the explosion risk
TRANSCRIPT
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The Explosion Risk
How to treat it ?
S.Radandt
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Risk Definitions
Definition From Guide 51risk
combination of the probability of occurrence of harm and the severity of that harm
Definition From Guide 73risk
combination of the probability of an event and its consequences
note: the term risk is used when there is at least the possibility of one negative consequence.
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RISK MANAGEMENT
RISK ASSESSMENT
RISK ANALYSIS
SOURCE IDENTIFICATION
RISK ESTIMATION
RISK EVALUATION
RISK TREATMENT
RISK AVOIDANCE
RISK OPTIMIZATION
RISK TRANSFER
RISK RETENTION
RISK ACCEPTANCE
RISK COMMUNICATION
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Determination of thelimits of the system
Risk evaluation
Risk reduction
Start
ENDYES
NO
Risk analysis Risk assessment
Hazard identification
Is the systemsafe?
Risk estimation
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Risk Management System
financeswork-structurework-processes quality environment
plant and processestechnology
• supplier• product liability• consumer safety
fitness of workers
machinery processessubstances
health knowledge
specific hazards
explosions dangerous substances
Management System withSpecific Targets Set and Strategies Used by a GivenOrganisation/Company
019
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Explosion venting of a 250 m³ vessel
Rapidly developing dust explosion( KSt-value = 300bar. m/s )
Long flame jet
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Explosion venting of a 250 m³ vessel,
Less rapidly developing dust explosion ( kSt-value < 200 bar. m/s )
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Venting of a silo bin into a machineryroom,
Secondaryexplosion in themachinery room
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Explosion venting of a bucket elevator
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Dust explosion in a feedproduction plant
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Disaster: Structure of Causes
Disaster
En(and) En(or)
E1 E2 En E1 En
Conditions/Causes
Conditions/Causes
!En Event with „and“ condition P(En)=P(E1)× P(E2)×……P(En)
En Event with „or“ condition P(En)=P(E1)+P(E2)+……P(En) !!P(En) Probabilities of events
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Important informations aboutpossible causes
Near miss:A hazardous situation, event or unsafe act where thesequence of events could have caused an accident ifit had not been interrupted.
Incident: Undesired events
Direct cause: The immediate reason why an incident occurred.
Root cause: The factors in a system which allow the direct cause to arise.
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Assessment of explosion risks 1
Any assessment shall be based on :
The likelihood that explosive atmospheres will occur and their persistenceThe likelihood that ignition sources will bepresent and become effectiveThe scale of anticipated effects
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Assessment of explosion risks 2
Ignitability shall be assessed by taking intoaccount,in particular :
The degree of dispersion of flammable and/orcombustible substancesThe concentration of flammable and/orcombustible substances
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Assessment of explosion risks 3
Explosion risk shall be assessed overall.The following are of particular importance :
InstallationsSubstances usedProcessesAnd their possible interaction
Places which are or can be connected via openingsshall be taken into account in assessing explosionrisk
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Explosion risks must be assessed overall.
Important factors are:
the work equipment used;
the building fabric and configuration;
the substances used;work and process conditions;
their possible interactions with each other and the working environment.
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I s t h e f o r m a t i o n o f a e x p l o s i v ea t m o s p h e r e p o s s i b l e ?
N o e x p l o s i o np r o t e c t i o n m e a s u r e sn e c e s s a r y
A r e f l a m m a b l e s u b s t a n c e sp r e s e n t ? N o
Y e s C a n s u f f i c i e n t d i s p e r s a l i n a i r g i v e r i s et o a n e x p l o s i v e m i x t u r e ? N o
Y e s
W h e r e c a n e x p l o s i v e a t m o s p h e r e so c c u r [ 2 . 2 . 3 ] ?
P r e v e n t t h e f o r m a t i o n o f h a z a r d o u s e x p l o s i v ea t m o s p h e r e s a s f a r a s p o s s i b l e
I s t h e f o r m a t i o n o f h a z a r d o u se x p l o s i v e a t m o s p h e r e sr e l i a b l y p r e v e n t e d ?N o
Y e s
I s t h e i g n i t i o n o f h a z a r d o u se x p l o s i v e a t m o s p h e r e s h i g h l yi m p r o b a b l e ?
Y e s N o
A v o i d e f f e c t i v e i g n i t i o n s o u r c e s i np l a c e s w i t h h a z a r d o u s e x p l o s i v ea t m o s p h e r e s a s p e r z o n i n g
Y e s N o
C o n t .
T o w h a t z o n e s c a n t h e p l a c e s w i t hh a z a r d o u s e x p l o s i v e a t m o s p h e r e s b ea s s i g n e d C o n t .
F u r t h e r e x p l o s i o n
p r o t e c t i o n m e a s u r e s n e c e s s a r y
E x p l o s i o n p r o t e c t i o n
m e a s u r e s n e c e s s a r y
N o e x p l o s i o np r o t e c t i o n m e a s u r e sn e c e s s a r y
N o e x p l o s i o np r o t e c t i o n m e a s u r e sn e c e s s a r y
F u r t h e r e x p l o s i o n
p r o t e c t i o n m e a s u r e s
n e c e s s a r y
M i t i g a t e t h e d e t r i m e n t a l e f f e c t s o f a n e x p l o s i o n s o a s t o e n s u r e t h e h e a l t h a n d s a f e t y o f w o r k e r s .
A p p l y a d e q u a t e a n d p r o p o r t i o n a t e m i t i g a t i o n m e a s u r e s
A p p l y a d e q u a t e e x p l o s i o n p r o t e c t i o n m e a s u r e s
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Explosion pressure depending on the filling method
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Belt Conveyor
Concentration = 538mg/m³
No Zone
Zone 21
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No Zone
Filling of a funnel: concentration = 592 mg/m³
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Filling of a silo-car
concentration = 569mg/m³
No Zone
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Build up of a Slag-heap
concentration = 632mg/m³
No Zone
Zone 21 No Zone
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No Zones
C = 41.5 mg/m³ C = 20.07 mg/m³
Filling of a Truck - Container
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No Zone
concentration = 650.4 mg/m³
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concentation = 60 mg/m³
No Zone
No Zone
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No Zone
Surface temperature of the engine: 280°C
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Dust layers at the engine
Burned dust layers
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Silo plant
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Grain elevator plant
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Produktsilos, Verladung, etc.
Lager- Silos
E l e v a t o r
E l e v a t o r
Sieb-maschine
Waage
Vorbehälter
Hammer-mühle
Bunker
Trogkettenförderer
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Ignition Hazard AssessmentProcedure for Equipment
The assessment procedure is divided into four steps:1. analysis of the ignition hazards and their
causes2. assessment of the ignition hazards regarding
frequency of occurrence3. determination of required protective measures4. concluding assessment and determination of the
equipment category
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Afterwards these ignition sources should be considered separately with regard to differences in
Intended use or possible application,
constructional variants,
operating conditions or working cycles including their variations (start, stop, load alternations etc.),
influences of the ambience (temperature, pressure, humidity, energy supply etc.),
material parameters or their interdependencies (metal, synthetic material, electrostatic chargeable liquids etc.),
interdependencies with components or other pieces of equipment and interdependencies with and between persons
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Zone 2/22 outside
Connected to Zone 1/21
Axial Fan for cat. 2 meetsexplosive atmosphereconnected to it and explosive atmosphereof surrounding
1 Blade tips/ 2 Hub to internal circular housing running clearance /3 Blade operating clearance /4 Internal anti-sparking impeller housing liner/ Motor spigot located on mounting flange/ Impeller housing
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Feed Material Input
Zone 21Zone 21
Feed Throat
Productcontainer
Connected to explosive atmosphere
Surrounding Condition
Zone22
Outsideignitionsourceduringmalfunction
Insideignitionsourceduringnormal operation
Assembly:single function is grinding
Information for use: e.g. inerting
Avoidance of explosive atmosphere: inerting
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Potential Ignition Sources outside
Feed Screw
Rolling Bearings
Belt Drive
(Inherent safe: v <1m/s)
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Potential Ignition Sources outside
ElectricalMotor
Gear Drive
Belt Drive
Cover
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Prevention of and protectionagainst explosions
Technical and/or organizational measuresappropriate to the nature of the operation in order of priority and in accordance with thefollowing principles :
Prevention of formation of explosive atmospheresAvoidance of ignition of explosive atmospheresMitigation of detrimental effects of an explosion to the health and safety of workers to an adequatelevel
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Planning principles
When planning new installations or themodification of existing ones , attentionshall be paid, in particular, to :
Normal operating conditions , including maintenanceworkConstructional factorsCommissioning and decommissioningMalfunctions , forseeable fault conditionsMisuse which may reasonable be anticipated
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Combine technical and organisationalmeasures
If there is a potential risk of explosion at a workplace, this also implies that the work organisation must meet certain requirements. Organisational measures must be taken where technical measures alone cannot ensure and maintain explosion protection at the workplace. In practice, the work environment can also be made safe by combining technical and organisational measures.
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The following organisational measures must be carried out:
• produce written operating instructions, where required by the explosion protection document;
• instruct workers in explosion protection;• ensure workers have adequate competence;• apply a permit-to-work system for dangerous work, where
required by the explosion protection document;• carry out maintenance;• carry out inspection and surveillance;• mark hazardous places, where necessary.
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The risk assessment by the manufacturer of equipment shall always be carried out for each individual situation.
Risk assessment includes the following elements:
a) Hazard identification. The safety data assist in the identification of hazards by demonstrating whether substances are flammable and indicate their ease of ignition;
b) determine whether an explosive atmosphere is likely to occur and the amount involved
c) determine the presence and likelihood of ignition sources that are capable of igniting the explosive atmosphere
d) determine the possible effects of an explosione) evaluate the riskf) consider measures for the minimization of risks
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The risk assessment shall take into account the ignition and explosion hazard from
- the equipment, protective systems, and components itself;
- the interaction, between the equipment, protective systems, and components and the substances being handled;
- the particular industrial process in the equipment, protective systems, and components;
- interactions of individual processes in different parts of the equipment, protective systems, and components;
- the surroundings of the equipment, protective systems, and components and possible interaction with neighbouring processes.
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Ignition hazard assessment
All equipment and all parts of it shall be subjected to a hazard analysis that identifies and lists all of the potential sources of ignition by the equipment and the measures to be applied to prevent them becoming effective.
Examples of such sources include:hot surfaces, naked flames, hot gases/liquids, mechanically generated sparks, adiabatic compression, shock waves, exothermic chemical reaction, thermite reactions, self ignition of dust, electrical arcing and static electricity discharge.
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The Role of intended Use
It is the manufacturers provision to determine the intended use as a starting point for the ignition hazard assessment procedure.
The instructions shall contain all restrictions and information necessary for a correct putting into service and a following safe operation.
It determines the intended use of the equipment as the essential precondition for the explosion protection.
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- ensure that ignition sources cannot arise
- ensure that ignition sources cannot become effective
- prevent explosive atmosphere reaching the ignition source
- contain the explosion and prevent flame propagation.
Protective measures/types of protection shall be considered and/or applied in the following order:
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Specify the service conditions
All intended service conditions for the equipment (e.g. rough handling, humidity effects, ambient temperature and pressure variations, effects of chemical agents, corrosion, vibration) shall be specified by the manufacturer and included in the required instructions for use.
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Technical measures for explosion protection
Prevent the formation of hazardous explosive atmospheres
Limiting of concentrationsInertingPreventing or limiting the formation of explosive atmospheres in the vicinity of plant( e.g. ventilation )Removal of dust depositsGas alarm
Avoid the ignition of hazardous explosive atmospheres
Zoning of hazardous placesAvoidance of ignition sources
Mitigate the effects of explosions so as to ensure thehealth and safety of workers
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Mitigation of the effects of explosion( mitigation measures )
Explosion resistant designFor maximum explosion overpressureFor reduced explosion overpressure associatedwith explosion relief or suppression
Explosion reliefExplosion suppressionPrevention of flame and explosionpropagation
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Weakexplosion
Strongexplosion
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Venting of Silo-Buildings
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What is?Danger
condition, circumstanceor occurrence, which can result in damage
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HazardWhat is a
?
danger related to aparticular person, an object, propertyor a situation;
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Hazardous event
a) event that can causedamage;
b) a triggering event(cause) is required toinitiate a hazardousevent;
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Damage
physical impairmentand/or damage tohealth or property
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Zone 0
Zone 1
Zone 2
Surface ofthe liquid
Example of zoning at a tank for flammable liquids
Sump
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Zone 22
Zone 20
Zone 21
Example of zoning for flammable dusts