A T E X - S O L U T I O N S F R O M A E R Z E N

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Harriet Francis
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1 A T E X - S O L U T I O N S F R O M A E R Z E N A E R Z E N E R M A S C H I N E N F A B R I K G M B H A EN

Customers benefit and ATEX-requirements Aerzener Maschinenfabrik has been manufacturing Positive Displacement blowers since 1868 and Screw compressors since 1943.

Technical competence, experienced employees and continuous dialogue with the customers are the basis for successful new developments from Aerzen.

2 Customers benefit and ATEX-requirements Aerzener Maschinenfabrik has been manufacturing Positive Displacement blowers since 1868 and Screw compressors since It is one of the oldest and biggest manufacturers worldwide and is in some ranges the market leader in Europe. Technical competence, experienced employees and continuous dialogue with the customers are the basis for successful new developments from Aerzen. The connection between changing regulations as well as the ATEX-guideline and additional benefit for customers by innovative products for plant manufacturers and operators is also in the focus. Ranges of application and use DELTA BLOWER units made by Aerzener and DELTA SCREW compressor units made by Aerzener were designed for conveying air and neutral gases and are used in chemistry- and process technology, for pneumatic transport of bulk materials and in many other ranges of the present industrial technology. The installation of the European machine directive 94/9/ EG for explosive areas in all applications plays a more and more important role. The blower- and compressor units made by Aerzener are especially designed for the requirements in categories 2 and 3 for dust- as well as for gas zones and certified accordingly by the manufacturer. Machines for category 1 however must be subject to an EG-type test referring to the individual case. For certain individual projects this was already carried out successfully. For special conditions in industrial vacuum technology the High vacuum blowers and the new canned motor blowers were subject to a complete successful type test. These machines, used in pressure ranges up to 10-5 mbar (abs.), are approved for zone 0 (internal) and certified by an appointed authority. Example of machine labelling Ex II 2 (o) G E Ex c T4 Temperature class concerning gas, surface temperature conc. dust T4 = 135 C Type of ignition protection constructive safety Explosion protection European standards EN Ex-atmosphere (G = gas, D = combustible dust) Internal / external explosive atmosphere (i = internal, o = external) Category 2 Device group II Label for prevention of explosions 2

3 Measurements taken Aerzen DELTA BLOWER units: (suction from ex-zone) (suction from ex-zone) Overpressure Overpressure (ex-free suction) (ex-free suction) (suction from ex-zone) (suction from ex-zone) Negative pressure Negative pressure (ex-free suction) Measures zone zone zone zone Gastight machine x - x x - x Explosion pressure proof accessories x - x x - x Additional strength test x - x x - x Disch. temperature monitoring x x x - - x x x - - Gas alarm device (at site) x Starting strainer x - x - x(g 2 ) - x(g 2 ) - x - x - x - x - Intake sided filter (filter silencer) x x(l 2 ) x x(g 2 ) x Intake sided filter (same design as zone separating filter but without suction valve, only DN ) - x Intake sided filter (at site) x - x - x(g 2 ) - x(g 2 ) - x x x x x x x x Zone separating filter (only DN ) x - x Intake pressure monitoring by pressure switch - x - x p-monitoring via zone separating filter x - x Protection via vacuum switch (suction valve not necessary) x x x x Vibration monitoring x x Electrical operating means Are always to be procured acc. to the corresponding zone Atex-certificate x x x x x x x x x x x x x x x x Additional label x x x x x x x x x x x x x x x x Additional operating manual x x x x x x x x x x x x x x x x 1 It must absolutely be avoided, that dust atmosphere develops inside the machine. In case of suction from a dust atmosphere or in case of suction-pneumatic applications a suitable filter is to be used acc. to the above chart. These Aerzen filters in connection with the corresponding monitoring facility serve as zone separating element. 2 G=gas-fuelled operation, L= air operation For zone 0-applications a type test by an appointed authority is necessary. For such machines a technical release is necessary. Aerzen DELTA SCREW compressor units: (ex-free suction) Measures zone zone zone zone Convey. chamber gastight, connect oil demister to continuing pipe, or flare x - x x - x Additional strength test x - x x - x Disch. temperature monitoring x x x - - x x x - - Gas alarm device (at site) x Coupling Is always to be procured acc. to the corresponding zone Starting strainer x - x - x(g) 4 - x(g) 4 - x - x - x x x x Suction-sided filter - x 3 - x x(l) 4 x x(l) 4 x Intake side filter (same design as zone separating filter but without suction valve (provided by - x customer) Intake sided filter (at site) x - x - x(g) 4 - x(g) 4 - x x x x x x x x Zone separating filter (provided by customer) x - x Intake pressure monitoring by pressure switch - x - x p-monitoring via zone separating filter (provided by customer) x - x Vibration monitoring x x Electrical operating means (driving motor, oil demister, instrumentation, Are always to be procured acc. to the corresponding zone electr. fan, etc.) Atex-certificate x x x x x x x x x x x x x x x x Additional label x x x x x x x x x x x x x x x x Additional operating manual x x x x x x x x x x x x x x x x 1 Is only possible for VM-machines (except VM 8R). Not possible for VML-machines. 2 It must absolutely be avoided, that dust atmosphere develops inside the machine. In case of suction from a dust atmosphere or in case of suction-pneumatic applications a suitable filter is to be used acc. to the above chart. These Aerzen filters in connection with the corresponding monitoring facility serve as zone separating element. 3 not for gearbox machines 4 G=gas-fuelled operation, L= air operation For zone 0-applications a type test by an appointed authority is necessary. For such machines a technical release is necessary. 3

4 Aerzen vacuum blowers series HV and CM: Vacuum pressure Measures zone zone Strength test as spot check x x not applic. x not applic. not applic Discharge temperature monitoring x x not applic. - not applic. not applic. x x - - Differential pressure monitoring * x - not applic. - not applic. not applic Differential pressure monitoring - - not applic. - not applic. not applic Starting strainer x x not applic. x not applic. not applic Vibration monitoring (online) x - not applic. - not applic. not applic Vibration monitoring (at intervals) - x not applic. - not applic. not applic. x x - - Bypass control not necessary, machine can be flown through via frequency converter and direct drive under atm. conditions Electrical equipment to be carried out acc. to corresponding zone Coupling with certificate - - not applic. - not applic. not applic. x x x x Atex certificate x x not applic. x not applic. not applic. x x x x Additional nameplate x x not applic. x not applic. not applic. x x x x Additional operating manual x x not applic. x not applic. not applic. x x x x * only necessary for zone 0, does not serve as monitoring unit, but controls the additional switching of the drive of the Roots pump when falling below 100 mbar, resp. as option with zone 0 the switching on /-off of monitoring units. Ex-protection for units acc. to ATEX guideline 137 The EU-directive 1999/92/EG (ATEX 137) fixes that employer (unit operator) fulfill certain requirements on the field of safety and health protection for employees who have to face the risks of explosive atmospheres. In the ex-proof document possible ignitian sources are analysed and technical (constructive) and preventive measures must be described. Prior to commissioning of new units this ex-proof document must be issued. Based on the ex-proof document the work halls need to be modified until 30th June 2006 according to the minimum regulations of EU-directive 1999/92/EG and to be documented correspondingly. Ex-protection in the pneumatic bulk material conveyance If combustible bulk material is conveyed pneumatically, in case of certain dust-/air concentrations inflammable gas mixtures may develop in the unit. Unit components are allocated to different zones. For example, silo content is declared with zone 21 as explosive atmosphere may be present continuously or for a longer period of time. The conveying piping is defined also as zone 21 as an explosive dust-/air mixture occurs only occasionally. For these two zones according to Atex guideline also in case of possible damages protection against explosion must be guaranteed. As zone 22 areas are marked where the explosive atmosphere hardly occurs or only for a short period of time. Diagrammatic section of pressure conveyance bulk material entrance bulk material entrance * Spark arrester * Spark arrester * Spark arrester can be omitted on use of Aerzener compressors Blower 4 * Spark arrester can be omitted on use of Aerzener blowers Compressor zone 20 zone 21 zone 22

External areas of constantly technically safe units are declared as zone-free, i.e. preferred installation place of blowers, compressors and pumps.

An aspect not being considered very often in the pneumatics is that in case of unusual failure the blower may produce sparks, these will then be blown into the conveying piping, where ingnition of

5 External areas of constantly technically safe units are declared as zone-free, i.e. preferred installation place of blowers, compressors and pumps. The zone clarification and definition of temperature class are carried out by the unit operator. An aspect not being considered very often in the pneumatics is that in case of unusual failure the blower may produce sparks, these will then be blown into the conveying piping, where ingnition of the dust/air mixture may take place. In case of a bearing damage caused by e.g. insufficient maintenance, the consequence might be that the rotary pistons touch and ignition sparks develop. Organic dust/air mixtures are inflammable at temperatures between C. One ignition spark reaches a temperature between approx. 800 C and 1000 C, so that in such a case some resulting damage cannot be excluded. Unit manufacturer and operators who consider this would install additional spark stops causing investment and considerable installation costs as well as pressure losses. Certified Aerzen base support Aerzener Maschinenfabrik has faced this challenge and has worked on a solution which was certified by the TÜV Nord. Base is DELTA BLOWER units serving as discharge silencer. The sound developed is dampened in this especially designed base support without application of absorption material. In expensive practical tests artificial sparks had been produced and fed through the base support for several minutes with an air flow corresponding air inlet to the conveyed volume flow of a blower with the consequence that the sparks are deleted by internal deviations. Therefore, costly spark traps fitted in addition can be omitted in future. The secret of success is the innovation of Aerzen discharge silencer. The absorption material normally used which is combustible and not foodstuff-compatible is not necessary anymore. The certification of Aerzen blower units includes the nominal widths from DN 50 to DN 250 and was extended besides the current designs (Generation 5) onto the Delta Blower-designs supplied since A subsequent certification for units already supplied (series Delta Blower) for preparing the explosion protection document is thus possible. This ATEX certification was extended to the new compressor units Delta Screw Generation 5 for which the innovative discharge silencer takes the function of the spark arrester. air deviating air outlet discharge piping base support of blower: diagrammatic section 5

Special filter element for the suction pneumatic (for blowers only) Depending on the product and system configuration bulk goods are conveyed however not only in overpressure operation, but also by

6 Special filter element for the suction pneumatic (for blowers only) Depending on the product and system configuration bulk goods are conveyed however not only in overpressure operation, but also by means of suction pneumatic transport. In suction operation it has to be ensured in case of a malfunction in the separation filter (e. g. filter fracture) that no combustible dust-air-mixture is sucked into the blower. For this reason normally an additional filter element (emergency filter) is provided by the plant manufacturer. Consequently an additional expenditure for project work, assembly and installation will occur. Therefore Aerzener Maschinenfabrik has developed a puncture-proof filter element which can be integrated in the suction silencer. The filter is monitored by a differential pressure measurement. Consequently the Aerzen special filter element replaces the previous additionally necessary emergency filter. Schematic description in case of suction conveyance (blowers) Separation filter Bulk material entrance Filter Separation filter Bulk material entrance Filter Emergency filter zone 20 zone 21 zone 22 Integrated emergency filter (option) Listing of customer benefit New puncture-proof Aerzen filter element (for blowers only) The innovative silencer operating without absorbent material realizes the spark arrester for the compressor. Subsequent certification of Aerzen units (series Delta Blower) for preparing the explosionprotection document is possible. With the innovative and certified Aerzen base support resp. discharge silencer unnecessary installations are avoided and consequently pressure- and energy loss prevented! Plant safety acc. to 1999/92/EC (explosion protection document) for the operator! Re-certification for Aerzen Blower Units (Delta Blower) possible in existing plants! Clear cost advantages by the new integrable Aerzen filter element (blowers). This replaces a costly external filter element. Aerzen Blower Units DELTA BLOWER (blower stage and pressure-containing accessories) can be designed to be pressure shock-proof up to an explosion overpressure of 13 bar (extra price). The acoustic hood ventilation is effected by a mechanically driven fan (Aerzen Standard for blowers and compressors). The costly electrical integration and monitoring of an explosion-proof motor for the necessary hood ventilation is not included. Thanks to optimized logistics attractive delivery dates as well as inexpensive additional documentation and marking! 6

ATEX-solutions for the vacuum technology The Aerzen Vacuum Blower series HV is designed for the conveyance of air and neutral gases and can specially be used in the industrial vacuum technology, for

7 ATEX-solutions for the vacuum technology The Aerzen Vacuum Blower series HV is designed for the conveyance of air and neutral gases and can specially be used in the industrial vacuum technology, for example, coating of glass and foils, in the packaging technology, the metallurgy and in many further applications. There are 19 blower sizes in the vacuum range covering suction flows from 180 m³/h up to m³/h as well as pressure ranges (abs.) from 10-3 mbar up to 200 mbar. Specially in the chemical industry, but also in other applications, the ATEX-requirements increase constantly. Many manufacturers interpret the ATEX-guideline so that machines, which are used in a pressure range of below 800 mbar, are not subject to certification. However this is only partly correct, as the harmonized standard EN :2001 (D) clearly supplements that in case of machines not within the range of validity of this standard, the suitability of the devices for possible application conditions have to be clearly shown and proven. Against this Aerzener Maschinenfabrik has decided, that the complete vacuum series is subject to a type testing acc. to guideline 94/9/EC to be able to offer the plant manufacturers and operators safe solutions corresponding to ATEX. Afterwards the Aerzen Vacuum Blower Series HV as well as the blowers with canned motor of the series CM were certified for zone 0 (internal), temperature class T3 (200 C) in April The blowers are externally admitted for zone 1, temperature class T4 (135 C). For zone 0 a temperature and vibration monitoring on the blowers is additionally to be provided. Materials of grey-cast iron or nodular cast iron can be used. A special advantage for the customer with the Aerzen ATEX-solution is that an extremely costly bypass - solution is omitted. The Aerzen ATEX-certification admits a so-called suction of the fore pump and a frequency converter operation at restricted speed of the Aerzen Vacuum Blowers. Sectional model GM 11.3 HV for the suction pneumatic Advantages for the customer Aerzen Vacuum Blowers external casing is designed for temperature class T4 guaranteeing safety for difficult applications! When using Aerzen Vacuum Blowers the application of an external bypass control is no longer necessary, causing a considerable cost saving in the plant manufacturing! The possible shutdown of the monitoring device below 50 mbar ensures process safety for the operator! Pressure shock resistance up to 13 bar! Inexpensive documentation! Conventional bypass pipe (marked in red) can be omitted in future!! Y ( ) TS+ PZS+ M M 7

8 A good address, everywhere Federal Republic of Germany Aerzener Maschinenfabrik GmbH. Reherweg Aerzen / Germany Tel Fax Vertriebsbüro Nord Weißer Kamp Bad Fallingbostel Germany Tel Fax Vertriebsbüro Ost Klosterstraße 8-9, Berlin / Germany Tel Fax Außenstelle Taucha: August-Bebel-Str. 13c Taucha / Germany Tel Fax Vertriebsbüro Mitte Erfurter Straße Kahl / Germany Tel Fax Vertriebsbüro Süd Föhrenweg Elchingen / Germany Tel Fax Vertriebsbüro West Taubenstraße Velbert / Germany Tel Fax Außenstelle Nahlbach Meisenweg Nahlbach / Germany Tel Fax Europe Aerzen-France S.A.S. 10, Avenue Léon Harmel Antony Cedex France Tel Fax for France, Algeria, Morocco and Tunesia Aerzen Machines Ltd. Aerzen House, Langston Road Loughton, Essex, IG 103 SL United Kingdom Tel Fax Aerzen Belgium NV Zone Guldendelle A. De Coninckstraat Kortenberg / Belgium Tel Fax for Belgium and Luxembourg Aerzen Nederland B.V. Fotograaf RR Duiven The Netherlands Tel Fax Aerzen Iberica S.A. c/urogallo Fuenlabrada / Spain Tel Fax Aerzen Iberica S.A. Rua: Sacadura Cabral, 216, 7 B S. João do Estoril Portugal Tel Fax Aerzen Svenska AB Östra Bangatan Arlandastad Sweden Tel Fax Aerzen Finland Oy AB Teollisuustie Veikkola / Finland Tel Fax Bran & Luebbe AS Sandviksveien Høvik / Norway Tel Fax for Norway and Iceland Aerzen Svenska AB Nakskovvej Valby / Denmark Tel Fax Aerzen Austria Handelsges. m.b.h. Gewerbepark Tresdorf II/ Tresdorf / Austria Tel Fax Aerzen (Schweiz) AG Zürcherstrasse Frauenfeld Switzerland Tel Fax for Switzerland and Liechtenstein Aerzen Italia SRL Via Vittor Pisani, Milano / Italy Tel Fax MANGRINOX S.A. 14, Grevenon Str Athens / Greece Tel Fax Aerzen Makine Sanayi Ve Ticaret Ltd. Sti. Yukarı Dudullu Bostancı Yolu Cad. Keyap Sitesi A-2 Blok No: Ümraniye - Istanbul Turkey Tel Fax Aerzen Polska S.A. Ul. Marconich 9/ Warszawa / Poland Tel Fax Aerzen Slovakia S.R.O. Mariánska Stupava / Slowakia Tel Fax Aerzen Hungária Kft. Bécsi ùt 52.III./ Budapest / Hungary Tel Fax Aerzen Cz s.r.o. Namesti TGM 729/ Breclav Czech Republic Tel Fax HAFI Engineering & Consulting Gesellschaft m.b.h. Mühletorplatz Feldkirch / Austria Tel Fax for the remaining countries in Eastern Europe Brasil, Mexico, USA, Canada and Asia Aerzen do Brasil Ltda. Rua Howard Archibaldi Acheson Jr. N 615 Jardim da Glória, Cep Cotia, SP / Brasil Tel Fax Aerzen México Av. San Rafael 31 Fraccionamiento Industrial Lerma Lerma Estado de México (Toluca) / México Tel Fax Aerzen USA Corporation 645 Sands Court Coatesville, PA / USA Tel Fax Aerzen Canada Blowers Compressors Inc Montée Labossière Vaudreuil, Quebec J7V8P2 Canada Tel Fax Aerzen Asia Pte. Ltd. 38 Woodlands Industrial Park E1 #04-01 Singapore Tel Fax Aerzen International Trading (Shanghai) Co. Ltd. No. 519 Tong Li Road Jiu Ting Town Song Jiang District Shanghai / P.R.China Tel Fax Aerzen Machines (India) Private Limited A Square Building 82-Urmi Society Productivity Road Vadodara / India Tel Tel. & Fax We would be pleased to provide the addresses of our representatives in the remaining continents, upon request. Aerzener Maschinenfabrik GmbH Reherweg Aerzen / Germany P.O. Box Aerzen / Germany Phone / Fax / info@aerzener.de

A E R Z E N S C R E W C O M P R E S S O R S

A E R Z E N S C R E W C O M P R E S S O R S Aerzen Screw Compressors VMY.56 for the refrigeration- and process gas industry A E R Z E N E R M A S C H I N E N F A B R I K G M B H V1-040 00 EN 2000 9.2008