Explosion Protection

Explosion protection and hazard analysis in plant construction

With us you get the suitable complete solution

From the recording of the process engineering
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to the identification of hazards,
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Identification of existing ignition sources
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and classification according to explosion zones
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to the preparation of all necessary/required documents,
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we will work out a solution customized to your operation.

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What does it mean?

You will receive from us a prepared explosion protection documentation according to the ATEX directives 99/92 EC as well as the Ordinance on Hazardous Substances and a hazard analysis according to 2014/34/EU (for manufacturers of devices and systems).

This provides you with proof of the identification and evaluation of possible explosion hazards and of the determination of suitable protective measures.

The explosion protection document provides evidence that all explosion hazards in the plant have been fully identified and evaluated, and that appropriate protective measures have been implemented.

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What is included in the explosion protection document?

There are no formal requirements for the structure of explosion protection documentation.

Rather, it is necessary to compile all the necessary documents and information that contribute to assessing the risk of an explosion and taking suitable countermeasures.

This includes hazard assessments as well as, for example, documentation of the machines and equipment used, escape route plans and markings, operating instructions or plans for hazard prevention.

The following contents must be included in an explosion protection document:

• Complete listing and evaluation of all explosion hazards in the plant.
• Description of the measures to prevent explosions
• Ex zone plan: Classification of the potentially explosive atmospheres into zones

Compliance with the minimum requirements according to Annex 4 of the BetrSichV. These include general and organizational measures as well as the use of equipment and protective systems suitable for the respective Ex zone.

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What measures are included in the explosion protection document?

Explosion protection measures are divided into three categories.

1. Top priority is given to all instruments that help to avert or limit as far as possible the formation of an explosive atmosphere (primary explosion protection).
2. The next step is to avoid all effective sources of ignition (secondary explosion protection).
3. Finally, the effects of a possible explosion must be reduced to a harmless level (tertiary explosion protection).

If the explosion protection document reveals that one protective measure alone is not sufficient, several precautions can be combined to achieve maximum protection for the worker.

We would be pleased to prepare a complete and informative explosion protection document for you, which complies with the requirements of the Hazardous Substances Ordinance and the ATEX directives, and to develop an explosion protection concept tailored to your company.

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The Hazardous Substances Ordinance

The legal basis for the explosion protection document is the Ordinance on Hazardous Substances (GefStoffV).

In paragraph 6, section 9, it prescribes a risk assessment by the employer.

As part of this assessment, all potential hazards to which employees are exposed in the course of their employment must be systematically recorded and evaluated.

The analysis includes, among other things, the identification of areas with explosive atmospheres and existing ignition sources as well as the classification of areas into explosion zones.

If it is determined during the assessment that the development of an explosive atmosphere and the associated risk to workers cannot be completely prevented, the preparation of explosion protection documentation by the operator of a plant is mandatory.

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Excerpt from the Ordinance on Hazardous Substancesaus

§ 11 Special protective measures against physico-chemical effects, in particular against fire and explosion hazards.

(1) On the basis of the risk assessment, the employer shall take measures to protect employees and other persons against physico-chemical effects. He shall determine the measures in such a way that the hazards are avoided or reduced as far as possible. This applies in particular to activities, including storage, where fire and explosion hazards may occur. In doing so, the employer must observe Annex I, numbers 1 and 5. The provisions of the Explosives Act and the legal regulations based thereon shall remain unaffected.

(2) In order to prevent fire and explosion hazards, the employer shall take measures in accordance with the following order of priority:

• Hazardous quantities or concentrations of hazardous substances that may result in fire or explosion hazards shall be avoided,
• ignition sources or conditions that may cause fires or explosions shall be avoided,
• harmful effects of fires or explosions on the health and safety of employees and other persons shall be reduced as far as possible.

(3) Work areas, workplaces, work equipment, and their interconnections shall be designed, constructed, assembled, installed, used, and maintained to prevent fire and explosion hazards.

(4) In the case of activities involving organic peroxides, the employer shall, in addition to the provisions of paragraphs (1) and (2) and of Annex I, item 1, in particular take measures to

• minimize the risk of an accidental explosion and
• limit the effects of fires and explosions.

In doing so, the employer shall observe Annex III.