An ATEX overpressure protection device in biogas installations has an average lifespan of 5 to 8 years, depending on environmental conditions and maintenance quality. Biogas environments are challenging due to corrosive gases such as hydrogen sulphide (H2S), humidity and temperature fluctuations. These factors can significantly affect the lifespan, making regular inspection and preventive maintenance crucial for reliable explosion safety and optimal performance.
What is an ATEX overpressure protection device and why is it crucial in biogas installations?
An ATEX overpressure protection device is a safety system that automatically releases excess pressure to prevent explosions in potentially explosive atmospheres. In biogas installations, this system protects against dangerous pressure build-up caused by uncontrolled gas production or system malfunctions.
Biogas installations produce methane and other combustible gases that can be explosive under unfavourable pressure-temperature conditions. ATEX certification guarantees that overpressure protection devices comply with European safety standards for explosive environments. These systems detect pressure increases and open automatically to safely release gas.
The crucial role of overpressure protection in biogas environments stems from the unique risks. Biogas contains not only methane, but also corrosive components such as H2S and CO2. This combination requires specialised safety systems that are resistant to chemical attack whilst providing reliable protection against explosion risks.
How many years does an ATEX overpressure protection device last on average in biogas environments?
In biogas applications, the average lifespan of an ATEX overpressure protection device is 5 to 8 years. This is shorter than in standard industrial environments, where these systems last 8 to 12 years. The aggressive biogas environment shortens the lifespan through chemical corrosion and mechanical stress.
The lifespan is mainly determined by material resistance to H2S corrosion. Hydrogen sulphide in biogas attacks metal components, causing seals and mechanical parts to wear faster. Temperature fluctuations between day and night cause expansion and contraction, which increases mechanical stress.
Comparison with other industrial environments shows that biogas installations present additional challenges. Petrochemical installations experience similar lifespans due to aggressive media, whilst the food industry and pharmaceutical applications typically achieve longer lifespans due to milder environmental conditions.
Which factors shorten the lifespan of overpressure protection devices in biogas installations?
H2S corrosion is the main factor that shortens the lifespan. Hydrogen sulphide forms sulphuric acid upon contact with moisture, which attacks metal components and degrades rubber seals. This chemical attack weakens critical components and reduces the reliability of the safety system.
Humidity significantly intensifies corrosion processes. Biogas contains water vapour that condenses during temperature changes, creating permanent moisture presence. This combination of moisture and corrosive gases creates ideal conditions for material degradation.
Mechanical factors also play an important role:
- Temperature fluctuations cause thermal stresses in components
- Pressure fluctuations due to variable gas production stress moving parts
- Contamination by organic compounds can block valves and springs
- Vibrations from nearby equipment can loosen fastenings and connections
How can you maximally extend the lifespan of your ATEX overpressure protection device?
Regular inspection and preventive maintenance significantly extend the lifespan. Schedule monthly visual checks for corrosion, leakage and mechanical damage. Perform quarterly functional tests to verify the correct operating pressure and response time.
Material choice is essential for longer lifespan. Choose overpressure protection devices with stainless steel components (minimum 316L) for better corrosion resistance. PTFE and Viton seals perform better than standard rubber in aggressive biogas environments.
Best practices for biogas installations include:
- Install gas cleaning upstream to reduce H2S concentrations
- Ensure adequate ventilation around overpressure protection devices
- Protect systems against direct weather influences
- Keep spare parts in stock for critical components
- Document all maintenance work and test results
When should you replace an ATEX overpressure protection device in biogas systems?
Replace an ATEX overpressure protection device when functional tests show deviations in operating pressure or response time. Visual signs such as corrosion, cracks in the housing or leakage at seals are direct indicators for replacement. Do not wait until complete failure occurs.
Recognising wear indicators requires systematic inspection. Look for discolouration of metal surfaces, white deposits (corrosion products) and hardened or cracked seals. Mechanical problems such as sluggish operating behaviour or irregular sounds indicate internal wear.
Test procedures for safety systems must maintain strict safety criteria:
- The operating pressure may not deviate more than 5% from the specification
- The response time must remain within factory limits
- The reclosing behaviour must be consistent and complete
- No visible leakage may occur after activation
Plan proactive replacement after 6 to 7 years of use to prevent unexpected failure. This prevents production interruptions and ensures the continuous safety of your biogas installation.
How Presscon helps with ATEX overpressure protection in biogas installations
We offer specialised expertise in ATEX overpressure protection for biogas applications, based on more than 25 years of experience with industrial safety in challenging environments. Our approach combines in-depth technical knowledge with practical experience in biogas projects.
Our services for biogas installations include:
- Selection of corrosion-resistant overpressure protection devices for biogas environments
- Custom engineering for complex safety systems
- Preventive maintenance contracts with specialised biogas expertise
- 24/7 breakdown service for critical safety systems
- Training of your personnel in maintenance and inspection
Our quality guarantees ensure reliable performance in aggressive biogas environments. We maintain strict material specifications and test all systems under realistic conditions before they are installed. For specific applications, we also offer ATEX vacuum overpressure protection that is suitable for underpressure situations.
Contact us for a consultation about optimal overpressure protection for your biogas installation. Our experts help you make the right choices for long-term safety and reliability.
Frequently Asked Questions
How can I check myself whether my ATEX overpressure protection device is still functioning properly?
Perform a monthly visual inspection for corrosion, leakage and mechanical damage. Test the operating pressure quarterly with a calibration kit and check that the system remains within 5% of the specification. Also watch for unusual sounds, sluggish operating behaviour or discolouration of components.
What are the costs of replacing versus repairing an ATEX overpressure protection device?
Repair typically costs 30-50% of the new price, but in biogas environments complete replacement is often more economical after 6-7 years of use. Repair of corrosion damage usually offers only a temporary solution, whilst new systems guarantee long-term reliability and comply with the latest safety standards.
Can I use a standard overpressure protection device instead of an ATEX-certified one?
No, this is not permitted and very dangerous. Biogas installations fall under ATEX regulations due to explosion risks. Standard protection devices are not designed for explosive atmospheres and can cause sparks. Always use ATEX Zone 1 or Zone 2 certified systems.
Which materials are most suitable for long lifespan in biogas environments?
Stainless steel 316L or higher (such as Hastelloy C-276) offers optimal corrosion resistance against H2S. For seals, PTFE and Viton are superior to standard rubber. Avoid carbon steel and aluminium due to rapid H2S corrosion.
How often should I have the operating pressure of my overpressure protection device calibrated?
Schedule annual calibration by a certified technician, with additional checks after each system activation. In aggressive biogas environments, we recommend six-monthly calibration to detect early deviations before safety problems arise.
What should I do if my overpressure protection device activates unexpectedly?
Stop all activities immediately, ventilate the area and check for gas leaks. Investigate the cause of pressure build-up (such as blocked pipelines or defective control) before resetting the system. Always have the system inspected after activation to rule out damage.
Are there warning signals before an overpressure protection device fails completely?
Yes, early signals are deviating operating pressure during tests, slower response time, visible corrosion or discolouration, and hardened seals. More frequent minor activations can also indicate wear. Monitor these signals systematically to be able to replace proactively.