Recursive operability analysis as a tool for ATEX classification in plants managing explosive dusts

Safety and prevention in workplaces are important issues, especially regards to risks with serious consequences for health and infrastructures, such as dust explosions, which have caused several industrial accidents during the last centuries and, actually, represent a critical issue in the industrial framework. The current European legislation, referred to as ATEX directive, identifies ATEX zones as parts of the plant where explosive atmospheres can be generated. In this work, a modified version of the classic Recursive Operability Analysis method, specifically tailored to define with an automatic procedure the ATEX zones related to flammable dust clouds, is proposed. The method is fast and effective, allowing for an automatic generation of fault trees from which the probability of occurrence defining the specific ATEX zone type can be estimated. This technique was successfully implemented in a chemical plant dedicated to the mixing of inert powders with a stearate powder, a hazardous dust classified as strongly explosible. The extent of all the ATEX zones identified within the plant was simulated with the ALOHA software, treating the dispersed dust cloud of stearate as a dense gas cloud. From the results, it was possible to identify not only type and extension of all the ATEX zones but also either the most critical parts of the plant or the most dangerous activities (e.g. human errors in the use of the forklift was found to account for about 97.7% to explosion probability in this type of plant).