BS EN 1012-3-2013 Compressors and vacuum pumps Safety requirements Process compressors《压缩机和真空泵 安全要求 加工压缩机》.pdf

1、BSI Standards PublicationBS EN 1012-3:2013Compressors and vacuumpumps Safety requirementsPart 3: Process compressorsBS EN 1012-3:2013 BRITISH STANDARDNational forewordThis British Standard is the UK implementation of EN 1012-3:2013.The UK participation in its preparation was entrusted to TechnicalCo

2、mmittee MCE/8/-/1, Compressors - Safety.A list of organizations represented on this committee can beobtained on request to its secretary.This publication does not purport to include all the necessaryprovisions of a contract. Users are responsible for its correctapplication. The British Standards Ins

3、titution 2013. Published by BSI StandardsLimited 2013ISBN 978 0 580 80944 6ICS 23.140; 23.160Compliance with a British Standard cannot confer immunity fromlegal obligations.This British Standard was published under the authority of theStandards Policy and Strategy Committee on 30 November 2013.Amend

4、ments issued since publicationDate Text affectedBS EN 1012-3:2013EUROPEAN STANDARD NORME EUROPENNE EUROPISCHE NORM EN 1012-3 November 2013 ICS 23.140; 23.160 English Version Compressors and vacuum pumps - Safety requirements - Part 3: Process compressors Compresseurs et pompes vide - Prescriptions d

5、e scurit - Partie 3: Compresseurs de procd Kompressoren und Vakuumpumpen - Sicherheitsanforderungen - Teil 3: Prozesskompressoren This European Standard was approved by CEN on 8 September 2013. CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions f

6、or giving this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN member. This European Standard exists in thr

7、ee official versions (English, French, German). A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management Centre has the same status as the official versions. CEN members are the national standards bo

8、dies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia,

9、Spain, Sweden, Switzerland, Turkey and United Kingdom. EUROPEAN COMMITTEE FOR STANDARDIZATION COMIT EUROPEN DE NORMALISATION EUROPISCHES KOMITEE FR NORMUNG CEN-CENELEC Management Centre: Avenue Marnix 17, B-1000 Brussels 2013 CEN All rights of exploitation in any form and by any means reserved world

10、wide for CEN national Members. Ref. No. EN 1012-3:2013 EBS EN 1012-3:2013EN 1012-3:2013 (E) 2 Contents Page Foreword 5 Introduction .6 1 Scope 7 2 Normative references 7 3 Terms and definitions 10 4 List of significant hazards Hazard analysis and risk assessment . 16 5 Safety requirements and/or pro

11、tective measures . 22 5.1 General . 22 5.2 Mechanical safety . 23 5.2.1 General . 23 5.2.2 Guards . 23 5.2.3 Fluid injection 24 5.2.4 Loss of stability . 25 5.2.5 Lifting and transportation of compressor units and parts . 25 5.2.6 Slip, trip and fall 30 5.2.7 Speed . 30 5.2.8 Loss of main energy sup

12、ply or short term power interruption 31 5.2.9 Reverse running of the compressor . 31 5.3 Electrical safety. 32 5.3.1 Generally applicable . 32 5.3.2 Protection from overload . 32 5.3.3 Protection from live parts 32 5.3.4 Protection from lightning . 32 5.3.5 Portable and skid-mounted compressor units

13、 32 5.4 Control systems 33 5.4.1 General . 33 5.4.2 Failure of safety related control system energy supply . 33 5.4.3 Start/restart 33 5.4.4 Manual suspension of safety functions . 34 5.4.5 Electrical control systems . 35 5.4.6 Pneumatic and/or hydraulic control systems 36 5.5 Thermal safety . 36 5.

14、6 Noise 37 5.7 Materials and substances processed, used or exhausted . 37 5.7.1 General . 37 5.7.2 Reactive gases 38 5.7.3 Oxygen compressors . 38 5.7.4 Acetylene compressors . 40 5.7.5 Compressors for H2S containing gases 41 5.7.6 Nitrogen and other inert gases 41 5.7.7 Access closures to process g

15、as containing parts 41 5.7.8 Compressor shaft seal systems 42 5.7.9 Static seals (Gaskets) for piping . 42 5.7.10 Micro-organisms, biological and microbiological substances 43 5.7.11 Compressors units driven by internal combustion engines 44 5.8 Fire and explosion 44 5.8.1 General . 44 5.8.2 Electro

16、static phenomena . 45 5.8.3 Oil-flooded rotary compressor units 45 BS EN 1012-3:2013EN 1012-3:2013 (E) 3 5.8.4 Oil-lubricated reciprocating process compressor units . 46 5.8.5 Compressor units driven by internal combustion engines 46 5.9 Ergonomic principles 46 5.9.1 General . 46 5.9.2 Manual handli

17、ng of compressor units and parts . 47 5.9.3 Portable and skid-mounted compressor units . 47 5.10 Integrity of machinery parts and other functional requirements . 47 5.10.1 Generally applicable 47 5.10.2 Snow, wind and seismic loads . 47 5.10.3 Break-up during operation . 48 5.10.4 Low temperature op

18、eration 48 5.10.5 Liquid shock 49 5.10.6 Coolant system 49 5.10.7 Process gas temperature rise 49 5.10.8 Turbo compressor . 49 5.11 Pressure limiting devices . 50 5.11.1 General . 50 5.11.2 Installation of pressure limiting devices . 50 5.11.3 Design specifications of pressure relief devices . 51 5.

19、11.4 Multi stage compressor units 51 5.11.5 Single and multi stage turbo compressors 51 5.12 Information and warning devices 51 6 Verification of safety requirements and/or protective measures . 52 6.1 Pressure testing 52 6.1.1 General . 52 6.1.2 Acetylene compressors 52 6.2 Leak tightness test for

20、hazardous gases 53 6.3 Test of electrical loops 53 6.4 Test of control systems 53 6.5 Noise . 53 6.5.1 General . 53 6.5.2 Sound power level of compressors used outdoors 54 6.6 Stability of portable compressor units 54 6.7 Structure of verification 54 7 Information for use 59 7.1 General requirements

21、 . 59 7.2 Accompanying documents. 60 7.2.1 Instruction handbook (Operating Manual) 60 7.2.2 Service instructions 66 7.2.3 Dismantling 68 7.2.4 Qualification . 68 7.3 Markings, signs and written warnings 68 7.3.1 Generally applicable 68 7.3.2 Compressor unit enclosures 69 7.3.3 Portable and skid-moun

22、ted compressor units . 69 7.3.4 Markings (in particular, data plate) 69 Annex A (informative) Graphical symbols 71 Annex B (informative) Measure to ensure a safety function while testing a safety device (example) . 78 B.1 Shutdown Override Switches . 78 B.2 Monitoring 78 Annex C (informative) Guide

23、to the application of current standards to the functional safety on safety related control of process compressors or compressor units . 79 C.1 Introduction 79 C.2 Scope 79 C.3 Standard and code references . 79 C.4 Standard abbreviations . 80 C.5 Risk reduction process and functional safety 81 BS EN

24、1012-3:2013EN 1012-3:2013 (E) 4 C.6 Relationship between EN 1012-3 and the standards for functional safety . 82 C.7 Process of functional safety 84 C.7.1 General . 84 C.7.2 Risk Assessment 85 C.7.3 Allocation of safety function to protection layers . 90 C.7.4 Safety Requirements Specification. 91 C.

25、7.5 Design and engineering . 91 C.7.6 Installation commissioning and validation 93 C.7.7 Verification 93 C.7.8 Assessment of functional safety . 93 C.8 Risk assessment of compressor and auxiliary system 94 C.9 Responsibilities 95 C.9.1 End user and manufacturer . 95 C.9.2 Compressor or compressor un

26、it manufacturer . 95 C.9.3 Example 1, using EN 61508, EN 61511 . 97 C.9.4 Example 2, using EN 61508, EN 61511 . 99 Annex ZA (informative) Relationship between this European Standard and the Essential Requirements of EU Directive 2006/42/EC . 101 Bibliography . 102 BS EN 1012-3:2013EN 1012-3:2013 (E)

27、 5 Foreword This document (EN 1012-3:2013) has been prepared by Technical Committee CEN/TC 232 “Compressors, vacuum pumps and their systems”, the secretariat of which is held by SIS. This European Standard shall be given the status of a national standard, either by publication of an identical text o

28、r by endorsement, at the latest by May 2014, and conflicting national standards shall be withdrawn at the latest by May 2014. Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. CEN and/or CENELEC shall not be held responsible for ide

29、ntifying any or all such patent rights. This document has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association, and supports essential requirements of EU Directive(s). For relationship with EU Directive(s), see informative Annex ZA, which is a

30、n integral part of this document. EN 1012, Compressors and vacuum pumps, is composed of the following parts: Part 1: Air compressors; Part 2: Vacuum pumps; Part 3: Process compressors (the present document). The responsibility of CEN/TC 232 includes coordination of safety standards with CEN/TC 182,

31、Refrigerating systems, safety and environmental requirements, and CEN/TC 234, Gas infrastructure. According to the CEN-CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyp

32、rus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the Unite

33、d Kingdom. BS EN 1012-3:2013EN 1012-3:2013 (E) 6 Introduction This document is a type C standard as stated in EN ISO 12100. The machinery concerned and the extent to which hazards, hazardous situations and events are covered are indicated in the scope of this document. When provisions of this type C

34、 standard are different from those which are stated in type A and B standards, the provisions of this type C standard take precedence over the provisions of the other standards for machines that have been designed and built according to the provisions of this type C standard. When published in 1996,

35、 Part 1 of EN 1012 applied to all types of compressor. The standard is now divided into 3 parts with Part 1 addressing compressors for compressed air, nitrogen and inert gases and Part 3 addressing compressors for process gases. Part 2 continues to address vacuum pumps. Separating requirements for p

36、rocess gas compressors from those for compressors for air, nitrogen and other inert gases was considered a practical move so that the requirements for one type of compressor could be changed without affecting the complete standard. Where texts parts of EN 1012-3 are identical with EN 1012-1:2010, th

37、ese are identified and formatted in italics. If common requirements for functional safety would be applied to all process compressors, the variety in the application of process compressors may cause significantly different levels of residual risk. Therefore, in addition to the requirements of this s

38、tandard, the application of risk assessment may be required for safety related control systems in the case of particular applications to specify performance levels and/or safety integrity levels for related aspects of functional safety. Informative Annex C has been included to provide guidance on ri

39、sk assessment for related aspects of functional safety, including the determination of safety integrity levels and/or performance levels. The manufacturer of the compressor is responsible for carrying out such a risk assessment and applying appropriate preventive measures. These tasks are outside th

40、e scope of this standard. BS EN 1012-3:2013EN 1012-3:2013 (E) 7 1 Scope This European Standard is applicable to process gas compressors and process gas compressor units having an operating pressure greater than 0,5 bar (gauge), an input shaft power greater than 0,5 kW and designed to compress all ga

41、ses other than air, nitrogen or inert gases which are covered in Part 1. This document deals with all significant hazards, hazardous situations and events relevant to the design, installation, operation, maintenance, dismantling and disposal of process gas compressors and process gas compressor unit

42、s, when they are used as intended and under conditions of misuse which are reasonably foreseeable by the manufacturer (see Clause 4). This part of EN 1012 includes under the general term compressor units those machines which comprise: the compressor; a drive system including the prime mover; any com

43、ponent or device supplied which is necessary for operation. This part of EN 1012 is not applicable to compressors which are manufactured before the date of publication of this document by CEN. The requirements of this European Standard do not take into account the interaction between the compressor/

44、compressor unit and other processes carried out on site. Excluded are: refrigerant compressors used in refrigerating systems or heat pumps for which the safety requirements are given in EN 60335-2-34 or EN 12693; the specification of performance levels and/or safety integrity levels for safety relat

45、ed parts of control systems. Performance levels and/or safety integrity levels are an important aspect of compressor design and should be determined by the manufacturer and the user based on a risk assessment (see Introduction). This European Standard does not cover those safety aspects of road tran

46、sport dealt with by EC legislation for trailers. 2 Normative references The following documents, in whole or in part, are normatively referenced in this document and are indispensable for its application. For dated references, only the edition cited applies. For undated references, the latest editio

47、n of the referenced document (including any amendments) applies. EN 626-1:1994+A1:2008, Safety of machinery Reduction of risks to health from hazardous substances emitted by machinery Part 1: Principles and specifications for machinery manufacturers EN 764-7:2002, Pressure equipment Part 7: Safety s

48、ystems for unfired pressure equipment EN 837-2, Pressure gauges Part 2: Selection and installation recommendations for pressure gauges EN 953:1997+A1:2009, Safety of machinery Guards General requirements for the design and construction of fixed and movable guards BS EN 1012-3:2013EN 1012-3:2013 (E)

49、8 EN 1005-2, Safety of machinery Human physical performance Part 2: Manual handling of machinery and component parts of machinery EN 1005-3, Safety of machinery Human physical performance Part 3: Recommended force limits for machinery operation EN 1127-1, Explosive atmospheres Explosion prevention and protection Part 1: Basic concepts and methodology EN 12021, Respiratory protective devices Compressed air for breathing apparatus EN 12195-1, Load restraining on road vehicles Safety Part 1: Calculation of securing forces EN 13001