Appendix 31

Hazardous Area Classification Report Dargavel Energy from Waste Facility ScotGen (Dumfries) Limited
Report: Version: Date:
SCOTTO01 HAC Report 2.0 06 October 2008
All data and information, both technical and commercial, contained in this report is confidential and shall not be copied or disclosed to other parties without the written permission of ABB Limited. This report remains the property of ABB Limited and shall be returned to ABB Limited or destroyed, at ABB Limited's request, together with any copies.
Dargavel Energy from Waste Facility - Hazardous Area Classification Report Rev 2.0
Report:
Ref. No: Version: Date:
SCOTTO01 HAC Report 2.0 06 October 2008
Prepared for:
Lloyd Brotherton Director Ascot House 51 Water Street Radcliffe Manchester M26 3DE Tel: 0161 724 1999 Mob: 07984 494609
Prepared by:
Mick Donley Senior Consultant Process Hazard Compliance ABB Engineering Services +44(0)773 005 1511
Telephone:
ABB Limited
Belasis Hall Technology Park PO Box 99 Billingham TS23 4YS

United Kingdom Tel: +44 (0)1642 372000 Email: contact@gb.abb.com
Report Ref. SCOTTO01 HAC Report Version 2.0 Page 2 of 22 Copyright ABB Limited 2009 All data and information, both technical and commercial, contained in this report is confidential and shall not be copied or disclosed to other parties without the written permission of ABB Limited. This report remains the property of ABB Limited and shall be returned to ABB Limited or destroyed, at ABB Limited's request, together with any copies.
Contents
1 2 3 4
Introduction Area Classification (Risk Assessment) Zoning Temperature Classification & Gas Group
4 15 20 20 21 22
Appendix A Properties of Flammable Materials Appendix B Hazardous Area Classification Layout Drawing
Report Ref.SCOTTO01 HAC Report Version 2.0 Page 3 of 22 Copyright ABB Limited 2009 All data and information, both technical and commercial, contained in this report is confidential and shall not be copied or disclosed to other parties without the written permission of ABB Limited. This report remains the property of ABB Limited and shall be returned to ABB Limited or destroyed, at ABB Limited's request, together with any copies.
Introduction
This document details the Hazardous Area Classification (HAC) Risk Assessment that was completed for the Dargavel Energy from Waste Facility (EFW) on 28 Feb 2008 at Otto Simon Offices, Cheadle, Manchester. The HAC assessed the current design basis of the planned facility, to be located at Dumfries, Scotland. The facility is designed to thermally treat waste and recover energy that would otherwise be lost to landfill. The treatment facility employs the EnerWaste Gasification technology. This is a batch gasification process, where the fuel is heated in refractory lined chambers to produce a synthesis fuel gas. The advanced thermal treatment process is a sequencing batch gasification system sourced through Planet Advantage Ltd. There will be 2 trains of equipment initially. Each train comprising 4 Primary Gasification Chambers and 1 Secondary Combustion Chamber, a boiler and gas cleaning station. A common turbine will be used for all streams and would ultimately provide approximately 6.2MW of electricity for export as well as other equipment to recover energy as heat. The facility will have an initial waste fuel capacity of 40,000 tonnes per year but the technology is modular in nature and can be scaled to the full planning limit of 60,000 tonnes in the future.
The Area Classification Risk assessment was a team event comprising: Lloyd Brotherton Finni Einarsson Stephen Cochrane Steve Townsend Derek Oldfield Dave Brindley Mick Donley Dargavel Facility Project Director (ScotGen) Dargavel Process Specialist (EnerWaste Europe Ltd) Dargavel Process Specialist (EnerWaste Europe Ltd) Dargavel Facility Project Manager (Otto Simon) Senior Control Electrical Project Engineer (Otto Simon) Senior Process Engineer (Otto Simon Ltd) Review Leader (ABB Consultant)
Ascot Environmental is the main contractor for ScotGen (Dumfries) Ltd who own and operate the site. Otto Simon are acting as the Clients Engineer providing specialist process engineering support to Ascot Environmental for the facility. EnerWaste Europe are providing the gasification equipment.
Guidance to assist with the area classification was taken from: BS EN 60079-10 Electrical apparatus for explosive gas atmospheres Part 10: Classification of hazardous areas. IEC 60079-20 Electrical apparatus for explosive gas atmospheres Part 20 : Data for flammable gases and vapours, relating to the use of Electrical Apparatus. BS EN 61241-10 Electrical apparatus for use in the presence of combustible dust Part 10 : Classification of areas where combustible dusts are or maybe present. Institute of Petroleum Area Classification Guideline Part 15 (IP15) 3rd Edition. Area Classification Code for Installations Handling Flammable Fluids. Part 15 of the IP Model Code of Safe Practise in the Petroleum Industry (Energy Institute London). ABB Guidance for Area Classification which provides Supplementary Guidance for BS EN 60079-10 and BS EN 50281-3. Safe Handling of Combustible Dusts (HSG 103) : Precautions against explosions. HSE Books. CFD Modelling of Low Pressure Jets for Area Classification HSL/2005/11 Health and Safety Laboratory. ATEX and DSEAR: Hazardous Area Classification and Laboratory Operations Health and Safety Executive HSE Technical Measures Document -Hazardous Area Classification and Control of Ignition Sources.
The HAC review process assesses plant equipment under normal and abnormal
conditions; it does not consider catastrophic failure of plant / equipment nor mechanical /
Report Ref. SCOTTO01 HAC Report Version 2.0
Page 5 of 22
Copyright ABB Limited 2009
process safety risk assessments. As prescribed by IEC 60079-10, it is not the aim of hazardous area classification to guard against the ignition of major releases of flammable materials under catastrophic failure of plant, e.g. the rupture of a pressure vessel or pipeline, or the cold failure of a tank which, in properly run facilities, has a very low probability of occurrence. The incidence of such releases must be kept within acceptable limits by correct design, construction, maintenance and operation of facilities.
The following Dargavel Project documents were used during the review: Title Drawing Number Rev
OttoSimon Project Drawings (Otto Simon Project No: 4106) Process Description Process Schematic Process Flow Diagram Site Layout 4106/AE/000/002 4106/AE/000/005 First Draft 06/02/08 Draft Draft P4 P6
Aptech (Powder Systems) Drawings Sodium Bicarbonate Storage & Dosing P&ID (Aptech (Powder Systems) EnerWaste Europe Ltd Drawings Process Diagram 002-C001-000 (4106SG-100-RP005 Rev B) Secondary Combustion Chamber (SCC) Primary Combustion Chamber (PCC) 002-C001-004 (4106SG-200-RP008 Rev B) 002-C001-005 (4106SG-100-RP007 Rev B) Edition 2 Edition 2 Edition 2 13041-7105 2
1.1
Properties of Flammable Materials A Properties of Flammable Materials list has been developed for the materials expected to be present, however for the benefit of the report the main materials present are reviewed below. Property data is taken from IEC 60079-20:2000 Data for Flammable Gases and Vapours, Relating to the Use of Electrical Apparatus, supported by MSDS sheets where required. The Dargavel Facility handles a range of commercial/industrial hazardous and nonhazardous wastes in solid form. Hazardous waste (including oily rags, resins and heavy sludges) is to be handled. No bulk liquids are to be handled as a waste fuel. Liquids in sealed containers of maximum quantity 5 litres will only be allowed as an unavoidable admixture within the waste fuel. Heavy semi-solids could be considered potentially flammable, however in reality they are most likely to be materials with relatively high flash points (higher than local ambient temperature). Waste fuels are transported on pallets or similar containers for loading by human operator using a telescopic handler or other similar mobile plant. Waste fuels are not stored in the facility for an extended period as the time delay between unloading from delivery vehicle to loading into the gasifiers is kept to a minimum. Any leaking containers would be separated from the pallet by facility operator at the unloading point and dealt with immediately by isolation and reject back to the delivering customer. These materials are considered nonflammable when external to the gasifiers. For the convenience of this report, the main materials are considered below. Waste ash from gasifiers is considered non-flammable. Heavy gas oil fuel (diesel) is used as a start up fuel for the primary and secondary chambers and to maintain temperature in the secondary chamber. This is stored in a bunded storage tank. For the purposes of this assessment this diesel fuel is considered as non-flammable (external to the chambers), due to its relatively high flash point. Sodium bicarbonate is non-combustible (has properties of fire-extinguishment).
Powdered Activated Carbon (PAC) is potentially combustible, with a minimum explosive concentration of 140g/m3 (approximately 3 times the density required for most typically explosive dusts). Flue gas dosing material (approx 95% Sodium Bicarbonate & 5% PAC). Due to the high proportion of Sodium bicarbonate (and the modest combustibility of PAC), the mix is considered non-combustible. Residue from Bag Filter considered non-combustible as made up from combination of fly ash and flue gas dosing material. Plant Effluent is essentially waste liquid, mainly water and hence considered noncombustible. It may contain trace oil from drips from delivery vehicles but is not a typical process effluent i.e. it is not process drains containing wash down solvents or oil leaking from process equipment. It should be noted that if the process materials, operating conditions or the process configuration are altered in the future, then an assessment to deem the requirements of a further area classification risk assessment should be undertaken by the responsible parties.
1.2
Ambient Temperature The Dargavel facility is located near to Dumfries in Scotland, and is subject to typical UK ambient temperature, with general max external temp of the site considered to be typically 20-30Deg C.
1.3
Process Description
1.3.1
Process Overview The Dargavel Energy from Waste (EFW) Facility is an advanced thermal treatment plant, designed to recover energy from solid commercial/industrial waste material and use this to generate electrical power and recover energy as heat.
The thermal treatment process involves gasification of the waste material to produce an energy rich fuel gas, known as synthesis gas (Syngas). This Syngas is combusted and the heat in the resulting flue gas recovered to generate super heated steam. This superheated steam is used to drive a turbine, which in turn drives an electrical generator to produce power and energy recovery as heat. The advanced thermal treatment process is a sequencing batch gasification system. There will be 2 trains of equipment initially. Each train comprising 4 Primary Gasification Chambers and 1 Secondary Combustion Chamber, a boiler and gas cleaning station. A common turbine will be used for all eventual streams and will provide approximately 6.2MW of electricity for export plus energy recovery as heat. The Dargavel EFW facility comprises a 2 stream plant rated for a waste throughput of 40,000tpa. The main equipment in each stream are: 1.3.2 4 Primary Gasification Chambers (PGCs) 1 Syngas Combustion Chamber (Secondary Combustion Chamber (SCC)) 1 Steam Boiler 1 Flue Gas Cleaning Plant
Waste Handling The facility handles solid commercial/industrial waste comprising a mix of hazardous and non-hazardous waste. Waste delivery is by road vehicle at a rate of less than 40 vehicles/day, Monday to Friday plus approximately 20 vehicles on Saturday mornings. Non-hazardous waste is tipped onto the facility floor by the road vehicle. Hazardous waste is supplied in sealed consignments often located on pallets. The pallets are unloaded by telescopic handler or similar suitably equipped mobile plant. Materials are loaded to the next available chamber. Non-hazardous waste (generally lighter/softer material with lower calorific value) is loaded at the base of the chamber, with hazardous waste loaded to the top of the chamber. The maximum amount of hazardous waste per chamber is unlikely to exceed half the
total weight for that chamber and would more usually be less than half.
Page 9 of 22
1.3.3
Waste Gasification Chambers Each stream comprises 4 refractory lined waste gasification chambers, operating on a batch basis. The gasification process cycle is 24hour process (approximately) and is defined by 5 distinct phases: 1. Waste Ignition (< 1hours) gas oil used as an accelerant 2. Gasification (6 to 8 hours) 3. Residual Carbon Reduction (6 to 8 hours ) 4. Cool Down (6 to 8 hours ) 5. De-ashing and Waste Loading (< 1 hour) To provide a continuous Syngas flow and energy recovery, the batch operation of the gasification chambers is staggered such that at least one gasification chamber is always producing Syngas. The process is therefore considered as being semi-continuous. Waste Gasification Phase Gasification chamber is loaded with waste, and the chamber sealed closed. Waste gasification in the gasification chamber is initiated by igniting the waste using an ignition burner fuelled by a small quantity of heavy fuel oil (diesel). As the temperature in the chamber increases, the waste gasification process becomes self sustaining and the use of fuel is no longer required (this is when gases from the chamber reaches a preset temp, usually 200DegC). During the gasification process, air is injected into the gasifier from underneath, and the flow is regulated to ensure that the gasification occurs in an oxygen deficient atmosphere. This phase ensures complete combustion of the waste material. Operating temp of the chamber is in the range of 850/900DegC. The Syngas generated by the gasification chamber is directed into the Syngas combustion chamber (secondary combustion chamber).
Residual Carbon Reduction Phase At the end of the waste gasification phase, the chamber enters the residual carbon reduction phase, where the chamber is operated with an excess of oxygen to oxidise residual carbon in the ash to ensure that waste incineration directives are satisfied. Cool Down Phase Following completion of the residual carbon reduction phase, the chamber begins a cool down phase. This cools the ash (using air) to a point where it can be safely handled. The heated air stream is directed to the Syngas combustion chamber and used in the combustion of the Syngas. De-Ashing and Waste Loading Phase When the ash in the gasifier chamber has been cooled down to acceptable limits, the gasification air flow is stopped and the gasification chamber is isolated from the Syngas combustion chamber. The ash is removed from the gasification chamber and a fresh batch of wastes loaded into the chamber ready for the beginning of the ignition phase.
1.3.4
Syngas Combustion Chamber (Secondary Combustion Chamber SCC) Each stream has one secondary combustion chamber serving the four gasification chambers. The Syngas combustion chamber has four gas inlet ports, one dedicated per gasification chamber. In normal operation, all four of the gas ports are in use. At least one port is receiving Syngas from the gasification chamber in gasification mode, two or three ports are receiving combustion air from the gasification chambers in residual carbon reduction and/or cool down mode. Only during the relatively short de-ashing and reloading is any individual gasification chamber isolated from the secondary chamber and so off-line.
As Syngas enters the Syngas combustion chamber and is mixed with combustion air it is combusted. The energy release during this combustion allows regulation of the temperature to those standards set by the Waste Incineration Directive (WID). In order to comply at all times with the Waste Incineration Directive, the Syngas combustion chamber incorporates a support fuel burner (diesel). This is not used in normal operation and is only necessary when the gasification facility is being started up from cold, during shutdown or when the waste fuel has a low calorific value. An emergency vent (venting externally) is located between the secondary combustion chamber and the waste heat boiler. This vent is primarily for the protection of any downstream equipment during abnormal events and any gas vented would be approximately 1100DegC and considered un-ignitable. Any venting operation will be of short duration. Comment on un-ignitable gas When the emergency vent operates, the air supply to the PGC will stop and there may be a small volume of pyrolisis gas released from the PGC that is in the gasification mode (due to the retained heat). It is anticipated that this would burn in the SCC together with air pulled from the other PGCs (due to chimney effect of emergency vent) and flue gas would be emitted to atmosphere. The project team consider it possible that a puff of Pyrolisis gas may be emitted into the building from the PGC prior to the emergency vent opening this will be for an extremely short duration. Recommendation. R1. Consider adoption of gas detectors within facility to confirm frequency and extent of any puff of Pyrolisis gas. These could be of portable type and would be most valuable during commissioning activities. 1.3.5 Steam Boiler Each stream incorporates a fire tube type boiler that is used to recover the heat from the flue gas stream exiting the Syngas combustion chamber. This cools the flue gas down to 180DegC prior to it being treated in the flue gas cleaning plant and emitted to atmosphere. The heat recovered from the flue gas is used in the boiler to heat boiler
Page 12 of 22
feed water and generate superheated steam at a pressure of 40BarG and a temperature of 400DegC.
1.3.6
Flue Gas Cleaning Plant The Flue Gas Cleaning plant uses a combination of Sodium Bicarbonate and Powdered Activated Carbon (PAC) to treat the acidity and other pollutants of the Flue Gas emissions in a standard design system. PAC is dosed in proportional to the Sodium Bicarbonate at approximately 5%PAC to 95% Sodium Bicarbonate. PAC is delivered in Fabric Intermediate Bulk Containers (FIBC). The cleaning plant has its own dedicated PAC supply system comprising FIBC discharge station, transfer screw, storage hopper (50litres) and volumetric feeder. FIBCs will be lifted by a fork lift truck (FLT) and placed on the FIBC discharge station. During loading of the FIBC to the station, the bag acts to essentially seal the transfer station, additionally dust extraction from the stations is used. The PAC transfer system including screw feeders is considered to operate as a filled system. The dosed flue gas passes through a bag filter before vent to atmosphere via the multiflue chimney. Spent residue from the bag filter is collected in big-bags for off-site disposal.
1.4
Facility Ventilation The assessment was completed on the facility achieving a ventilation rate of at least 7-9 air changes per hour.
1.5
Material Handling Practices & Spillages The facility is operated by a dedicated team of operators, maintaining the facility to general industrial standards of cleanliness and housekeeping. Dust layers are controlled
through routine cleaning operations supported by specific cleaning following any maintenance activities that have resulted in material deposits outside normal standards.
2
2.1
Area Classification (Risk Assessment)

Waste Delivery to Facility Floor Waste Reception Hall The Waste Reception Hall contains non-hazardous waste tipped to the floor from road vehicle, and hazardous waste sealed in specific consignments, usually held on pallets or similar. The materials are held here prior to loading. Although nominally hazardous materials are present the area is classed as nonhazardous as the hazardous materials are all relatively high flash point materials, held in sealed containers. Assessment. Non-Hazardous Area.
2.2
Gasification Chambers The gasifier is controlled by its own Burner Management System (BMS), supplied complete as part of the EFW facility and is considered to be of standard BMS design. The BMS is considered to achieve a standard burner management type basis of safety and it is not considered appropriate to apply hazardous area classification techniques to ensure a basis of safety. Assessment. Gasifier classified as a Non-Hazardous Area.
Comment on emergency shutdown and possible release of short puff of synthesis gas. It is considered possible that the release of a small puff of synthesis gas from the PGC following emergency shutdown. In line with the general DSEAR approach to burners and burner systems, it is not considered appropriate or helpful to zone based on this potential puff situation, as zoning (and the associated selection of appropriate Ex rated equipment) will not achieve a satisfactory basis of safety as any gas released will likely still find an ignition source in the form of hot surfaces on the burner system. Instead this assessment relies on the application of correct design, construction, maintenance and operation principles for the facility. Additionally as per described elsewhere in the report,
the PGC is controlled by its own Burner Management System (BMS) considered appropriate to achieve a standard burner management type basis of safety. This report contains a recommendation to monitor for this puff of gas situation. If the findings of any monitoring are outside the design basis of the facility then the operators should consider the need to reassess the basis of safety of the facility. However it is advised that zoning would still not achieve any reliable basis of safety for the reasons described above, particularly the predictable likelihood that a hot surface will act as an ignition source for any gas released.
2.3
Secondary Combustion Chamber The secondary combustion chamber is controlled by its own Burner Management System (BMS), supplied complete as part of the EFW facility and is considered to be of standard BMS design. The BMS is considered to achieve a standard burner management type basis of safety and it is not considered appropriate to apply hazardous area classification techniques to ensure a basis of safety. Assessment. Secondary Combustion Chamber classified as a Non-Hazardous Area.
Comment on emergency venting and possible puff of pyrolysis gas. The operational description of the SCC noted the possibility of the release of a small puff of pyrolysis gas following emergency vent operation. In line with the general DSEAR approach to burners and burner systems, it is not considered appropriate or helpful to zone based on this potential puff situation, as zoning (and the associated selection of appropriate Ex rated equipment) will not achieve a satisfactory basis of safety as any gas released will likely still find an ignition source in the form of hot surfaces on the burner system. Instead this assessment relies on the application of correct design, construction, maintenance and operation principles for the facility. Additionally as per described elsewhere in the report, the SCC is controlled by its own
Burner Management System (BMS) considered appropriate to achieve a standard burner management type basis of safety. This report contains a recommendation to monitor for this puff of gas situation. If the findings of any monitoring are outside the design basis of the facility then the operators should consider the need to reassess the basis of safety of the facility. However it is advised that zoning would still not achieve any reliable basis of safety for the reasons described above, particularly the predictable likelihood that a hot surface will act as an ignition source for any gas released.
2.4
Flue Gas Treatment Facility MSDS for PAC material states that it is potentially combustible, but requires a minimum concentration of 140g/m3 which is a relatively dense dust cloud. Dust clouds of this density are not considered realistic outside of the PAC system due to the combination of: The action of lowering the FIBC on to the FIBC discharge station acts to essentially seal the station. The system post the FIBC station is essentially powder filled The dust extraction system present at the FIBC will experience only small quantities of dust, significantly below the 140g/m3 threshold for combustible clouds. The PAC is mixed with 95% Sodium Bicarbonate which renders the mix noncombustible. PAC Storage - For the 2 stream plant, PAC store will contain 6 bags + 2 bags on the FIBC discharge stations Assessment. Treatment area classified as Non-Hazardous.
2.5
Bag Filter The Bag Filter only handles materials considered as non-combustible (95% Sodium Bicarbonate/5%PAC dosing mix and flue gas) Assessment. Area is classified as Non-Hazardous.
2.6
CEMS Area - Hydrogen Bottle Storage X2 These 2 hydrogen bottle are stored outside in dedicated secure cage. They are used to supply the VOC analyser. The bottles are located in a naturally well ventilated area and operate at ambient temperatures. The screwed connections at the tops of the gas bottles are considered to act as secondary sources of release and give rise to a zone in which a flammable atmosphere is not likely to occur in normal operation and if it does will only exist for a short time and hence is classified as Zone 2. This zone extends to a sphere of 1.0m radius around the bottle top connections. The most likely cause of the potential release path at the screwed connections is created by pick up of small dirt particles at the screw threads created during bottle change-over. In reality the both the frequency of bottle change-over and the likely hood of dirt pick up is considered to be relatively low, however the possibility is acknowledged. Assessment Zone 2 spheres of 1meter radius at gas bottle top screwed connections. VOC Analyser The VOC analyser (supplied with hydrogen via continuous pipeline from hydrogen bottles covered above) is considered as a piece of standard laboratory equipment and in line with general DSEAR principles and specific HSE guidance for laboratory applications, is not considered suitable for zoning. Instead a safe basis of operation is achieved via the following: Analyser is on the low pressure side of the regulator, hence any release (considered highly unlikely) will be low rate and quickly dispersed
Pipe work connections will be leak tested during installation/commissioning, minimising any likelihood of leak
Pipe work connections will be subjected to repeat leak testing following any need for connections to be broken, minimising any likelihood of leak
Analyser is sited such that good practise is achieved to ensure equipment is not subject to any obvious forms of vibration or impact damage.
Due to the above the analyser is not considered as zoned and is considered as a safe area.
3
3.1
Zoning
Hydrogen Bottle Store (2 Gas Bottles) for CEMS Zone 2 sphere of 1.0m radius around the bottle top screwed connections.
4
4.1
Temperature Classification & Gas Group

Temperature Classification This defined for the Zone 2 area at the Hydrogen Bottles associated with the CEMS equipment. Temp class T1 determined.
4.2
Gas Group This defined for the Zone 2 area at the Hydrogen Bottles associated with the CEMS equipment. Gas group IIC determined.
Appendix A
Properties of Flammable Materials
A separate Properties of Flammable Materials listing has been produced - Doc Ref SCOTTO01/FlamProp/0001.
Appendix B
Hazardous Area Classification Layout Drawing
Refer to Hazardous Area Classification Drawing Doc Ref. SCOTTO01/AC Drg/0001.

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Appendix 31

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Hazardous Area Classification Report Dargavel Energy from Waste Facility ScotGen (Dumfries) Limited

Report: Version: Date:

SCOTTO01 HAC Report 2.0 06 October 2008

Ref. No: Version: Date:

SCOTTO01 HAC Report 2.0 06 October 2008

Belasis Hall Technology Park PO Box 99 Billingham TS23 4YS

Report Ref. SCOTTO01 HAC Report Version 2.0

Copyright ABB Limited 2009

Report Ref. SCOTTO01 HAC Report Version 2.0

Copyright ABB Limited 2009

Report Ref. SCOTTO01 HAC Report Version 2.0

Copyright ABB Limited 2009

Area Classification (Risk Assessment)

Temperature Classification & Gas Group

Properties of Flammable Materials

Hazardous Area Classification Layout Drawing

Refer to Hazardous Area Classification Drawing Doc Ref. SCOTTO01/AC Drg/0001.

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