Complete EPD for an upper-tier Seveso site in phosphate chemistry

Context:
An upper-tier Seveso company active in phosphate chemistry wanted to update and expand its existing explosion protection documents (EPD). Given the complexity and the presence of various production units, a standard EPD was no longer sufficient. An overarching general EPD was needed, supplemented by specific EPDs for each installation.

Approach:
Prohead Engineering took on the full coordination and drafting of the EPD project, in close cooperation with the accredited inspection body, so that a complete and conclusive outcome could be guaranteed.

General EPD: this document brings together site-wide information, such as the inventory of hazardous substances, overview plans, organisational measures (training, PPE, procedures for contractors, hot work, MOC) and the coordination of responsibilities.

Specific EPDs: separate files were drawn up for each installation, detailing the process risks, ATEX zoning and technical measures. Each was linked to detailed studies such as HAZOP or ignition source analyses.

Installations that were zoned included:

• tank farms and unloading stations,
• silos and conveying systems for powders and granulates,
• mixing and reactor installations where solvents are used,
• pump pits and tank bunds,
• internal waste water and sewer systems (risk of vapour accumulation),
• the complete sulphur installation, including storage, dosing and processing.

Technical specifics:

• Integration of existing HAZOP studies and SWIFT analyses into the explosion risk assessment.
• Update of the zoning drawings with a detailed report, in accordance with NBN EN IEC 60079-10.
• Inclusion of measures for underground piping, dust separation and fire compartmentation.
• Review of maintenance and work permit procedures against ATEX requirements.
• Execution of a lightning risk assessment (according to IEC 62305) to evaluate the need for lightning protection systems.

Engineering services: in addition to the documentation, Prohead Engineering also provided substantive engineering support through technical notes:

• sizing of ventilation and extraction in critical zones,
• recommendations for material selection and electrical equipment,
• validation of emergency infrastructure and detection systems.

Result:
The result is a complete EPD package with which the site demonstrably meets the requirements of ATEX 153, the AREI and Belgian well-being at work legislation. Thanks to the combination of a general EPD, installation-specific EPDs, the lightning risk assessment and the close cooperation with the accredited inspection body, the operator has a practical and audit-ready file.

Added value:
By integrating both organisational measures and technical engineering advice, the EPD delivers not only compliance but also concrete guidance for safe design, operation and maintenance. The company can thus demonstrate with confidence that it controls its explosion risks – a crucial requirement for upper-tier Seveso sites in the chemical sector.