REMBE - Explosion Protection Basics

EXPLOSION PROTECTION
BASICS
REMBE® GmbH Safety + Control

Kwan Kum Nyin B.Eng (Hons)
Consulting | Engineering | Products | Service
Mar 2016
OVERVIEW
1. Explosion Basics
2. Explosion Prevention
3. Explosion Venting / Explosion Doors / Vent

Ducts
4. Flameless Venting w. Q-Rohr® / Q-Box
5. Explosion Suppression
6. Explosion Isolation
Page 2
Mar 2016
What is ATEX?
Our customers always ask for:
• ATEX Approval
• ATEX Certification
• and etc.
What does this really means?
ATEX = Atmosphères Explosibles
ATEX refers to two separate (but related) European Union (EU) Directives
describing what „equipment“ and „work environment“, is allowed in an
environment with an Explosive Atmosphere
Page 3
Mar 2016
ATEX DIRECTIVE 94/9/EC and DIRECTIVE 99/92/EC
ATEX
Concerns equipment Concerns calssification of

manufacturers and sale of Dir. 94/9/EC Dir. 99/92/EC Hazardous Areas and correct
Ex equipment selection, installation,
inspection, & maintenance of
Equipment Workplace Ex equipment
Applies minimum Essential Directive Directive
Health & Safety
Requirements (EHSR) on Requires all Equipment with
the Equipment to avoid For Equipment potential ignition source to
For OEMs
safety being a barrier to Users comply with 94/9/EC. All
trade Equipment sold/installed in
EEA after July 2003 must
EC-Type Examination Cert comply with 94/9/EC
issued against EHSR given 01.07.2003 Zoning+
in Annex II of the Directive equipment EPD
Page 4
Mar 2016
ATEX EC-Type Examination Certificate
Page 5
Mar 2016
DID YOU KNOW?
That most of the bulk solids and dusts which are handled in the industry are
combustible and could lead to explosion hazards?
ORGANIC METALLIC INORGANIC
Page 6
Mar 2016
WHAT MATERIALS ARE COMBUSTIBLE DUSTS?
Page 7
Mar 2016
Affected Sectors...
Page 8
Mar 2016
WHAT ARE THE CONDITIONS TO GENERATE A
DUST EXPLOSION?
Page 9
Mar 2016
IMPORTANT VALUES RELATING TO
COMBUSTIBLE DUST EXPLOSIONS?
o Kst Value – Maximum pressure rise (dp/dt) during an explosion in an enclosed vessel. Kst measures
the relative explosive severity compared with other dusts. To find the Kst values of combustible
dust, please visit: http://www.dguv.de/ifa/en/gestis/expl/index.jsp
o Pmax – The maximum pressure developed in a contained deflagration of an optimum mixture
o Pred – The maximum pressure developed in a vented enclosure during a vented deflagration
o Pstat - Pressure that activates a vent opening when the pressure is increased slowly
Page 10
Mar 2016
COMBUSTIBLE DUSTS ARE CLASSIFIED
ACCORDING TO THEIR Kst VALUES
o St 1 – Dusts with Kst values of > 0 to 200 Bar m/s (most bulk materials)
o St 2 – Dusts with Kst values of 201 to 300 Bar m/s (only about 2% to 5% of all dusts)
o St 3 – Dusts with Kst values of > 300 Bar m/s (typically metallic powders e.g. Aluminum powder)
Page 11
Mar 2016
OTHER PARAMETERS CONCERNING
COMBUSTIBLE DUSTS
• Dust Particle Size
• Dust concentration
• Moisture Content
• Oxygen
• Minimum Ignition Energy (MIE)
• Minimum Ignition Temperature (MIT)
• Lower Explosive Limits (LEL)
• and many more….
Page 12
Mar 2016
THE MOST IMPORTANT SAFETY VALUES
for dusts
example
„feature“ simple „explanation“ wood
„dust-propensity“ Likelihood of dust clouds varies

Probability (Ease)
MIT (dust layer) „igniteability“ for hot surfaces 300 °C
MIE „igniteability“ for hot sparks < 100 mJ
MIT (dust cloud) „igniteability“ for hot surfaces < 400 °C
BI (Burning Index) Smouldering fire possible? 5

Severity
Pmax max. pressure 10 bar
Kst-Value „speed of an explosion“ 200 bar*m/s
Page 13
Mar 2016
HAZARDOUS AREA CLASSIFICATION FOR DUST
EXPLOSIONS
Zone 20 An atmosphere where a cloud of combustible dust in the air is present frequently,
continuously, or for long periods.
Zone 21 An atmosphere where a cloud of combustible dust in the air is likely to occur
occasionally during normal operation.
Zone 22 An atmosphere where a cloud of combustible dust in the air is not likely to occur in
normal operation but, if it does occur, will persist for only a short period.
Page 14
Mar 2016
TYPICAL MDF LINES ZONING
Page 15
Mar 2016
HOW TO ASSESS THE EXPLOSION RISK
Page 16
Mar 2016
Are Flammable substances

present?
Can sufficient dispersal in air give

rise to an explosive atmosphere?
Page 17
Mar 2016
Dispersion in air giving rise to an explosive

atmosphere:
Examples:
Formation of dust/air mixture during
• Grinding or Screening
• Conveying, Filling or Discharging
• Drying
• and etc...
Particles size <500µm fine fractions is of interest
Page 18
Mar 2016
Where can explosive atmospheres

occur?
Is formation of a hazardous
explosive atmosphere possible?
Page 19
Mar 2016
Hazardous explosive atmosphere can exist

when:
Examples:
• more than 10 litres of explosive atmosphere in a
confined space, irrespective of the size of the
room
• for most combustible dusts, a deposit less than
1mm deep evenly distribute over whole floor
area is sufficient (when raised into suspension)
to fill an entire room with explosive dust / air
mixture
• when in a confined vessel that is incapable of
withstanding explosion pressures, much smaller
volumes than indicated above must be regarded
as hazardous
Page 20
Mar 2016
Is formation of hazardous
explosive atmosphere reliably
prevented?
Page 21
Mar 2016
HOW TO ASSES THE EXPLOSION RISK
To what zones can the places

with hazardous explosive
atmospheres be assigned?
Is the ignition of hazardous

explosive atmospheres highly
improbable?
Page 22
Mar 2016
EXPLOSION PROTECTION MEASURES, MEANS
Page 23
Mar 2016
OVERVIEW
1. Explosion Basics

Ducts
Page 24
Mar 2016
PREVENTION
Ventilation
Page 25
Mar 2016
PREVENTION
Cleaning
Page 26
Mar 2016
PREVENTION…
of ignition sources
Page 27
Mar 2016
PREVENTION…
of ignition sources
Page 28
Mar 2016
PREVENTION…
of ignition sources
Page 29
Mar 2016
PREVENTION
of ignition sources
Page 30
Mar 2016
PREVENTION: GROUNDING
• Explosion Prevention / Earth &

Ground Monitoring Units
Page 31
Mar 2016
#1 STATIC
Grounding of Road Tanker
Page 32
Mar 2016
EXPLOSION PROTECTION (MITIGATION
MEASURES)
Page 33
Mar 2016
OVERVIEW
1. Explosion Basics

Ducts
Page 34
Mar 2016
EXPLOSION VENTING
Page 35
Mar 2016
REMBE® PORTFOLIO FOR EXPLOSION VENTING
Page 36
Mar 2016
BUT, HOW TO APPLY EXPLOSION VENTING?
How to know:
• Quantity of Vent Panel(s) to be applied?

• Size of Vent Panel(s) to be applied?
to properly protect an enclosure
Calculate / Size the „Required Explosion Venting Area“
Remember, Important values for calculation / sizing:
• Kst (bar.m/s)
• Pmax (bar)
• Pred (bar)
• Pstat (bar)
• AND physical dimensions of the enclosure
Page 37
Mar 2016
WINVENT 4.0 – SIZING SOFTWARE
• Winvent 4.0
• Software to calculate explosion venting area for dust and gas
explosions as well as for hybrid mixtures
Page 38
Mar 2016
SIZING - EXAMPLE
Silo dimensions
Page 39
Mar 2016
SIZING - EXAMPLE
Calculated Required Vent Area = 23.22m²
Page 40
Mar 2016
CHOOSE THE CORRECT QTY & SIZE OF VENT
PANEL
Calculated Required Vent Area = 23.22m²

24pcs of EX-GO-VENT 1000x1000
Page 41
Mar 2016
IS IT IMPORTANT TO PERFORM CORRECT SIZING!
Page 42
Mar 2016
WHAT ELSE IS IMPORTANT?
ENSURE THE VENT PANEL OPENS CORRECTLY!
Page 43
Mar 2016
WHAT ELSE IS IMPORTANT?
BEWARE WHERE THE VENT PANEL IS FACING!
Page 44
Mar 2016
CONSIDER FLAME, DUST AND PRESSURE WAVE!
Page 45
Mar 2016
WHAT IF THE PROTECTED ENCLOSURE IS
INDOORS?
ALL standards do not allow Indoor Venting by INDOOR OUTDOOR

Explosion Venting Panels!
Venting Duct to safely direct explosion flames

and pressures to a „safe outdoor location“
Be careful where the vent duct is facing!
Page 46
Mar 2016
DESIGN VENT DUCT CORRECTLY!
Page 47
Mar 2016
NEGATIVE EFFECT OF VENT DUCT
Page 48
Mar 2016
NEGATIVE EFFECT OF DUCTWORK
• will this ever work?
Page 49
Mar 2016
OVERVIEW
1. Explosion Basics

Ducts
Page 50
Mar 2016
THE SOLUTION: FLAMELESS VENTING
Q-Rohr® and Q-Box
Page 51
Mar 2016
FLAMELESS VENTING
HOW IT WORKS
Page 52
Mar 2016
FLAMELESS VENTING
Page 53
Mar 2016
FLAMELESS VENTING
Page 54
Mar 2016
FLAMELESS VENTING
External effects:
• Stainless steel mesh captures ALL flames and sparks from escaping
• Safe indoor venting
• Lowers heat from dust explosion to minimal level (<200°C for 1s)
• Comparison purpose: 250°C for 10s would lead to red skin
• Low external pressure levels (<10mbar)
• Comparison purpose: 145mbar would lead to rupture of eardrum
• Minimal noise level during activation (<120db(A) for less than 1s)
• Comparison purpose: 120db(A) is equivalent to loud music
Page 55
Mar 2016
FLAMELESS VENTING
Q-Rohr®
Features:
•Flameless, dust, and dangerous pressure
wave free explosion venting
• substitutes vent ducts
• Allowing optimum plant layout
•Metallic dust version available
•Up to Kst 400 bar.m/s
•Re-usable after an explosion
• Just clean and replace vent panel
Page 56
Mar 2016
Q-ROHR® APPLICATIONS
Page 57
Mar 2016
Q-ROHR® APPLICATIONS
Page 58
Mar 2016
FLAMELESS VENTING
Q-Box
Features:
•Flameless, dust, and dangerous pressure
wave free explosion venting
• substitutes vent ducts
• Allowing optimum plant layout
•Up to Kst 200 bar.m/s
•Re-usable after an explosion
• Just clean and replace vent panel
•305 x 610 and 586 x 920 – retrofitting to
existing panels possible
•Cost effective solution for ST1 dust
applications
Page 59
Mar 2016
FLAMELESS VENTING
Q-Box
Page 60
Mar 2016
OVERVIEW
1. Explosion Basics

Ducts
Page 61
Mar 2016
Q-BIC – SUPPRESSION / CHEMICAL BARRIER
• Explosion rise in
pressure is detected by
pressure sensor
• Output Signal to safety

controller
• Triggering of
suppressors to suppress
the explosion ~ 30 to
85ms
Page 62
Mar 2016
SUPPRESSION / CHEMICAL BARRIER
Q-Bic
Features p-RED:
• Redundant dynamic pressure detector
• 3 Algorithms to determine pressure rise is from an

explosion – prevent false alarm
Page 63
Mar 2016
Q-Bic
Features IR Detector:
• Ultra fast detection of flames, sparks, embers
allowing shorter installation distances
• Adjustable sensitivity to minimize false alarm
Page 64
Mar 2016
Q-Bic
Features:
• Suppression Safety Controller for activation of
chemical barriers
• Single / Multi zone available
• Automatic self test function, redundant electronic

system, SIL 2 rated for reliability
Page 65
Mar 2016
Q-Bic
Features:
• 5l Suppression bottle
Page 66
Mar 2016
Q-Bic
Applications:
Page 67
Mar 2016
OVERVIEW
1. Explosion Basics

Ducts
Page 68
Mar 2016
WHY EXPLOSION ISOLATION?
Industrial plant processes - interconnected

to multiple pieces of equipment
Interconnection allows explosion flames &

pressure waves in an equipment (protected /
Unprotected) to spread to other enclosures or
equipment – subsequent damages
Page 69
Mar 2016
WHY EXPLOSION ISOLATION?
Consequences when an explosion is allowed to propagate
**Grain Handling Plant, Blaye

France after explosion in Aug
1997
Explosions are propagated by flames. It is important to detect, extinguish, or block the

flame front at an early stage to isolate the explosion by Explosion Isolation Devices
Page 70
Mar 2016
EXPLOSION ISOLATION DEVICES
What does the term „explosion isolation devices“ cover?
• No flame release
e.g. via filling devices of tanks for combustible liquids
• No explosion propagating
e.g. via duct work, screw conveyors, elevators
• No broad-flame jet ignition
in downstream enclosures
• No pressure piling
in downstream enclosures
• No transition to detonation (supersonic / flames speed up to 2000m/s,
pressure up to 20 barg)
e.g. in the duct work
Page 71
Mar 2016
#3 ISOLATING
Page 72
Mar 2016
DIFFERENT MEANS OF EXPLOSION ISOLATION
PASSIVE ACTIVE
isolation systems isolation systems
without additional with additional

monitioring- and monitoring- and
triggering systems triggering systems
Partial OR Complete System

Only isolate pressure wave and/or flame propagation
Page 73
Mar 2016
Passive Isolation Systems
Non-return Flap
Poppet Valve
Explosion Diverter
Page 74
Mar 2016
PASSIVE EXPLOSION ISOLATION (COMPLETE)
Q-FlapCompactII
Location of Q-Flap®
Explosionstechnische Entkopplung
Page 75
Mar 2016
Q-FlapCompactII
• Aspiration lines only
• Single direction
Page 76
Mar 2016
VENTEX
• Single / Double acting
• Only for clean air
Page 77
Mar 2016
PASSIVE EXPLOSION ISOLATION (PARTIAL)
Explosion Diverter
• Re-directs explosion due to 180 degree elbow
• Partial isolation solution, prevents pressure

piling in downstream equipment / enclosures
Page 78
Mar 2016
Active Isolation Systems
EXKOP, Quench Valve Chemical Barrier
Fast Acting Valves
Page 79
Mar 2016
ACTIVE EXPLOSION ISOLATION (COMPLETE)
EXKOP® System
Features:
• isolates interconnected equipment safely
• Rubber sleeve close by compress air
• Cost effective solution for pneumatic tranfer
lines
• easy and quick reset
Page 80
Mar 2016
EXKOP® SYSTEM
Explosion Isolation with EXKOP® System

Vent Panel Signaling Unit
EXKOP® System-controller
Filter
EXKOP® QV II
Explosion
Page 81
Mar 2016
EXKOP® SYSTEM
Spark quenching with EXKOP® System

EXKOP® System-controller Produktstrom
Filter
IR-unit
Product EXKOP® QV II
Page 82
Mar 2016
EXKOP® SYSTEM INSTALLATION
Page 83
Mar 2016
ACTIVE EXPLOSION ISOLATION (PARTIAL)
Suppressor Bottle
Controller
IR Detector
Pressure wave / Flame front High rate discharge
Page 84
Mar 2016
ACTIVE EXPLOSION ISOLATION (COMPLETE)
Fast acting valves

Page 85
Mar 2016
WHAT DO YOU HAVE TO CONSIDER?
In general:
• min./max. mounting distance
• dust type and safety values (KSt, pmax, pred, organic/inorganic)
• position (horizontal/vertical)
When using active systems:
• sensor type (flame/pressure/BIRD)

• mounting distance of sensors
Page 86
Mar 2016
EXPERT KNOWLEDGE: MOUNTING DISTANCES
The minimum distance…

• to the protected enclosure depends on the velocity of the explosion flames and the
response time of the detection and closing time of the isolation system
The maximum distance…
• to the protected enclosure arises from the possibility of deflagration transition to

detonation
Page 87
Mar 2016
OF ACTIVE SYSTEMS
sensor barrier
ta tb
L, td
te
ta + tb < te + td
Page 88
Mar 2016
But always consider: The Flamefront varies with ignition starting point!
ms
ft
Page 89
Mar 2016
Worst case when using pressure detectors  start next to outlet

• slow pressure raise in case of low KSt-Values
• long mounting distance required due to late detection of pressure wave
Worst case when using IR-detectors  start in the vessel

• long mounting distance due to late detection of flame and high flame speed
Page 90
Mar 2016
Solution: Detection via both – pressure and IR-detectors
• short mounting distance due to low flame velocity in case of explosion starting at
the outlet (detection via IR-sensor)
• short mounting distance in case of explosion starting in the vessel via early
pressure detection
Page 91
Mar 2016
Maximum mounting distance = Transition of deflagration to detonation
• Gases / hybride mixtures:

40 x diameter of ductwork
max. 15 m / 50 ft
• Dusts:
80 x diameter of ductwork
max. 20 m / 65 ft
Page 92
Mar 2016
SOLE EXPLOSION VENTING IS ONLY HALF THE
BATTLE!
Explosion isolation Filter with flameless venting
Page 93
Mar 2016
ASIDE: VENTING DEVICE AS ISOLATION DEVICE
Clean gas
Q-Box (without
bursting disc for
return air isolation)
Q-Flap®
Raw gas
Rotary valve
Dust discharge
Page 94
Mar 2016
THANK YOU
FOR
YOUR ATTENTION
Gallbergweg 21
59929 Brilon, Germany
T +49 2961 7405-0
F +49 2961 50714
info@rembe.de
www.rembe.de

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EXPLOSION PROTECTION

REMBE® GmbH Safety + Control

Consulting | Engineering | Products | Service

3. Explosion Venting / Explosion Doors / Vent

4. Flameless Venting w. Q-Rohr® / Q-Box

Our customers always ask for:

What does this really means?

ATEX = Atmosphères Explosibles

Concerns equipment Concerns calssification of

ORGANIC METALLIC INORGANIC

„feature“ simple „explanation“ wood

„dust-propensity“ Likelihood of dust clouds varies

MIT (dust layer) „igniteability“ for hot surfaces 300 °C

MIE „igniteability“ for hot sparks < 100 mJ

MIT (dust cloud) „igniteability“ for hot surfaces < 400 °C

BI (Burning Index) Smouldering fire possible? 5

Pmax max. pressure 10 bar

Kst-Value „speed of an explosion“ 200 bar*m/s

Are Flammable substances

Can sufficient dispersal in air give

Dispersion in air giving rise to an explosive

Particles size <500µm fine fractions is of interest

Where can explosive atmospheres

Hazardous explosive atmosphere can exist

To what zones can the places

Is the ignition of hazardous

3. Explosion Venting / Explosion Doors / Vent

4. Flameless Venting w. Q-Rohr® / Q-Box

• Explosion Prevention / Earth &

3. Explosion Venting / Explosion Doors / Vent

4. Flameless Venting w. Q-Rohr® / Q-Box

• Quantity of Vent Panel(s) to be applied?

to properly protect an enclosure

Calculate / Size the „Required Explosion Venting Area“

Remember, Important values for calculation / sizing:

Calculated Required Vent Area = 23.22m²

Calculated Required Vent Area = 23.22m²

ALL standards do not allow Indoor Venting by INDOOR OUTDOOR

Venting Duct to safely direct explosion flames

Be careful where the vent duct is facing!

• will this ever work?

3. Explosion Venting / Explosion Doors / Vent

4. Flameless Venting w. Q-Rohr® / Q-Box

3. Explosion Venting / Explosion Doors / Vent

4. Flameless Venting w. Q-Rohr® / Q-Box

• Output Signal to safety

• 3 Algorithms to determine pressure rise is from an

• Adjustable sensitivity to minimize false alarm

• Single / Multi zone available

• Automatic self test function, redundant electronic

3. Explosion Venting / Explosion Doors / Vent

4. Flameless Venting w. Q-Rohr® / Q-Box

Industrial plant processes - interconnected

Interconnection allows explosion flames &

**Grain Handling Plant, Blaye

Explosions are propagated by flames. It is important to detect, extinguish, or block the

What does the term „explosion isolation devices“ cover?

without additional with additional

Partial OR Complete System

• Aspiration lines only

• Single / Double acting

• Only for clean air

• Re-directs explosion due to 180 degree elbow