CSE ExProtection+
Integrated Explosion Protection with CSE Expertise
Complete ExProtection at all times. More services if needed.
Explosion protection is not a standalone regulatory requirement. Legally compliant explosion protection results from an Explosion Risk Assessment (ERA ) in accordance with Directive 1999/92/EC, ideally supported by a technical risk analysis such as HAZOP, LOPA, QRA, or other methods.
This is exactly where CSE ExProtection+ comes in: Drawing on our expertise from hundreds of GBUs and risk analyses, we serve as your partner in the assessment process and guide you through the entire process to create a legally compliant explosion protection document that stands the test of time. Discover your Plus !
Here’s what you can expect:
Outstanding performance in explosion protection—exactly to the extent you need, safely and cost-effectively.
High availability when needed; pragmatic, solution-oriented implementation throughout the project.
Scalable services ranging from document review prior to an audit to the implementation of tertiary measures.
CSE specialists with proven qualifications in explosion protection for various industries.
Substances | Facilities and Processes | Focus Topics
Gases
Typical Substances:
- e.g., hydrogen, methane, propane, acetylene
Facilities and Processes:
- Gas Supply
- Compressors | Pressure Regulation Systems
- Gas Storage
- Refrigeration Systems | Heat Pumps
- Gas Production | Filling
- Biogas | Power-to-Gas
Focus Topics:
- Release | Dispersal
- Ventilation | Gas Detection Technology
- Inerting | Depressurization
- Zone allocation
Fluids & Vapors
Typical Substances:
- e.g., gasoline, ethanol, methanol, isopropanol, acetone, toluen
Facilities and Processes:
- Oil Terminals
- Filling Systems
- Mixing and Dosing Systems
- Solvents | Cleaning Processes
- Pumps
Focus Topics:
- Substance Release | Evaporation
- Filling, Emptying, Tank Venting
- Ventilation | Inerting
Dust particles
Typical Substances
- e.g., flour, sugar, wood dust, aluminum, magnesium, coal
Facilities and Processes:
- Silos | Bunkers
- Filters | Dust Collection Systems
- Mills
- Conveyor Systems
- Mixers
- Filling | Packaging Systems
Focus Topics:
- Dust clouds | Deposits
- Aspiration
- Electrostatics
- Pressure relief | -decoupling
Special Cases
Typical Substances:
- e.g., fog, aerosols, hybrid mixtures
Facilities and Processes:
- Combined Gas and Dust Processes
- Spraying and Coating Processes
- High-Pressure Systems
- Mixing Processes
Focus Topics:
- Droplet Size | Atomization
- Safety Parameters of Hybrid Mixtures
- Complex Mixture Compositions
CSE ExProtection
Hazard Assessment in Accordance with the GefStoffV
Assess hazards posed by flammable gases, vapors, mists, or dusts—with CSE experts by your side. As the basis for the explosion protection plan, the following topics are systematically addressed in a structured workshop:
- Where and under what operating conditions can explosive mixtures occur?
- What potential ignition sources are present, and could they become active?
- What impact would an explosion have on employees, facilities, and surrounding areas?
Step by step, we identify the specific actions you need to take to ensure explosion protection for your facility.
Explosion Protection Concept
There is no explosion protection without a robust concept: as safe as necessary, and as practical and cost-effective as possible. A clear order of priority applies: avoid hazardous explosive mixtures as much as possible, prevent effective ignition sources, and reliably limit the effects of a potential explosion. A protection concept consisting of primary, secondary, and tertiary explosion protection measures is developed specifically for your facility.
Explosion Protection Document
Documenting risk assessments and explosion protection plans—clear, compliant with regulations, and verifiable. We prepare your explosion protection document in accordance with Section 6(9) of the GefStoffV and meet all applicable legal requirements—from the systematic identification of explosion hazards, through appropriate explosion protection measures, to the specification of inspections in accordance with the BetrSichV. The result is a robust document that ensures your explosion protection and fulfills your operator obligations.
Zone Classification & Zone Map
Where can potentially explosive atmospheres occur, and into which zones must these areas be classified? As part of the development of the explosion protection plan, we handle the proper classification of Zones 0, 1, and 2 for gases, vapors, and mists, as well as Zones 20, 21, and 22 for combustible dusts. The result is a practical zoning plan that not only defines the spatial boundaries of the zones but also serves as the basis for the requirements governing the selection of ATEX-compliant equipment in potentially explosive atmospheres.
Audit and Review Support
The next audit is coming up—and you’re fully prepared! From updating your documents and addressing any identified deficiencies to communicating with auditing organizations, we’ll guide you through upcoming audits and help you meet your operator obligations.
Ignition Source Assessment for End-of-Life Equipment
“Never change a running system”: Proven technology can continue to be used, provided that the safe operation of existing legacy equipment in your facility can be plausibly demonstrated. We assist you with the systematic assessment of ignition sources in legacy equipment and define measures to ensure safe operation. This provides you, as the operator, with a sound basis for decision-making regarding continued, safe operation.
Training & Coaching
CSE Academy
With the CSE Academy’s Applied Safety Premium Seminar on Explosion Protection and Electrostatics, you can ensure that your employees gain a thorough understanding of the methodology and its practical application. Also available as in-house training.
Plus Services
Process Risk Analyses
Process risk analysis and hazard assessment in explosion protection are two closely interrelated topics in safety engineering. Scenarios described in the process risk analysis can, for example, be incorporated into the hazard assessment and addressed as part of the explosion protection plan. A systematic evaluation based on established methods leads to a thorough assessment and mitigation of explosion risks.
Measurement and Control Equipment in Accordance with TRGS 725
When measurement, control, or regulation devices are used as part of an explosion protection measure, their required reliability must be systematically defined and verified. But what level of availability does the defined safety function require? What failure rates are permissible for the prevention of hazardous explosive atmospheres or effective ignition sources by measurement, control, and regulation devices as part of risk mitigation? We define your explosion-proof equipment in accordance with TRGS 725 and establish the necessary requirements. Where appropriate, we also take into account proven methods of functional safety in accordance with DIN EN 61508 and DIN EN 61511.
Dispersion Calculation
In the event of leaks, venting operations, or defined releases of flammable substances, the potentially explosive atmosphere must also be defined spatially. But how large is this area? We answer this question using well-founded dispersion calculations in accordance with the state of the art. The results lead to a clear and transparent definition of potentially explosive areas and complement your zone classification and the zone plan to be prepared.
Safety technical characteristics
Safety parameters form the basis of every explosion protection assessment. Only when the properties of the substances used are known can hazards be realistically assessed and effective protective measures determined. We assist you in determining, evaluating, and verifying the plausibility of safety parameters for flammable gases, vapors, mists, and dusts.
Sizing of Technical Measures
Explosion protection does not end with the development of a protection concept. The defined measures must be tailored to the actual process, properly dimensioned, and coordinated with adjacent plant components. We support you in the calculation of explosion pressure relief systems, ventilation systems, inerting systems, and explosion-protection-related monitoring and shutdown functions.
Laws, Standards, Guidelines
Standards
- Richtlinie 1999/92/EG – ATEX-Betriebsrichtlinie
- Richtlinie 2014/34/EU – ATEX-Produktrichtlinie
- Gefahrstoffverordnung – GefStoffV
- Betriebssicherheitsverordnung – BetrSichV
- Arbeitsschutzgesetz – ArbSchG
- TRGS 720 – 727
- DIN EN IEC 60079
- DIN EN 1127-1 – Explosionsfähige Atmosphären: Explosionsschutz, Grundlagen und Methodik
- DIN EN ISO 80079-36: Nicht-elektrische Geräte für den Einsatz in explosionsfähigen Atmosphären – Grundlagen und Anforderungen
- DIN EN ISO 80079-37
- DIN EN 14491 – Schutzsysteme zur Druckentlastung von Staubexplosionen
- DIN EN 14994 – Schutzsysteme zur Druckentlastung von Gasexplosionen
- DIN EN 61508
- DIN EN 61511
- VDI/VDE 2180
- DGUV Regel 113-001 – Explosionsschutz-Regeln, EX-RL
- DGUV Information 213-106 – Explosionsschutzdokument
Let’s get to know each other.
Book an appointment of your choice:
M.Sc.
Marvin Schwanitz
Head of Explosion Protection
Process Safety Engineer
mail Send an e-mail
phone +49 721 6699 4709
An Overview of the Project Workflow
Required Documents:
The following information and documents are typically required when addressing explosion protection issues:
- Process Description
- R&I-R&ID flowcharts or PDF drawings
- Safety Data Sheets for the Substances Handled
- Operating Conditions | Design Conditions
Optional:
- Process Risk Analysis (e.g., HAZOP)
- Existing explosion protection document or zone plan
- Experimental studies on reaction enthalpy (see also reaction calorimetry) or on the flammability or explosive behavior of substances
- Site conditions for the facility (e.g., the facility’s surroundings and neighboring buildings)
For urgent cases, our Priority Service offers expedited processing of your project. Once you place an order, we begin analyzing your documents and project parameters that very same day. Within 24 hours, you’ll receive an initial assessment from us regarding the scope of the project, any gaps in the documentation, the projected timeline, and the required resources.
Based on this, we will coordinate the next steps with you and, depending on the scope of the project, carry it out in such a way that it can be completed within the same week, if desired.
Note: The “CSE ExSchutz Plus” video animation was developed by CSE-Engineering using Claude AI
Image source for “Anklam Sugar Factory”: Suiker Unie GmbH, Public domain, via Wikimedia Commons,
Image source ”Oil mist”: AI Chat GPT
