Concept engineering – safe and compliant hammer mill installation

Context:

A hammer mill reduces dry bulk products with rotating hammers that drive the product through a screen until the desired particle size is reached. A dust analysis of the product showed no explosion hazard, so ATEX measures did not apply to this part.

Approach (concept phase):

• Scope definition & layout of the hammer mill, feed/dosing, dust collection/extraction, discharge and E&I interfaces (access/maintenance provided).
• Risk assessment and safety philosophy focusing on mechanical risks: guarding of rotating parts, interlocked inspection hatches, emergency stop and LOTO accessibility; attention to noise and vibration.
• Conformity path mapped out against Machinery Directive 2006/42/EC, the Belgian Code on Well-being at Work, the AREI and relevant basic standards (EN ISO 12100, EN ISO 13849/IEC 62061).
• Functional requirements (FRS) with core interlocks (hood/cover monitoring, speed/bearing monitoring, overload), alarms and reset/restart philosophy; basic cause & effect and interlock/alarm lists.
• Documents for execution: concept PFD/P&ID, layouts, main IO list and specification(s) with material/performance specifications, test and acceptance criteria (FAT/SAT), plus cost estimate.

Deliverables:

• Concept note + safety philosophy.
• PFD/P&ID (concept) and layout sketches.
• FRS with interlock/alarm lists and basic cause & effect.
• Concept specification(s) and cost estimate.

Result:
A validated concept that covers the essential safety and compliance requirements and can be used directly for detailed engineering and tendering.