News

Working at height is a risky business, and the wind energy sector is no exception. In 2021/22 there were 29 work-related fatalities due to falls from a height in the UK – representing almost 24% of all worker deaths.[i] While total industry deaths are falling year-on-year, the people behind these statistics remind us that there is still a long way to go.

For those responsible for the safety of their workers, choosing appropriate systems is a huge responsibility when there is so much to consider. Here, Tim Bissett, Technical Manager at MSA Safety, explores the importance of adhering to the latest safety standards and explains some important considerations users and installers should be looking out for when it comes to choosing an appropriate vertical fall protection system for wind turbines.

Being proactive about safety

In 2020, over 500 safety incidents were reported at the UK’s onshore wind farms.[ii] Maintaining turbines can see workers having to climb as heigh as 30m at a time, which along with the often-limited access and frequent requirement to work in a confined space can contribute to workers’ risks. Therefore, being proactive about safety includes getting all relevant teams fully trained, competent, and comfortable working in these conditions, as well as knowledgeable about the chosen fall protection system and how it operates. Doing this will help to minimise the risk to workers.

Complying with safety standards

Safety standards vary across different locations and legislations, so it’s important to be aware of which standards you should be paying attention to. For example, for fall protection equipment certifications in Europe it’s EN standards. The EN standard used to apply in the UK as well but, following Brexit, the UKCA mark is now required as of 1 January 2023.

Even after initial selection consider regular checks of your fall protection systems for elements that could include:

• The compliance certificates of your equipment and systems for expiry dates and that the life of your system is still in date.
• You have regular inspections scheduled, including to check wear and tear.

Having simple checks like these in place will help you to increase your control over the systems used by your workforce.

And if you’re in the UK and Europe, to enhance the health and safety of your wind turbine workers, consider whether your safety equipment adheres to EN 353-1:2018 (EN 353-1:2014+A1:2017) - the newest update to fall protection system requirements.

• Some key features of EN 353-1:2018 that companies can check, depending on their circumstances, are:
• Dynamic performance testing – to check the maximum arrest force
• Cold condition testing – checking locking function in cold conditions
• Minimum distance testing – to replicate the user falling close to the anchor line
• Fall back testing – which replicates the user falling back and down
• Guide bracket testing – looking at the strength of the bracket and anchor line and the locking function of a fall arrester in the event of a fall
• Sideway fall testing – to replicate the user falling in a sideways direction
• Leaning angle testing – considering the locking function of the fall arrester with the anchor line leaning forward and sideways
• Static strength requirements - testing to check the overall strength of the system.

As this list shows, the EU type-examination process for EN 353-1:2018 is rigorous and it incorporates several dynamic tests that covered many scenarios. Updating to this standard can help give your workers added confidence that their safety at height is a top priority.

Ease of use

Another element to consider when choosing fall protection systems for wind turbines, is how simple it is for workers to use. After all, there are advantages to systems that workers understand fully and will use. These fall protections systems should balance the users’ accessibility with their needs for relevant applications, such as considering whether a restriction or complex process reduces users’ risk.

At MSA Safety, We Know What’s At Stake

Keeping workers safe is a top priority and as safety professionals, it’s our mission to help make sure that workers go home to their family at the end of the working day. That’s why compliance and product testing are at the core of what we do.

For more information and resources on fall protection systems, please visit MSA Safety.

This article can also be found in the issue below.

SELECT, Scotland’s largest construction trade association, has welcomed three major new enterprises to its growing Associate Membership Scheme as it continues to attract an impressive line-up of market-leading manufacturers and organisations.

Schneider Electric, Robus LED Group and CompEx have all joined the 25 existing Associates who have built mutually beneficial relationships with SELECT’s member businesses over the past 18 months.

The three new Associate Members will now be able to engage with SELECT’s experts and members, enjoy access to a wealth of services and benefits and work with the organisation to share the latest ideas and in-depth knowledge to the advantage of the wider industry.

Iain Mason, Director of Membership and Communications at SELECT, said: “Everyone at SELECT is delighted that enterprises of the size and stature of Schneider Electric, Robus and CompEx have joined our Associate Membership scheme.

“Becoming an Associate is an opportunity for partner organisations to build stronger relationships with key players in the electrical contracting industry, and also to ally themselves with an established and successful trade body.”

SELECT, which represents around 1,250 electrical firms and 15,000 contractors across the country, launched the scheme early in 2022 to help develop a mutually complementary network of industry-specific partners.

Mr Mason added: “Since its launch, the scheme has proved extremely popular and has allowed Associates to speak to our members both through our print and digital channels and also face-to-face at the many events we run across Scotland throughout the year.

“It has also strengthened our own relationship with some of the industry’s most renowned names and allowed us to develop and grow events such as our Toolbox Talks, President’s Cup and President’s Lunch.”

Schneider Electric, which traces its history back to 1838, drives digital transformation by integrating world-leading process and energy technologies to help businesses make efficiency and sustainability gains across their organisations.

David Pownall, Vice President of Services at Schneider Electric UK & Ireland, said: “We have had a long and fruitful association with SELECT over the years, including sponsoring organisation awards, and we are proud to be included in an Associate Membership scheme which brings so many benefits to the electrical industry.”

Robus is a Dublin-headquartered global lighting wholesaler with customers in more than 40 countries around the world. Established in 1984, it is now the biggest lighting company in Ireland.

Mick G Slein, Chief Executive of Robus, said: “Becoming an Associate Member of SELECT completely aligns with our best-in-class mindset and our vision of being our customers’ most trusted LED lighting brand. We look forward to building strong and trusted relationships with SELECT members as we continue to grow internationally.”

CompEx is the international scheme for competency validation and certification of people who work in explosive atmospheres. First established 30 years ago with the support of industry, its suite of training and assessment modules are delivered through a network of independent training and assessment centres to support electrotechnical practitioners in sectors including oil and gas, chemicals, pharmaceuticals, food and beverage manufacturing and utilities.

Huw Bement, Managing Director of CompEx, said: “Our international safety and competency scheme is rooted in certifying electrotechnical technicians and engineers operating in hazardous areas – so becoming a SELECT Associate Member is hugely important for us. It’s a fantastic opportunity for CompEx to establish new industry connections and to continue building our existing relationships.”

The trio’s arrival follows the announcement of Legrand UK & Ireland as SELECT’s 25th Associate Member earlier this year. The electrical and digital infrastructure specialist is part of Legrand Group, which has a presence in nearly 90 countries and employs more than 38,000 people.

Other SELECT Associate Members include Hispec, V-Tac, Aico, Aurora, Electrium, Hager, Luceco, Megger, Scolmore and Thorn Lighting.

SELECT has just completed its annual Toolbox Talks roadshows and is now involved in the organisation of the second Green Home Festival as a leading member of the Construction Industry Collective Voice (CICV).

The organisation also continues to spearhead a long-running and high-profile campaign for regulation of the electrical industry, with the submission to Scottish Parliament of a Members’ Bill calling for Protection of Title

This article can also be found in this issue below.

The Requirements for ATEX/UKCA

One of the most misunderstood aspects of ATEX and UKCA Ex Certification is the ‘blend’ of Self Certification and Notified/Approved Body Certification.  There are many routes to certification, and this is explained in legislative documents, but for end users and manufacturers it can be very confusing. An example of the routes to conformity is shown below….

So what exactly does this mean?

• Electrical equipment that is CAT 1 and CAT 2 (normally for use in in Zone 0 or 1) requires Notified Body Certification for the EU and UK Approved Body Certification for the UK (no self-certification is allowed unless the equipment is Simple Apparatus*)
• Non-electrical equipment for CAT 1 (Zone 0)requires Notified/Approved Body Certification.
• Equipment that is purely non-electrical requires a ‘technical file lodging’ with a Notified/Approved Body for CAT 2 (Zone 1) and the Notified/Approved Body will normally issue proof or receipt.
• All ‘Protective Systems’ (mitigation) require Notified/Approved Body Certification
• Associated Apparatus (even in the safe area) may require Notified/Approved Body Certification
• Simple Apparatus can be self-declared even for Zone 0 if you are competent (e.g. CompEx EX12) and produce a DSD (the DSD is effectively the Certification). Simple Apparatus must still be assessed against the appropriate Standards and appropriately marked for inspection.

It is also worth noting that electrical products which are certified as a ‘component’ (a ‘U’ on the end of the certificate number) requires recertification by a Notified/Approved body before they can be used in a potentially explosive atmosphere for CAT 1 and CAT 2.

Equipment Manufacturers Self Declaration (commonly referred to as ‘Self Certification’)

Manufacturers ‘Self Declaration’ under CE or UKCA Marking makes the person who signs the ‘declaration’ legally responsible for the equipment compliance as there is no legal requirements for 3^rd party certification and no quality control over what is produced other than internal control of production. Regulatory Authorities may request the evidence (for example clause by clauses standards assessment and test reports) for the standards claimed on the Declaration.

Category 3 Electrical and Category 2 and 3 Non-electrical can be voluntarily certified (and this is sometimes required by end users/buyers) in the following ways…

• A Conformity Certificate from a Certification Body but with no Quality Control on production (so there can be no Notified/Approved Body number under the CE/UKCA Marking)

• A Unit Verification Certificate where the Certification Body inspects the equipment for compliance and lists it on the Certificate by serial number (this can be a full Notified/Approved Body Certification with the Body number under the CE/UKCA Marking)

The Requirements for IECEx

IECEx always requires a fully accredited and regulated ‘IECEx Certification Body’ to issue the certification, there is no self certification route. All IECEx Certificates also control the manufacturing quality related aspects via an IECEx QAR.

It’s easy to see why IECEx has become the ‘international’ scheme and why many end users prefer the simplicity and control of an IECEx Certificate. It should be noted however that although IECEx is the ‘baseline’ for most international schemes (including UKCA and ATEX), National Certification is normally required ‘in addition’ to the IECEx Certification, but the process should be far simpler than achieving multiple National Certification that may not be accepted in other countries…

Sean Clarke CEng MSc FIET is the Managing Director of ExVeritas who a UKCA Approved ‘Ex’ Body, an ATEX Notified Body and IECEx Test and Certification Body. With ‘Ex’ test laboratories in the UK and USA. www.exveritas.com

The Requirements for ATEX/UKCA

One of the most misunderstood aspects of ATEX and UKCA Ex Certification is the ‘blend’ of Self Certification and Notified/Approved Body Certification.  There are many routes to certification, and this is explained in legislative documents, but for end users and manufacturers it can be very confusing. An example of the routes to conformity is shown below….

So what exactly does this mean?

• Electrical equipment that is CAT 1 and CAT 2 (normally for use in in Zone 0 or 1) requires Notified Body Certification for the EU and UK Approved Body Certification for the UK (no self-certification is allowed unless the equipment is Simple Apparatus*)
• Non-electrical equipment for CAT 1 (Zone 0)requires Notified/Approved Body Certification.
• Equipment that is purely non-electrical requires a ‘technical file lodging’ with a Notified/Approved Body for CAT 2 (Zone 1) and the Notified/Approved Body will normally issue proof or receipt.
• All ‘Protective Systems’ (mitigation) require Notified/Approved Body Certification
• Associated Apparatus (even in the safe area) may require Notified/Approved Body Certification
• Simple Apparatus can be self-declared even for Zone 0 if you are competent (e.g. CompEx EX12) and produce a DSD (the DSD is effectively the Certification). Simple Apparatus must still be assessed against the appropriate Standards and appropriately marked for inspection.

It is also worth noting that electrical products which are certified as a ‘component’ (a ‘U’ on the end of the certificate number) requires recertification by a Notified/Approved body before they can be used in a potentially explosive atmosphere for CAT 1 and CAT 2.

Equipment Manufacturers Self Declaration (commonly referred to as ‘Self Certification’)

Manufacturers ‘Self Declaration’ under CE or UKCA Marking makes the person who signs the ‘declaration’ legally responsible for the equipment compliance as there is no legal requirements for 3^rd party certification and no quality control over what is produced other than internal control of production. Regulatory Authorities may request the evidence (for example clause by clauses standards assessment and test reports) for the standards claimed on the Declaration.

Category 3 Electrical and Category 2 and 3 Non-electrical can be voluntarily certified (and this is sometimes required by end users/buyers) in the following ways…

• A Conformity Certificate from a Certification Body but with no Quality Control on production (so there can be no Notified/Approved Body number under the CE/UKCA Marking)

• A Unit Verification Certificate where the Certification Body inspects the equipment for compliance and lists it on the Certificate by serial number (this can be a full Notified/Approved Body Certification with the Body number under the CE/UKCA Marking)

The Requirements for IECEx

IECEx always requires a fully accredited and regulated ‘IECEx Certification Body’ to issue the certification, there is no self certification route. All IECEx Certificates also control the manufacturing quality related aspects via an IECEx QAR.

It’s easy to see why IECEx has become the ‘international’ scheme and why many end users prefer the simplicity and control of an IECEx Certificate. It should be noted however that although IECEx is the ‘baseline’ for most international schemes (including UKCA and ATEX), National Certification is normally required ‘in addition’ to the IECEx Certification, but the process should be far simpler than achieving multiple National Certification that may not be accepted in other countries…

Sean Clarke CEng MSc FIET is the Managing Director of ExVeritas who a UKCA Approved ‘Ex’ Body, an ATEX Notified Body and IECEx Test and Certification Body. With ‘Ex’ test laboratories in the UK and USA. www.exveritas.com

AMETEK Land, the world's leading manufacturer of monitors and analysers for industrial non-contact temperature measurement, has increased its support for customer applications in hazardous areas with two new housing enclosures.

 The new EXSH1 flameproof housings have been developed for use with the EX SPOT pyrometer range and LWIR-640 thermal imager and are approved for operation in hazardous areas.

 Manufactured from 316/316L stainless steel and highly resistant to corrosion, both enclosures have a certified temperature range of -40 to +70 °C (-40 to 158 °F).

 Ingress protection to IP66 and IP68 means that they can be exposed to dust, water immersion and high-pressure water jets, making them suitable for use in almost any application in the harshest of environmental conditions, including those where explosive mixtures are present.

 The housing has a gridless design, allowing an unobstructed field of view, and is certified for use in areas with dust and gas hazards. Additionally, the enclosure does not require purge air for safety.

 The EXSH1 EX SPOT housing is designed for use with the EX SPOT range, a family of fully-featured, high-performance pyrometers for fixed, non-contact, infrared spot temperature measurements.

 EX SPOT pyrometers are available in a range of operating wavelengths, temperatures, and process requirements, and the new housing will enhance their capabilities in continuous annealing lines, semiconductor growth, and applications in the hydrocarbon processing and chemical industries.

 The EXSH1 LWIR housing has been created specifically for the LWIR-640 thermal imager, a long-wavelength instrument providing measurements between -20 and 1000 °C (-4 and 1832 °F) in three ranges with a choice of different optics and lenses.

 The LWIR-640 measures and streams live true-temperature images at up to 60 frames per second, providing high-precision temperature measurements and thermal profiles to continuously control, document, and visualise industrial processes.

 The new housing protects the LWIR-640 in applications including flare stack monitoring, critical vessel monitoring, storage pile monitoring, and operations within the hydrocarbon processing and chemical industries.

 With ATEX, IECEx and UKEX certifications, the housings comply with multiple international standards. This means that a common specification can be used for worldwide applications, greatly simplifying the task of specifying and quoting the product.

 A range of accessories is available for the housings, including various mounting brackets with pan and tilt adjustment, a sun shield for outdoor applications, and a spoolpiece adaptor. An environmental protection tube is offered for the LWIR housing, for flare stack applications, while further accessories for the EX SPOT housing include purges and a vertical mounting stand.

 Derek Stuart, Product Manager, said: “The EXSH1 housing allows customers in many new industries, including hydrocarbons and semiconductors, to benefit from the accuracy and reliability of AMETEK Land’s thermometers and thermal imagers.”

 For more information, and to download the EXSH1 brochures, go to: ametek-land.com.

 This article can also be found in the issue below.

Globally, companies are seeking opportunities to reduce waste and the carbon footprint of their products. This has increased demand for environmentally responsible packaging, and the manufacturing company Futamura has become the world’s largest producer of sustainable cellulose packaging films, including their leading NatureFlex™ range.

The production of sustainable films requires precise monitoring and control of process conditions. Highly accurate temperature and humidity measurement is therefore essential, particularly during the film drying process and when finished products are stored.

Futamura UK uses Vaisala measurement equipment across their site, including Vaisala HUMICAP® humidity and temperature transmitters HMT360 in their coating towers inside their conditioners. The coating towers contain solvents which are flammable, so the products used in these areas must be certified for the Ex environment. The Vaisala HMT360 transmitters, now superseded by the ATEX-certified HMT370EX, are intrinsically safe, making them ideal for use in hazardous areas such as these.

Vaisala measurement instruments can also be found on Futamura UK’s casting machines, installed in the dryer ducting, measuring humidity and temperature. The Vaisala humidity and temperature meter Series HMT330 is designed to provide highly accurate measurements in demanding industrial applications. These transmitters control a valve which manages the amount of steam that goes into the dryers, allowing the humidity to be maintained at the drying set-point needed for each type of film. Moisture content is a significant factor in the properties of the final film, so accurate control is important to ensure product quality and minimise waste. The HMT330 is an older model, so, seeking to future-proof their measurement instrumentation, Futamura contacted Vaisala for advice.

A member of Vaisala’s technical sales team therefore visited Futamura’s UK site in Wigton, Cumbria to demonstrate the benefits of switching to Vaisala’s Indigo platform, and to discuss the options with Electrical Engineering Chargehand, David Carr, and Technical Engineers David Mansergh and Chris Reid.

“We described the applications for the HMT330 series instruments and the Vaisala representative suggested we try the Indigo520 display with a relative humidity and temperature probe HMP5,” explains David Carr. “We were more than happy with the suggestion. His vast product knowledge and expertise in engineering and process systems was a huge benefit in the decision-making process. He also went through the calibration process and explained how to set up the equipment with our electrical engineers. Vaisala’s service and support have been first class – they have gone above and beyond to help us.”

The Indigo520 can connect with two separate probes simultaneously and has a simple, clear, intuitive touchscreen display. Futamura particularly appreciates the screen size and easy-to-read graphs, as well as the ability to swap out probes for calibration. It has also been advantageous that the new HMP5 probes work mechanically in the same way as the previous devices, with which they were already very familiar.

The key benefit of using Vaisala’s measurement instruments in Futamura’s manufacturing process is that they enable accurate control of the production process, which ensures consistent product quality and reduces waste.

Summarising David Carr said: " Futamura has been using Vaisala measurement instruments for many years helping us ensure the quality of our sustainable packaging films, and we will continue to do so in the future. When you find products, and a company, that you can trust, it makes good business sense to continue the relationship. As a plant we like to standardise because it makes spares management and equipment replacement simpler. It’s safe to say that Vaisala is our brand of choice because of product reliability and ease of installation and operation."

www.futamuragroup.com

This issue can also be found in the issue below.

ATEX protection is all centred around preventing an explosion from happening when there is a presence of combustible dust or flammable gas, this means considering all potential ignition sources. When looking at sources, most people will look for sparks and flames as an obvious risk, but the gas or dust properties themselves are an important aspect to protect against.

One of these properties is their temperature characteristics. Flammable gases have specific ignition temperatures, known as autoignition temperatures. These temperatures represent the minimum temperatures at which a gas mixture will spontaneously ignite in the absence of an external ignition source such as a spark or a flame. As an example, the auto ignition temperature of hydrogen air or hydrogen-oxygen, is from 510 – around 584’C.

Let’s consider the principle of hot surface ignition – lots of processes, such as combustion, will utilise a gases auto ignition temperature to ignite a gas on contact with a hot surface (often a coil, thread, plate etc). This works as the high temperature of the surface transfers heat to the gas, raises the temperature to its auto ignition point, igniting, and sustaining combustion. Great for purposeful processes but when this is not considered when handling potentially hazardous gases, this can be the cause for the explosion.

The principle of hot surface ignition, and the avoidance of auto ignition is handled with surface temperature limitations. ATEX fan selections consider the maximum allowable surface temperature of fan motors that come into contact with these potentially flammable gases and dusts in hazardous ATEX environments. This concept is known as maximum surface temperature. It’s important to note that maximum temperature limitations are not in place primarily for the prevention of hot surface ignition, the main principle is to protect the motor components themselves to ensure their safe operation by preventing excessive heat build-up, but will also prevent the fan and motor from becoming a source of potential ignition by keeping temperatures below any auto ignition temperatures.

For those of you who are unfamiliar with the make-up of an industrial fan suitable for potentially hazardous environments, ATEX fans are constructed and classified in two parts, one label that explains the motor classification and protection, and secondly a rating for the overall fan construction including the casing, impeller, and materials. Part of the motor classification shows the end user the maximum surface temperature that the motor is limited to reach to prevent component getting so hot that it initiates the auto-ignition temperature of the surrounding flammable substances.

Your fan supplier should always ask for your hazardous area classification information, this will inform them of the gases or dusts present, their presence to determine the ATEX zone, the temperature limitations that must be considered, the materials required to ensure longevity and safe operation and the level of ATEX protection required from electrical components such as motors. Under DSEAR and ATEX legislation it is the sole responsibility of the end user to conduct or contract a hazardous area classification. Suppliers will not be able to supply equipment for hazardous areas without this information from the end users.

For more information, visit www.axair-fans.co.uk

It is generally understood that all equipment for use in hazardous locations such as flour mills, coal mines, petrochemical plants and fuel transfer facilities, needs to be “intrinsically safe”. In other words, incapable of igniting an explosive atmosphere. However, some not so obvious hazardous locations include water treatment plants, tunnels and underground passageways or any location where a build-up of naturally occurring flammable material (such as methane or dust) could occur.

Wastewater pumping and treatment facilities, for example, emit flammable gases and vapours. These emissions come from substances that the wastewater could be carrying (e.g. oils, solvents or fuels from accidental spills) and from anaerobic digestion of organic matter (producing methane and hydrogen sulphide). According to NFPA 820 (Standard for Fire Protection in Wastewater Treatment and Collection Facilities) most pumping stations, spaces and buildings that make up a wastewater treatment plant must be considered hazardous locations.

In many of these hazardous locations there is a requirement for condition based monitoring (CBM), for example by monitoring the vibration of rotating machinery to predict failure. Particularly in the water treatment industry, the consequences of an unexpected breakdown can be catastrophic. In the event of pump failure, wastewater can back-up and overflow, resulting in accidental discharge of untreated sewage into water courses (rivers, lakes and oceans). This has led to water treatment companies being fined literally millions, to say nothing of the environmental damage!

The Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) require employers to control the risks to safety from fire, explosions and substances corrosive to metals. This entails compliance with BS EN 1127 (Explosive atmospheres - explosion prevention and protection), which in turn requires that any electrical equipment used is intrinsically safe and complies with BS EN IEC 60079. Hence any CBM equipment needs to be IECEx/ATEX certified for use in hazardous locations.

Affordable intrinsically safe condition based monitoring

Intrinsically safe devices typically cost many times more than their non-intrinsically safe counterparts. This is mainly due to the increased manufacturing costs (e.g. additional safety components and encapsulation) but also due to the high cost of the required testing and certification. Test Products International (TPI) believes it has broken the ATEX cost barrier with the TPI 9080Ex vibration analyser, priced at a very affordable £3,500. IECEx and ATEX certified for use in Zone 1 and with North American approval for Class I, Zone 1, the TPI 9080Ex is certified for use in hazardous locations anywhere in the world.

The TPI 9080Ex is supplied with an industry standard (IEPE) intrinsically safe accelerometer and offers on-meter analysis for the detection of machine faults such as unbalance, misalignment, looseness and bearing wear. The TPI 9080Ex features colour coded alarm levels and zoomable on-screen vibration frequency plots with cursor readout. It can store lists (routes) of machines (up to 1000), each with up to 10 measurement points, all with full vibration waveform and frequency spectrum (FFT) capture.

Routes and readings can be transferred between the TPI 9080Ex and the packaged free, subscription free, PC based trending and reporting software in a variety of different ways.  Via the included USB docking cradle, wirelessly via Bluetooth or remotely via a Bluetooth link with a smart phone or tablet, running the free TPI Bridge App. This allows service personnel to receive and return routes and readings, no matter where they are in the world.  The PC software, includes automatic email notification of alarms and report generation, allowing you to implement a full CBM solution. 

For more information please contact TPI Europe’s head office on +44 1293 530196 or take a look on the website at www.tpieurope.com or email This email address is being protected from spambots. You need JavaScript enabled to view it.

This artilce can also be found in the issue below.

It is generally understood that all equipment for use in hazardous locations such as flour mills, coal mines, petrochemical plants and fuel transfer facilities, needs to be “intrinsically safe”. In other words, incapable of igniting an explosive atmosphere. However, some not so obvious hazardous locations include water treatment plants, tunnels and underground passageways or any location where a build-up of naturally occurring flammable material (such as methane or dust) could occur.

Wastewater pumping and treatment facilities, for example, emit flammable gases and vapours. These emissions come from substances that the wastewater could be carrying (e.g. oils, solvents or fuels from accidental spills) and from anaerobic digestion of organic matter (producing methane and hydrogen sulphide). According to NFPA 820 (Standard for Fire Protection in Wastewater Treatment and Collection Facilities) most pumping stations, spaces and buildings that make up a wastewater treatment plant must be considered hazardous locations.

In many of these hazardous locations there is a requirement for condition based monitoring (CBM), for example by monitoring the vibration of rotating machinery to predict failure. Particularly in the water treatment industry, the consequences of an unexpected breakdown can be catastrophic. In the event of pump failure, wastewater can back-up and overflow, resulting in accidental discharge of untreated sewage into water courses (rivers, lakes and oceans). This has led to water treatment companies being fined literally millions, to say nothing of the environmental damage!

The Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) require employers to control the risks to safety from fire, explosions and substances corrosive to metals. This entails compliance with BS EN 1127 (Explosive atmospheres - explosion prevention and protection), which in turn requires that any electrical equipment used is intrinsically safe and complies with BS EN IEC 60079. Hence any CBM equipment needs to be IECEx/ATEX certified for use in hazardous locations.

Affordable intrinsically safe condition based monitoring

Intrinsically safe devices typically cost many times more than their non-intrinsically safe counterparts. This is mainly due to the increased manufacturing costs (e.g. additional safety components and encapsulation) but also due to the high cost of the required testing and certification. Test Products International (TPI) believes it has broken the ATEX cost barrier with the TPI 9080Ex vibration analyser, priced at a very affordable £3,500. IECEx and ATEX certified for use in Zone 1 and with North American approval for Class I, Zone 1, the TPI 9080Ex is certified for use in hazardous locations anywhere in the world.

The TPI 9080Ex is supplied with an industry standard (IEPE) intrinsically safe accelerometer and offers on-meter analysis for the detection of machine faults such as unbalance, misalignment, looseness and bearing wear. The TPI 9080Ex features colour coded alarm levels and zoomable on-screen vibration frequency plots with cursor readout. It can store lists (routes) of machines (up to 1000), each with up to 10 measurement points, all with full vibration waveform and frequency spectrum (FFT) capture.

Routes and readings can be transferred between the TPI 9080Ex and the packaged free, subscription free, PC based trending and reporting software in a variety of different ways.  Via the included USB docking cradle, wirelessly via Bluetooth or remotely via a Bluetooth link with a smart phone or tablet, running the free TPI Bridge App. This allows service personnel to receive and return routes and readings, no matter where they are in the world.  The PC software, includes automatic email notification of alarms and report generation, allowing you to implement a full CBM solution. 

For more information please contact TPI Europe’s head office on +44 1293 530196 or take a look on the website at www.tpieurope.com or email This email address is being protected from spambots. You need JavaScript enabled to view it.