Have you ever considered the severe consequences of an explosion in a manufacturing facility if a thorough explosion risk assessment is not conducted? Mistakes at this stage can lead not only to production line downtime but, more importantly, to threats to the health and safety of employees. Here, we provide a practical overview of explosion risk assessment based on PN-EN ISO 1127-1, highlighting how it aligns with the ATEX directive, machinery directive, and the EU Regulation 2023/1230.
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Explosion Risk Assessment According to PN-EN ISO 1127-1
The PN-EN ISO 1127-1 standard specifies how to conduct an analysis and assessment of risks associated with potential explosive atmospheres. It forms the basis for meeting European directive requirements, particularly:
- ATEX Directive (2014/34/EU), which regulates equipment and protective systems in explosive atmospheres.
- Machinery Directive (2006/42/EC), focusing on machine safety, including explosion prevention aspects.
- Regulation 2023/1230, introducing new requirements for machine design and operation, including explosion safety.
How can these regulations be translated into practical actions within a company?
What Does an Explosion Risk Assessment Entail?
Defining the Scope and Conditions of the Process
The assessment begins with identifying where flammable substances (dusts, gases, vapors) are present in the installation. This identification considers:
- material properties (flash point, lower and upper explosive limits),
- machine operating conditions (pressure, temperature),
- potential sources of leaks.
Determining Probability and Consequences
Next, estimate how often a hazardous explosive atmosphere might occur and the potential consequences. The higher the frequency, the stricter the requirements for equipment (ATEX categories, e.g., 1, 2, or 3).
Developing a Safety Strategy
Based on the risk assessment results, a plan of action is created:
- design systems that mitigate the effects of a potential explosion (venting, suppression, isolation),
- limit explosive substances or monitor their concentration outside explosive limits,
- eliminate or secure potential ignition sources.
Explosion Risk Assessment: Identifying Hazards
The first step is always mapping potential sources of flammable substances (gases, vapors, mists, or dusts). According to PN-EN ISO 1127-1, consider whether a hazardous explosive atmosphere could form at any point in the process. This includes:
- technological process conditions (e.g., temperature, pressure),
- chemical and physical properties of substances,
- potential leak points (flange connections, valves, gaskets),
- areas where disruptions or failures might occur (e.g., faulty ventilation systems).
The more detailed the analysis of potential hazard sources, the more accurate the risk assessment will be.
Explosion Risk Assessment: The Role of Ignition
Even if an explosive mixture appears in the system, an ignition source is still necessary for an explosion to occur. The ATEX directive requires a detailed assessment and elimination (or minimization) of possible ignition sources, such as:
- hot surfaces (e.g., machine parts with elevated temperatures),
- mechanical sparks (friction, impacts),
- static electricity,
- electrical equipment,
- atmospheric discharges,
- improper welding work.
According to the machinery directive and the new Regulation 2023/1230, analyzing these hazards must be integrated from the machine design stage and included in the technical documentation.
Approaching Ignition Source Analysis
In practice, several steps are applied:
- Checklist
Identify all possible ways sparks or local overheating could occur (e.g., in bearings, belts, electrical devices). - Classification of Explosion Hazard Zones
Based on the frequency and duration of explosive atmosphere presence. This directly affects the selection of protections and equipment categories (e.g., ATEX category 1, 2, or 3). - Application of Relevant Standards
Besides PN-EN ISO 1127-1, standards such as EN 60079 series concerning electrical equipment and protection methods (intrinsic safety, explosion-proof construction, etc.) are crucial. - Verification and Testing
Including grounding resistance measurements, surface temperature checks, and gas or dust concentration measurements.
Reducing Explosion Risk – Practical Solutions
Effectively reducing risk to an acceptable level often requires combining several methods:
- Elimination or Limitation of Flammable Substances
Through technology changes, maintaining concentrations below explosive limits, or using inertization (e.g., with nitrogen). - Preventing Emissions and Leaks
Good design practices, additional seals, and monitoring potential leak points. - Avoiding Ignition Sources
Using Ex-marked equipment, anti-static systems, and training for safe hot work (welding, grinding). - Limiting Explosion Effects
Including explosion venting, flame suppression, explosion isolation, or explosion-resistant construction. - Training and Procedures
Personnel must know the risks, emergency procedures, and proper machine maintenance practices to prevent explosion-prone situations.
Explosion Risk Assessment: Implementing Requirements and Avoiding Mistakes
The requirements set by directives (ATEX, machinery) and PN-EN ISO 1127-1 can seem complex, especially in the context of Regulation 2023/1230, which further tightens certain guidelines. If you need support with:
- creating documentation and analyzing explosion risk,
- implementing protective systems,
- selecting ATEX-compliant equipment,
- training operators and engineering staff,
it is advisable to seek expert assistance.
Engineering Shield offers comprehensive consulting and training services in explosion risk assessment and machine compliance with current regulations. With our experts, you can avoid costly downtime and penalties, and most importantly, ensure the safety of employees and infrastructure.
Explosion risk assessment according to PN-EN ISO 1127-1 is not just a formal requirement but a real tool for protecting people and assets. Proper hazard identification, ignition source analysis, and appropriate risk-reducing measures should be the foundation of any installation or process involving flammable substances. Remember, effective implementation of these solutions requires both technical knowledge and regulatory awareness—hence, leveraging the support of experienced partners is beneficial.
FAQ: Explosion Risk Assessment
Yes. If your company handles flammable substances (e.g., dusts, gases, vapors) and there is a potential for explosive atmospheres, conducting an explosion risk assessment is mandatory. The PN-EN ISO 1127-1 document facilitates compliance with the ATEX directive, machinery directive, and the new Regulation 2023/1230.
The duration and cost depend mainly on the size of the installation, the complexity of processes, and the type of flammable substances. During the initial discussion, we assess the project’s scope and then propose a schedule and budget tailored to your company’s needs.
Safety of people and property: you reduce the risk of accidents and failures that can lead to material and reputational losses.
Compliance with regulations: you avoid financial penalties and issues related to inspections by supervisory authorities.
Operational efficiency: properly designed and maintained installations are less prone to failures, resulting in fewer downtimes.
You can prepare some data yourself (e.g., process information, machine documentation), but a full assessment usually requires specialist knowledge, including familiarity with current standards, ATEX and machinery directives, and Regulation 2023/1230. Collaborating with an experienced advisor or engineering firm (such as Engineering Shield) allows for a thorough and efficient analysis.
Classification of explosion hazard zones and selection of equipment with the appropriate ATEX category.
Application of methods to limit explosion effects, such as venting, suppression, or isolation.
Ensuring measures to eliminate ignition sources, such as eliminating sparking, static electricity, hot surfaces.
Creating organizational procedures (training, maintenance instructions) ensuring long-term safety.