Product category:
Machine Safety Components
News Release from: Exide Technologies | Subject: ATEX-approved batteries
Edited by the Engineeringtalk Editorial
Team on 20 May 2004
Safely operating electric vehicles in
ATEX areas
ATEX-approved batteries can be the key to operating electric vehicles in explosive atmospheres.
Since July 2003 it has been mandatory for all new pieces of electrical equipment, mechanical equipment and protective systems that are to be used in potentially explosive atmospheres (flammable gases, vapours, or dust) to comply with ATEX Directive 94/9/EC Products that do not comply with these essential health and safety requirements should not have the CE mark applied
This article was originally published on Engineeringtalk on 11 Dec 2003 at 8.00am (UK)
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ATEX is a European Directive developed in part by the International Electrotechnical Commission (IEC).
It has its roots in the mining industry, but standards have been constantly evolving and spreading to other areas - notably oil, chemicals and pharmaceuticals - and becoming BS and latterly European (EN) standards.
Such concerns have been brought increasingly under the spotlight by recent world events.
Government organisations are justifiably concerned about the risk posed by explosions, particularly on the general population, as the distances between industrial and residential areas get ever smaller.
Many industries may now come under the jurisdiction of ATEX, including food processing, manufacturing and warehousing.
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Chloride Motive Power has launched two new ranges of single-phase battery chargers for small electric vehicles such as cleaning machines and pallet trucks.
Lead acid gel battery powers novel "milk float"
CMP Batteries of Bolton has provided the battery for the Electric Mercury prototype Specialist Delivery Vehicle (SDV).
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Batteries fall within the scope of the directive and Chloride Motive Power is one of the few UK traction battery manufacturers to be ATEX certified (by SIRA) constructing 160mm BS cells and 200mm DIN cells to the increased safety level ('e').
In addition to the products themselves, CMP's manufacturing plant and processes are also assessed and certified by SIRA Services.
Batteries are unique amongst the products covered by the ATEX directive in that they need to 'breathe'.
A battery generates its own gases that are potentially explosive.
Standards are set for different hazardous zones: Zone 1 carries the most potential danger in that a hazardous atmosphere will exist at some time.
The concentration of gases generated by a battery is largely governed by the shape, design and ventilation of the battery.
Compliance has historically been achieved by increasing the amount of headspace between the cells and the battery lid.
Unfortunately, this has resulted in batteries with smaller cells and, therefore, capacity.
CMP has been compliant with ATEX standards years before the mandatory requirements and have therefore been able to keep ahead of most rivals by being able to offer Zone 1 and Zone 2 EExe ATEX standard traction batteries with the same capacity as their non-ATEX compliant counterparts.
This has largely been achieved by the design of the batteries and the passage/ventilation of air which prevents the build-up of hydrogen.
They also incorporate insulated linings within the battery box partitions to restrict leakage to earth in the event of damage.
CMP can therefore ensure that electric vehicles operating in ATEX areas are operational for as long as those in non-ATEX areas.
ATEX certified batteries have been tested for shock, against vibration and materials must resist ignition.
As well as different groups of gases/vapours, there are also temperature (T) groups.
The surface temperature of products is rated T6 being the most difficult to achieve at 85C.
This means that they are able to operate in an area where a temperature of just 85C would cause the gases, vapours or dust to ignite.
Most products however have a T1 or T2 rating (450C and 300C respectively).
CMP manufacture products that achieve a T6 rating.
The impact for users of electric vehicles in a T6 rated area is that unless every component on the vehicle is T6 rated, the vehicle cannot operate in that area.
A vehicle that has just one component that is only rated to T1 means that the whole vehicle is restricted to T1 areas reducing its operational effectiveness.
Employers have a number of obligations under directive 1999/92/EC including risk assessment, display of 'Ex' signage and explosion protection policies including the provision of appropriate clothing for staff.
All replacement parts need to be ATEX compliant, so that companies can no longer order like-for-like replacement products.
Companies like CMP are working with notified certification bodies such as SIRA and the Field Operations Division of the Health and Safety Executive to ensure that companies fulfil their obligations and to find practical solutions to logistical and operational problems that might otherwise hinder production processes.
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