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Practical tools. Guideline for creating the explosion protection document

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1 Practical aids Guidelines for preparing the explosion protection document

2 Guidelines for preparing the explosion protection document

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4 Contents 1. General 4 2. Guidelines for preparing the explosion protection document 6 3. Examples from practice Painting work in a spray booth Painting work in a spray booth Paint drying in a drying oven Storage Safety cabinets Laboratory fume cupboard Electroplating Hard chrome plating Battery charging station Spray cans with flammable propellants and solvents Operating instructions Spray cans Plastic dust at the GRP processing Metal dusts during laser welding Powder coating Frequently asked questions and answers on explosion protection Regulations and rules Internet addresses 46 3

5 1. General In 6 of the Ordinance on Industrial Safety and Health (BetrSichV), the legislature requires that the employer must prepare an explosion protection document regardless of the number of employees in the presence of a dangerous, potentially explosive atmosphere (in short: g.e.a.). The document is intended to show that possible explosion hazards have been identified and assessed. It also serves to record the necessary protective measures and the spatial division of the work area into zones in which ignition sources are to be avoided. The creation of documentation is always an additional task for the company, as it often means collecting signatures and defining responsibilities for the commissioned employee in addition to the formulation work. This is most likely also the intention of the legislature to set an internal process in motion by dealing with the document, which takes sufficient account of possible hazards from a dangerous, explosive atmosphere. In addition to the BetrSichV, the Occupational Safety and Health Act (ArbSchG) and the Ordinance on Hazardous Substances (GefStoffV) also require the assessment and documentation of hazards and measures. In 12 in connection with Annex III No. 1 of the GefStoffV, fire and explosion hazards are dealt with separately and necessary protective measures are shown. With these numerous documentation obligations, the question inevitably arises: Why do I have to create an additional explosion protection document now? As part of the risk assessment according to GefStoffV and ArbSchG, the dangers of a g.e.a. essential points have already been clarified. These include: the general avoidance of a g.e.a. by using substitute materials or by reducing the concentration detection of hazardous substances by ventilation systems monitoring of the measures taken by sensors, volume flow measurement, etc. avoiding dangerous chemical reactions due to mixing avoiding the risk of ignition avoiding structural measures for fire and explosion protection (escape routes, fire extinguishers, labeling) organizational measures (Training of employees, supervision, work permit, etc.) The risk assessment is usually activity-related and is carried out either for an individual employee or for a group of employees. Under certain conditions, however, work equipment and its effectiveness (e.g. verified by testing) can also be part of the risk assessment. At this point there is an overlap with the BetrSichV. The BetrSichV also requires a risk assessment to be carried out in 3. With regard to the risk of explosion, however, the mandate in the BetrSichV has been expanded. Is a g.e.a. exists and if this cannot be prevented by measures according to the GefStoffV, the probability of occurrence, possible ignition sources and the effects of a possible explosion must be determined. This approach goes beyond the activity-related aspect and requires a holistic assessment of the production plant, i.e. including the suction channels and the storage rooms. The explosion protection document serves as evidence in the context of tests and audits that the specific hazards have been identified and the necessary protective measures have been installed. In this context, the potentially explosive areas must be divided into zones during operation, which necessitates additional requirements for the equipment to be free of ignition sources. From this it can be deduced from when an explosion protection document is to be created in addition to the risk assessment. If there is a likelihood of the formation of a dangerous, explosive atmosphere in a work process, which necessitates a spatial division into zones, these hazards must be considered separately in an explosion protection document. A g.e.a. occurs if, after ignition of the mixture, injury to the employee cannot be ruled out. In TRBS 2152 Part 1 "Dangerous explosive atmospheres Assessment of the risk of explosion", a volume of approx. 10 l is used as a simple guide. It is important to consider how close the employee is to this area when working and whether there are additional hazards from other released substances. It should be noted that the term volume is a g.e.a. The mixture of air and vaporized flammable solvent, gas or dust is to be understood and not the liquid volume of the flammable liquid. Furthermore, it must be clarified to what extent operationally-related technical malfunctions and repair and maintenance work must be taken into account. The latter must be considered in any case, as unusual operating conditions can occur during maintenance work due to additional ignition sources or increased consumption of solvents. 4th

6 1. General Technical malfunctions within the meaning of the BetrSichV are malfunctions that occur in everyday operations and that can be estimated based on existing operational experience. This includes, for example, the spillage of liquids during manual filling, leaking transport containers, and the release of acetylene when changing bottles. A possible power failure and the resulting additional hazards should also be taken into account. However, the considerations should not go so far as to include all conceivable negligent behavior by employees. In general, the operational disturbance must be clearly distinguished from the incident in environmental protection law (12th BImSchV). Environmental protection law treats released quantities on a scale that poses a risk to the population and the environment. Below are examples of activities / work equipment for which, according to the current state of knowledge, no separate explosion protection document needs to be drawn up in addition to a risk assessment: Single bottle systems with liquid gas or acetylene Individual battery charging stations in large halls Hand-operated grinding workstations in compliance with the general dust limit Impregnation resin systems with temperature control and flash point> 32 C Short-term use of spray cans with flammable propellants in ventilated rooms The required contents of an explosion protection document result from the BetrSichV and the BGR 104 (Figure 1). Zoning makes it necessary to analyze all ignition sources during normal operation and in the event of a malfunction. Electrical and non-electrical devices must be designed and marked in accordance with the zones (RL 94/9 / EC see guidelines) and must be checked regularly. Older devices that were installed before can continue to be used if they meet the minimum requirements according to Appendix 4 A of the BetrSichV. Even devices and work equipment without their own potential source of ignition, e.g. B. Pipelines that are electrostatically charged or heated by friction must be taken into account in the analysis. 1. Specification of the endangered operating area 2. Responsible person, creation date 3. Brief description of the structural and local conditions 4. Description of the process with the parameters 5. Material data, quantities 6. Risk assessment Can an explosive atmosphere occur? Is it threatening? 7. Protection concept Technical protective measures Zone classification Organization Figure 1: Content of the explosion protection document Plants, devices and protection systems or safety, control or regulation devices in potentially explosive areas are assessed as plants requiring monitoring in accordance with the BetrSichV and must be checked at regular intervals (at least every 3 years) by a »qualified Person «should be checked. Qualified in the sense of explosion protection (TRBS 1203 Part 1) is someone who has completed professional training, has experience with Ex devices and is familiar with the associated regulations. Collection of examples The explosion protection documents in the collection of examples are the result of the assessment of existing systems from member companies of the BG ETEM. For this reason, they contain detailed technical information on materials and ventilation parameters. The documents can be downloaded as Word files from the Internet address under the heading Tools / Control of occupational safety. The user must do his own additional operational research to check to what extent the example can be transferred to his system and what additional technical information is required. The printed documents are therefore a suggestion and should help in the proverbial search for "the common thread". 5

7 2. Guideline for creating the explosion protection document This guideline provides information on which content, questions, and assessments have to be dealt with under the individual headings in the explosion protection document. Explosion protection documentation BetrSichV 6 Date: Responsible: Signature: 1 General information Company name Work area Designation of the system Description of the process Address of the company Telephone / here as precisely as possible name hall / area. Should the g.e.a. (dangerous explosive atmosphere), they would have to be listed here. Specify the manufacturer's designation of the system and the year of construction. Brief description of the main procedural process steps with information on temperature, throughput, type of aerosol / vapor mixture and information on ventilation technology. 2 Associated documents The BetrSichV (6, Paragraph 5) allows reference to be made to existing documentation and reports that have already been created on the basis of other legal provisions. These include: Hazardous substances directory Risk assessment Safety data sheets Site plan Ex zone plan Test certificates Operating instructions Proof of instruction EC type-examination certificate 6

8 2. Guideline for preparing the explosion protection document 3 Input materials and safety-related key figures For the assessment of the g.e.a. In addition to the amount used (daily amount), the safety-related key figures (STK) are also of essential importance. As a rule, this information for preparations with solvents can be found in the safety data sheet under point 9 »Physical and chemical properties«. In the case of pure solvents or preparations with a main component, the STK can be determined from the »Gestis« substance database of the German Social Accident Insurance. Internet: The following STK are important for activities with flammable solvents: Flash point LEL / OEG Ignition temperature Minimum ignition energy Boiling temperature Vapor pressure In the case of dusts, the STK can also be determined from the safety data sheet if it is so-called technical dust. In the case of dusts released in the process, these data must be determined by additional tests in a laboratory. The IFA has compiled the STK for numerous examined dusts in the substance database »Gestis-Staub-Ex«: Internet: The following STK are important for activities with combustible dusts: Particle size distribution LEL / OEG Dust class Minimum ignition energy Ignition temperature Smoldering temperature Burning number If mixtures of different solvents or Mixtures of dusts and solvents is an estimate of the gea to be carried out for the components with the most unfavorable STK (e.g. lowest flash point or LEL or high vapor pressure). 4 Assessment of the risk of explosion If a dangerous, explosive atmosphere occurs, it must be assessed how large the volume and the probability of the occurrence of a g.e.a. is in the system and in the vicinity of the system (TRBS 2152 Part 1). As a simplified rule of thumb, a volume of 10 l applies to mixtures of air and a flammable substance (gas, steam, mist, dust). Dust deposits with a thickness of more than 1 mm can also cause a g.e.a. produce. 7th

9 2. Guideline for preparing the explosion protection document With the frequency of occurrence of a g.e.a. In normal operation, a distinction is made as follows: Ex zone Occurrence of the g.e.a. Zone 0 (gas or steam-air mixture) continuously and over long periods of time (often) Zone 20 (dust-air mixture) Zone 1 (gas or steam-air mixture) occasionally Zone 21 (dust-air mixture) Zone 2 (gas or vapor-air mixture) normally not or only briefly (rarely) Zone 22 (dust-air mixture) The frequency of occurrence and the volume can be reduced or even avoided entirely through additional protective measures. Protective measures within the meaning of TRBS 2152 Part 2 include: Concentration limitation Inerting Sealing of system parts Ventilation measures Monitoring the concentration Removal of dust deposits If one of these additional measures succeeds in g.e.a. To reduce or even avoid completely, the division of the work area into zones can be omitted or at least reduced. It should be noted that the protective measure is permanently ensured by monitoring / testing. Furthermore, possible operational malfunctions and maintenance and repair work must be taken into account as part of the assessment. Can the formation of a g.e.a. do not exclude, possible ignition sources must be determined (point 5.3). The assessment of the impact of an explosion on the system or in neighboring areas leads to the area of ​​tertiary explosion protection e.g. B. by installing pressure relief flaps or quick-closing slides. 5 Measures Note: To avoid a g.e.a. In practice there are a large number of procedures based on the application of different physico-chemical methods (TRBS 2152 Part 2). In this guide, the documentation is carried out using the example of ventilation as the most common protective measure. 5.1 Technical protective measures Ventilation Room ventilation Object extraction Natural ventilation Determination of the necessary ventilation parameters Volume flow Flow velocity (extraction systems) Air exchange rate 8

10 2. Guidelines for preparing the explosion protection document In order to be able to determine these parameters, an estimate of the leakage or swelling strength of the flammable substance is necessary. The set ventilation parameters must be ensured by technical monitoring and control of the system. 5.2 Zone classification If by the o. E. Measures the formation of a g.e.a. is not reliably prevented, the work area / facility must be divided into zones (Exzone plan). Examples of some common standard procedures can be found in BGR 104. In general, the following applies to zones: Zone 0 (gases, vapors, mists) or 20 (dusts): the g.e.a. occurs frequently or for long periods of time. This is usually the case inside the system or close to the point of origin. More than 1000 events per year can be viewed as a clue for the term often. Zone 1 or 21: the g.e.a. Occasionally occurs during normal operation. These areas can be found in the immediate vicinity of zone 0 or 20 or comparable sources. Zone 2 or 22: the g.e.a. occurs only rarely in normal operation and then for a short time. These areas can be found in the vicinity of zone 1 or 21 or the assessment of the work area allows this due to the low concentrations and frequencies. Less than 10 events per year, which then last less than 0.5 h, can be regarded as a clue for the term seldom. 5.3 Possible ignition sources, selection of equipment After the zone classification, the possible ignition sources must be identified. 13 different types of ignition sources are described in the literature (BGR 104). These include: hot surfaces open flames sparks electrical systems and devices electrostatics chemical reactions The selection of electrical and non-electrical work equipment, protection and control devices according to Article 1 of RL 94/9 / EC results from the analysis of the ignition sources and the zoning . Non-electrical work equipment with its own source of ignition include: Motors, agitators, fans. The latter must be distinguished from non-electrical work equipment without its own potential source, which does not fall under Directive 94/9 / EC. These are, for example, pipelines, conductors, foils, which under certain circumstances can become electrostatically charged or heated during the process. 9

11 2.Guideline for creating the explosion protection document Identification of electrical and non-electrical equipment that falls under RL 94/9 / EC: Ex area in which the device can be used Identification of work equipment Zone 0, 1, 2 II G 1 Zone 1, 2 II G 2 Zone 2 II G 3 Zone 20, 21, 22 II D 1 Zone 21, 22 II D 2 Zone 22 II D 3 The use of devices and protective systems in accordance with RL 94/9 / EC results in special requirements from the BetrSichV (system requiring monitoring) to the person qualified to test the devices (TRBS 1203 Part 1) and the scope and time of the test (at least every 3 years). Personal protective equipment z. B. to understand dissipative footwear. Older devices that were installed before can continue to be used if they meet the minimum requirements according to Annex 4 A of the BetrSichV. 5.4 Constructive explosion protection In the member companies of BG ETEM, constructive explosion protection is rarely found. In dust filter systems there are pressure relief flaps, explosion suppression by means of extinguishing agents and occasionally quick-closing slides for mechanical decoupling. As a rule, a precise analysis and calculation of the g.e.a. necessary so that this data can be adopted in the ex-document. 5.5 Organization of inspections of work equipment and exhaust systems Determination of cleaning intervals (e.g. cleaning with a vacuum cleaner, removal of waste containing solvents). EC Declaration of Conformity and Type Examination Alarm Plan Operating Instructions Instruction Procedure when using external companies Approval procedure for maintenance and repair work 5.6 Marking according to BGV A8 According to BGV A8, the areas must be marked with the following symbols: 10

12 3.1 Painting work in a spray booth Explosion protection documentation BetrSichV 6 Date: Responsible: Signature: 1 General information Company name Work area Mustermann GmbH Example street Suggestion city Production TX carrier, Hall 9T7 Designation of the system Paint spray booth from OLT 1989 / L Description of the process In the airless Various 1-component paints are used in the spraying process. The daily consumption is approx. 30 kg per day. The painted TX beams then dry at room temperature on a drying section (60 m). 2 Associated documents List of hazardous substances (folder GS10) Ex zone plan (folder Bau09) Risk assessment (folder GS10) Test certificates (folder Sifa1) Safety data sheets (folder GS-Sida) Operating instructions (anteroom H12) Site plan (folder Bau09) Evidence of instruction (folder GS09) 3 ingredients and For safety-related key figures, see the Safety Data Sheets folder. To assess the risk of explosion, paint P from Garberts with the lowest flash point was used. Lacquer P Flash point: 24 C Boiling point: 127 C LEL: 1.2 Vol-% (58 g / m 3) UEL: 7.5 Vol-% (350 g / m 3) 11

13 3.1 Painting work in a spray booth 4 Assessment of the risk of explosion Dangerous explosive atmospheres can occur: in the area of ​​the spray mist when filling the spray cup cleaning the spray gun on the drying section close to the ground (summer) suction channels 5 measures 5.1 technical ventilation number of air changes: approx. 8-10 times in the Proximity of the spray booth, volume flow in the suction channel is not known and is not monitored Monitoring of the effectiveness: locked with the function of the spray gun Test: annual maintenance by Roberst, Aurich 5.2 Zone classification, fire hazard 1 m Zone 2 5 m flame point. > 21 C no heating technical ventilation Spray booth: Zone 2, 1 m radius around the spray booth, all around Environment: fire hazard (5 m radius) Suction channels: Zone 2 drying section: 1.50 m above the floor, Zone 2 filling and cleaning station: close range (0.5 m) Zone 1, another 1 m Zone 2 see: Ex zone plan and site plan (see point 2) 5.3 Equipment in Zone 2 Selection criterion: Equipment group: II Equipment category: 3 G Ceiling lights: annual inspection of spray gun with hose: according to manufacturer II 2 G, earthed, annual test spray material: earthed via a transport chain Exhaust fan: II 3 G (non-electrical devices) clothing (shoes, protective suit): conductive footwear 12

14 3.1 Painting work in a spray booth 5.4 Constructive explosion protection no constructive explosion protection 5.5 Organization of the alarm plan Operating instructions (see point 2) Instruction (see point 2) Tests (see point 2) Approval procedure 5.6 Marking according to BGV A8 Comment When using different paints, for reasons of clarity the coating material with the most unfavorable safety-related key figures are included in the explosion protection document. The protective measures should be aimed at this preparation. In the case of substitutes such as B. Water-based paints, the explosion protection document is usually not required, as no g.e.a. occurs. The flammability of water-based paints depends on the remaining organic solvents and solids. This can be determined by calculation (BGI 740). In the case of newer paint spray booths and booths that have been manufactured in accordance with EN) and EN), the flash point is not used as the assessment criterion, but compliance with the LEL (<25% = zone 2). For this purpose, a formula for calculating the concentration is specified in the standard. Extended cleaning work with flammable solvents, e.g. B. for maintenance and repair work, must be considered separately. Literature BGI 740 Painting rooms and facilities for liquid coating materials Structural facilities, fire and explosion protection, operation 1) EN coating systems, spray booths for liquid organic coating materials, safety requirements 2) EN coating systems, combined spray and drying booths, safety requirements 13

15 3.2 Painting work in a spray booth 3.2 Painting work in a spray booth Explosion protection documentation BetrSichV 6 Date: Responsible: Signature: 1 General information Company name Work area Mustermann GmbH Example street Suggested town Production TX carrier, Hall 9T7 Designation of the system Paint spray booth from OLT 1989 / L Description of the process Various 1-component paints are processed in the airless spray process. The daily consumption is approx. 30 kg per day. The painted TX beams then dry at room temperature on a drying section (60 m) outside the booth. 2 Associated documents List of hazardous substances (folder GS10) Exzone plan risk assessment (folder GS10) Test certificates (folder Sifa1) Safety data sheets (folder GS-Sida) Operating instructions (anteroom H12) Site plan (folder Bau09) Evidence of instruction (folder GS09) 3 Input materials and safety-related key figures see folder Safety data sheets To assess the risk of explosion, paint P from Garberts with the lowest flash point was used. Lacquer P Flash point: 24 C Boiling point: 127 C LEL: 1.2 Vol% (58 g / m 3) UEL: 7.5 Vol% (350 g / m 3) 14

16 3.2 Painting work in a spray booth 4 Assessment of the risk of explosion Dangerous explosive atmospheres can occur: in the area of ​​the spray mist when filling the spray cup cleaning the spray gun on the drying section close to the ground (summer) suction channels 5 measures 5.1 technical ventilation number of air changes: approx. 8-10 times monitoring of the Effectiveness: locked with the function of the spray gun Test: annual maintenance by Roberst, Aurich 5.2 Zone classification according to BGR 500 chap. (Example 3) fire hazard zone 2 5 m flame point. > 21 C no heating technical ventilation spray booth: zone 2 inside environment: fire hazard, up to 5 m around the booth suction channels: zone 2 drying section: 1.50 m above the floor, zone 2 filling and cleaning station: close range (0.5 m ) Zone 1 for another 1 m Zone 2 see: Ex zone plan and site plan (see point 2) 5.3 Equipment in Zone 2 possible ignition sources Selection criterion: Equipment group: II Equipment category: 3 G Ceiling lights: annual inspection Spray gun with hose: according to manufacturer II 2 G, grounded, annual test; Spray material: earthed via a transport chain Exhaust fan: II 3 G (non-electrical devices) Clothing (shoes, protective suit): conductive footwear 15

17 3.2 Painting work in a spray booth 5.4 Constructive explosion protection no constructive explosion protection 5.5 Organization of the alarm plan Operating instructions (see point 2) Instruction (see point 2) Tests (see points 2 and 5.1) Approval procedure 5.6 Marking according to BGV A8 Comment When using different paints, from For reasons of clarity, the coating material with the most unfavorable safety-related key figures should be included in the explosion protection document. The protective measures should be aimed at this preparation. In the case of substitutes such as B. Water-based paints, the explosion protection document is usually not required, as no g.e.a. occurs. The flammability of water-based paints depends on the remaining organic solvents and solids. This can be determined by calculation (BGI 740). In the case of newer paint spray booths and booths that have been manufactured in accordance with EN) and EN), the flash point is not used as an assessment criterion, but compliance with the LEL (<25% = zone 2). For this purpose, a formula for calculating the concentration is specified in the standard. Extended cleaning work with flammable solvents, e.g. B. for maintenance and repair work, must be considered separately. Literature BGI 740 Painting rooms and facilities for liquid coating materials Structural facilities, fire and explosion protection, operation 1) EN coating systems, spray booths for liquid organic coating materials, safety requirements 2) EN coating systems, combined spray and drying booths, safety requirements 16

18 3.3 Drying paint in a drying oven 3.3 Drying paint in a drying oven Explosion protection documentation BetrSichV 6 Date: Responsible: Signature: 1 General information Company name Work area Description of the system Description of the process Mustermann GmbH Example street Suggestion city Production department: F22 Paint shop Paint drying oven type NLTO, Fa. Afotek interior drying oven with coated components temperature-controlled paint drying at a temperature of up to a maximum of 220 C. The painted components are placed in the oven after a pre-drying time of 30 minutes. After approx. 1.5-2 hours, the drying process is completed when the final temperature is reached. Usable space: 9.4 m 3 Total vapor space: 28 m 3 Heating: 120 kw (natural gas) Maximum permissible solvent quantity: 500 g Fresh air volume: 29.4 m 3 / min (13.3 m 3 / min with throttling) 2 Associated documents List of hazardous substances (folder GS10) Exzone plan (folder Bau09) Risk assessment (folder GS10) Inspection certificates (folder Sifa1) Safety data sheets (folder GS-Sida) Operating instructions (anteroom H12) Site plan (folder Bau09) Evidence of instruction (folder GS09) 3 Input materials and safety-related indicators see folder Safety data sheets for To assess the risk of explosion, the Delta Seal Silver paint from Dörken MKS-Systeme with the lowest flash point and the highest proportion of 1-methoxy-2-propyl acetate was used. Paint Delta Seal Silver: Ignition temperature: 315 C OEG: 10.8% by volume (590 g / m 3) Flash point:> 23 C LEL: 1.5% by volume (82 g / m 3) 17

19 3.3 Drying paint in a drying oven 4 Assessment of the risk of explosion An increase in the solvent concentration is to be expected at the beginning of the drying program. If the maximum permissible amount of solvent and the fresh air volume are adhered to, no g.e.a. inside the drying oven. There is no ignition from hot surfaces (paint ignition temperature 315 C), as the temperatures in the heating register are below 250 C. 5 Measures 5.1 Technical ventilation and procedures Due to the pre-drying time of 30 minutes, approx. 50% of the solvent volume evaporates before drying. The manufacturer stated the maximum amount of solvent to be 500 g. With 70% solvent content in the paint, taking into account the pre-drying time, the maximum permissible paint application amount is 1400 g. The amount is adhered to through the process. Inspection of the system: annually by Karl Runge, Wedel 5.2 Zone classification 5.3 Equipment in zone 2 Possible ignition sources Zone 2 inside the drying oven Selection criterion: Device group: II Device category: 3 G exhaust fan II 3 G (non-electrical devices) Heating register with heat exchanger (surface temperature T 250 C) 5.4 Constructive explosion protection 5.5 Organization no constructive explosion protection Alarm plan Operating instructions (see point 2) Instruction (see point 2) Tests (see point 2) Approval procedure 5.6 Labeling according to BGV A8 Commentary Critical concentrations could occur in the drying oven in the first minutes of the drying process . If the maximum permissible solvent quantities calculated by the manufacturer of the drying oven in accordance with DIN EN 1539 are complied with and the suction performance is reliably guaranteed according to these specifications, there is no risk of g.e.a. and the zoning inside the drying oven can be canceled. In general, the calculation of the maximum permissible solvent quantity should be carried out together with the manufacturer of the drying oven who has the current version of DIN EN 1539. Information on the calculation of the amount of solvent can be found in BGG 909 "Principles for the ventilation calculation of chamber dryers and continuous dryers". 18th

20 3.4 Storage 3.4 Storage of explosion protection documentation BetrSichV 6 Date: Responsible: Signature: 1 General information Company name Work area Designation of the system Description of the process Mustermann GmbH Example street Suggestion city Production TX carrier Hall 9T7 Paint store for TX carriers Storage of highly flammable paints and solvents ( R11). No bottling or mixing. Total storage amount 1500 kg. Natural ventilation. 2 Associated documents List of hazardous substances (folder GS10) Exzone plan risk assessment (folder GS10) Test certificates (folder Sifa1) Safety data sheets (folder GS-Sida) Operating instructions (anteroom H12) Site plan (folder Bau09) Evidence of instruction (folder GS09) 3 Input materials and safety-related key figures see folder Safety data sheets To assess the risk of explosion, the solvent methyl ethyl ketone (MEK) was used as an example. The storage quantity of approx. 400 liters is the largest proportion of a working substance in the total storage quantity. MEK has the lowest flash point of all stored materials. Methyl ethyl ketone Flash point: -10 C Boiling point: 80 C Ignition temperature:> 450 C Vapor pressure at 20 C: approx. 100 hpa LEL: 1.5 Vol-% (45 g / m 3) UEL: 12.6 Vol-% (378 g / m 3) 19th

21 3.4 Storage 4 Assessment of the risk of explosion Dangerous explosive atmospheres can occur: Not at all during normal storage operations. A g.e.a can arise in the event of technical malfunctions (e.g. leaks, breakage of containers). Here mainly near the ground. 5 Measures 5.1 Ventilation Natural ventilation with supply and exhaust air via floor grids, with an exhaust air grille connected directly to the outside air. 5.2 Zone classification (TRbF 20, BGR 104) no heating natural ventilation Room volume: 25 m 3 Zone 2: entire room see: Exzone plan and site plan (point 2) 5.3 Equipment in Zone 2 possible ignition sources Selection criterion: Equipment group: II Equipment category: 3 G ceiling lights, Switch: Check (every 3 years by Elektro-Harms, Oldenburg) 5.4 Constructive explosion protection 5.5 Organization no constructive explosion protection Alarm plan Operating instructions (see point 2) Instruction (see point 2) Tests (see point 2) Approval procedure 5.6 Marking according to BGV A8 Comment The zone classification results from the specifications of the collection of examples for BGR 104 and TRbF 20. If additional filling and transferring processes are to be carried out in the storage room, zone 1 must also be introduced in this area. 20th

22 3.4 Storage Exzone plan for paint store TX Exhaust air, solvents and cleaning agents Filling and transferring Other paints and hardeners Storage area Supply air zone 1 Entrance zone 2 Example of a zone plan with filling 21

23 3.5 Safety cabinets 3.5 Safety cabinets Explosion protection documentation BetrSichV 6 Date: Responsible: Signature: 1 General information Company name Work area Designation of the system Description of the process Mustermann GmbH Example street Suggested city Quality control R 345 XL Safety cabinet for storing hazardous substances at the workplace In the safety cabinet (Düpersecos , Model DF1), all chemicals are stored that are required to test the components of the AB3-D series for physical and chemical stability. The cabinet is connected to the central extraction system. 2 Associated documents List of hazardous substances for cabinet contents (folder GS10) Test certificates (folder Sifa1) Risk assessment (folder GS10) Operating instructions (anteroom H12) Safety data sheets (folder GS-Sida) Evidence of instruction (folder GS09) Site plan (folder Bau09) 3 Input materials and safety-related key figures In the safety cabinet are among others inorganic alkalis and acids stored. The following substances are important for assessing the risk of explosion: Hazardous substance Quantity Labeling Flash point LEL R-phrases [C] Vol-% Methyl ethyl ketane 5 l F, R Acetone 10 l F, R11

24 3.5 Safety cabinets 4 Assessment of the risk of explosion If flammable liquids are stored properly, no dangerous explosive atmosphere occurs.Due to spillage, falling over or other malfunctions, a g.e.a. arise. 5 Measures 5.1 Technical ventilation The safety cabinet is connected to the exhaust air system of the production hall. The amount of air corresponds to a 10-fold air exchange rate. A failure of the ventilation is recognized by an acoustic warning signal in the production hall; further measures are regulated in the operating instructions. 5.2 Zone classification inside safety cabinet: Zone 2, outside safety cabinet: none 5.3 Equipment in Zone 1 There are no other electrical or non-electrical equipment in the cabinet. 5.4 Constructive explosion protection no constructive explosion protection 5.5 Organization of the alarm plan Operating instructions (see point 2) Instruction (see point 2) Tests: The technical ventilation test is carried out annually by Walter (53332 Meinsberg). The result is documented and stored. The safety cabinet is checked annually by the company Düpersecos (54444 city map). 5.6 Labeling according to BGV A8 Comment The basis for the assessment of the zone is Annex L to TRbF 20. If only flammable liquids are stored with a flash point sufficiently above room temperature or if tight containers are stored without any transfer process, the zone classification can be canceled (collection of examples for BGR 104) . 23

25 3.6 Laboratory fume cupboard 3.6 Laboratory fume cupboard Explosion protection documentation BetrSichV 6 Date: Responsible: Signature: 1 General information Company name Work area Designation of the system Description of the process Mustermann GmbH Example street Suggested city Chemical laboratory for sample testing from production Chemical fume cupboard in the laboratory, area ZN Use of acetone as a solvent for Opening of electronic components. The daily consumption is approx. 500 ml per day. 2 Associated documents List of hazardous substances (folder GS10) Ex zone plan (folder Bau09) Risk assessment (folder GS10) Test certificates (folder x) Safety data sheets (folder GS-Sida) Operating instructions (next to the fume cupboard) Site plan (folder Bau09) Evidence of instruction (folder x) 3 ingredients and safety indicators Acetone vapor pressure (20 C): 246 mbar Flash point: <- 20 C LEL: 2.5 Vol-% (60 g / m 3) UEL: 14.3 Vol-% (345 g / m 3) Ignition temperature: 535 C 24

26 3.6 Laboratory fume cupboard 4 Assessment of the risk of explosion Dangerous explosive atmospheres can occur: If the potting compound is dissolved and the exhaust system is switched on, no g.e.a. When transferring and filling acetone, accidental spillage can cause a g.e.a. arise. But this is seldom and then for a short time. 5 Measures 5.1 Technical ventilation and procedures The technical ventilation switches on automatically when the fume cupboard door is operated. This is indicated visually. Air volume flow is 700 m / h and is controlled by flow monitors. Manufacturer: Wesman Laboreinrichtungen, Durlach 5.2 Zone 2 classification inside the fume cupboard 5.3 Equipment in zone 2 possible ignition sources Selection criterion: Device group: II Device category: 3 G lighting inside the fume cupboard. Electrical connections are outside the zone. The fume cupboard complies with EN The use of electrical devices or open flames (Bunsen burners) in the fume cupboard may only be carried out under supervision. It must be ensured that if a larger amount of acetone is released, the gas supply can be safely interrupted immediately. 5.4 Constructive explosion protection 5.5 Organization no constructive explosion protection Alarm plan Operating instructions (see point 2) Instruction (see point 2) Annual inspection with documentation by in-house specialists (Building Technology Department) 5.6 Marking according to BGV A8 Comment Work in fume cupboards is carried out by trained personnel. In addition to the danger of explosion, the dangers of harmful vapors, aerosols and dusts must be taken into account. The correct setting of the sash is of decisive importance here. The area inside the fume cupboard should not be used for the storage of hazardous substances (TRGS 526 laboratories). 25th

27 3.7 Electroplating hard chrome plating 3.7 Electroplating hard chrome plating Explosion protection documentation BetrSichV 6 Date: Responsible: Signature: 1 General information Company name Mustermann GmbH Example street Suggestion city Work area hard chrome plating, machine Hall 2 Designation of the system Description of the process Appendix A2 In Appendix A2, steel parts are initially placed on racks cleaned and then hard chrome plated. The system consists of 13 baths, which are approached by the transport vehicle according to the control. The bathrooms are mostly provided with edge suction. The following are operated with external current: Hard chrome plating bath (3000 A) Electrolytic degreasing (1000 A) 2 associated documents List of hazardous substances (folder GS10) Exzone plan risk assessment (folder GS10) Test certificates (folder Sifa1) Safety data sheets (folder GS-Sida) Operating instructions (anteroom H12) Site plan (folder Bau09) Evidence of instruction (folder GS09) 3 Input materials and safety-related key figures see folder Safety data sheets To assess the risk of explosion, the two baths with external flow were used and the hydrogen development was estimated. Hydrogen: LEL: 4 Vol .-% UEL: 77 Vol .-% Gas density (0 C, 1013 mbar): 0.08989 g / l Relative gas density: 0.07 Ignition temperature: 560 C 26

28 3.7 Electroplating, hard chrome plating 4 Assessment of the risk of explosion Dangerous explosive atmospheres can occur: on the bath surface when starting and stopping the ventilation in the ceiling area above the system 5 Measures 5.1 Technical ventilation bath extraction: about 1200 m 3 / h per bath Monitoring the effectiveness: Locked with electricity for the electrolysis test: annual maintenance by Roberst 5.2 zoning technical ventilation in the bath ceiling openings free bath: Zone 0: Zone 1: Zone 2: Surrounding area: surface of the bath up to 0.2 m above the bath surface 1 m radius around the bath up to the ceiling (cylindrical shape) flammable suction: no zone (sufficient volume flow, therefore the hydrogen concentration is well below LEL) see: Ex zone plan and site plan (see point 2) 5.3 Equipment in zones 0 to 2 possible ignition source Selection criterion: Equipment group: II Explosion group: IIC Zone 2 device category: 3 G Zone 1 device category: 2 G Zone 0 device category: 1 G Ceiling lights: Elect r.Devices: Transport trolley: Exhaust air system: annual inspection, three-year inspection by SV grounded, annual inspection, annual inspection, disconnection of the current via system control before removal of the racks (tear-off sparks) Clothing (shoes, protective suit): conductive footwear 5.4 Constructive explosion protection No constructive explosion protection 27

29 3.7 Electroplating, hard chrome plating 5.5 Organization, alarm plan, operating instructions, instruction, tests, approval procedure, see point Labeling in accordance with BGV A8. This is made up of the two components flammable gas and oxygen. The amount of combustible gas, in this case hydrogen, results from the strength of the current in hard chrome plating. The volume flow of hydrogen can be calculated from the current available for electrolysis and Faraday's constant. The amount of air supplied for dilution depends on the ventilation system. Usually measuring the air flow is the most practical way. With the help of the BG-BGIA report 3/2001 calculation method and modeling in the work area analysis, the amount of air (Chapter 4) can be calculated mathematically, especially with natural ventilation. The following diagram (Fig. 1) can be used to roughly estimate whether the resulting mixture of air and hydrogen is explosive: V: Volume flow of air with which the resulting hydrogen is diluted in m 3 / h (from system data, measurement or calculation ). I: Amperage in the bathroom (operating data). A current efficiency of 10% was assumed for hard chrome plating. If this is lower in reality, more hydrogen is produced. 28

30 3.7 Electroplating Hard chrome plating Hydrogen quantity Hydrogen concentration 10 4% 10 Anodizing 4% 1% Anodizing hard chrome. 10% 2% hydrogen in m 3 / h 1 0.1 anodizing hard chrome. Anodizing hard chrome 10% 1% 10% 2% 1% 0.1% 4% 2 4% 1% 4 0.1% 2% 2% 1% 0.1% 1 0.1 hydrogen in m 3 / h anodizing hard chromium. 1 4% 1% 0.1% 3 anodizing hard chromium. 2% 0,, current strength in A air flow in m 3 / h Fig. 1: Diagram for estimating the hydrogen concentration Based on the current strength (1), the resulting amount of hydrogen is obtained through the intersection with the method used. If you follow this volume flow to the right (2), the point of intersection with the amount of air set (3) results in approximately the mixture concentration (4). If the mixture (inclined straight line of the same concentration) is sufficiently far below 4% (lower explosion limit of hydrogen), there is no need to fear an explosive atmosphere in the mixed state. However, it must be taken into account here that in the area in which the hydrogen mixes with the supply air, potentially explosive concentrations can occur locally. Ex zone plan 1 m zone with ventilation opening zone 2, otherwise zone 1 zone 1 zone 0 bathroom 1 m bathroom Fig. 2: Ex zone plan 29

31 3.8 Battery charging station 3.8 Battery charging station Explosion protection documentation BetrSichV 6 Date: Responsible: Signature: 1 General information Company name Work area Mustermann GmbH Example street Suggested city Transport Logistics IV Designation of the system Battery charging station in building VI, room 432 Description of the process After the end of the shift, the batteries (600 Ah , 80 V) charged by 2 forklifts with the Micomp charger from IEB (max Ah, IUI technology, charging program 3) for 10 hours. The batteries remain connected at the weekend. Water losses are replenished before the forklifts are used. The room has the dimensions 10 m x 5 m x 4.5 m, is enclosed on all sides with an opening (2.5 m x 3 m) to the hall. There are two skylights (1 m x 1 m) in the ceiling area. 2 Associated documents Risk assessment (folder GS10) Operating instructions (anteroom H12) Site plan (folder Bau09) Proof of instruction (folder GS09) Test certificates (folder Sifa1) 3 Input materials and safety-related key figures sulfuric acid, deionized water, hydrogen. Hydrogen is of crucial importance for assessing the risk of explosion. Gas density (0 C, 1013 mbar): 0.08989 g / l Relative gas density: 0.07 Ignition temperature: 560 C LEL: 4.0% by volume (3.3 g / m 3) UEL: 77% by volume (65 g / m 3) 30

32 3.8 Battery charging station 4 Assessment of the risk of explosion During the charging process, especially towards the end of the charging process, hydrogen is released. The hydrogen rises and can collect below the ceiling. 5 Measures 5.1 Technical ventilation There is no technical ventilation. Natural ventilation is provided by the two skylights. The skylights are technically adjusted so that an opening of approx. 3-4 cm is always guaranteed. There are no other sinks in the ceiling. 5.2 Zone classification in Zone 2 in the area of ​​the ceiling up to 1.5 m below the ceiling. 5.3 Equipment in Zone 2 All electrical equipment, junction boxes, etc. have been removed from the ceiling area. The room is illuminated by 3 halogen spotlights (150 W) that are attached to the walls at a height of 2 m. All other electrical supply lines are in the range of 0-2 m in height. The skylights are operated mechanically. 5.4 Constructive explosion protection no constructive explosion protection 5.5 Organization of the alarm plan Operating instructions (see point 2) Instruction (see point 2) Tests: The battery charging station is serviced and checked every 2 years by IEB. 5.6 Labeling according to BGV A8 Comment An explosion protection document is only necessary if the risk assessment shows that a dangerous, explosive atmosphere can be created by hydrogen. This is usually not the case in large, well-ventilated halls. Furthermore, the formation of hydrogen can be prevented by electronically regulating the charging process below the gassing voltage. In the present case, the opening of the skylights is approx. 50 cm below the ceiling, so that a g.e.a. cannot be ruled out. 31

33 3.9 Aerosol cans with flammable propellants and solvents 3.9 Aerosol cans with flammable propellants and solvents (no Ex document, see comment) Risk assessment Documentation 7 para. 6 GefStoffV Creator: Responsible: Date: Work area: Activity: Assembly work at customers and on construction sites Cleaning of cable surfaces Description of activities Kabelfix is ​​used for cleaning and degreasing cable ends before the socket assembly, e.g. B. used in the installation of house connections. Usually, a thin application of the cleaner on the surface is sufficient. To do this, the spray can is actuated for approx. 1-2 seconds. Hazardous substances used / released Designation Labeling / R-phrases Quantity Kabelfix F 190 F +, R ml per assembly group 8000 ml p.a. for approx. 3 assembly groups Assessment There is a risk of explosion due to the flammable propellant gas butane / propane. When stored in the sun or in warm places, there is a risk of the container exploding (approx. 9 bar pressure increase at 50 C). Protective measures / effectiveness Protection level 2 Responsibility (date) A replacement product without butane / propane as a propellant is currently being sought. Use only in well-ventilated rooms. If this is not possible, possible sources of ignition must be removed. Do not store the spray can in the sun or take the spray with you when leaving the vehicle. 32