Explosion prevention and explosion protection

according to ATEX guidelines

Safe extraction and separation • Metallic dust

• Organic dust
of explosive dust • Paint and spray dust

Comprehensive information concerning

"Explosion prevention and explosion
protection according to ATEX guide-
lines" can be found on our website
www.exschutz.net
Extracted dust may create dust explosions

A precondition for a A dust explosion does not occur by creates a homogeneous mixture. As
Combustible Ignition source
dust explosion is an chance. Reactive substances with soon as a specific dust density is
dust
explosive environment suitable mixing ratios will create a attained below certain particulate
potentially explosive situation. dimensions, an explosive environment Dispersion of Enclosure
is produced. However, in general, dust (during the (filter housing)
Metallic, organic or paint and spray cleaning process)
explosion limits are not limited just Oxygen
dusts can create an explosive combi-
to a certain particle size of combus- (environmental)
nation in the presence of oxygen.
tible dusts. Dust explosions only occur under certain
conditions.
Explosion limits (LEL, lower explosion
A criterion for a dust explosion is limit) can only be detected by per-
dispersed dust consisting of a mix of forming specific tests.
dust particles of various sizes plus gas
molecules. The differences in density
generate a continuous circulation that

Organic and metallic Organic dusts Metallic dusts

dusts are prone to
Such as CFC, GRP, GMPU, including Typically, metallic dusts are minerals The very large surface area of metallic
explosion
carbon, powder, cocoa, starches, lum- such as magnesium, aluminum and dust particles generates heat quickly
ber, fibers, feedstuff, as well as paint fine blasting dust such as steel. and presents an explosion hazard.
and spray dusts. Dusts from the treat-
With a particularly small particle size
ment and processing of these products
(e.g., dust) even substances that are
and substances are flammable and are
not normally combustible in solid form,
assigned to dust explosion class St 1.
can suddenly ignite.

No ignition source – A potentially explosive situation does

Combustible Ignition source
no dust explosion not necessarily produce a reaction! dust

To initiate an explosion, there must be

Dispersed Enclosure
an ignition source. This also includes dust (during the (filter housing)
the ability to self-ignite (automatic cleaning process)
Oxygen
combustion). (environmental)

The Filter cleaning The risk of an explosion exists par- To benefit from this advantage safely,
can lead to an explo- ticularly during filter cleaning in a mechanical and procedural precautions
sive environment dry dust separator. An explosion can should be taken to prevent the entry of
occur upon the precisely timed entry of an ignition source into the filter area –
an ignition source into the filter area. or to control the effects of a potential
However, dry separation systems are explosion.
obviously still a superior economic
solution for many processes in the
separation of emissions.

2
Explosion protection according to EU guidelines

ATEX 137 Explosion protection guideline 1999/92/ corresponding need for action. Keller
(operator guideline) EC (ATEX 137) contains basic safety offers detailed recommendations.
defines the operator's requirements concerning hazards from Although this topic does not always
responsibility "explosive atmospheres". Occupational raise the necessary awareness, in the
safety is an important subject. However, event of damage, the operator must
the operator cannot always recognize provide a corresponding explosion pro-
potential explosion hazards and the tection document as proof.

Dust sample provides A dust sample can provide verification such tests as part of a service package
confirming data of explosive potential and detect the at a fixed cost. (www.exschutz.net)
existence of explosive parameters. If
necessary, Keller offers to perform

Examples of explosion The maximum explosion pressure pmax

parameters: is influenced by the housing.
Explosion pressure
The rapid pressure increase dp/dt
and explosion severity
reflects the potential severity of an
explosion. It is defined as the primary
origin in the deviation point of the pres-
sure/time curve and used as parameter
Kst-value for classification into dust
explosion classes St 1, St 2 and St 3.

Pressure curve of a dust explosion in 1 m2 ball pressure tank.

Dust explosion The dust explosion classes are the Dust explosion KSt Testing parameters to determine the
classifications basis for designing constructive class [bar m/s] Kst-value and pmax are defined in
protection measures in addition to the directives VDI 2263 sheet 1 guidelines,
St 1 0 – 200
maximum explosion pressure pmax. and EN 14034.
St 2 201 – 300
St 3 > 300

3
 Explosion parameters for evaluating risk of explosion

Explosion The opposite explosion parameters

Type of dust pmax [bar] KSt [bar m/s]
parameters are examples from previously com-
pleted projects. An in-depth overview PVC 8,5 98
is provided in the GESTIS-DUST-EX da-
Polyethylene 8,8 131
tabase.
Coal dust 8,2 135
The tolerances are basically relatively
high (+/- 20 %). A distinction between Tin-Copperdust 4,5 80
KSt 180 and KSt 200, for example, is
Polyethylene dust <8 < 100
generally not useful.
Stitching and milling dust 7 113
Plastics
Rubber milling dust 8,4 160
Aluminum milling dust 8,5 160
Paint overspray 8,2 162
Aluminum dust with aerosols from 9 165
MQL
Fabric fibers (laminate residues) < 10 < 200
Zinc dust 9,5 250

Explosion protection The operator is obligated to create an • Probability and duration of the • Extent and effect of an explosion
document explosion protection document to de- presence of explosive conditions. (explosion parameters)
termine suitable protective measures. The explosion endangered areas
will be classified into zones
The explosion protection document
must be recorded and must include at • Probability of the existence, initia-
least the following points: tion and prevalence of ignition
sources (including electrostatic dis-
charges)

Mandatory actions to Following clarification of the explo- Critical safety measures: The ATEX guideline is implemented
be taken for a potential sion risk, detection of explosive dust nationally by Industrial Safety Regulation
• Zone division depending on the
explosion hazard parameters such as ignition tempera- BetrSichV.
explosion risk
ture, minimum ignition energy (MIE),
The following regulations are manda-
lower explosion limit (LEL), Kst value ... • Labelling hazardous areas
tory:
the company is required to take steps
• Determine which protective actions
according to ATEX 137. • DGUV standard 113-001
to implement
(former BGR 104)
• Operating instructions for employees
• TRBS 2152 / TRGS 720
• Creating an explosion prevention
• TRBS 2152-1 / TRGS 721
document containing all available
data and effective procedures • TRBS 2152-2 / TRGS 722
• TRBS 2153 / TRGS 727

4
Machinery Guideline and ATEX 114

Machinery Guideline Appendix 1, point 1.5.7. of the general Download link for the application:
2006/42/EC machinery guideline: http://www.exschutz.net/images/
machinery_guide.pdf
"Machinery must be designed and
constructed in such a manner as to
avoid any risk of explosion posed by
the machinery itself or by gases,
liquids, dust, fumes or other substances
produced or used by the machinery."

ATEX 114 The 2014/34/EU directive of the Euro-

(product guideline) pean Parliament and Council (gener-
for products in ally known as ATEX 114) primarily
explosion risk areas applies to manufacturers.
ATEX-Logo
and applications
The guideline encompasses protec-
ATEX derives its name from French
tive systems and all machinery and
Atmosphère Explosive
systems located in potentially
explosive areas. Electrical and non-
electrical systems are also relevant
since they possess their own poten-
tial ignition source.

Manufacturer's • Performing a risk evaluation of the • EC-type evaluation by an authorized

obligation according product agency if an electrical system
to ATEX 114 belongs to categories 1 or 2, a non-
• Clarification of intended use and
electrical system to category 1, or if
operating conditions
it is a matter of a protective measure.
• Classification into system categories
• Labelling on a printed plate

Category 1 2 3
Level of safety very high high normal
Application in zone 0/1/2 20/21/22 1/2 21/22 2 22
Environment D G D G D
Classification into system category

5
 Coordinating between ATEX 114 and ATEX 137

Keller Lufttechnik There is a mutual reliance between an Basic requirements for

offers experienced operator's guideline and the manufac- Operator (ATEX 137) Manufacturer (ATEX 114)
advice regarding turer's guideline.
Designating zones for a single system; Location selection, specification of the
this subject
It therefore necessitates the coordina- selection of corresponding devices system category/category
tion of scheduled projects with essen-
Zone 0 / 20 Category 1:
tial clarifications between the operator
Zone 1 / 21 Category 2:
and the system manufacturer.
Zone 2 / 22 Category 3:
Keller Lufttechnik provides experi-
Compliance with applicable require- The systems must meet all requi-
enced advice ranging from the initial
ments for installation, commissioning rements for occupation health and
conception of emissions extraction
and maintenance safety
while taking into consideration ATEX
guidelines 114/137, to the coordination Performance of a risk analysis, Performance of a ignition source
of fire protection measures, and to the requiring coordination analysis for the systems
possible inclusion of heat exchange
Completion of an explosion protection Completion of a declaration of confor-
facilities.
document mity
We will be pleased to assist you in
Continuous updating Adequate quality assurance
fulfilling all the mandatory require-
ments.

Zone division The areas of operation must be divided Device group I Range of applications according to
according to ATEX into zones (ATEX 137/VDI 2263-6/ product guidelines ATEX 114
Includes systems for underground and
DGUV standard 113-001 (former BGR
surface mining In zone 20 use only device category 1D
104):
Device group II In zone 21, systems in device category
Environment: Gas/mist/ fumes
2D (+1D) are permissible.
Classification of all systems in
Concentration > = 100 % of LEL
remaining explosion prone areas. All For zone 22, suitable device category
Zone 0
the following information pertains to 3D (+2D and 1D).
Concentration 50 – 99 % of LEL device group 2.
Zone 1
Device category 1
Concentration 20 – 49 % of LEL
Hazard potential: continuous, frequent
Zone 2
or over an extended period of time
Requirement: very strict safety
Environment: Dust
procedures
Hazard if content is more than 50 % of
Device category 2
the operation or continuous Zone 20
Hazard potential: occasional
Occasional hazard if less than 50 % of
Requirement: strict safety measures
the process Zone 21
Device category 3
No hazard during normal operation or
rare and short-lived Zone 22 Hazard potential: rare or short-lived red: Zone 20
Requirement: normal safety measures green: Zone 22
Classification into device categories
according to ATEX 114 Zone division VARIO

6
Explosion prevention

Preventing an Avoiding a potential explosion preven- Inertisation

explosive environment tion seems to be an obvious safety
When using inertisation, the separator
measure – however, it may not be suit-
is supplied with inert material such
able for all processes.
as limestone powder to avoid the
Wet separation creation of an explosive atmosphere.
The mixture ratio must ensure that the
For this process, possible ignition
combination of inert material and
sources are flushed with water, pre-
explosive dust/air cannot set off an
venting the creation of an explosive
explosion in itself. The economic
atmosphere in the dust separator.
feasibility depends on the volume of
Depending on the variety of processes,
dust created and the need for inert
this technology is not universally
material.
applicable.

Ignition source free An explosion can only be set off in the Eliminating ignition sources in the Grounding prevents electrostatic spark
operation presence of an ignition source (second- separation system discharge.
ary explosion protection)
Inadequate for especially ignition- Additional conductive and grounded
Procedural measures sensitive dusts with MIE < 10 mJ and filter elements can be installed.
hybrid mixtures.
This is to avoid common ignition sources
such as welding, smoke and other All components inside EX zones must Combustible dust Ignition source
(light metals) (glowing embers)
sources of open flames. be approved according to ATEX in order
to be ruled out as an ignition source. Dispersed dust Enclosure
(during cleaning) (filter housing)
If the entry of an ignition source from
outside of the separation system can Oxygen
be prevented safely, grounding the (environmental)

system components is sufficient. Explosion pentagon

Despite an explosive environment, an explosion
is impossible without an ignition source.

Protection concept For dusts with MIE > 10 mJ with rare Ignition source monitoring
ProSens ignition sources and low dust concen- The suction ductwork is monitored by
trations. a spark sensor.

nted During the next scheduled filter

pate Cleaning during system downtimes
element cleaning, the potential of an
If the separation process is interrupted
explosive situation can be thwarted
d to clean the filter elements, no ignition
teste by the control in case the entry of an
FSA- sources exist.
ignition source has been detected.

ProSens ignition source monitoring

7
 Explosion protection

Explosion protection If the above mentioned measures are The standards describe the following • Explosion-proof construction
inadequate to prevent an explosion protective measures: • Explosion pressure relief
and its effects, additional explosion • Explosion suppression
protection methods can be installed. • Prevention of flame and explosion
transfer

Containment design Explosion pressure resistant Explosion pressure-surge resistant

Designed for a maximum explosion Explosion potential is rare if the sys-
pressure or a reduced maximum explo- tem is designed according to this cat-
sion pressure, the filter housing should egory, or to the maximum or reduced
withstand an explosion without any explosion pressure. As a general rule,
distortion. basic safety measures are applied
here. The housing might deform as a
consequence of an explosion.

Determining the Keller Lufttechnik performed explosion ance. Depending on the application it
pressure shock tests for its filter housings at the Ger- is possible to design the housings with
resistance to man FSA (Research Centre for Applied a pressure surge resistance of 0.2 bar
explosion System Safety and Industrial Medicine) or 0.4 bar excess pressure (in individual
to determine the pressure surge resist- cases up to 2 bar).

Testing the explosion potential of filter housing at the FSA facilities

8
Explosion protection –
pressure relief outdoors or to the outside

Venting panels Explosion pressure relief for dust extrac-

tion systems outdoors or installed adja-
cent to the exterior wall of the plant.
Safety range depends on the system
size: 10 - 25 m.
Effective relief surface: 0.5 m2

Burst disk Filter unit with burst disks

Reduction of the Outdoor installation: Burst channel For indoor installation and relief
safety zone To reduce the safety zone when us- through exterior wall: Targo-Vent
ing burst disks, it is possible to install The safety distance can be reduced by
burst channels, enabling burst disks to using Targo Vent for installation indoors
be placed vertically instead of horizon- and relief through outer wall. The funnel-
tally. The flames are deflected by 90°.
shaped enclosure deflects the flames by
45°.
Effective relief surface: 0.4 m2

Effective relief surface: 0.35 m2

Burst channel

Relief using Targo-Vent

Example of safety
zones for a VARIO 4

3 10 15 [m] distance
els nt 5m
c h ann o -Ve k>
1
g s
urs
t
3m ar
h T . 10
m
st di
i t h b prox. wit pprox h bur
w ap a wit
9
 Explosion protection with indoor installation

Flameless pressure relief

For organic dust through ProVent Explosion suppression

Vario with ProVent Round filter with container for extinguishing

agent

The protection concept ProVent Explosion prevention by automatic ap-

ensures flameless explosion pressure plication of an extinguishing agent. A
relief. The safety zone is 5 m and can safety zone is not required. Suitable for
be reduced to 0.5 m. reduced maximum explosion pressure.
Perfect for toxic dust.

Features: Features:
• Maximum Kst-Value: 200 bar x m/s • Approved for Kst-Values up to 500
• Dust with MIE > 3 mJ bar x m/s
• Safety distance: 5 m for people; • Ideally suited for installation in the
0.5 m for objects/walls workplace where toxic dust or gas
explosion hazards may exist
Effective explosion surface: 0.35 m2 • Explosion decoupling with extin-
guishing agent achieved with small
additional step, since detection and
control are already available

For metal dust Flameless pressure relief by Flameless pressure relief by

means of TR-1 ProVentPlus means of ProPipePlus
ing
a c cord 0
d 6
Teste EN 144
D I N
to

nted
pate

TR-1 ProVentPlus ProPipePlus Explosion suppressed by ProPipePlus

TR-1-ProVentPlus single separator en- Patented ProPipePlus flame trap en- It has been demonstrated that a safety
sures flameless pressure relief without sures safe explosion suppression inside zone is not required with this particular
a designated protective zone. closed rooms. The special stainless design.
steel construction is approved for metal
dusts, and since 2013 there is an ad-
10
ditional design available in aluminum.
Explosion decoupling

Decoupling of dirty Additional means with a ProFlap

air ductwork back pressure flap
Dust extraction systems with explo-
ding sion-proof design and e. g., explosion
d a ccor 47 pressure relief, must be decoupled
Test e 164
N EN
to DI
from connected dirty air ductwork.

ProFlap back pressure flap prevents the

spread of explosion pressure and
nted The downstream mounted back pressure flap is kept open by means of the air flow
pate flames into other areas.

Staff working at the collection points

or suction-equipped components are
thereby protected from the effects of
an explosion.

During an explosion inside the protected system, the flap is closed

by the advancing pressure inside the ductwork

Decoupling of clean An example using filter elements

air ductwork
With filter elements we assume ad-
equate flame decoupling (not unusable
as a protection system). Additional
pressure decoupling may be required.
Keller Lufttechnik demonstrated the
isolation of filters elements from the
effects of an explosion.

VARIO with KLR-Filter

Decoupling of An additional method is with rotary A lock achieves the same result. As
dust disposal valves. an alternative, pressure shock-proof
design of the dust collection container
The blocking function of a rotary valve is possible.
can be used to stop an explosion from
spreading. A modified design prevents
ignition from materializing.

Rotary valve

11
Explosion prevention and explosion protection
according to ATEX guidelines

Additional information Is my dust explosive? What types of

measures can be taken? Answers and
a quick solution can be located on our
special website www.exschutz.net

Project Our expert staff is pleased to be at your

recommendations disposal for additional information. Feel
free to benefit from our experience.

Intercontinental Full member Explosion demonstrations

Association of Experts
for Industrial Explosion
Protection e.V.
(IND EX e.V.)

We are full member of IND EX and par- Our filtration systems are also used for
ticipate in research work in the field of explosion demonstrations during IND EX
explosion protection. For this reason we special events.
always stay current with the technology.
© Keller Lufttechnik - all rights reserved - subject to modifications. 05/2017

Keller Lufttechnik GmbH + Co. KG

Neue Weilheimer Straße 30
73230 Kirchheim unter Teck
Fon +49 7021 574-0
Fax +49 7021 52430
[email protected]
www.keller-lufttechnik.de