions must be
considered for ATEX
certification
The legal regulations demand that the testability and maintenance ability must be
considered during the certifying process (94/9/EG, Appendix II, 1.0.3).
All heated InSitu probes with non visible ignition protection relevant components do not allow the user
a regular check.
If hot corrosive flue gas is not considered by a test house as the normal operational ambient condition
when testing these products, these products are suitable for ambient air measurement only.
All heated InSitu probes with certificates, which do not specify foreseeable flue gas conditions have a
certificate for ambient air conditions only. This certificate is invalid if this product is used in hot
corrosive flue gas.
The legal regulations demand that the foreseeable process conditions have
to be considered during the certifying process (94/9/EG, Appendix II, 1.0.4).
Foreseeable process conditions must
be considered for ATEX certification
The legal regulations demand that the entire equipment (e.g. an O
2
measuring probe) is to be examined
and certified as one unit.
In each case an ATEX certificate must refer to the complete probe assembly.
All probes, which are certified for two different temperature classifications (e.g. T1/T6) and for two
different gas groups (e.g. EExd IIB/IIC), do not comply with the EU-Directives.
All manufacturers who assemble probes using some ATEX approved components, such as flame
arrestors or terminal boxes, do not comply with the EU-Directives.
These probes are not qualified for hazardous areas installations, even if some Ex-markings
remain on any components.
All certified probes where a temperature class is mentioned, do require a certified failsafe
temperature limitation.
Foreseeable process conditions must
be considered for ATEX certification
Responsibilities
The plant owner has the responsibility for safe operation of his plant.
It is his responsibility to judge the explosion risks and to divide areas into zones
accordingly.
He must ensure that all installed equipment is suitable for safe plant operation
under all foreseeable process conditions.
He must ensure that all installed equipment is certified according to the
regulations for all foreseeable process conditions before initial use.
The equipment must be kept in a safe status by means of regular inspection and
maintenance.
Responsibilities
Responsibilities
The plant owner has the responsibility for all arising damages.
The manufacturer of explosion protected equipment has the
responsibility for mandatory tests as close as possible to
foreseeable process conditions.
Certification and documentation of the construction, the material
and test procedures are required to ensure that each manufactured
device complies with the certified design.
Responsibilities
Do not put your trust only in certificates!
We thank you for paying attention
Look at all specifics of a product before using it!
Install proven product quality for your plant safety.
For more information, please contact us at the Multi Instruments booth
Appendix
Basic information for your safe
operation in Hazardous areas
Areas with risk of explosion are divided into zones, depending on frequency and
duration of the occurrence of combustible atmosphere (Directive 1999/92/EG).
Gases, Vapours, Mists Dusts (coal, flour, metal,
finely ground powder)
Zone 0 Zone 20
Zone 1 Zone 21
Zone 2 Zone 22
Equipment with relevant Ex-protection can be safely operated in each zone
according to its certification.
Category 1 G Category 1 D
Category 2 G Category 2 D
Category 3 G Category 3 D
Area, in which explosive atmosphere...
is continuously, long-term or frequently existent (Guiding value, not
standardised: more than 1000 h per year)
in normal operations occasionally occurs (Guiding value, not standardised:
10 1000 h per year)
in normal operations normally not or with only short-term occurrences
(Guiding value, not standardised: less than 10 h per year)
Devices of this category are to be designed and manufactured in such a way that...
ignition sources, even in case of equipment faults which seldom arise, are to be avoided. Also if two
faults arise within the equipment, it may not come to an ignition.
In the event of frequently arising or expected disturbances (defects of the equipment) retain the
necessary level of safety to ensure that no ignition source is created.
ignition sources which can be expected and which can occur with normal usage, are avoided.
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Zone 0
Zone 1
Zone 2
Definition of Hazardous
Areas into Zones
An explosion is the sudden chemical reaction (oxidation) of a
flammable material with oxygen under release of high energy.
Flammable Material
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Ignition
Triangle
Explosion Limit
An explosion can only occur, if the flammable material is present within a certain
concentration range. If the concentration is too small (too lean) or to high (too rich) no
explosion takes place, but a slow oxidation without a visible flame may happen.
Substance
Designation
Lower Explosion Limit in
Mixture with Air [Vol.%]
Upper Explosion Limit in
Mixture with Air [Vol.%]
Acetylene 1,5 82
Gasoline 0,6 8
Natural Gas 4,5 13,5
Carbon monoxide 12,5 75
Three factors must be met to induce an explosion :
The explosion limits depend on the
ambient pressure and the oxygen
content.
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Definition of an Explosion
Device
Group
I Electrical apparatus for
mining
II Electrical apparatus for all
remaining potentially
explosive atmospheres
Equipment
Category
1 = qualified for zone 0, 1 and 2
2 = qualified for zone 1 and 2
3 = qualified for zone 2
G = gas
D = dust
Kind of
Atmosphere
Conformance
Marking
EEx The equipment corresponds to valid EN
standards and is certified from a recognized
European laboratory.
Method of
Protection
d flameproof enclosure
e increased safety
i intrinsic safety
m encapsulation
n type of protection
o oil immersion
p pressurized apparatus
q powder filling
Explosion
Group
I firedamp endangered mine workings
(methane)
IIA experimental safe gap > 0,9 mm
typical gas: propane, gasoline
IIB experimental safe gap 0,5 mm to 0,9 mm
typical gas: town gas, ethylene
IIC experimental safe gap < 0,5 mm
typical gas: acetylene, hydrogen
Max. surface
temperature of
equipment:
T1 450C
T2 300C
T3 200C
T4 135C
T5 100C
T6 85C
I
II
1
2
3
G
D
EEx
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I
IIA
IIB
IIC
T1
T2
T3
T4
T5
T6
Type-exami-
nation tested
(Probe)
(Electronic Unit)
ATEX, the European Ex-Marking
Surface
Temperature