Atex 137 Ignition Hazard Assessment - Single Seal Pump

Page 1
IHA Fans april 2005 versie 1.xls
ATEX 137 IGNITION HAZARD ASSESSMENT (prEN 15198:2005)

Equipment identification:
Design:
Function:
Operations (temporary/continuous):
Maintenance and inspection:
Actual/foreseeable ambient conditions:
IHA 01A
Failure effect
(EN 1127-1)
Generic Assessment For Zone 2/22

Identification Number:
2/22
Zone External:
Substance/Material:
Not specified
Gas Group:
IIB
Dust Safety Characterison temeperature >300 oC, Layer Ignition Temperat
T3 (200 oC)
Equipment Temperatur
Centrifugal Pump with single / double / tandem seal / stuffing box

To pump fluids
Continuous or intermittent
Outdoors
1. Ignition Hazard Identification
2. Ignition Hazard Estimation
Possible ignition sources
Assessment of effectiveness and likelihood of occurrence of potential ignition sources

(EUC, i.e. including existing control measures, but without maintenance & protective measures)
Part of equipment
and/or component
which is affected
Failure mechanism
(initiating event)
Failure causes:
- Mechanical failure
- Control failure
- Power failure
- Human failure
- External hazards
Frequency of effective
ignition source
Potential ignition source

during modes of use
Justification if ignition
source not effective
1. normal operation,
including start-up and
shutdown
Coolant flow (own

medium) is clean. Orifice A2. expected malfunction
not likely to be clogging
(1x/100yr)
in one week
Frequency Justification or
Measures to be Implemented
Maximum duration of
effective ignition
source
4. Safety Measures
. Ignition Hazard Evaluatio
Criticality Level (IHA Matrix Possible protective measures from which one is required to acceptably reduce the likelihood and/or duration that the identified potential ignition source becomes
Duration Justification or Measures

to be Implemented
Failure detection
method
Equivalent Fault
Tolerance level without
additional protective
measures, suitable for
mentioned hazardous
zone.
Technical measures
With outcome FT -1,
additional measures shall
be described in next
columns
Operational measures Inspection/Maintenance
Standards/Notes
Evidence/Verification
No
Hot surface
Mechanical Seals
Loss of coolant flow to
seal faces through the
(Single mechanical
orifice in the flush line.
seal, product
lubricated, API flush
plan 11) considered to
be a machinery
element.
loss of function of heat
exchanger in the flush
line. (only if applicable)
Break up of seal faces

due to misalignment.
Mechanical Seals
(double, pressurised
mechanical seal, API
flush plan 53B),
considered to be a
machinery element.
Mechanical failure due to

clogging of the the flush
line and/or orifice
mechanical failure
Loss of coolant and

lubricating oil between
inboard and outboard
seal (dry run)
mechanical failure
(leakage of inboard or
outboard seal)
Stuffing box (only if

applicable)
n/a
Personnel on plant tours are NOT likely

to detect problem
n/a
FT 2 (Cat.1**)
Zone 0/20
IHF 2.10-3/yr
install temperature
indicator and check
temperature during
regular operator rounds
n/a
Typical human error rate of 1 in 1000

for a routine activity . Installation to be 2. detection within 1
undertaken by competent supervised
shift (10hr)
personnel
Personnel on plant tours are likely to

detect problem
Human detection based

on sight and smell of
failure.
FT 1
Zone 1/21
IHF 2.10-3/yr
n/a
A1. rare malfunction

(1x/1000yr)
0. not considered as an
effective ignition source
This scenario is not

relevant for zone 2
because it is a double
fault initiating event,
Normally misalignment
will start with
sealleakage.
B1. during plant

operation (1x/1000yr)
normal wear leads to

higher seal leakage.
Cooling of sealfaces is
still available.
B1. during plant

SABIC average MTBF 3,5-4 years

(2006)
2. detection within 1
shift (10hr)
Seal leakage will be detected during

operator rounds

on sight and smell of
failure.
FT 1
Zone 1/21
IHF 2.10-3/yr
n/a
shutdown
Not applicable. Single

seal mounted

(1x/1000yr)
best guess
0. not applicable

detect problem

on sight of failure (oil
level)
FT 2 (Cat.1**)
Zone 0/20
IHF 2.10-3/yr
low pressure alarm can

be installed to detect oil
content of accumulator.
Not applicable. No heat

exchanger installed
B1. during plant

best guess
0. not applicable
best guess
0. not applicable
mechanical failure
(leakage of outboard
seal)

(1x/1000yr)
SABIC average MTBF 3,5-4 years.

Normal seal leakage does normally no 2. detection within 1
lead to an ignition source. Seal leakage
shift (10hr)
can be detected.
shutdown
Not applicable. Single

seal mounted

(1x/1000yr)
best guess
0. not applicable

exchanger installed
B1. during plant

best guess
0. not applicable
shutdown
n/a
3. foreseeable misuse,
during: installation,
operation, inspection or
maintenance
n/a
Personel on plant tours

shall check if the flush
line is still effective. By
temperature
measurement or feel
whether the flush line is
warm/cold.
Personel on plant tours
shall check if the flush
line is still effective. By
temperature
measurement (e.g. infra
red thermometer) or feel
wheter the flush line is
warm/cold.
n/a
Het seal zal langzaam vervuilen. Hierdoor zal de temp niet binnen een
week boven de T klasse stijgen. Hierop is de frequentie van een week
gebaseerd.
n/a
Seal shall be changed by

competent personnel. During operator rounds
Cartridge mechanical pumps shall be checked
on seal leakage.
seals are repaired by a
specialized company.
n/a
n/a
During operator rounds

pumps shall be checked
on seal leakage.
n/a
n/a
Personel shall check oil

content of seal oil
reservoir every operator
round
n/a
n/a/
FT 2 (Cat.1**)
Zone 0/20
IHF 2.10-3/yr
mechanical failure at end

of the normal working life
Loss of cooling function plugging/clogging

heat exchanger (if
applicable)
normal wear
n/a

exchanger installed
shutdown
Loss of coolant and

lubricating oil between
inboard and outboard
seal (dry run)
FT 0
Zone 2/22
IHF 2.10-3/yr
shutdown
Human error during
installation
Loss of cooling function plugging

heat exchanger
Mechanical Seals
(double, NON
pressurised
mechanical seal, API
flush plan 52),
considered to be a
machinery element.
n/a
plugging / clogging / loss

of cooling water
normal wear (including

wear due to high
vibration, start up
failures, fouling etc.)
normal wear
3. detection during
Personnel on plant tours are NOT likely
inspection
to detect problem
1x/week (100hr)
best guess

Personnel on plant tours are likely to on sight of failure (oil
level) and frequent need
detect problem
to refill
FT 1
Zone 1/21
IHF 2.10-3/yr
low pressure alarm can

be installed to detect oil
content of accumulator.
n/a

content of seal oil
reservoir and monitor
refill time. Sealleakge
can be seen, droplets of
oil will come out of the
seal.

on sight of failure (oil
level)
FT 2 (Cat.1**)
Zone 0/20
IHF 2.10-3/yr
low level alarm
n/a

content of seal oil
refill time
n/a

detect problem
FT 2 (Cat.1**)
Zone 0/20
IHF 2.10-3/yr
mechanical failure at end

ofthe normal working life
A2. expected malfunction Normal seal leakage does normally no 2. detection within 1 Personnel on plant tours are likely to on sight of failure (oil
detect problem
level) and frequent need
lead to an ignition source. Seal leakage
(1x/100yr)
shift (10hr)
FT 0
Zone 2/22
IHF 2.10-3/yr
low level alarm
n/a.

content of seal oil
refill time
n/a

on sight, stufing box
needs liquid leakage)
FT 0
Zone 2/22
IHF 2.10-3/yr
n/a
n/a.
Personel shall check

installation and
adjustment
a procedure for
adjustment and
installation shall be
available.
n/a
condition based:
operators to check
vibration level and noise
of pump unit. In case of
doubt or higher vibration
level a vibration
measurement should be
carried out by technical
department.
n/a
n/a
condition based:
operators to check
level a vibration
department.
n/a
SABIC average MTBF 3,5-4 years.
can be detected.
to refill
wear and hot surface

stuffing box mounted too
due to installation failure. tight.
B3. related to TA
(1x/10yr)
Packing needs regular adjustment ( 2. detection within 1

average once every 2 weeks)
shift (10hr)

detect problem
Bearings
Normal wear
Mechanical failure at end

of the specified working
life
shutdown
Human error during
Abnormal wear leads to installation, misalignment
bearing damage
between pump and
driver.
maintenance
n/a
n/a

(1x/1000yr)
If the bearing is properly selected,

L10h life time implies 10% of bearings
fail before the calculated lifetime. For 3. detection during
reliability reasons most bearings will be
inspection
exchanged before breakdown. It is
SABIC experience to find a breakdown 1x/week (100hr)
1 x/1000yr. Also see column
"evidence".

detect problem; It is expected that
once the bearing temperature is above
on sound of failure or
200 C, its break down will be
vibration level.
detected or self revealed within one
shift
B1. during plant

Typical human error rate of 1 in 50-100

for a routine activity (implies bearing
changed once per year). Because
installation is to be undertaken by
3. detection during
competent supervised personnel and
inspection
alignement is checked by aligning
1x/week (100hr)
instruments (optalign), the human
error rate for the use of this instrument
is also 1 in 50-100. Maximum
frequency is 1x/2500year

vibration level.
shift
Page 1 of 3
FT 1
Zone 1/21
IHF 2.10-3/yr
FT 1
Zone 1/21
IHF 2.10-3/yr
n/a
n/a
Paper "Ignition hazard assessment

on explosion-protected non-electrical equipment", Michael Beyer,
Physikalisch-Technische Bundesanstalt (PTB), states bearing failure can
be taken as equivalent to rare malfunction (once initial ignition hazard
and
typical safety measures are taken into account) and that well maintained
bearings will normally meet zone 1 requirements
5. Residual Ignition Hazard
Resulting Fault Tolerance (FT)
Page 2

Design:
Function:
IHA 01A
Failure effect
(EN 1127-1)

2/22
Zone External:
Substance/Material:
Not specified
Gas Group:
IIB
T3 (200 oC)

To pump fluids
Outdoors

Part of equipment
and/or component
which is affected
Failure mechanism
(initiating event)
Failure causes:
- Control failure
- Power failure
- Human failure
- External hazards

during modes of use
ignition source
Maximum duration of
effective ignition
source
4. Safety Measures

to be Implemented
Failure detection
method
Equivalent Fault
mentioned hazardous
zone.
Technical measures
With outcome FT -1,
columns
Standards/Notes
No
Human error during
installation, wrong
interference fit between 3. foreseeable misuse,
Abnormal wear leads to bearing and shaft (shaft
out of tolerance), shaft operation, inspection or
bearing damage
bent, impeller unbalance
maintenance
causing vibrations during
operation.
Human error during

design results in
specifying incorrect
Abnormal wear leads to
bearing, excessive L/D
bearing damage
ratio, large overhung
span, causing vibration
during operation.
maintenance
Bearing damage due to

operation outside the
allowable operating
window (e.g. cavitation,
bearing damage
operation far from BEP,
vibration)
maintenance
bearing failure due

during stand still of the
bearing damage
pump (standriefen)
maintenance

bearing damage
maintenance
Lack of bearing
lubrication
Lack of bearing
lubrication
bad quality bearing

supplied.
Human error, failing to

renew lubrication in
bearings that require in
service renewal
Mechanical Failure of
seals that retain bearing
lubricant
maintenance
shutdown
n/a
n/a
n/a
n/a
n/a
n/a
n/a
B1. during plant


changed once per year). For reliability 3. detection during
reasons this bearing failure mode will
inspection
be detected before breakdown. It is
1x/week (100hr)
SABIC experience to find a breakdown
1 x/1000yr

vibration level.
shift
B1. during plant


changed once per year). Specification 3. detection during
of bearings to be undertaken by
inspection
competent supervised personnel,
1x/week (100hr)
supported by a QA system reduces
the human error rate by a factor 10

vibration level.
shift
3. detection during
inspection
1x/week (100hr)

vibration level.
shift
3. detection during
inspection
1x/week (100hr)

vibration level.
shift
3. detection during
inspection
1x/week (100hr)

vibration level.
shift
B2. during plant

B1. during plant


(1x/1000yr)
B1. during plant

A2. expected malfunction

(1x/100yr)
best guess based on experience
Manufacturers QA system avoids

frequencies < 1x/1000yr

for a routine activity. Because
regreasing is to be undertaken by
competent supervised personnel and 3. detection during
regreasing interval is checked by
inspection
running hours on hour counters, the
human error rate for the interpretation 1x/week (100hr)
of the regreasing list is also 1 in 50100. Maximum frequency is
1x/2500year

detect problem; It is expected that Human detection based
once the bearing temperature is above on sound of failure or
vibration level and oil
level/color
shift
3. detection during
inspection
1x/week (100hr)

level/color
shift
n/a
condition based:
operators to check
level a vibration
department.
n/a
n/a
condition based:
operators to check
level a vibration
department.
n/a
n/a
condition based:
operators to check
level a vibration
department.
n/a
stand by pump to be
turned every 1 - 4 weeks
or every 3 - 6 months,
depending on the
location in the plant
condition based:
operators to check
level a vibration
department.
n/a
FT 1
Zone 1/21
IHF 2.10-3/yr
condition based:
operators to check
level a vibration
department.
n/a
FT 1
Zone 1/21
IHF 2.10-3/yr
n/a
condition based:
operators to check oil
level, oil color and
level a vibration
department. In case of
dark or white (milk
coloured) oil inform
technical department by
notification.
n/a
n/a
Predictive maintenance
programme such as
vibration checks or
monitoring
Preventive maintenance
to lubricate bearing
during normal life and
replace bearing before
end of working life
reached
n/a

and
n/a
condition based:
level a vibration
dark or white (milk
notification.
n/a

and
n/a
condition based:
level and vibration level
and noise of pump unit.
In case of doubt or
higher vibration level a
vibration measurement
should be carried out by
technical department.
n/a
Checking bearing
running temperatures Emergency maintenance
after detection of high
inspection and
seal gas pressure
replacement or bearing
peaks. Shut down or
grease following high
plan to if temperatures seal gas pressure peaks
high
n/a
FT 1
Zone 1/21
IHF 2.10-3/yr
FT 1
Zone 1/21
IHF 2.10-3/yr
FT 0
Zone 2/22
IHF 2.10-3/yr
n/a
n/a
n/a
FT 1
Zone 1/21
IHF 2.10-3/yr
FT 0
Zone 2/22
IHF 2.10-3/yr
n/a
n/a

Lack of bearing
lubrication
lube oil
problems:contamination
of lube oil due to solids
(e.g. sand) and water.
shutdown
n/a

(1x/1000yr)

3. detection during
inspection
vibration level.
1x/week (100hr)
FT 1
Zone 1/21
IHF 2.10-3/yr
n/a
shift

Lack of bearing
lubrication
lube oil problems: too

high or low oil level.
shutdown
n/a

3. detection during
A2. expected malfunction Level of lube oil systems are subject to
inspection
surveillance by operators.
(1x/100yr)
1x/week (100hr)
level/color
FT 0
Zone 2/22
IHF 2.10-3/yr
n/a
FT 0
Zone 2/22
IHF 2.10-3/yr
Detection of high seal

gas pressure peaks
shift
Lack of bearing
lubrication
Control system failure.

Lubricant blown out of
bearing due to pressure
peaks and emission of
seal gas (Nitrogen),
where such seals are
adjacent to bearings
shutdown
n/a
3. detection during
A2. expected malfunction frequency for control loop failure 1 per
50- 100 each year. Only around 10%
inspection
(1x/100yr)
of these are dangerous failures
1x/week (100hr)

detect problem
Page 2 of 3

on sound, sight and
smell of failure.
Increased power usage
Typical worst case 1 in 10 human error chance of personnel not

responding quickly and correctly to a high density of alarms. Gives at
least an order of magnitude protection against high seal gas pressure
peaks causing bearing failure
Page 3

Design:
Function:
IHA 01A
Failure effect
(EN 1127-1)

2/22
Zone External:
Substance/Material:
Not specified
Gas Group:
IIB
T3 (200 oC)

To pump fluids
Outdoors

Part of equipment
and/or component
which is affected
Failure mechanism
(initiating event)
Failure causes:
- Control failure
- Power failure
- Human failure
- External hazards

during modes of use
ignition source
Maximum duration of
effective ignition
source
4. Safety Measures

to be Implemented
Failure detection
method
Equivalent Fault
mentioned hazardous
zone.
Technical measures
With outcome FT -1,
columns
Standards/Notes
n/a

and
No
corrosion
Flames and hot gases

(including hot
particles)
None identified
None identified
corrosion occurs during

stand still of bearings
operated at high
temperatures, due to
condensation
FT 1
Zone 1/21
IHF 2.10-3/yr
n/a
n/a
condition based:
level a vibration
dark or white (milk
notification.
FT 2 (Cat.1**)
Zone 0/20
IHF 2.10-3/yr
n/a
n/a
n/a
n/a
#N/A
n/a
n/a
n/a
n/a
FT 2 (Cat.1**)
Zone 0/20
IHF 2.10-3/yr
proper earthing
n/a
n/a
n/a
FT 2 (Cat.1**)
Zone 0/20
IHF 2.10-3/yr
Suitable earthing to
prevent static electricity
build up.
n/a
check earthing system

integrity
n/a
General construction and bolting of equipment will normally be sufficient t

prevent static build up without additional earth connections. CLC/TR
50404 in 11.3.5 only requires special earthing connections for equipment
mounted on non-conductive supports or contamination which affects the
insulation could develop across a joint.
FT 0
FT 0
Zone 2/22
IHF 2.10-3/yr
Suitable earthing to
prevent static electricity
build up.
n/a
check earthing system

integrity
n/a
General construction and bolting of equipment will normally be sufficient t

prevent static build up without additional earth connections. CLC/TR
50404 in 11.3.5 only requires special earthing connections for equipment
mounted on non-conductive supports or contamination which affects the
insulation could develop across a joint.
FT 0
shutdown
n/a

(1x/1000yr)

3. detection during
inspection
1x/week (100hr)
level/color
shift
None identified
No credible sources of
this type were identified

(1x/1000yr)
0. not applicable
Mechanically
generated sparks
None identified
Static electricity
Outside of pump
casing
Isolated conductor
accumulates and
discharge a static
charge
Human Error. Failure to

specify or connect
appropriate earthing
Human Error. Failure to

main appropriate
earthing
10
Lightening
Radio frequency (RF)

electromagnetic waves
from 104 Hz to 3 x 1012
Hz
Electromagnetic
waves from 3 x 1011 Hz
to
3 x 1015 Hz
Ionising radiation
Loss of pump rotation will be become process disturbance and

immediately apparent
plant alarms
Not applicable
Stray electric currents
6
0. not applicable
Not applicable
B1. during plant

0. not applicable
In less than 1%
special earthing is
required. Human
error rate for failing
to specify and
connect earthing,
with two
independent checks
is less than
B1. during plant
(1/50)^3=10-5.
Probability of earth
resistance > 10^6
Ohm reduces the
probability for
generating sparks to
less than 10-7. For
zone 1 and zone 2
this is acceptable.
0. not applicable
Static Electricity is a low probability

event, as explained in column
"evidence"
maintenance
n/a
B2. during plant

Typical human error rate for

failing to connect earhting is
3. detection during
ATEX trained plant personel will notice
1x/50-100. Only for those
inspection
loose earthing connections
cases where special earthing is 1x/week (100hr)
required
Item is shielded by
surrounding structures
B1. during plant

0. not applicable
FT 2 (Cat.1**)
Zone 0/20
IHF 2.10-3/yr
n/a
n/a
n/a
n/a
B1. during plant

0. not applicable
FT 2 (Cat.1**)
Zone 0/20
IHF 2.10-3/yr
n/a
n/a
n/a
n/a
B1. during plant

0. not applicable
FT 2 (Cat.1**)
Zone 0/20
IHF 2.10-3/yr
n/a
n/a
n/a
n/a
B1. during plant

0. not applicable
n/a
n/a
n/a
n/a
0. not applicable
n/a
n/a
n/a
n/a
0. not applicable
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
Not applicable
Not applicable
Not applicable
11
Ultrasonics
Not applicable
B1. during plant

12
Adiabatic compression
and shock waves
Not applicable
B1. during plant

13
Exothermic reaction,
including self ignition
of dusts and/or dust
layers
Not applicable
B1. during plant

FT 2 (Cat.1**)
Zone 0/20
IHF 2.10-3/yr
FT 2 (Cat.1**)
Zone 0/20
IHF 2.10-3/yr
FT 2 (Cat.1**)
Zone 0/20
IHF 2.10-3/yr
FT 2 (Cat.1**)
Zone 0/20
IHF 2.10-3/yr
0. not applicable
Values in IHA tables are justified in columns K, N and O and are based on case specific assessments or extracted from the SABIC equipment reliability method (economic assessment) summarised below.
These values presume a TurnAround at the given frequency (0,167 means overhaul after 6 years), because
malfunctioning is expected within the next operation period until the next TurnAround (after again 6 years)
This is not a chance of malfunctioning for a large population
For the ATEX IHA we assumed the frequency higher than or equal to 0,2 as normal operation including start-up
for that situation the freqency of effective ignition source is less than 1 times every year
frequency values less than 0,2 in the IER table are assumed to be less than 1 times every 10 years
figures not related to wear, shall be assessed, as they have only a chance to occur in the mentioned frequency,
due to external causes. The frequency for external causes will standard be set to less than 1 time every 100 years
Page 3 of 3

Atex 137 Ignition Hazard Assessment - Single Seal Pump

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Page 1

IHA Fans april 2005 versie 1.xls

ATEX 137 IGNITION HAZARD ASSESSMENT (prEN 15198:2005)

Generic Assessment For Zone 2/22

Centrifugal Pump with single / double / tandem seal / stuffing box

1. Ignition Hazard Identification

2. Ignition Hazard Estimation

Possible ignition sources

Assessment of effectiveness and likelihood of occurrence of potential ignition sources

Potential ignition source

Coolant flow (own

Duration Justification or Measures

Operational measures Inspection/Maintenance

Break up of seal faces

Mechanical failure due to

Loss of coolant and

Stuffing box (only if

Personnel on plant tours are NOT likely

Typical human error rate of 1 in 1000

Personnel on plant tours are likely to

Human detection based

A1. rare malfunction

This scenario is not

B1. during plant

normal wear leads to

B1. during plant

SABIC average MTBF 3,5-4 years

Seal leakage will be detected during

Human detection based

Not applicable. Single

A1. rare malfunction

Personnel on plant tours are likely to

Human detection based

low pressure alarm can

Not applicable. No heat

B1. during plant

A1. rare malfunction

SABIC average MTBF 3,5-4 years.

Not applicable. Single

A1. rare malfunction

Not applicable. No heat

B1. during plant

Personel on plant tours

Seal shall be changed by

During operator rounds

Personel shall check oil

mechanical failure at end

Loss of cooling function plugging/clogging

Not applicable. No heat

Loss of coolant and

Loss of cooling function plugging

plugging / clogging / loss

normal wear (including

Human detection based

low pressure alarm can