Pipeline Technology Conference 2022, Berlin

17th Pipeline Technology Conference

Estrel Convention Center
Berlin, Germany
7-10 Mar 2022

ATEX (Zone 1) Certification for In-line Pipeline Isolation Solutions

Author:
Gary Anderson, Offshore Market Development Director, T.D. Williamson, Inc.
Newcastle-Upon-Tyne, United Kingdom
Henning Bø, Technical Authority, T.D. Williamson, Inc. Stavanger, Norway

ABSTRACT

Explosive atmospheres in the workplace have been a challenge since before the
Industrial Revolution.
Many workplaces contain or have activities that produce explosive or potentially
explosive atmospheres. Examples are processes that create or release flammable
gases or vapors, or fine organic dusts or generate grains.
Atmosphéres Explosives (ATEX) is a European set of directives for controlling
explosive atmospheres. Its purpose is to provide minimum requirements for
improving the health and safety protection of workers potentially at risk from
explosive atmospheres.
Within the specific work areas, zones are demarcated depending on the severity
level of the explosive risk (and/or likelihood for an explosive atmosphere to be
present). Equipment developed for use in an ATEX environment will be very specific
as to which zone it will be allowed to operate in.
Hydrocarbon transportation under pressure through pipelines falls into a very specific
ATEX certification group.
It is recognized in Europe on most offshore and onshore pipeline facilities that
equipment to be used within the pipeline will require certification for zone 1. Most
pigging operations such as cleaning or inline inspection are now conducted with
ATEX certified equipment as standard.
Inline isolation or plugging has to date been waived from this requirement. Such work
instead requires extensive risk assessments and hot work permits to ensure as safe
a working environment as possible.
This paper covers the challenges faced to certify an inline isolation tool (SmartPlug®
tool) for use in a zone 1 ATEX work area, from equipment development challenges to
final certification and execution of an in-line isolation project with full certification
package.
 Pipeline Technology Conference 2022, Berlin
17th Pipeline Technology Conference
Estrel Convention Center
Berlin, Germany
7-10 Mar 2022
1. INTRODUCTION

1.1. THE EXPLOSION TRIANGLE

The late 18th century saw the rise of the Industrial Revolution in Europe and the
United States. This was the transition from previously localised farming practices
and hand production methods to new manufacturing processes and the rise of the
mechanized factory system.
During this period, the iron production, chemical manufacturing, mining and textiles
industries evolved, there was an increased use of steam and waterpower, and
agriculture became an industry.

The Industrial Revolution was accompanied by an unprecedented rise in population

growth, which in turn increased demands for produce and outputs from the newly
created factory systems.

These new industries generated flammable gases and liquids, dust, and grains, all of
which could contribute to an explosion on a scale that had not been seen before the
Revolution.

The mining industry is a testament to the dangers involved in these industries. It paid
a heavy price for demands of the modern world.

In the UK alone, pre-Industrial Revolution, there was approximately 300 deaths

recorded in the mining industry. Post-Industrial Revolution this figure sits at over
164,000. Not all these deaths were caused by explosions, but they would have still
been a major contributor.

Explosions require three elements to be present: oxygen, fuel, and an ignition

source. This is represented by the explosion triangle (Figure 1).

Figure 1 - Explosion triangle, source: Internet

 Pipeline Technology Conference 2022, Berlin
17th Pipeline Technology Conference
Estrel Convention Center
Berlin, Germany
7-10 Mar 2022
In simple terms, all that’s required to prevent an explosion is to break one segment of
the triangle. This can be any of the three elements. However, some are easier to
remove than others.

Oxygen, one of the most dominant gases in our atmosphere (21%), is present in
most processes. Humans need oxygen to exist, so it needs to be always there during
the process if humans are to be part of the operation. Therefore, removing oxygen
can be a challenge, and create additional risks to human life.

In industrial operations, fuel is often the output product, or biproduct of the process
itself.

In the coal industry, coal is a flammable fuel, with coal dust being produced during
the excavation process. This is applicable in the textile industry, and most certainly
in the oil and gas industry.

Removal of the fuel from the triangle is often impractical, as it typically stops the
whole production process.

This leaves the ignition source as the fundamental target for breaking the chain of the
explosion triangle.

History has shown that this has been the focal safety point in all industries, with some
innovative solutions being developed along the way.

One such development was the Davy lamp, named after Sir Humphrey Davy and
used in the coal mining industry (Figure 2). The Davy lamp evolved in the early
1800s when the only form of light in a coal mine was a naked flame, which was an
obvious potential ignition source.
 Pipeline Technology Conference 2022, Berlin
17th Pipeline Technology Conference
Estrel Convention Center
Berlin, Germany
7-10 Mar 2022

Figure 2 – Davy lamp and components, source: Internet

The principle of the Davy lamp was to have a dual mesh barrier between the flame
and the outside oxygen and gases. The mesh allowed oxygen into the flame area but
prevented the flame from migrating to the outside atmosphere, which had potentially
explosive mixtures in it. This relatively simple invention broke the explosion triangle
by preventing ignition of any gases in the vicinity during its use.

It is the prevention of the ignition source from reaching the fuel source that forms
many of the design principles of today’s safety methods, including protection
principles by ATEX.

1.2. ATMOSPHÉRES EXPLOSIBLES – ATEX

As safety measures evolved, including varying degrees of performance and levels, a

recognition for standardization arose.

Standards unification started in the 1970’s with the German Standards Institute (DIN)
and the British Standards Institute (BSI) being influential forces in this process.

As part of the facilitation of trade in the European Community (EC), and to maintain
the initial set of unified standards, the European Standards organization (CENELEC)
was created in 1973.
CENELEC generated the first directive for devices used in hazardous areas in 1975.
This, in turn, led to further agreements within Europe with the publication of the ATEX
Directive 94/9/EC known as the ATEX equipment directive and Directive 99/92/EC,
 Pipeline Technology Conference 2022, Berlin
17th Pipeline Technology Conference
Estrel Convention Center
Berlin, Germany
7-10 Mar 2022
the ATEX Workplace Directive, in 1996. This ultimately became rule of law in the
EC.
The name ATEX is derived from the French directive 94/9/EC ‘Appareils destinés à
être utilisés en Atmospherés Explosives’ or devices to be used in explosive
atmospheres. This 94/9/EC directive [1] has later been replaced by directive
2014/34/EU [2].
In the industry today one can find several standards related to protection from
explosive atmospheres. These may be international, or national covering certain
geographical areas. Figure 3 below may give some insight into the application,
including certification schemes according to IECEx (global), ATEX (Europe/EU),
UKCA (UK), NEC (US) and CEC (Canada).

Figure 3 - Regulations covering potentially explosive atmospheres, Source: ABB

1.3. ATEX CLASSIFICATIONS

ATEX classifications were created to cover the industries that equipment was to be
used in, as well as the environment and hazardous risks they could operate in.

The reason behind this was that equipment operating in a flammable dust
environment will have very different constraints from equipment used in an offshore
high hydrocarbon condition. Both sets of equipment may be “ATEX proof”, but they
will hold very different certifications.
Similarly, the severity of risk in the area they will perform will determine their
certification.

Other aspects covered are equipment protection, explosion classifications,

temperature operation and equipment protection levels (Figure 4).
 Pipeline Technology Conference 2022, Berlin
17th Pipeline Technology Conference
Estrel Convention Center
Berlin, Germany
7-10 Mar 2022

Figure 4 - ATEX classifications, source - Internet

1.4. ATEX REQUIREMENTS FOR PIGGABLE DEVICES IN PIPELINES

When ATEX was introduced in Europe in 1996, the intention and the vision were to
have all equipment used in explosive atmospheres certified and tested accordingly.
This was not going to happen overnight, and adaptation of ATEX requirements was
spread over a long period of time and varied between industries.

Service industries utilizing re-usable equipment took longer to adjust than the
manufacturing industry supplying ATEX required components and equipment.
In the oil and gas business, specifically the pipeline industry, adaptation of ATEX for
the in-line inspection (ILI) tools and pigging products began in the early 2000s.
Most ILI vendors pushed for this certification, and by the late 2000s, they expected
ATEX certification would be required within Europe, especially offshore in the North
Sea.

Certification requirements for ILI tools are influenced by the fact that the tools
combine mechanical and electronic assemblies and are used in various locations
around the pipeline.
 Pipeline Technology Conference 2022, Berlin
17th Pipeline Technology Conference
Estrel Convention Center
Berlin, Germany
7-10 Mar 2022

Figure 5 - Typical ATEX Certified ILI tool, Source: TDW

1.5. INLINE ISOLATION PROJECTS AND ATEX

Inline isolation is a technology developed during the late 1990s. It was primarily
developed for large diameter transmission pipelines transporting hydrocarbons from
the Norwegian sector of the North Sea to onshore facilities. These pipelines required
isolation close to the offshore facilities to allow maintenance/replacement of features
on the pipeline. Locally isolating the pipeline prevents depressurizing the full pipeline
length, which is both expensive and impractical (Figure 6).

Figure 6 – Inline isolations enable local depressurization for pipeline maintenance, Source: TDW
 Pipeline Technology Conference 2022, Berlin
17th Pipeline Technology Conference
Estrel Convention Center
Berlin, Germany
7-10 Mar 2022
The principle of in-line isolation is to pig the isolation tool to the set location at which
point flow will be stopped and the isolation tool will remain at this position. The tool is
set using remote through wall communication which activates a hydraulic system on
the tool. Once the isolation is established and an isolation certificate issued work can
commence on any remedial work. The in-line isolation tool remains in place until the
work is completed.

Figure 7 - Typical inline isolation tool, Source: TDW

Upon completion of the maintenance work, the isolation tool is unset and retrieved
from the pipeline, either at the receive end of the pipeline using conventional pigging
methods, or by using the pressurized energy of the isolated pipeline to push the tool
back to the point of entry.
These isolation tools have an established core design. Technology upgrades within
the design have been localized to sub-assemblies and component levels.
As a result, ATEX certification has not been available to the in-line isolation market.

To overcome the need for (and mitigate the lack of) ATEX certification, rigorous
checks and procedures have to be followed prior to any mobilization of such tools.
Requirements will vary client-to-client based on the project, but typically include
numerous risk assessments ahead of mobilization and subsequent onsite
assessments at the time of mobilization. Specific hot work permits are put in place to
ensure the necessary level of safety.

These activities add time and effort to every project. In offshore projects, time can
become a major expense.
However, to date, this has been accepted, and recognized as the only way to carry
out such isolations.
 Pipeline Technology Conference 2022, Berlin
17th Pipeline Technology Conference
Estrel Convention Center
Berlin, Germany
7-10 Mar 2022
In 2016, TD Williamson (TDW) set out to try and change that and introduce a certified
isolation service that would fully comply to requirement of ATEX and IECEx. Prior to
this the tracking and communications equipment used external to the pipeline have
had ATEX and IECEx certification since 2007. This equipment is used to track and
operate isolation tools and tracking units installed in pigs.
The entire process was completed with the involvement of a notified body, where the
design was reviewed and necessary testing including the explosion testing was
performed and the certification was obtained, issued by the independent, third party,
stating compliance with the requirement [3], [4] and [5] of both ATEX and IECEx.

1.6. FORESEEN CHALLENGES WITH ATEX FOR IN-LINE ISOLATION

Before the redesign of isolation tools for the ATEX market, an understanding of the
requirements to fulfil such a design was required.
The explosive mixture that an isolation tool will have to endure will contain
hydrocarbon gas. This will either be a gas product or gaseous mixture given off by
liquid hydrocarbons.
In ATEX gas requirements, which hydrocarbon pipeline facilities come under, there
are three recognized zones that equipment can operate in.
• Zone 0 – This is where there will continuously be an explosive atmosphere
present.
• Zone 1 – This is where there is likely to be an explosive atmosphere present
during normal operation.
• Zone 2 – This is where an explosive mixture is not likely to occur in normal
operation and if it does it will be for a short period of time.

This can be explained in the form of a garage forecourt or gas station, (Figure 8).
The underground storage tanks and refueling tanks are zone 0, where an explosive
atmosphere is always present.
The refueling points on the underground tanks and the car tanks are zone 1, where
an explosive mixture is likely to be present during normal operation.
The remaining garage forecourt and surrounding area are considered zone 2, where
explosive mixture is not likely to occur in normal operation and if it does it will be for a
short period of time.
 Pipeline Technology Conference 2022, Berlin
17th Pipeline Technology Conference
Estrel Convention Center
Berlin, Germany
7-10 Mar 2022

Figure 8 - ATEX zones on a garage forecourt, Source: Internet

In offshore or onshore hydrocarbon processing facilities, the levels of risk are

dictated by the same zonal divisions. Since in-line isolation tools, are introduced to
the pipeline via the launch or receive pigging traps, to comply with ATEX certification
requirements, the isolation and communication equipment will have to be zone 1
certified to enter zone 1 (Figure 9).

Figure 9 - Inline isolation tool entering a pig trap, Source: TDW

 Pipeline Technology Conference 2022, Berlin
17th Pipeline Technology Conference
Estrel Convention Center
Berlin, Germany
7-10 Mar 2022
In addition to the zone 1 equipment requirements, ancillary and support equipment
may be zone 2 requirement. This needs to be identified and categorized.

Isolation tools are assembled with a series of mechanical and/or electronic sub-
assemblies. Electronic sub-assemblies have the potential to generate a spark, which
is an ignition source. To function in a hydrocarbon gas environment, electronic,
spark potential components must be contained in a vessel protecting them from the
gaseous mixtures.

In addition to this protection, it must be shown that if an explosive mixture enters the
container and ignites, the vessel will contain the explosion and not allow any
migration outside of the vessel. All potential leak paths will have to provide adequate
protection.

Figure 10 – Illustration of flame proof vessel and protection principle, Source: Internet

These requirements are achieved through design of flame paths and flame arrestors
where required and completing third party testing, giving the sub-assembly housing
an EX-d proof rating, with an explosion protection level (EPL) of Gb (Figure 4).
.

This aspect of ATEX certification is the major element in moving isolation equipment
towards an ATEX capability in a zone 1 environment, and is the most challenging
part of the process.

An isolation tool control system is the major electronic functioning system on an

isolation tool. It provides the intelligence to the system during an inline isolation.
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17th Pipeline Technology Conference
Estrel Convention Center
Berlin, Germany
7-10 Mar 2022

Electr. Wiring
Control System (MTM) Control System (CM)
Plug Modules
Figure 11 – Layout of an inline isolation tool, Source: TDW

Once the tool is launched this element provides to means of tracking the tool to the
set location. This is via an electro-magnetic system using extremely low frequencies
(ELF) to allow accurate and reliable transmission of signals.
This is via an electronic transceiver system which is positioned outside of the pipe
communicating with the tool via an onboard antenna.
This transceiver may well have to be positioned in a zone 1 area of the pipeline
system, so will be required to be ATEX zone 1 certified as well.

Figure 12 Tracking an Isolation Tool through the pipeline, Source: TDW

Once the tool is in the desired position, the ELF transmissible signals prompt the tool
to start the setting sequence via electric motor and hydraulic pump.

After the tool is set, sensors provide pressure and temperature readings which are
requested for and transmitted via the two-way communication system.
Unsetting of the tool is a reverse of the setting process, all done again through the
communication channels.
The engineering around this technology has evolved over a number of years. To
then redesign the whole package with improvements and add on ATEX zone 1
capability at the same time, was the challenge.
Space constraints of the control system housing was still there, maybe to a greater
extent due to the requirement to implement a flame proof design through introduction
of flame paths and flame arrestors within the same package.
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17th Pipeline Technology Conference
Estrel Convention Center
Berlin, Germany
7-10 Mar 2022
Additional functionality with additional hardware encroached on the space window,
and the built-in antenna had to achieve at least what previous systems could to.
Other elements which had to be designed and tested for were:
Intrinsic safety within the system to minimize spark generation. This was achieved to
Protection concept Ex Ib.
Gases are also categorized within the ATEX structure. To operate within a
hydrocarbon pipeline industry sub-groups of gases had to be considered. This gave
a Gas Subgroup rating of IIB, covering methane, propane and ethylene.
Temperatures within pipelines can vary, both product wise and geographically. On
this basis a range and maximum temperature had to be achieved to cover all
potential realistic options. Certification was attained for a temperature range of -20ºC
to +60ºC, with a surface temperature of 135ºC achieved, giving a Temperature class
of T4.
This gave an ATEX certification for the control system of:
Ex II 2 (2) G Ex d [ib Gb] IIB T4 Gb (-20°C ≤ Tamb≤+60°C)
(Figure 13).

Figure 13 – Isolation tool control system – ATEX protection details, Source: TDW

The control system is just one element of the isolation tool. The monitoring and
tracking system, pressure sensor unit, transponders and externally placed
transceivers all require their own certification, which is equivalent to what is shown in
the control system certificate.
 Pipeline Technology Conference 2022, Berlin
17th Pipeline Technology Conference
Estrel Convention Center
Berlin, Germany
7-10 Mar 2022

Figure 14 Examples of ATEX certified communication equipment (cabled to PC or wireless via handheld devices),
Source: TDW

When carrying out a pipeline isolation program, the isolation tools consist of several
mechanical sub-assemblies as well as the electronic systems which carry their own
certification.
To comply with ATEX zone 1 requirements, these mechanical elements have to be
reviewed in accordance with EN ISO 80079-36 (Non-electrical equipment for
explosive atmospheres), which can involve material and operational procedural
changes.

With the electronic systems certificates in place and mechanical elements assessed
for compliance, an overall ATEX Zone 1 package can be delivered to carry out a
pipeline isolation project.

2. CASE STUDIES

2.1. ATEX ZONE 1 - PIPELINE ISOLATION

A North Sea operator required valves to be repaired in two parallel 16-inch pipelines.
The valves were located topside on the offshore facility.

The isolation equipment was delivered to site with a certification package for ATEX
zone 1 operation.

This allowed for a reduction in the risk assessments carried out before the isolation
as well as the specific hot work permit in place for the isolation duration.

Operationally, the isolations were carried out the same way they would be in similar
projects. The tool was launched, set, monitored, and unset as any other operation.
 Pipeline Technology Conference 2022, Berlin
17th Pipeline Technology Conference
Estrel Convention Center
Berlin, Germany
7-10 Mar 2022

Figure 15 - ATEX zone 1 isolation operation, Source: TDW

3. CONCLUSION

With the onset of the Industrial Revolution supply and demand increased with a
phenomenal rate. Unfortunately, with this increase in production, came risks and
ultimately accidents and deaths.
Very early on in this change process, safety became a key objective to overcome
this. The Davy lamp is one example where engineering designs were adapted within
an industry and became the accepted norm.
All industries set their required standards and expectations. The oil and gas industry
is no exception here.
In summary, an industry demand for increased safety of isolations is now met though
introduction of ATEX and IECEx certified inline isolation equipment.
When third-party certified isolation equipment for operating in ATEX Zone 1 is
available, this will set a new standard for inline isolation services. This adaptation has
already been proven successful through several isolations completed to date, and
the field experience is currently expanding. The additional benefits are reduced
efforts to mitigate the lack of ATEX compliant equipment: like risk assessments,
dispensations, hot work permits, etc.
The standards that are set today will not be reversed. They will be improved upon
and added to over time, making the workplace even safer than it is today.
It is in all parties interest to embrace these standards and push the boundaries
further to ensure the accidents of the past remain in the history books.
 Pipeline Technology Conference 2022, Berlin
17th Pipeline Technology Conference
Estrel Convention Center
Berlin, Germany
7-10 Mar 2022
4. REFERENCES

[1] ATEX 95 Directive; 94/9/EC (replaced by 2014/34/EU in 2016)

[2] ATEX 114 Directive; 2014/34/EU
[3] EN IEC 60079-0 - Explosive atmospheres - Part 0: General requirements
[4] EN IEC 60079-1 - Explosive atmospheres - Part 1: Equipment protection by flameproof enclosures "d"
[5] EN IEC 60079-11 - Explosive atmospheres - Part 11: Equipment protection by intrinsic safety "i"
[6] EN ISO 80079-36 - Non-electrical equipment for explosive atmospheres - Basic method and
requirements