oSIST prEN 1012-3:2008

SLOVENSKI STANDARD
oSIST prEN 1012-3:2008
01-julij-2008
.RPSUHVRUMLLQYDNXXPVNHþUSDONH9DUQRVWQH]DKWHYHGHO3URFHVQL
NRPSUHVRUML
Compressors and vacuum pumps - Safety requirements - Part 3: Process compressors
Ta slovenski standard je istoveten z: prEN 1012-3
ICS:
23.140 .RPSUHVRUMLLQSQHYPDWLþQL Compressors and pneumatic
VWURML machines
23.160 Vakumska tehnologija Vacuum technology
oSIST prEN 1012-3:2008 en,fr
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

---------------------- Page: 1 ----------------------
EUROPEAN STANDARD
DRAFT
prEN 1012-3
NORME EUROPÉENNE
EUROPÄISCHE NORM
April 2008
ICS

English Version
Compressors and vacuum pumps - Safety requirements - Part 3:
Process compressors
This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee CEN/TC 232.
If this draft becomes a European Standard, CEN members are bound to comply with the CEN/CENELEC Internal Regulations which
stipulate the conditions for giving this European Standard the status of a national standard without any alteration.
This draft European Standard was established by CEN in three 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 Management Centre has the
same status as the official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland,
France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal,
Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.
Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are aware and to
provide supporting documentation.
Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without notice and
shall not be referred to as a European Standard.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre: rue de Stassart, 36  B-1050 Brussels
© 2008 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 1012-3:2008: E
worldwide for CEN national Members.

---------------------- Page: 2 ----------------------
prEN 1012-3:2008 (E)
Contents Page
Introduction .4
1 Scope.5
2 Normative references.5
3 Terms and definitions .7
3.1 General terms.7
3.2 Specific terms.8
4 Summary of safety requirements and measures .9
4.1 Hazard analysis and risk assessment .9
5 Safety requirements and measures.12
5.1 Electrical safety.12
5.1.1 Electrical installation.12
5.1.2 Eletrostatic phenomena.12
5.1.3 External influences on electrical equipment .12
5.2 Thermal safety.13
5.3 Materials and substances processed, used or exhausted.13
5.3.1 Gases and substances processed.13
5.3.2 Fire and explosion.17
5.4 Failure of energy supply, breaking down of machinery parts and other functional
disorders.18
5.4.1 General.18
5.4.2 Pneumatic and/or hydraulic control systems.19
5.4.3 Breaking down of machinery parts.19
5.5 Safety related measures and means.19
5.5.1 Safety systems to monitor and control the compressor.19
5.5.2 Guards.20
5.5.3 Pressure relief devices.20
5.5.4 Installation of pressure relief devices .21
5.5.5 Design specifications of pressure relief devices .21
5.5.6 Information and warning devices.21
5.5.7 Emergency stops.22
5.6 Noise.22
6 Markings, signs and written warnings.22
6.1 Data plate.22
6.1.1 General.22
6.1.2 Electrically driven.22
6.1.3 Portable and skid-mounted compressors.22
7 Information for use .23
7.1 General.23
7.2 Instruction Manual.23
7.2.1 Data plate information.23
7.2.2 Drawings, diagrams, instructions and information.23
7.2.3 Information affecting the application.24
7.2.4 Information relating to operation .24
7.2.5 Decommissioning.25
7.2.6 Noise.25
7.2.7 Training.25
7.2.8 Instructions for specific types of compressors .25
7.3 Maintenance instruction.26
2

---------------------- Page: 3 ----------------------
prEN 1012-3:2008 (E)
8 Verification.27
8.1 Pressure tests.27
8.1.1 General.27
8.1.2 Acetylene compressors.27
8.2 Leak tightness test for hazardous gases.27
8.3 Noise measurements.28
Annex A (informativ) Measure to ensure a safety function while testing a safety device (Example) .29
Annex ZA (informative) Relationship between this European Standard and the Essential
Requirements of EU Directive 2006/42/EC.30
Bibliography.31

3

---------------------- Page: 4 ----------------------
prEN 1012-3:2008 (E)
Foreword
This document (prEN 1012-3:2008) has been prepared by Technical Committee CEN/TC 232 “Compressors -
Safety”, the secretariat of which is held by SIS.
This document is currently submitted to the CEN Enquiry.
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 Manchinary Directive.
For relationship with EU Directive, see informative Annex ZA, which is an integral part of this document.
 Part 1: Air compressors
 Part 2: Vacuum pumps
 Part 3: Process compressors
Introduction
This document is a type C standard as stated in EN ISO 12100-1.
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 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 EN 1012-1 was published in 1996, it applied to all types of compressors. Aspects related to process
compressors are now moved into this part 3 of the EN 1012 series. It was considered a practical move so that
if there were provisions that were laid down for compressors covered by CEN/TC 12 or ISO/TC 67 then any
revision or amendments could be done to the process compressor part without affecting the provisions laid
down for air compressors covered by this part of EN 1012.
4

---------------------- Page: 5 ----------------------
prEN 1012-3:2008 (E)

1 Scope
This part of EN 1012 is applicable to compressors having an operating pressure greater than 0,5 bar and
designed to utilise all gases other than air, nitrogen or inert gases which are covered in part 1. The standard
lists the significant hazards associated with compressors and specifies safety requirements applicable to the
design, installation, operation, maintenance and dismantling of compressors during their foreseeable lifetime
and subsequent disposal.
This part of EN 1012 includes under the general term compressors, those machines which comprise;
 the compressor itself
 a prime mover
 any component or device supplied which is necessary for safe operation of the compressor.
In addition it applies to partly completed compressors having a compressor in combination with some of these
components as well as compressor assemblies operating in combination.
Excluded are refrigerant compressors used in refrigerating systems or heat pumps as defined in EN 378-1.
2 Normative references
The following referenced documents are indispensable for the application of this document. For dated
references, only the edition cited applies. For undated references, the latest edition of the referenced
document (including any amendments) applies.
EN 294 Safety of machinery; safety distances to prevent danger zones from being reached by the
upper limbs
EN 349  Safety of machinery; minimum gaps to avoid crushing of parts of the human body
EN 378-1 Refrigerating systems and heat pumps - Safety and environmental requirements - Part 1:
Basic requirements, definitions, classification and selection criteria
EN 614-1 Safety of machinery - Ergonomic design principles - Part 1: Terminology and general
principles
EN 626-1 Safety of machinery - Reduction of risks to health from hazardous substances emitted by
machinery - Part 1: Principles and specifications for machinery manufactures
EN 837-1 Pressure gauges - Part 1: Bourdon tube pressure gauges; dimensions, metrology,
requirements and testing
EN 953 Safety of machinery - Guards - General requirements for the design and construction of
fixed and movable guards
EN 1088 Safety of machinery - Interlocking devices associated with guards - Principles for design
and selection
EN 1127-1 Explosive atmospheres - Explosion prevention and protection - Part 1: Basic concepts and
methodology
5

---------------------- Page: 6 ----------------------
prEN 1012-3:2008 (E)
EN 13309 Construction machinery - Electromagnetic compatibility of machines with internal electrical
power supply
EN 13861 Safety of machinery - Guidance for the application of ergonomics standards in the design of
machinery
EN 60079 Electrical apparatus for explosive gas atmospheres – Part 0: General requirements
EN 60204-1 Safety of machinery - Electrical equipment of machines - Part 1: General requirements
EN 61000-6-2 Electromagnetic compatibility (EMC) - Part 6-2: Generic standards - Immunity for industrial
environments
EN 61000-6-4 Electromagnetic compatibility (EMC) - Part 6-4: Generic standards; Emission standard for
industrial environments
EN 61310-1 Safety of machinery - Indication, marking and actuation - Part 1: Requirements for visual,
auditory and tactile signals
EN 61310-2 Safety of machinery - Indication, marking and actuation - Part 2: Requirements for marking
EN ISO 2151 Acoustics - Noise test code for compressors and vacuum pumps - Engineering method
(grade 2)
EN ISO 4126-1 Safety devices for protection against excessive pressure - Part 1: Safety valves
EN ISO 11203 Acoustics - Noise emitted by machinery and equipment - Determination of emission sound
pressure levels at a work station and at other specified positions from the sound power level
EN ISO 12100-1 Safety of machinery - Basic concepts, general principles for design - Part 1: Basic
terminology, methodology
EN ISO 12100-2 Safety of machinery - Basic concepts, general principles for design - Part 2: Technical
EN ISO 13732-1 Ergonomics of the thermal environment - Methods for the assessment of human responses
to contact with surfaces - Part 1: Hot surfaces
EN ISO 13849-1 Safety of machinery - Safety-related parts of control systems - Part 1: General principles for
design principles
EN ISO 13850 Safety of machinery - Emergency stop - Principles for desi
EN ISO 14121-1 Safety of machinery - Principles for risk assessment
IEC 60417 Graphical symbols for use on equipment
ISO 3457 Earth-moving machinery - Guards - Definitions and requirements
ISO 3857-1 Compressors, pneumatic tools and machines; Vocabulary; Part I: General
ISO 3857-2 Compressors, pneumatic tools and machines; Vocabulary; Part II: Compressors
ISO 4126-1 Safety devices for protection against excessive pressure - Part 1: Safety valves
ISO 4871 Acoustics - Declaration and verification of noise emission values of machinery and
equipment
6

---------------------- Page: 7 ----------------------
prEN 1012-3:2008 (E)
ISO 15156-1 Petroleum and natural gas industries - Materials for use in H S-containing environments in
2
oil and gas production - Part 1: General principles for selection of cracking-resistant
materials
ISO 80416-2 Basic principles for graphical symbols for use on equipment - Part 2: Form and use of
arrows
ISO/TR 11688-1 Acoustics - Recommended practice for the design of low-noise machinery and equipment -
Part 1: Planning
ISO/TR 11688-2 Acoustics - Recommended practice for the design of low-noise machinery and equipment -
Part 2: Introduction to the physics of low-noise design
prEN 1012-1:2007 Compressors and vacuum pumps, safety requirements - Part 1: Compressors
3 Terms and definitions
For the purposes of this standard, the definitions given in EN ISO 12100-1 apply. Definitions specifically
needed for compressors are listed below and in the standards ISO 3857-1 and ISO 3857-2.
3.1 General terms
3.1.1
compressor
a device which compresses air, gases or vapours to a pressure higher than the inlet.
3.1.2
compressor unit
comprises the compressor, drive system and ancillary equipment integrated for a specific application.
3.1.3
hazard
a potential source of injury or damage to health.
3.1.4
inert gases
a chemically inactive gas which retains this characteristic even at elevated pressures.
3.1.5
pressure
pressure in this standard means effective (gauge) pressure unless otherwise stated.
NOTE. The unit bar for pressure is used. 1 bar = 100 kPa.
3.1.6
liquid shock
the excessive force resulting from an attempt to compress incompressible media.
3.1.7
maximum allowable working pressure
the maximum pressure for which the compressor(s) or compressor assembly is designed, as specified by the
manufacturer.
3.1.8
maximum allowable working temperature
the maximum operating temperature, as specified by the manufacturer.
7

---------------------- Page: 8 ----------------------
prEN 1012-3:2008 (E)
3.1.9
nominal discharge pressure
the pressure at the outlet of the compressor, as specified by the manufacturer.
3.1.10
normal operating conditions
is considered to be when the compressor is properly maintained and operated within admissible limits in
particular ambient temperature, as specified by the manufacturer compressing the specified media.
3.1.11
tripping
automatic stopping of a compressor to avoid a hazardous situation.
3.2 Specific terms
3.2.1
air compressor
a compressor intended for compression of air, nitrogen or inert gases
3.2.2
compressor assembly
an assembly of compressor unit(s) and ancillary equipment integrated for a specific application. The limits of
the assembly are as defined by the manufacturer.
3.2.3
oil-free air compressor
a compressor design in which the compressed air does not come in contact with oil
3.2.4
oil-lubricated air compressor
a compressor design in which the compressed air may come in contact with oil but excluding oil-flooded air
compressors
3.2.5
oil-flooded air compressor
a compressor design in which the compressed air and the oil are mixed.
3.2.6
high pressure compressor
a compressor for maximum allowable working pressures above 50 bar.
3.2.7
portable compressor
a compressor which is wheel mounted and can be towed
3.2.7.2
gross mass
is the maximum specified mass of the portable compressor including tools, equipment and fuel
3.2.8
skid-mounted compressor
a compressor which is mounted on skids and which can be towed short distances or transported.
3.2.9
water-injected compressor
a compressor design in which the compressed gas and the water are mixed.
8

---------------------- Page: 9 ----------------------
prEN 1012-3:2008 (E)
3.2.10
main energy supply
energy which forces the prime driver of the compressor to turn.
3.2.11
auxiliary energy supply
energy which forces auxiliary systems (e.g. oil systems, cooling system or valves) to operate.
3.2.12
control energy supply
energy supply for the control system (e.g. control voltage).
4 Summary of safety requirements and measures
4.1 Hazard analysis and risk assessment
To provide the suitable level of safety taking into consideration the design, guarding and the provision of
information the appropriate risk assessment procedure shall be adopted in accordance with the principles
identified in EN ISO 12100-1, EN ISO 12100-2 and EN ISO 14121-1.
Hazards listed in Table 1 are related to all compressors within the scope of this standard. Indication of the
type of verification adopted to establish that the identified hazard has been reduced to the lowest acceptable
risk is given in the Table 1.
The table shows the references to EN1012-1 which covers identical requirements and measures applicable
for process and air compressors.
9

---------------------- Page: 10 ----------------------
prEN 1012-3:2008 (E)
Table 1 – Hazard listing
Reference to clauses of
Safety Reference
this standard covering
Safety Visual Function
integration Measurement to other
requirement check check safety integration
principle standards
Design Guard Warn
Safety Ergonomics  7.2.3, EN 1012-1
integration
5.6
X X
7.2.4
EN 614-1
EN 13861
Safety system 5.5.2 5.5.1.1,. EN 1012-1
th
7.3 8
5.6
indent
6.2.2, 6.2.1
EN 953

EN ISO
13850
Controls
EN ISO
13849-1
IEC 60417
Emergency stop 5.5.7  EN ISO
X X 13850
EN 61310-1
Cutting, severing, 5.4.3 7.2.8.1 EN 1012-1
drawing in, b), c) 5.1.1
trapping,
6.2.1
entanglement,
x X x EN 294
friction and
EN 349
abrasion
EN 953
EN 1088
Mechanical
Ejection of parts 8.1  EN 1012-1
hazards
5.1.3
X X
5.1.3.1
Stability  7.2.7.1 EN 1012-1
d) 5.1.4.
X x
EN ISO
12100-2
Guards X X 5.5.2  EN 953
10

---------------------- Page: 11 ----------------------
prEN 1012-3:2008 (E)

Reference to clauses of
Reference
this standard covering
Safety Visual Function
Measurement to other
requirement check check safety integration

standards
Design Guard Warn
Fluid injection 8.1 7.2.7.1 EN 1012-1
X X
b), c) 5.1.2
Electrical safety 5.1.2 EN 1012-1
electrostatic
5.2.1.2
phenomena
X x
EN 60204-1
ISO 3457
External 5.1.3  EN 61000-6-
influences on 4
electrical

EN 61000-6-
equipment
2
EN 13309
Thermal safety 5.2 5.2 5.2 EN ISO
x x
13732-1
Noise  7.2.5 EN 1012-1
5.4
7.2.4
4163,
ISO/TR
Other
11688-1
hazards
 x
ISO/TR
11668-2
EN ISO
2151
EN ISO
11203
Gases and ? ? ? EN 1012-1
substances
 x
5.5.2
processed
7.2.4
Fire and 5.3.2 7.2.3 EN 1012-1
explosion  x 5.5.3.3
5.5.3.4
Biological and  EN 1012-1
microbiological X 5.5.4
substances
Energy supply x X 5.4 7.2.3
Errors of fitting  EN 1012-1
x X
5.7.3
EN 1012-1
5.7.2.1
Breaking down x X
5.4.3 7.2.8.1
5.7.2.2
5.7.2.3
Liquid shock  EN 1012-1
x X
5.5.1
11

---------------------- Page: 12 ----------------------
prEN 1012-3:2008 (E)
Pressure relief 5.5.3 5.5.3,
EN 1012-1
devices 5.5.4, 5.8.3.1
5.5.5
x X x
5.5.5
5.8.3.2
ISO 80416-2
Maintenance Slip, trip, fall  7.2.7.2 EN 1012-1
5.1.5
 x
EN ISO
12100-2
Indicators Warning device,  5.5.6, EN 1012-1
safety signs and 6.1
x X
tags 6.2
EN 837-1

5 Safety requirements and measures
5.1 Electrical safety
5.1.1 Electrical installation
The electrical installation of a compressor shall fulfil the requirements of EN 60204-1.
Protection devices and protection switches shall be so designed and connected as to fulfil the requirements of
‘fail-safe’. The over-current protection of the power circuit may be installed outside the compressor enclosure
on site. In such a case the Instruction Manual shall state that the user has to make provision for the
installation of the over-current protection of the power circuit. Where the compressor is not fitted with an
electrical disconnecting device, the Instruction Manual shall specify that this device is to be provided by the
user. Electrical and instrument cables shall:
 be adequately secured and protected,
 not be in contact with hot surfaces;
 have adequate electrical insulation.
5.1.2 Eletrostatic phenomena
The build-up of electrostatic charges shall be avoided by earthing all conductive stationary components.
E.g. in oil injected compressors the separator element shall be electrically bonded to the containing vessel.
5.1.3 External influences on electrical equipment
The safety system and other electrical equipment shall be so designed and constructed that they cannot give
rise to a hazardous situation in case of disturbances such as:
 short circuiting;
 external impacts;
 interruptions or variations in the supply voltage;
 electromagnetic fields (see EN 61000-6-2, EN 61000-6-4 and EN 13309);
12

---------------------- Page: 13 ----------------------
prEN 1012-3:2008 (E)
 earthing faults.
5.2 Thermal safety
Where high or low temperature of the processed medium, lubricant or cooling medium can cause a hazard to
personnel, the temperature shall be monitored and if the limits are exceeded the compressor shall be brought
to a safe condition.
Pipework or other parts with an external surface temperature above +70 C or below -10 C and which may be
accidentally touched by personnel during normal operation of the machine shall be guarded, insulated or carry
an adequate warning. (See EN ISO 13732-1). Other high temperature pipework shall be clearly marked in
accordance with annex C in EN 1012-1.
Any piping shall be free to move with changing temperature and hot piping shall not be in contact with wood or
flammable material.
0
If the starting of oil injected air compressors at ambient temps below 0 C is required then appropriate
measures shall be taken to ensure safe operation.
Compressors installed in an area with potentially explosive atmosphere must have limited surface
temperatures and any other ignition sources shall be avoided, see EN 60079 and EN 1127-1.
5.3 Materials and substances processed, used or exhausted
5.3.1 Gases and substances processed
5.3.1.1 General
Effects on the lubrication or on ingested liquid due to low temperature of the media being compressed or due
to low temperature of the environment during starting, stopping or unloading conditions shall be prevented by
suitable means.
For gases or vapours, especially those not treated in this standard, advice on hazards shall be sought from
competent bodies (see also Annex A) and the following precautions shall be taken.
a) Hazards caused by reactions of the gas inside the compressor shall be avoided as applicable by;
 limiting the compression temperature by design or by installing tripping devices on the discharge of each
casing or cylinder,
 preventing ignition hazard, e.g. hot surfaces or friction;
 choice of suitable lubricant and/or use of sparkless material pairing where friction is possible;
 using materials resistant to corrosion caused by the processed gas;
 arranging connections so that adequate purging of the compressor system with inert gas can be
achieved;
 using filters or other appropriate measures to avoid solid impurities in the processed gas;
 ensuring that the compressor installation undergoes a leak tightness test at commissioning.
b) If the requirements of clause a) cannot be fulfilled or are insufficient and there is a risk from
decomposition of the gas or of an explosion in the gas, the system shall be built to resist the resulting
pressure. If this is not possible, the Instruction Manual shall state that personnel shall not have access to
the danger zone.
13

---------------------- Page: 14 ----------------------
prEN 1012-3:2008 (E)
c) The gas dispersal into the environment shall be minimised by the following measures:
 preventing leakage of toxic, flammable or other harmful gases;
 providing double sealing with intermediate venting or with a sealing medium;
 using gaskets suitable for the gases processed at prevailing pressures and temperatures;
 neutralising, diluting to a safe level or venting into a safe area;
 taking
...