Flowserve ATEX E User Manual [de, fr, en]
ATEX E/F/D/N
ATEX Safety Manual for centrifugal and
positive displacement pumps
User instructions: to ensure compliance with
European Directive 94/9/EC. Original instructions.
English 3
Manuel de sécurité ATEX relatif aux pompes
centrifuges et volumétriques
Instructions utilisateur: assurer la conformite avec la Directive
Europeenne 94/9/CE. Notice originale.
ATEX-Sicherheitshandbuch für Kreisel- und
Verdängerpumpen
Anweisungen für den Benutzer: zur sicherstellung der einhaltung
der Europäischen Richtlinie 94/9/EG. Original-anweisungen.
ATEX Veiligheidshandleiding voor Centrifugale
en Verdringingspompen
Gebruikershandleiding: om overeenstemming te verzekeren
met Europese Richtlijn 94/9/EG. Oorspronkelijke
gebruiksaanwijzing.
Manual Part No: ATEX E/F/D/N 11-09
Français 7
Deutsch 11
Nederlands 16
ATEX- E/F/D/N - 11-09
CONTENTS - ENGLISH
Page
1 GENERAL ..............................................................3
1.1 ATEX Directive 94/9/EC.................................3
1.2 Disclaimer.......................................................3
1.3 Personnel qualifications and training..............3
2 SAFETY..................................................................3
2.1 Summary of safety marking............................3
2.2 Products used in potentially explosive
atmospheres ..................................................3
2.3 Scope of compliance ......................................3
2.4 Marking...........................................................4
2.5 Avoiding excessive surface temperatures......4
2.6 Preventing the build up of explosive
mixtures..........................................................5
2.7 Preventing sparks...........................................5
2.8 Preventing leakage.........................................5
2.9 Maintenance to avoid the hazard ...................6
TABLE DES MATIERES - FRANCAIS
Page
1 GENERALITES ......................................................7
1.1 Directive ATEX 94/9/CE.................................7
1.2 Décharge de responsibilité.............................7
1.3 Qualification et formation du personnel..........7
2 SECURITE..............................................................7
2.1 Résumé des marquages de sécurité..............7
2.2 Produits utilisés dans des atmosphères
potentiellement explosibles............................7
2.3 Portée de la conformité ..................................8
2.4 Marquage........................................................8
2.5 Eviter les températures de surface
excessives .....................................................8
2.6 Empêcher la création de mélanges
explosifs.........................................................9
2.7 Empêcher les étincelles..................................9
2.8 Empêcher les fuites ......................................10
2.9 Entretien pour éviter tout danger..................10
INHALT - DEUTSCH
Seite
1 ALLGEMEINES ................................................... 11
1.1 ATEX-Richtlinie 94/9/EG.............................. 11
1.2 Haftungserklärung........................................ 11
1.3 Qualifikationen und Schulung des
Personals.....................................................11
2 SICHERHEIT........................................................11
2.1 Zusammenfassung der
Sicherheitskennzeichnungen...........................11
2.2 Geräte zur Verwendung in
explosionsgefährdeten Bereichen....................12
2.3 Konformitätsumfang...........................................12
2.4 Kennzeichnung...................................................12
2.5 Vermeidung übermäßiger
Oberflächentemperaturen.................................12
2.6 Vermeidung der Entstehung explosiver
Gemische .................................................... 14
2.7 Vermeidung von Funkenbildung .................. 14
2.8 Vermeidung von Undichtheiten....................14
2.9 Wartung zur Gefahrenvermeidung............... 14
INHOUD - NEDERLANDS
Pagina
1 ALGEMEEN......................................................... 16
1.1 ATEX Richtlijn 94/9/EG................................16
1.2 Disclaimer..................................................... 16
1.3 Bevoegdheid en training personeel ............. 16
2 VEILIGHEID......................................................... 16
2.1 Overzicht van Veiligheidsmarkeringen......... 16
2.2 Producten die gebruikt worden in potentieel
explosieve omstandigheden........................ 16
2.3 Omvang van de certificatie........................... 17
2.4 Markering ..................................................... 17
2.5 Voorkomen van excessieve
oppervlaktetemperaturen ............................ 17
2.6 Voorkomen van de opeenhoping van
explosieve mengsels ................................... 18
2.7 Voorkomen van vonken ............................... 19
2.8 Voorkomen van lekkage............................... 19
2.9 Onderhoud ter voorkoming van gevaar ....... 19
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ATEX- E/F/D/N - 11-09
English
1 GENERAL
These instructions must always be kept
close to the product's operating location or
directly with the product.
These instructions are intended to facilitate
familiarisation with the product and its permitted use
to help satisfy ATEX safety requirements. The
instructions may not have taken into account local
regulations; ensure such regulations are observed by
all, including those installing the product. Always
coordinate repair activity with operations personnel,
and follow all plant safety requirements and applicable
safety and health laws/regulations.
These instructions must be read prior
to installing, operating, using and maintaining the
equipment in any region worldwide and in
conjunction with the main user instructions
provided. The equipment must not be put into
service until all the conditions relating to safety
instructions have been met. Failure to follow and
apply the present User Instructions is considered
to be misuse. Personal injury, product damage,
delay or failure caused by misuse are not covered
by the Flowserve warranty.
1.1 ATEX Directive 94/9/EC
It is a legal requirement that machinery and
equipment put into service within certain regions of
the world shall conform with the applicable CE
Marking Directives for Equipment for Potentially
Explosive Atmospheres (ATEX).
Where applicable the Directive covers important
safety aspects relating to the equipment, its use and
the satisfactory provision of technical documents.
Where applicable this document incorporates
information relevant to these Directives. To establish
if the product itself is CE marked for a Potentially
Explosive Atmosphere check the nameplate and the
Certification provided.
1.2 Disclaimer
Information in these User Instructions is believed
to be reliable. In spite of all the efforts of
Flowserve Corporation to provide sound and all
necessary information the content of this manual
may appear insufficient and is not guaranteed by
Flowserve as to its completeness or accuracy.
1.3 Personnel qualification and training
All personnel involved in the operation, installation,
inspection and maintenance of the unit must be
qualified to carry out the work involved.
If the personnel in question do not already possess
the necessary knowledge and skill, appropriate
training and instruction must be provided. If required
the operator may commission the manufacturer/
supplier to provide applicable training.
2 SAFETY
2.1 Summary of safety marking
These instructions contain the following specific
ATEX safety marking where non-observance of the
instruction will cause a hazard.
This symbol indicates explosive atmosphere
marking according to ATEX. It is used in safety
instructions where non-compliance in the hazardous
area would cause the risk of an explosion.
This symbol is used in safety instructions to
remind not to rub non-metallic surfaces with a dry
cloth; ensure the cloth is damp. It is used in safety
instructions where non-compliance in the hazardous
area would cause the risk of an explosion.
2.2 Products used in potentially
explosive atmospheres
Measures are required to:
• Avoid excess temperature
• Prevent build up of explosive mixtures
• Prevent the generation of sparks
• Prevent leakages
• Maintain the pump to avoid hazard
The following instructions for pumps and pump units
when installed in potentially explosive atmospheres
must be followed to help ensure explosion protection.
Both electrical and non-electrical equipment must meet
the requirements of European Directive 94/9/EC.
2.3 Scope of compliance
Use equipment only in the zone for which it is
appropriate. Always check that the driver, drive
coupling assembly, seal and pump equipment are
suitably rated and/or certified for the classification of the
specific atmosphere in which they are to be installed.
Where Flowserve has supplied only the bare shaft
pump, the Ex rating applies only to the pump. The
party responsible for assembling the pump set shall
select the coupling, driver, seal and any additional
equipment, with the necessary CE Certificate/
Declaration of Conformity establishing it is suitable for
the area in which it is to be installed.
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ATEX- E/F/D/N - 11-09
rature
Temperature
The output from a variable frequency drive (VFD) can
cause additional heating affects in the motor and so, for
pump sets with a VFD, the ATEX Certification for the
motor must state that it covers the situation where
electrical supply is from the VFD. This is particular
requirement still applies even if the VFD is in a safe area.
2.4 Marking
An example of ATEX equipment marking is shown
below. The actual classification of the pump will be
engraved on the nameplate.
II 2 GD c IIC 135 ºC (T4)
Equipment Group
I = Mining
II = Non-mining
Category
2 or M2 = high level protection
3 = normal level of protection
Gas and/or dust
G = Gas
D = Dust
c = Constructional safety
(in accordance with EN13463-5)
Gas Group (Equipment Category 2 only)
IIA – Propane (typical)
IIB – Ethylene (typical)
IIC – Hydrogen (typical)
Maximum surface temperature (Temperature Class)
(see section 2.5)
2.5 Avoiding excessive surface
temperatures
ENSURE THE EQUIPMENT TEMPERATURE
CLASS IS SUITABLE FOR THE HAZARD ZONE
2.5.1 Pump liquid temperature
Pumps have a temperature class as stated in the
ATEX Ex rating on the nameplate. These are based
on a maximum ambient of 40 °C (104 °F); refer to
Flowserve for higher ambient temperatures.
The surface temperature on the pump is influenced by
the temperature of the liquid handled. The maximum
permissible liquid temperature depends on the
temperature class and must not exceed the values in the
table applicable below.
The temperature rise at the seals and bearings and due
to the minimum permitted flow rate is taken into account
in the temperatures stated.
Maximum permitted liquid temperature for pumps
which do not have a magnetic drive or selfpriming casing:
Tempe
class to
EN13463-1
T6
T5
T4
T3
T2
T1
Maximum
surface
temperature
permitted
85 °C (185 °F)
100 °C (212 °F)
135 °C (275 °F)
200 °C (392 °F)
300 °C (572 °F)
450 °C (842 °F)
Temperature limit of liquid
handled (* depending on
material and construction
variant - check which is lower)
Consult Flowserve
Consult Flowserve
115 °C (239 °F) *
180 °C (356 °F) *
275 °C (527 °F) *
400 °C (752 °F) *
Maximum permitted liquid temperature for pumps
with magnetic drive or self priming casing:
class to
EN13463-1
T6
T5
T4
T3
T2
T1
Maximum
surface
temperature
permitted
85 °C (185 °F)
100 °C (212 °F)
135 °C (275 °F)
200 °C (392 °F)
300 °C (572 °F)
450 °C (842 °F)
Temperature limit of liquid
handled (* depending on
material and construction
variant - check which is lower)
Consult Flowserve
Consult Flowserve
110 °C (230 °F) *
175 °C (347 °F) *
270 °C (518 °F) *
350 °C (662 °F) *
The responsibility for compliance with the
specified maximum liquid temperature is with the
plant operator.
Temperature classification “Tx” is used when the
liquid temperature varies and when the pump is
required to be used in differently classified potentially
explosive atmospheres. In this case the user is
responsible for ensuring that the pump surface
temperature does not exceed that permitted in its
actual installed location.
2.5.2 Pumps with key driven impellers
If an explosive atmosphere exists during the
installation, do not attempt to check the direction of
rotation by starting the pump unfilled. Even a short
run time may give a high temperature resulting from
contact between rotating and stationary components.
2.5.3 Pumps with threaded on impellers
Do not attempt to check the direction of rotation with
the coupling element/pins fitted due to the risk of
severe contact between rotating and stationary
components.
2.5.4 Pumps with mechanical seal
Where there is any risk of the pump being run against a
closed valve generating high liquid and casing external
surface temperatures it is recommended that users fit an
external surface temperature protection device.
Avoid mechanical, hydraulic or electrical overload by
using motor overload trips or a power monitor and
make routine vibration monitoring.
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ATEX- E/F/D/N - 11-09
In dirty or dusty environments, regular checks must
be made and dirt removed from areas around close
clearances, bearing housings and motors.
2.5.5 Additional requirements for pumps with
magnetic drive
It is recommended for users to fit a temperature
monitor in the magnetic drive bearing/shell area when
pumping liquids with solids content or liquids that can
polymerize or freeze.
In unmanned locations where a magnetic drive is
used it is advisable to fit a vibration monitor.
2.5.6 Additional requirements for self-priming
casing pumps
Where the system operation does not ensure control of
priming, as defined in the User Instructions, and the
maximum permitted surface temperature of the T Class
could be exceeded it is recommended that users fit an
external surface temperature protection device.
2.5.7 Additional requirements for sump pumps
and vertical wet pit pumps with line shafts
Level control shall be fitted in the sump to prevent
liquid level dropping below minimum acceptable.
It is recommended that a Service Plan with vibration
monitoring is adopted. Alternatively the user should
fit external bearing housing surface temperature
protection device(s) to ensure the temperature class
(ie maximum surface temperature) is not exceeded.
For external flush the flow should be monitored.
2.6 Preventing the build up of explosive
mixtures
ENSURE PUMP IS PROPERLY FILLED AND
VENTED AND DOES NOT RUN DRY
Ensure the pump and relevant suction and discharge
pipeline system is totally filled with liquid at all times
during the pump operation, so that an explosive
atmosphere is prevented. In addition it is essential to
make sure that seal chambers, auxiliary shaft seal
systems and any heating and cooling systems are
properly filled.
If the operation of the system can not avoid this
condition it is recommended that you fit an
appropriate dry run protection device (eg liquid
detection or a power monitor).
To avoid potential hazards from fugitive emissions of
vapour or gas to atmosphere the surrounding area
must be well ventilated.
2.7 Preventing sparks
To prevent a potential hazard from mechanical
contact, the coupling guard must be non-sparking.
To avoid the potential hazard from random induced
current generating a spark, the earth contact on the
baseplate must be used.
Avoid electrostatic charge. Do not rub nonmetallic surfaces with a dry cloth; ensure the cloth is
damp.
The coupling must be selected to comply with
94/9/EC and correct alignment must be maintained.
2.7.1 Additional requirements for metallic pumps
on non-metallic baseplates
When metallic components are fitted on a nonmetallic baseplate they must be individually earthed.
2.8 Preventing leakage
2.8.1 Pumps with mechanical seal
The pump must only be used to handle liquids for
which it has been approved to have the correct
corrosion resistance.
Avoid entrapment of liquid in the pump and associated
piping due to closing of suction and discharge valves,
which could cause dangerous excessive pressures to
occur if there is heat input to the liquid. This can occur if
the pump is stationary or running.
Bursting of liquid containing parts due to freezing
must be avoided by draining or protecting the pump
and ancillary systems.
Where there is the potential hazard of a loss of a seal
barrier fluid or external flush, the fluid must be
monitored.
If leakage of liquid to atmosphere can result in a
hazard, the installation of a liquid detection device is
recommended.
2.8.2 Additional requirements for pumps with
magnetic drive
If protection greater than Categories 2 and M2 is
required, then liquid detection should be provided in
the bearing housing/support head.
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ATEX- E/F/D/N - 11-09
2.9 Maintenance to avoid the hazard
CORRECT MAINTENANCE IS REQUIRED TO
AVOID POTENTIAL HAZARDS WHICH GIVE A
RISK OF EXPLOSION
The responsibility for compliance with maintenance
instructions is with the plant operator.
To avoid potential explosion hazards during
maintenance, the tools, cleaning and painting
materials used must not give rise to sparking or
adversely affect the ambient conditions. Where there
is a risk from such tools or materials, maintenance
must be conducted in a safe area.
It is recommended that a maintenance plan and
schedule is adopted, in line with the User Instructions
provided, to include the following:
a) Any auxiliary systems installed must be monitored,
if necessary, to ensure they function correctly.
b) Gland packings must be adjusted correctly to give
visible leakage and concentric alignment of the
gland follower to prevent excessive temperature of
the packing or follower.
c) Check for any leaks from gaskets and seals. The
correct functioning of the shaft seal must be
checked regularly.
d) Check bearing lubricant level, and if the hours run
show a lubricant change is required.
e) Check that the duty condition is in the safe
operating range for the pump.
f) Check vibration, noise level and surface
temperature at the bearings to confirm satisfactory
operation.
g) Check dirt and dust is removed from areas around
close clearances, bearing housings and motors.
h) Check coupling alignment and re-align if
necessary.
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