factsheetw i t h t h e c o m p l i m e n t s o f E P M s o l u t i o n s L t d

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K E Y FA C T S O N D S E A R , A T E X A N D C M M S I M P L E M E N T A T I O N A N D H O W T H E Y R E L A T E T O E A C H O T H E R .

DSEAR1. Dangerous SubstancesAny substances used or present at work that could, if not properly controlled, cause harm to people as a result of a fire or explosion. They can be found in nearly all workplaces and include such things as solvents, paints, varnishes, flammable gases, such as liquid petroleum gas (LPG), dusts from machining and sanding operations and dusts from foodstuffs2. Relationship between fire and explosionsIn many cases where an explosive atmosphere can form, any ignition will cause a fire rather than an explosion. Both fire and explosion cause danger to workers, and the precautions required to prevent an ignition are often the same. 3. Assessing risksBefore work is carried out, employers must assess the fire and explosion risks that may be caused by dangerous substances. This should be an identification and careful examination of: the dangerous substances in the workplace; the work activities involving those substances and the ways in which those substances and work activities could harm people.4. Control measuresWhere the risk cannot be eliminated, control measures must be applied in the following priority order: reduce the quantity of dangerous substances to a minimum; avoid or minimise releases of dangerous substances; control releases of dangerous substances at source; prevent the formation of a dangerous atmosphere; collect, contain and remove any releases to a safe place (for example, through ventilation); avoid ignition sources; avoid adverse conditions (for example, exceeding the limits of temperature or control settings) that could lead to danger and keep incompatible

substances apart. These control measures should be consistent with the risk assessment and appropriate to the nature of the activity or operation.5. MitigationThese measures should be consistent with the risk assessment and appropriate to the nature of the activity or operation and include: reducing the number of employees exposed to the risk; providing plant that is explosion resistant; providing explosion suppression or explosion relief equipment; taking measures to control or minimise the spread of fires or explosions and providing suitable personal protective equipment.6. Places where explosive atmospheres may occur DSEAR places additional duties on employers where potentially explosive atmospheres may occur in the workplace. These duties include: identifying and classifying areas where potentially explosive atmospheres may occur; avoiding ignition sources in zoned areas, in particular those from electrical and mechanical equipment; where necessary, identifying the entrances to zoned areas; providing appropriate anti-static clothing for employees and before they come into operation, verifying the overall explosion protection safety of areas where explosive atmospheres may occur.

DSEAR ATEX CMMS

Is a set of UK regulations which is concerned with protection against risks from fire, explosion and similar events arising from dangerous substances used or present in the workplace.

Is a set of European Directives defining duties of employers to take measures to prevent the formation of an explosive atmosphere in the workplace and provide protection to their workers. Also places duties on Manufacturers / Suppliers to ensure their equipment meet Essential Health & Safety Requirements for use in potentially hazardous explosive atmospheres.

Computerises Maintenance Management System provides a company with a powerful tool for the identification of their assets, proactive planned maintenance of their equipment, improving efficiency reliability & ultimately safety in pursuit of compliance with DSEAR & ATEX.

© 2009 EPM Solutions Ltd. EPM Solutions endeavours to ensure that the information in this factsheet is up to date and accurate. However, where concerned you are advised to consult with the appropriate bodies for further details.

EPM Solutions Ltd., Abbey Mill, 1010-1012 Mile End, Seedhill, Paisley, PA1 1TJ.T. 0141 848 6609 F. 0141 848 7749 E. info@epmsolutions.co.uk www.epmsolutions.co.uk

Key facts - DSEAR, ATEX and CMMS

For more information on hazardous environments, DSEAR, ATEX and CMMS implementation please contact EPM Solutions on 0141 848 6609

CMMS implementation1. A Computerises Maintenance Management System provides a company with a powerful tool for the identification of their assets, proactive planned maintenance of their equipment, improving efficiency reliability & ultimately safety in pursuit of compliance with DSEAR & ATEX.2. Site surveys and asset registersBefore you begin CMMS implementation you will need to gather accurate asset information in order to complete the maintenance management system. Areas to be considered include: mechanical and electrical process equipment, civil and structural infrastructure, portable appliances and laboratory equipment. 3. P & I diagrams and reference drawingsUpdates to P & I diagrams and reference drawings may need to be undertaken, and adding asset numbers to drawings as a cross-reference to the CMMS asset register should be considered.4. System identification and taggingAssets should have a physical tag attached to identify them when inspections or maintenance work is carried out. This tag number should cross-reference to your drawings and CMMS register.5. Project management - structure developmentDetailed discussions should take place on site with your engineering and operational staff to help develop the asset and maintenance management system structure. Also, you should identify key assets for critical analysis and consequence of failure review. 6. Defect reporting systemYou should develop a defect-reporting system for all of your assets that is integral to the CMMS. This involves developing and measuring defects and faults for operational plant and site services equipment including the analysis of fault codes and downtimes for all areas of your site. 7. Criticality analysisYou should identify critical equipment requiring routine or increased planned maintenance and inspection. You should then carry out the development of maintenance strategies based on the results of the critical analysis. 8. Develop coding structure and maintenance philosophyA matrix of equipment and asset categories should be compiled for all maintainable equipment across your facilities. This matrix will form the basis for implementation of maintenance schedules in the planned maintenance system, and should remain as a controlled working document.9. Coding structureThis involves the development of the asset and task coding structure carried out to complement the Maintenance Matrix. Codes should be standardised across your facility to include coding for assets, maintenance schedules, trades and personnel, maintenance service and category, site systems and registers.10. Maintenance planningMaintenance schedules should be compiled for each equipment type and job frequency in accordance with the categories developed during the maintenance philosophy and coding phase of the project. 11. CodingYour CMMS coding should then be developed and standardised across your entire facility. This can be used as a master for other facilities if required.

DSEAR cont’d 7. DrawingsArea classification studies usually take the form of drawings identifying the hazardous zones and areas and cross refer to the DSEAR risk assessments.8. Providing information, instruction and training for employeesEmployees must be provided with relevant information, instructions and training. This includes: the dangerous substances present in the workplace and the risks they present including; the findings of the risk assessment and the control measures put in place as a result (including their purpose and how to follow and use them) and emergency procedures.

Information, instruction and training need only be provided to other people (non-employees) where it is required to ensure their safety. It should be in proportion to the level and type of risk. The contents of pipes, containers, etc must be identifiable to alert employees and others to the presence of dangerous substances. If the contents have already been identified in order to meet the requirements of other law, this does not need to be done again under DSEAR.

ATEX cont’d 7 Providing anti-static clothingEmployers must provide workers who work in zoned areas with appropriate clothing that does not create the risk of an electrostatic discharge igniting the explosive atmosphere, e.g. anti-static footwear. The clothing provided depends on the level of risk identified in the risk assessment.8. Confirming (verifying) overall explosion safetyBefore a workplace containing zoned areas comes into operation for the first time, the employer must ensure that the overall explosion safety measures are confirmed (verified) as being safe. This must be done by a person or organisation competent to consider the particular risks in the workplace, and the adequacy of the explosion control and other measures put in place9. Equipment - Addition, Relocation, Replacement, Removal or ScrappingSound change control processes will be required to ensure all status changes to equipment is carefully controlled to ensure continued compliance. This is normally achieved through a proactive planned maintenance system, improving efficiency reliability & ultimately safety in pursuit of compliance with DSEAR & ATEX.

ATEX1. ATEX Defined All necessary measures must be taken to ensure that the workplace, work equipment and any associated connecting device made available to workers have been designed, constructed, assembled and installed, and are maintained and operated, in such a way as to minimise the risk of an explosion.2. Hazardous Zonesidentify and classify areas where potentially explosive atmospheres may occur. Area classification studies usually take the form of drawings identifying the hazardous zones and areas and cross refer to the DSEAR risk assessments.3. Equipment in Hazardous ZonesAreas classified into zones must be protected from sources of ignition. Electrical / Mechanical Equipment, associated equipment and protective systems intended to be used in zoned areas should be selected to meet the requirements of the Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres Regulations 1996. Equipment already in use before July 2003 can continue to be used indefinitely provided a risk assessment shows it is safe to do so, in particular: Carry out inspections on all equipment within hazardous zones; Record information about equipment; Identify any systems that support equipment within zones; Carry out Risk Assessments (RAs) and identify any potential hazards when the equipment is in position; Seek guidance from manufactures - equipment changes because of the directive and if necessary make recommendations for modifications or changes as a result of the RA’s.4. Equipment ManufacturersManufacturers/suppliers (or importers, if the manufacturers are outside the EU) must ensure that their products meet essential health and safety requirements and undergo appropriate conformity procedures. This usually involves testing and certification by a ‘third-party’ certification body (known as a Notified Body) but manufacturers/suppliers can ‘self-certify’ equipment intended to be used in less hazardous explosive atmospheres. Once certified, the equipment is marked by the ‘EX’ symbol to identify it as such. Certification ensures that the equipment or protective system is fit for its intended purpose and that adequate information is supplied with it to ensure that it can be used safely.5. Explosion Protection Document (EPD)The EPD is based on the risk assessment. Once the risk assessment has been carried out and identified the likelihood that workers may be exposed to an explosive atmosphere, an EPD must be drawn up. The EPD must demonstrate that all explosion risks have been determined and assessed. Those locations or areas which have been identified as “hazardous locations” shall be identified in the EPD.6. Warning SignsWhere necessary, the entry points to areas classified into zones must be marked with a specified ‘EX’ sign. The requirement for a warning sign is in line with the Health & Safety Signs (Safety Signs & Signals) Regulations 1996. The purpose of these regulations is to encourage the standardisation of safety signs throughout the EC member states so that signs, wherever they are seen, have the same meaning.

The warning sign must be triangular in shape, utilise black lettering on a yellow background with black edging. The yellow background must constitute

at least 50% of the area of the sign. Other explanatory data may be added to the sign.