ISO 80079-36:2016

/ ISO 80079-36:2016 / By

ISO 80079-36:2016 is part of the ISO 80079 series, which deals with explosive atmospheres. This particular standard, ISO 80079-36:2016 titled “Explosive atmospheres — Part 36: Non-electrical equipment for explosive atmospheres — Basic method and requirements”, establishes the basic methodology and general requirements for the design, construction, testing, and marking of non-electrical equipment intended for use in explosive atmospheres.

Key points about ISO 80079-36:2016:

  • It applies to non-electrical equipment, which can cause ignition in explosive atmospheres through mechanical friction, hot surfaces, or other physical effects.
  • The standard specifies risk assessments that manufacturers should perform to identify possible ignition sources in their equipment.
  • It is commonly used alongside ISO 80079-37, which provides more detailed methods for protection.
  • It includes general principles for preventing the equipment from becoming an ignition source in hazardous areas, like gas, vapors, or dust.

This standard is critical in industries such as oil and gas, chemical processing, and mining where explosive atmospheres may be present.

What is required ISO 80079-36:2016

ISO 80079-36:2016 specifies the basic methodology and general requirements for the design, construction, testing, and marking of non-electrical equipment intended for use in explosive atmospheres. Below are the key requirements outlined in the standard:

1. Risk Assessment

  • Manufacturers must carry out a risk assessment to identify possible ignition sources within the equipment.
  • This assessment should account for potential hazards caused by mechanical parts, surfaces, and other non-electrical components.
  • The risk assessment must address various conditions, such as normal operation, expected malfunctions, and rare malfunctions.

2. Ignition Source Control

  • Equipment must be designed and constructed to prevent ignition sources from becoming active under both normal and fault conditions.
  • Ignition sources may include hot surfaces, mechanical sparks, static electricity, or friction.
  • Controls should minimize the risk of ignition by reducing energy levels, isolating components, or incorporating safety barriers.

3. Temperature Control

  • Equipment must be designed to ensure that the surface temperatures do not exceed the ignition temperature of flammable materials, gases, vapors, or dust present in the atmosphere.
  • It must consider ambient temperature variations that could influence the equipment’s performance.

4. Design and Construction

  • Materials, components, and construction methods should be selected to avoid the possibility of creating ignition hazards.
  • The mechanical strength of the equipment must be sufficient to withstand both normal use and foreseeable misuse.
  • Adequate sealing and protection measures should be in place to prevent the ingress of dust or gas into hazardous areas of the equipment.

5. Marking and Documentation

  • Equipment must be clearly marked with information, including:
    • Manufacturer’s name or trademark
    • Product model or type
    • Maximum surface temperature
    • Type of protection used (if applicable)
    • Marking of explosive atmospheres, including the type of hazardous material (e.g., gas, dust).
  • Instructions for installation, maintenance, and safe use should be provided with the equipment.

6. Protection Concepts

  • While ISO 80079-36 deals with non-electrical equipment, it may require the use of other protection techniques (such as Ex h) to ensure safe operation in explosive atmospheres.
  • The equipment must meet the protection concepts outlined in ISO 80079-37, such as control of mechanical sparks, surface temperatures, and static electricity.

7. Testing

  • The equipment must undergo appropriate tests to confirm that it meets the safety requirements for use in explosive atmospheres.
  • Tests might include mechanical integrity tests, thermal testing, and ignition risk assessments.

8. Maintenance and Inspection

  • The equipment should be designed for ease of inspection, servicing, and maintenance to ensure continued safety throughout its operational life.
  • Regular inspections and maintenance checks must be included in the user documentation.

9. Compliance with ATEX or IECEx

  • Manufacturers may be required to comply with regional certification schemes such as ATEX in the EU or IECEx globally, which align with ISO 80079-36 standards.

In summary, ISO 80079-36:2016 requires a thorough assessment of ignition risks, precise design and construction to prevent ignition sources, and proper marking and documentation to ensure that non-electrical equipment can operate safely in explosive atmospheres.

Who is required ISO 80079-36:2016

ISO 80079-36:2016 is required by various stakeholders involved in industries where explosive atmospheres may exist, and non-electrical equipment could pose a potential ignition hazard. Below are the groups who typically need to comply with this standard:

1. Manufacturers of Non-Electrical Equipment

  • Manufacturers who design, produce, or sell non-electrical equipment intended for use in hazardous areas where explosive atmospheres of gas, vapors, or dust might be present.
  • Industries such as oil and gas, chemicals, mining, pharmaceuticals, food processing, and energy are common sectors that require such equipment.
  • This standard ensures that their equipment meets safety criteria to prevent ignition in explosive atmospheres.

2. Certification Bodies

  • Testing and certification organizations involved in assessing and certifying equipment for use in hazardous areas need to follow ISO 80079-36 to evaluate if non-electrical equipment meets the required safety standards.
  • These bodies often work within frameworks like ATEX (Europe) or IECEx (international), both of which reference ISO 80079-36 for certifying non-electrical equipment for explosive atmospheres.

3. Engineering and Design Firms

  • Engineering firms that design facilities or plants where explosive atmospheres might exist must ensure that all non-electrical equipment specified for installation meets ISO 80079-36.
  • This applies to companies designing plants for refineries, chemical processing plants, or grain silos where mechanical equipment could potentially create sparks or heat sources.

4. Plant Owners and Operators

  • Owners and operators of facilities in hazardous areas are responsible for ensuring that all equipment installed in explosive atmospheres, including non-electrical devices, complies with safety regulations such as ISO 80079-36.
  • This is especially relevant in industries like mining, petrochemicals, agriculture (grain processing), and pharmaceuticals where explosive dust, vapors, or gases are present.
  • Plant operators must also ensure that the equipment is regularly inspected, maintained, and documented in accordance with the standard.

5. Health and Safety Regulatory Authorities

  • Regulatory bodies responsible for enforcing safety regulations in industries dealing with hazardous or explosive atmospheres may require compliance with ISO 80079-36.
  • They ensure that industries comply with international standards to minimize the risk of explosions caused by non-electrical equipment.
  • In the European Union, for example, regulators may mandate compliance with ISO 80079-36 under the ATEX directive.

6. Maintenance and Inspection Companies

  • Companies that perform maintenance and inspection services for equipment in explosive atmospheres must be familiar with ISO 80079-36 requirements.
  • They need to ensure that equipment continues to comply with the standard throughout its operational life and that repairs or modifications do not introduce new risks.

7. Consultants and Safety Auditors

  • Consultants who specialize in hazardous area classification, risk assessments, and safety auditing will use ISO 80079-36 as part of their analysis when evaluating non-electrical equipment for compliance in explosive atmospheres.
  • These professionals provide expertise to organizations on how to meet the standard’s requirements and avoid potential hazards.

8. Educational and Training Institutions

  • Institutions that provide training on explosive atmospheres or offer courses related to ATEX/IECEx certification would need to incorporate ISO 80079-36 into their curriculum to educate future safety engineers and designers on non-electrical equipment safety.

In conclusion, manufacturers, facility operators, engineering firms, safety regulators, and certification bodies all require ISO 80079-36:2016 to ensure that non-electrical equipment used in explosive atmospheres is safe and compliant with international standards.

When is required ISO 80079-36:2016

ISO 80079-36:2016 is required in the following situations where non-electrical equipment is used or may be installed in explosive atmospheres (also referred to as hazardous areas):

1. When Equipment Is Used in Hazardous Areas

  • Explosive atmospheres exist in industries where flammable gases, vapors, dust, or mists may be present. This includes sectors such as oil and gas, chemical processing, mining, agriculture (grain handling), food processing, and pharmaceuticals.
  • ISO 80079-36:2016 is required when non-electrical equipment (such as pumps, compressors, mechanical gears, conveyors, and fans) is used in these areas, as the equipment may create ignition sources like hot surfaces or sparks.

2. During Design and Installation of New Equipment

  • When new plants or facilities are being designed or existing ones are being modified, ISO 80079-36:2016 is needed to ensure that all non-electrical equipment intended for use in hazardous areas complies with the required safety standards.
  • Engineering and design firms must consider this standard when selecting equipment for ATEX (EU) or IECEx (international) classified hazardous zones.

3. When Conducting a Risk Assessment

  • A risk assessment is required whenever non-electrical equipment is being considered for use in an explosive atmosphere. ISO 80079-36:2016 specifies the methodology to assess potential ignition sources and provides guidance on how to reduce or eliminate these risks through design and protection techniques.
  • This standard is essential in the early stages of equipment design and specification to ensure compliance with safety standards.

4. When Modifying or Retrofitting Existing Equipment

  • If existing equipment in a hazardous area is being modified or retrofitted, ISO 80079-36:2016 must be applied to verify that the modifications do not introduce new ignition hazards.
  • For example, adding or altering mechanical components in a device could create friction or heat, which may lead to ignition risks. The equipment must be re-evaluated according to the standard.

5. During Equipment Certification

  • ISO 80079-36:2016 is required for certification purposes when seeking to obtain ATEX, IECEx, or other relevant certifications for non-electrical equipment intended for use in explosive atmospheres.
  • Equipment must comply with this standard before being marketed or installed in hazardous areas. Testing and certification bodies follow ISO 80079-36 as a guideline when certifying products for safe use.

6. During Regular Maintenance and Inspection

  • Regular maintenance and inspection of equipment used in explosive atmospheres are crucial for ensuring that it continues to operate safely. ISO 80079-36:2016 is required during these processes to ensure that the equipment still complies with the original design standards and that no changes or wear have introduced ignition risks.
  • Maintenance teams must verify that non-electrical equipment does not develop hot surfaces, static discharge, or other potential hazards over time.

7. When Seeking Compliance with Regulations

  • ISO 80079-36:2016 is often required to meet national and international regulations that govern the safety of equipment used in explosive atmospheres.
  • In regions like the European Union, compliance with the ATEX directive is mandatory, and ISO 80079-36 is referenced for non-electrical equipment. Similarly, in international markets, IECEx certifications rely on this standard.

8. When Developing Safety Audits and Assessments

  • Companies conducting safety audits or performing hazardous area classifications will reference ISO 80079-36:2016 to ensure that all non-electrical equipment in hazardous zones adheres to the correct safety protocols.
  • Audits may be conducted during commissioning, regular operations, or as part of a regulatory inspection process.

9. In the Event of an Incident Investigation

  • In case of an incident or explosion where non-electrical equipment is involved, ISO 80079-36:2016 would be used as a benchmark to investigate whether the equipment design or operation deviated from the prescribed safety requirements.
  • The standard helps determine whether an ignition source from the equipment contributed to the incident.

Summary

ISO 80079-36:2016 is required in multiple scenarios, particularly when dealing with non-electrical equipment in hazardous or explosive environments, including the design, risk assessment, certification, installation, modification, and maintenance of such equipment. It is used to ensure that equipment does not become a potential ignition source and complies with global safety standards, including ATEX and IECEx.

Where is required ISO 80079-36:2016

ISO 80079-36:2016 is required in environments and industries where explosive atmospheres may exist, and non-electrical equipment poses a risk of ignition. It is specifically relevant in any location where flammable gases, vapors, dust, or mists could be present, as these conditions create the potential for explosions. The standard is used globally, particularly in sectors with high safety risks. Here’s where ISO 80079-36:2016 is typically required:

1. Industries with Explosive Atmospheres

ISO 80079-36:2016 is commonly required in the following industries:

  • Oil and Gas Industry: In offshore platforms, refineries, petrochemical plants, and natural gas processing facilities where explosive gases and vapors are prevalent.
  • Chemical Industry: In chemical manufacturing and storage plants where flammable chemicals may create explosive atmospheres.
  • Mining Industry: In underground mines and other mining operations where explosive gases (such as methane) or dust may be present.
  • Agriculture and Grain Handling: In silos, mills, and processing plants where combustible dust from grains and other materials can create a risk of explosion.
  • Pharmaceutical Industry: In plants where powders or chemicals are used and stored, leading to the possibility of dust explosions.
  • Food Processing Industry: In facilities that handle powdered ingredients, such as flour or sugar, which may generate combustible dust.
  • Energy Sector: In power generation plants, especially those using biomass or fossil fuels, where dust or gas might accumulate.

2. Hazardous Zones in Facilities

ISO 80079-36:2016 is required in specific hazardous zones within facilities where explosive atmospheres are likely to occur:

  • Zone 0 (Gas) and Zone 20 (Dust): Areas where an explosive atmosphere is present continuously or for long periods.
  • Zone 1 (Gas) and Zone 21 (Dust): Areas where an explosive atmosphere is likely to occur in normal operation.
  • Zone 2 (Gas) and Zone 22 (Dust): Areas where an explosive atmosphere is not likely to occur in normal operation but may occur for short periods.

These classifications follow ATEX in the European Union and IECEx globally, both of which require compliance with ISO 80079-36 for non-electrical equipment in these zones.

3. Facilities Handling Flammable Substances

Any facility where flammable liquids, gases, or combustible dusts are processed, stored, or transferred may require equipment certified to ISO 80079-36:2016. Common examples include:

  • Refineries and Fuel Storage Depots: Where fuels such as gasoline or kerosene are stored.
  • Chemical Storage Warehouses: Where volatile substances are handled.
  • Paint Shops and Coating Facilities: Where flammable vapors from paints, solvents, or coatings may accumulate.
  • Textile Mills: Where explosive cotton or other fiber dust may be present.

4. Regions with Specific Regulatory Requirements

Compliance with ISO 80079-36:2016 is required in regions that adopt international safety standards for explosive atmospheres, such as:

  • European Union: Under the ATEX Directive (2014/34/EU), non-electrical equipment must meet specific safety standards, including ISO 80079-36.
  • International Markets: Through the IECEx Certification System, many countries recognize and require compliance with ISO 80079-36:2016 for non-electrical equipment used in explosive atmospheres.
  • Countries with National Regulations: Many countries have safety regulations for hazardous areas based on ISO 80079 standards. For instance, industries in Australia, Brazil, India, China, and South Africa may also require compliance with ISO 80079-36.

5. During Plant Design, Construction, and Commissioning

When designing new plants or facilities where there is a risk of explosive atmospheres, ISO 80079-36:2016 is required to ensure the safety of all non-electrical equipment used in those areas. This applies to both greenfield projects (new constructions) and brownfield projects (expansion or renovation of existing facilities).

6. When Certifying or Testing Equipment

Manufacturers producing non-electrical equipment that will be used in hazardous areas must ensure their products comply with ISO 80079-36:2016. Compliance is required for certification through schemes like:

  • ATEX (EU) certification for the European market.
  • IECEx for global markets.
  • Other regional certification schemes, such as NEC in North America.

7. Maintenance and Inspection in Hazardous Locations

  • When performing regular maintenance or inspections in facilities with hazardous areas, the equipment used must meet ISO 80079-36:2016 to ensure it remains safe for operation in an explosive atmosphere.
  • Maintenance activities in plants with hazardous zones, such as those in oil refineries, chemical plants, or grain handling facilities, will reference ISO 80079-36 to ensure that mechanical equipment (e.g., rotating machinery, conveyors) is not creating ignition risks.

8. When Retrofitting or Upgrading Equipment

  • Upgrades or retrofits to existing equipment in hazardous areas must comply with ISO 80079-36 to ensure that any modifications do not introduce new ignition risks.
  • This is common in industries like chemical processing, energy, or mining, where older equipment needs to be modernized without compromising safety in explosive atmospheres.

In summary, ISO 80079-36:2016 is required in industries, facilities, and regions where explosive atmospheres are present, including hazardous areas defined by ATEX and IECEx, and it applies to the design, operation, maintenance, and certification of non-electrical equipment in those environments.

How is required ISO 80079-36:2016

The implementation of ISO 80079-36:2016 requires a systematic approach to ensure that non-electrical equipment is safe for use in explosive atmospheres. Here’s a step-by-step explanation of how ISO 80079-36:2016 is required and applied:

1. Risk Assessment

  • Initial Assessment: The process starts with a hazard identification and risk assessment of the non-electrical equipment to determine if it has the potential to ignite an explosive atmosphere. This includes evaluating possible ignition sources such as hot surfaces, friction, mechanical impact, static electricity, and chemical reactions.
  • Assessment Process: The standard requires the identification of all potential ignition sources and the conditions under which they might arise. This may include mechanical equipment with moving parts that can generate sparks, heat, or other ignition sources.
  • Protection Methods: The risk assessment must outline the necessary preventive measures, such as minimizing heat, using appropriate materials, or applying protective systems to reduce the likelihood of an ignition event.

2. Design and Construction Requirements

  • Design for Safety: The standard requires that the equipment be designed and constructed to prevent the release of energy that could cause an explosion. This may involve specific design techniques such as:
    • Encapsulation of components.
    • Use of non-sparking materials in moving parts.
    • Limiting temperatures to prevent hot surfaces.
    • Use of friction-reducing materials to avoid ignition through mechanical contact.
  • Control of Ignition Sources: The design must take into account all possible ignition sources during normal operation and foreseeable malfunctions. It requires that equipment is constructed to avoid any contact between hazardous materials (gases, vapors, dust) and potential ignition sources.
  • Category Classification: Equipment must be classified into categories based on the risk of ignition. ISO 80079-36 outlines how equipment can be categorized based on the environment (Zone 0, 1, 2 for gases; Zone 20, 21, 22 for dust) and its operational conditions.

3. Certification and Conformity Assessment

  • Conformance to Standards: The equipment must be tested and verified against the requirements of ISO 80079-36:2016 to demonstrate compliance. Testing involves:
    • Thermal tests to ensure surface temperatures remain below ignition levels.
    • Mechanical tests to check for friction, impact resistance, and material compatibility.
  • Certification Process: The equipment undergoes a conformity assessment to ensure it meets the standards. This is essential for obtaining ATEX (EU) or IECEx (international) certification.
    • Manufacturers need to provide detailed documentation showing that the equipment has been designed and tested according to the safety principles outlined in the standard.
  • Third-Party Testing: A recognized testing body must certify that the equipment complies with the standard. The certification process involves both design verification and production control to ensure ongoing compliance.

4. Marking and Documentation

  • Product Marking: Equipment must be clearly marked to indicate its suitability for use in explosive atmospheres, including its category, zone, and temperature rating. This allows users to identify whether the equipment can be safely installed in a specific hazardous environment.
  • Documentation: Manufacturers must provide detailed technical documentation and instructions on the safe use, installation, and maintenance of the equipment. This includes:
    • Operating manuals with safety instructions.
    • Documentation of ignition hazard assessment results.
    • Installation guides ensuring that equipment is installed in a way that maintains its explosion protection.

5. Installation Requirements

  • Safe Installation: During installation, the equipment must be installed according to the instructions provided by the manufacturer and in compliance with local regulations for explosive atmospheres (such as ATEX or IECEx standards). This includes:
    • Ensuring that no modifications are made that could create new ignition hazards.
    • Verifying that the equipment is compatible with the hazardous area classification (e.g., Zones 0, 1, 2, 20, 21, 22).
    • Confirming that protective measures like ventilation, sealing, and grounding are properly implemented to prevent the accumulation of explosive gases or dust.

6. Maintenance and Inspection

  • Regular Maintenance: Equipment must be regularly inspected and maintained to ensure it continues to meet the safety standards. This includes:
    • Routine checks for signs of wear, corrosion, or damage that could lead to the creation of ignition sources.
    • Cleaning and ensuring that dust or debris does not accumulate, as it could cause overheating or sparks.
    • Replacement of parts using certified components to maintain the integrity of the equipment’s explosion protection.
  • Inspection Frequency: ISO 80079-36 requires that non-electrical equipment is regularly inspected, especially in environments where wear and tear may increase ignition risks. Inspections may be periodic or continuous, depending on the level of risk associated with the equipment’s operation.

7. Modification and Retrofitting

  • Assess Modifications: Any modification or retrofitting of equipment must be assessed to ensure it does not introduce new ignition risks. This involves updating the risk assessment and, in many cases, re-certifying the equipment.
  • Re-Certification: After significant modifications, the equipment may need to go through the certification process again to ensure it still meets the required safety standards.

8. Training and Competency

  • Training for Personnel: Personnel involved in the design, installation, operation, and maintenance of non-electrical equipment must be trained on ISO 80079-36:2016 to understand the requirements for explosion protection and the correct handling of equipment in hazardous areas.
  • Competency Verification: Workers in charge of maintaining and inspecting equipment need to be qualified and certified to ensure that they can competently assess equipment compliance and safety.

9. Continuous Compliance Monitoring

  • Ongoing Audits: ISO 80079-36 requires continuous compliance monitoring through internal audits and third-party inspections to ensure that the equipment continues to operate safely in hazardous environments.
  • Record-Keeping: Proper documentation and record-keeping are essential for tracking the equipment’s maintenance history, inspection results, and any modifications made.

Summary

The requirements of ISO 80079-36:2016 involve:

  1. Conducting risk assessments for potential ignition sources.
  2. Designing and constructing equipment to eliminate or minimize ignition risks.
  3. Certifying the equipment through third-party testing bodies.
  4. Marking equipment with relevant zone and safety information.
  5. Ensuring proper installation, regular maintenance, and inspection.
  6. Conducting ongoing compliance audits and ensuring personnel are trained and competent to handle the equipment safely.

By following these steps, manufacturers and operators ensure that non-electrical equipment is safe for use in explosive atmospheres, minimizing the risk of ignition and explosions.

Case Study on ISO 80079-36:2016

Case Study: Implementation of ISO 80079-36:2016 in a Petrochemical Refinery

Background

A large petrochemical refinery located in the Middle East was undergoing an expansion to increase its processing capacity. The refinery handles various flammable gases and liquids, which creates the potential for explosive atmospheres. Most equipment used in the refinery falls under the non-electrical category, such as compressors, pumps, and mechanical conveyors, all of which have the potential to create sparks, hot surfaces, or friction that could ignite an explosive atmosphere.

To ensure the safety of the workers and prevent explosions, the refinery decided to implement ISO 80079-36:2016 as part of its broader compliance with safety regulations for explosive atmospheres.

Problem

During routine operations, refinery managers noticed that some non-electrical equipment showed signs of wear and tear, with friction potentially generating heat and sparks. Additionally, the planned expansion would introduce more non-electrical equipment into hazardous zones. The refinery needed to ensure that all new and existing non-electrical equipment complied with ISO 80079-36:2016 to avoid catastrophic failures and possible explosions.

Objectives

  1. Assess Ignition Hazards: Conduct a risk assessment of all non-electrical equipment to identify potential ignition sources.
  2. Ensure Equipment Compliance: Retrofit or replace non-compliant equipment to meet ISO 80079-36:2016 standards.
  3. Prevent Future Incidents: Implement ongoing monitoring, inspection, and maintenance plans for non-electrical equipment to ensure long-term safety.
  4. Certify the Equipment: Obtain certification under ATEX and IECEx for all non-electrical equipment in hazardous areas.

Approach

Step 1: Risk Assessment of Non-Electrical Equipment

A detailed risk assessment was conducted in collaboration with engineers and safety specialists to assess the potential for equipment to act as an ignition source. The assessment covered:

  • Hot surfaces on pumps and compressors.
  • Potential sparks generated by mechanical components (e.g., metal-to-metal friction in rotating parts).
  • Static electricity in large moving machinery.
  • Potential chemical reactions that could occur between equipment surfaces and the flammable substances present in the refinery.

The refinery identified multiple ignition risks in its current equipment, including:

  • Friction between moving parts in pumps that were wearing out.
  • Static discharge from rotating conveyor belts.
  • Surface temperatures on compressors that were close to the auto-ignition temperature of the surrounding gases.
Step 2: Equipment Upgrades and Compliance

Based on the risk assessment, the refinery took the following actions to comply with ISO 80079-36:2016:

  • Non-Sparking Materials: Where feasible, equipment was upgraded with non-sparking alloys and components that reduced the risk of generating sparks. This included replacing components like fan blades and rotating shafts.
  • Friction Control: The pumps and compressors were fitted with friction-reducing materials and enhanced lubrication systems to prevent overheating and reduce wear.
  • Static Electricity Mitigation: Conveyor systems were grounded, and anti-static belts were installed to minimize the risk of electrostatic discharge.
  • Temperature Control: Surface temperature control measures were installed, including heat shields and thermal insulation, to ensure that equipment remained below the ignition temperature of any flammable gases or dust in the area.
  • Protective Casings: Protective casings were added to enclose parts of machinery that had potential ignition risks, isolating them from explosive atmospheres.
Step 3: Certification Process

The refinery’s engineering team worked with an accredited third-party certification body to ensure that all non-electrical equipment complied with ISO 80079-36:2016 and associated standards under the ATEX and IECEx frameworks. This involved:

  • Design review of all upgraded and new equipment to ensure adherence to ISO 80079-36 design principles.
  • Testing and validation of non-electrical equipment, such as pumps, compressors, and conveyors, in simulated hazardous environments to verify their performance under real-world conditions.
  • Documentation of all safety features, including material choices, temperature control mechanisms, and protective devices.

Upon successful certification, the refinery received an ATEX certificate for equipment used in the European Union and an IECEx certificate for international operations.

Step 4: Maintenance and Ongoing Compliance

To maintain compliance with ISO 80079-36:2016 and ensure long-term safety, the refinery implemented a maintenance program that included:

  • Regular inspections of all non-electrical equipment, focusing on potential wear and tear.
  • Scheduled replacement of high-risk components such as seals, bearings, and fan blades before they deteriorated to dangerous levels.
  • Temperature monitoring systems on critical equipment to detect and mitigate overheating.
  • Training programs for personnel on the correct procedures for maintaining non-electrical equipment in hazardous zones.

The refinery also set up an internal audit system to periodically review compliance with ISO 80079-36, ensuring that all future modifications to equipment maintained the required safety standards.

Outcomes

  1. Improved Safety: The refinery achieved significant improvements in safety, with no reported incidents of near misses or potential ignitions involving non-electrical equipment after the implementation of ISO 80079-36:2016.
  2. Reduced Downtime: The upgraded equipment, particularly with better friction control and non-sparking materials, experienced fewer mechanical failures, resulting in a reduction in equipment downtime.
  3. Global Compliance: The refinery’s certification under ATEX and IECEx allowed it to expand operations internationally with confidence that its non-electrical equipment met global safety standards for explosive atmospheres.
  4. Cost Savings: Although initial equipment upgrades required a capital investment, the refinery reported long-term savings due to lower maintenance costs and improved equipment reliability.
  5. Regulatory Alignment: The refinery was able to demonstrate compliance with local and international safety regulations, which was critical for securing operating licenses and permits for its expansion.

Lessons Learned

  • Early Risk Assessments: Conducting detailed risk assessments early in the design phase of the expansion allowed the refinery to identify potential ignition risks and mitigate them proactively.
  • Continuous Monitoring: Implementing ongoing monitoring and maintenance programs was key to ensuring that equipment remained compliant with ISO 80079-36:2016 over time.
  • Collaboration with Certification Bodies: Working closely with certification bodies facilitated a smooth certification process and ensured that all equipment met the required standards.

Conclusion

The implementation of ISO 80079-36:2016 at the petrochemical refinery provided a robust framework for ensuring the safety of non-electrical equipment in hazardous areas. Through proactive risk management, design improvements, and ongoing compliance efforts, the refinery was able to enhance operational safety and meet international regulatory requirements for explosive atmospheres.

White Paper on ISO 80079-36:2016

White Paper: ISO 80079-36:2016 – Non-Electrical Equipment for Explosive Atmospheres

Executive Summary

ISO 80079-36:2016 provides a standardized framework for ensuring the safety of non-electrical equipment used in explosive atmospheres. This standard addresses the unique risks posed by mechanical equipment, such as potential sparks, hot surfaces, and friction, in hazardous environments. Industries such as oil & gas, petrochemicals, mining, and manufacturing frequently encounter such environments, making adherence to this standard crucial for ensuring operational safety and compliance with international regulations.

This white paper provides an overview of the key components of ISO 80079-36:2016, its application across industries, benefits of compliance, challenges in implementation, and the role it plays in protecting workers, equipment, and the environment from the risks of explosions.

Introduction

Explosive atmospheres present serious hazards in many industrial sectors, particularly those handling flammable gases, vapors, mists, and dusts. While much focus has traditionally been on electrical equipment in such environments, non-electrical equipment—such as pumps, compressors, and mechanical conveyors—also poses significant ignition risks. These risks arise from friction, impact, mechanical failure, and high surface temperatures.

To address this gap, ISO 80079-36:2016, titled “Explosive atmospheres — Part 36: Non-electrical equipment for explosive atmospheres — Basic method and requirements,” provides guidance on the design, construction, and testing of non-electrical equipment used in hazardous areas.

Overview of ISO 80079-36:2016

Scope and Applicability

ISO 80079-36:2016 applies to non-electrical equipment that may act as an ignition source in potentially explosive atmospheres. The standard outlines a risk-based approach for identifying and mitigating potential ignition sources related to mechanical and thermal processes. Key areas of application include:

  • Oil & Gas Industry: Drilling platforms, refineries, and pipelines.
  • Petrochemicals: Storage tanks, processing plants, and transport systems.
  • Mining: Handling and transport of combustible dusts in underground and surface operations.
  • Manufacturing: Operations that generate flammable mists, gases, or dusts.

The standard does not apply to electrical equipment, which is covered by standards like IEC 60079-0.

Main Elements
  1. Ignition Risk Assessment (IRA): ISO 80079-36 mandates a systematic process for assessing and identifying potential ignition sources within non-electrical equipment. This assessment includes:
    • Friction and impact.
    • Hot surfaces and flames.
    • Sparks caused by mechanical components.
    • Static electricity.
    • Chemical reactions.
  2. Design Principles: The standard outlines design considerations that must be incorporated to eliminate or reduce identified risks. These include:
    • Use of non-sparking materials.
    • Limiting surface temperatures.
    • Enclosing mechanical components to prevent ignition risks.
    • Implementing measures to control static electricity.
  3. Mechanical Equipment Protection Levels (MPL): ISO 80079-36 specifies different protection levels based on the risk of equipment causing ignition, similar to the zones used for electrical equipment:
    • Equipment Protection Level (EPL): Specifies equipment’s level of safety integrity.
    • Zone Classification: Equipment must be suitable for use in zones 0, 1, 2 (gas) or zones 20, 21, 22 (dust), depending on the level of explosion risk.
  4. Testing and Certification: Non-electrical equipment must undergo testing to ensure it meets the requirements of ISO 80079-36. Manufacturers must work with accredited certification bodies to receive ATEX or IECEx certifications.

Key Benefits of ISO 80079-36:2016 Compliance

  1. Improved Safety ISO 80079-36 provides a rigorous framework for identifying and mitigating ignition risks, leading to safer operating environments. Compliance reduces the likelihood of catastrophic explosions, protecting personnel, property, and the surrounding community.
  2. Regulatory Compliance Many countries and regions, such as the European Union (through ATEX) and international markets (through IECEx), require non-electrical equipment used in explosive atmospheres to comply with standards like ISO 80079-36. This ensures that industries meet local and international safety regulations.
  3. Enhanced Risk Management By conducting a detailed risk assessment of potential ignition sources, organizations can better understand their vulnerabilities. This allows them to prioritize risk mitigation measures and develop comprehensive safety plans.
  4. Cost Savings Preventing explosions and fires reduces downtime, costly repairs, and potential legal liabilities. While the upfront cost of implementing ISO 80079-36 may be high due to equipment upgrades and certification, the long-term savings far outweigh these expenses.
  5. Global Market Access Certification under ISO 80079-36 opens up opportunities in markets that require strict compliance with safety standards, such as the EU and other international regions. This enables companies to expand their operations globally.

Challenges in Implementing ISO 80079-36:2016

  1. Complex Risk Assessment Identifying and assessing potential ignition sources in non-electrical equipment can be technically challenging. Companies must have access to skilled engineers and safety specialists who are knowledgeable about both mechanical systems and explosive atmospheres.
  2. Retrofit Costs For existing operations, retrofitting non-compliant equipment to meet ISO 80079-36 can require significant capital investment. This can include replacing mechanical parts with non-sparking materials, installing temperature control devices, and grounding systems to mitigate static discharge.
  3. Certification Process Obtaining certification through ATEX or IECEx can be time-consuming and expensive. Equipment must undergo rigorous testing, and documentation requirements are stringent, which may be burdensome for smaller manufacturers.
  4. Maintenance and Monitoring Compliance with ISO 80079-36 is an ongoing process. Equipment must be regularly inspected, and maintenance plans must be implemented to ensure that safety features remain effective over time. Training programs for personnel are critical to maintaining high safety standards.

Case Example: Oil & Gas Sector

In the oil and gas sector, non-electrical equipment such as pumps, compressors, and valves are commonly used in areas where flammable gases are present. A major oil refinery in Europe undertook a safety upgrade project to comply with ISO 80079-36:2016.

  • Risk Assessment: The refinery conducted an ignition risk assessment and identified mechanical pumps as potential ignition sources due to friction between moving parts.
  • Equipment Upgrades: The pumps were retrofitted with non-sparking materials, and lubrication systems were enhanced to reduce friction.
  • Certification: The equipment was tested and certified under ATEX and IECEx standards.
  • Outcome: The refinery achieved compliance, reducing the risk of ignition-related accidents. This allowed the refinery to expand its operations and secure new contracts in regions with stringent safety regulations.

Future Trends

The growing complexity of industrial operations and the increasing emphasis on safety and environmental protection are driving the adoption of ISO 80079-36:2016. As industries evolve, the standard may see further updates to incorporate new technologies, such as advanced monitoring systems and automated safety mechanisms.

Additionally, the demand for standardized global regulations is likely to grow, further emphasizing the importance of international standards like ISO 80079-36. This trend will encourage greater collaboration between manufacturers, certification bodies, and regulatory agencies to ensure consistent safety measures across different regions.

Conclusion

ISO 80079-36:2016 plays a critical role in ensuring the safety of non-electrical equipment in explosive atmospheres. By providing a standardized approach to risk assessment, design, and testing, the standard helps industries mitigate ignition risks and prevent devastating explosions. While the implementation of the standard presents challenges, particularly in terms of risk assessment and certification, the benefits in terms of safety, regulatory compliance, and cost savings are substantial.

As industries face increasingly complex safety challenges, ISO 80079-36:2016 will remain a cornerstone of explosive atmosphere safety, helping to protect workers, equipment, and the environment from the dangers of non-electrical ignition sources.

References

  1. ISO 80079-36:2016. Explosive atmospheres – Part 36: Non-electrical equipment for explosive atmospheres – Basic method and requirements.
  2. ATEX Directive 2014/34/EU. European Union.
  3. IECEx Certification System for Explosive Atmospheres.
  4. Case Study on Refinery Compliance with ISO 80079-36.

This white paper presents a comprehensive understanding of ISO 80079-36:2016, its importance, and the challenges involved in compliance.

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