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 Directive 1999/92/EC

(for Manufacturers)
Conformity Assessment
Potential ignition source
(electrical and non electrical) during
normal operation, expected or rare
unit malfunction:
(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 450°C
T2 300°C
T3 200°C
T4 135°C
T5 100°C
T6 85°C
Explosion Sub Groups
A (examples: methane, ethane, ammonia, gasoline,…)
B (B+H2) (examples: ethylene, ethylene oxide, hydrogen sulphide,..)
C hydrogen, acetylene, carbon disulphide
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 / IEC 60079-0 general requirements

EN 60079-1 / IEC 60079-1 flameproof enclosure „d“
EN 60079-2 / IEC 60079-2 pressurized enclosure „p“
EN 60079-5 / IEC 60079-5 powder filling „q“
EN 60079-6 / IEC 60079-6 oil immersion „o“
EN 60079-7 / IEC 60079-7 increased safety „e“
EN 60079-11 / IEC 60079-11 intrinsic safety „i“
EN 60079-15 / IEC 60079-15 type of protection „n“ (category 3G)
EN 60079-18 / IEC 60079-18 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 ICA’s (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
measuring
Limited Leakage cell

physical state normal

malfunction case
of sample operation
gas or liquid no no A
gas or liquid no yes B
gas yes yes C sample lines
(restricted flow)

liquid yes yes STOP

power and
data cables
Analysers “EEx p Packaged”

Introduction of Flammable Samples: hazardous area

Case A “fail-safe containment”

electronics
measuring
Valid for gases and liquids cell
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
sample lines
Installation in Zone 2 (restricted flow)

according to simplified procedure

for instance
welded power and
connections data cables
Analysers “EEx p Packaged”

Introduction of Flammable Samples: hazardous area

Case A “fail-safe containment”
electronics

Overpressure of purged cabinet > sample pressure measuring

cell

Only valid for gases

Purge gas: air sufficient
Purge gas loss compensation
Installation in Zone 1
automatic EEx p control system
sample lines
precautions that overpressure of containment is (restricted flow)
50 Pa above sample pressure at any time
simple screw
Installation in Zone 2 fittings, power and
according to simplified procedure O-rings, etc. data cables
Analysers “EEx p Packaged”

Introduction of Flammable Samples:

hazardous area
Case B “containment with limited leakage”
only during failure situation electronics
Method 1 measuring
cell
Dilution via permanent air purge

Valid for gases

ICA’s outside dilution zone
Installation in Zone 1
automatic EEx p control system
precautions that purge gas dilutes leaking gas to
sample lines
< 25% LEL (restricted flow)
Installation in Zone 2
according to simplified procedure simple screw
fittings, power and
same precautions as Zone 1 O-rings, etc. data cables
Analysers “EEx p Packaged”

Introduction of Flammable Samples: hazardous area

Case B “containment with limited leakage”
only during failure situation electronics
measuring
Method 2 cell
Inert gas purge (N2, CO2, Ar) with loss compensation
Gases and liquids
Oxygen content < 2%
UEL < 80%
Installation in Zone 1
automatic EEx p control system sample lines
Installation in Zone 2 (restricted flow)

according to simplified procedure

simple screw
fittings, power and
O-rings, etc. data cables
Analysers “EEx p Packaged”

Introduction of Flammable Samples:

hazardous area
Case B “containment with limited leakage”
only during failure situation electronics
Method 3 measuring
cell
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
sample lines
content to < 2% (restricted flow)
Installation in Zone 2
according to simplified procedure simple screw
fittings, power and
same precautions as Zone 1 O-rings, etc. data cables
Analysers “EEx p Packaged”

Introduction of Flammable Samples: hazardous area

Case C “containment with limited leakage”
normal operation and failure situation electronics
Dilution via permanent air purge measuring
cell

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 sample lines
(restricted flow)
according to simplified procedure
same precautions as Zone 1 simple screw
fittings, power and
O-rings, etc. data cables
Required Hardware

ATEX certified EEx p Control Unit

for instance control units from BARTEC

Cabinet which fulfils the requirements of APEX for Zone 1

EN 60079-02
EN / IEC 60079-0
IP code according to IEC 60529

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. TÜV 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 (TÜV 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 (TÜV 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 BENKE’s
Compact Air Conditioning Unit
ATEX certified for Zone 1
TÜV 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 55°C 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

AR SSR
1 5 2
General Purpose
Area
3

Sluice

1 Ex-Air Conditioning Unit 4 Bottle Cabinet LEL-Sensor

2 Bypass/Fast Loop 5 Analyser AR = Analyser Room
3 Sampling System 6 Flash Light, Horn SSR = Sampling System
Room
Safety of Analyser Houses
Assembly Example for Shelters in Zone 1
GENERAL PURPOSE AREA

ZONE 2

ZONE 1
4

AR SSR
1 5 2
General Purpose
Area
3

Sluice

1 Ex-Air Conditioning Unit 4 Bottle Cabinet LEL-Sensor

2 Bypass/Fast Loop 5 Analyser AR = Analyser Room
3 Sampling System 6 Flash Light, Horn SSR = Sampling System
Room
Safety of Analyser Houses
Assembly Example for Shelters in Zone 2
GENERAL PURPOSE AREA

ZONE 2

1 5 2
AR 3

General Purpose
Area

SSR

1 Ex-Air Conditioning Unit 4 Bottle Cabinet LEL-Sensor

2 Bypass/Fast Loop 5 Analyser AR = Analyser Room
3 Sampling System 6 Flash Light, Horn SSR = Sampling System
Room
Safety of Analyser Houses
Assembly Example for Shelters in Zone 2
GENERAL PURPOSE AREA

ZONE 2

1 5 2
AR 3

General Purpose
Area

SSR

1 Ex-Air Conditioning Unit 4 Bottle Cabinet LEL-Sensor

2 Bypass/Fast Loop 5 Analyser AR = Analyser Room
3 Sampling System 6 Flash Light, Horn 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