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    Chapter 6

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    alex_alexutzuu

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    Chapter six: Special electrical practice for oil, gas and chemical tankers Tanker Classification Hazardous Zones Electrical Ignition of Gas Apparatus Gas Groups ‘Temperature Class Types of Explosion Protection Ex‘d’ Flameproof Enclosure Ex‘i’ Intrinsic Safety Exte’ Increased Safety Ex‘n’ Non-Sparking Ex‘q’ Sand Filled Ex‘o’ Oil Immersed Ex‘p’ Pressurised Enclosure Ex‘s’ Special Protection Certification and Identification Electrical Testing in Hazardous Areas Maintenance of Ex-protected Apparatus Ships that transport bulk quantities of oi, ga5 and liquid chemicals are subject to special codes of practice regarding their electrical installations. Statutory authorities and classification societies generally base their tecommendations on Publication 92 of the International Electrotechnical Commission. The object of all such guidance isto prevent the hazards of fire and explosion occurring on board these tank ships Spaces in tankers where explosive gas-air mixtures may be expected to be present are called ‘dangerous’ or ‘hazardous’. All other areas being regarded as ‘safe’. The best way (0 avoid explosions caused by electrical equipment is simply not to install such equipment in the hazardous areas. However. special electrical equipment is permitted and this chapter will provide a guide to the range and maintenance of such explosion (Ex)-protected equipment. Tanker classification Shore practice for hazardous areas is to divide the areas into three zones (01,2) which recognises the degree of hazard by indicating the likelihood of an explosive gas-air mixture being present. This practice is not used on tankers. However, electtical equipment is manufactured on the basis of such zones - see tater section on z0nes On tankers, areas are designated as either ‘dangerous space’ or ‘normally-safe’ spaces. A dangerous space is defined as an area where Rammable gas-air mixtures would normafly b& expected to occur. The degree of hazard or danger presented by a dangerous space is determined, initially, by the nature of the flammable cargo of the tanker. On this basis, four types of tanker are recognised: TYPE A ~ Oil tankers intended for the catriage in bulk of non-boiling oi) cargoes having a flash point (closed test) of 60°C or less. These include crude oil carriers. gasoline carriers, etc TYPE B - Oil tankers intended for carriage in bulk of non-boiling oil cargoes having a flash Point (closed test} in excess of 60°C. These include tankers for carrying bituminous or asphaltic products, or for carrying diesel or fuel oils. 6! TYPE C- Gas carriers intended for the carriage in bulk of liquetied petsotewm 835 (LPG) or Yiquified natural gas (LNG), TYPE D - Tankers for the carsiage in bulk of other flammable liquid cargoes. This includes, those cargoes which are potentially more dangerous than those conveyed by TYPE. A and TYPE C tankers, and those products which exhibit chemical instability TYPE A TANKERS DANGEROUS SPACES Cargo tanks. Cofferdams adjoining cargo tanks. ‘Cargo pump rooms Enclosed or semi-enclosed spaces immediately above cargo tanks, or having bulkheads above and in line with the cargo tank bulkheads. s Enclosed os semi-enctosed spaces immediately above cargo pumprooms, or above vertical cofferdams adjoining cargo tanks, unless separated by a gastight deck and suitably mechanically ventilated. 6. Spaces. otter than cofferdams, adjoining and below the top of the cargo tanks, e.g trunks, passageways and holds. 7. reason open deck, or semi-enclosed spaces on open deck. within at least 3m of any cargo oil tank outlet or gas oF vapaut outlet 8. reason open deck over all cargo tanks, including all ballast tanks within the cargo tank block and to the full width of the vessel plus 3m forward and aft on open deck. up to a height of 2.4m above the deck 9. Compartments for cargo hoses. 10. Enclosed af sentivenclosed spaces having a direct opening into any oF the spaces or areas mentioned above. Electrical equipment and cables should anty be focates im dangerous spaces when It is absolutely necessary. Only intrinsically Safe (Exi) electrical equipment iy allowed inside cargo tanks. Electric motors are not permitted in cargo pump roaras. Flameptoof (Exd) of Pressurised (Exp) luminaires may be used in pumprooms. The switches and fuses for the tuminaises must be located in 4 normally safe space outside the pumproom. At least two independent circuits must be provided for the lighting. Uf maintenance is carried ‘out on the luminaires of one circuit this circuit must be de-energised while the other circuit provides sufficient light for the wark to be safely completed. QUESTION ‘Tanker pumprooms require two separate lighting circuits. How ean the circuits be arranged so that the luminaires can only be opened up when the cortect circuit has been isolated? ANSWER Many tankers use the following arrangement: The luminaires on one of the circuits have bolts With a different size oF type of head to thave on the Suminaires supplied by the other eircuit Typically, these would be two different types of triangular bolt head. The keys to remove the bolts ure actually the operating handles of the circuit isalators. A key can only be removed from its trapped position on the switch after the circuit has been isolated. ‘This key can only open up those luminaires connected to the cireuit which has been isolated. Cable runs are permitted through most dangerous spaces except cargo tanks, providing they ace contiauausly monitored for earth leakage Flameproof (Exd) or Pressurised (Exp) luminaires ace permitted in enclosed or semi-enclosed spaces immediately above a cargo tank. above a cargo pump room and in compartments for storing cargo hoses. The switches and fuses must be located in normally safe area and must switch hoth lines of the circuit (i.e, double pole switching), 62 TYPE B TANKERS Dangerous spaces are not defined for vessels of this type, but it is recommended that care be exercised so that potential sources of ignition are reduced as far as possible. Also, the following practices shoud be followed: 1 Use intcinsicalty safe (Exi) for any monitoring or instrumentation equipment which is in direct contact with oil in the cargo tanks or in the Oil circuits. 2. Cargo pump motors should be increased safety (Exe} type if they are located in the cargo pump room. 3. Allportable electrical equipment used in the cargo tanks mast be suitably explosion protected TYPE C TANKERS (Gas Carriers) DANGEROUS SPACES 1 A space in the cargo area which is not equipped with approved arrangements to censure that its atmosphere is at all times maintained in a safe condition 2 An enclosed space outside the cargo area through which any piping terminates, unless approved arrangements are installed to prevent any escape of product vapour into the atmosphere of that space 3 A cargo containment system with cargo piping 4) ahold space where cargo is carried in a cargo containment system requiring secondary barrier: (3) ahold space where cargo is carried in a cargo containment system not requiring a secondary barrier 4. Aspace separated from a hold space described ia (i) hy asingle gastightsteet boundary, 3. A cargo pump room and cargo compressor room. 6. Azone on open deck. or semi-enclosed space on open deck. within 3m of any cargo tank outlet, gas oF Vapour outlet. cargo piped Mange, cargo valve or of entrances und vemilation openings to a cargo pumproom and cargo compressor rooms. 7. The open deck over the cargo area and 3m forward and aft of the cargo area on open deck up to a height of 2.4m above the weather deck. 8. A zone within 2.4m of the outer surface of a cargo containment system where such surface is exposed to the weather 9. Aneenclosed or semi-enclosed space in which pipes containing products are located. 1). A vompartment for cargo hoses 11, Anenclosed or semi-enclosed space having a direct opening into any dangerous space oF arew The recommendations for the use of electrical equipment in dangerous spaces are the same {or this type of vessel as they are for TYPE A tankers, There are. however, two important ._ additional recommendations for gus carriers Cargo Pump Motors Submerged cargo pump motors and their cables are permitted in cargo tanks subject (0 the atmosphere of the tank being controlled to prevem presence of a gas-air mixture when the motors are energised Gas Compressor Motors - These motors are allowed. undet certain circumstances. tobe sited in the same space as the compressors, In these instances the motors are required to be pressurised (Exp) with air. inert gas or water ‘Alternatively. an increased safety motor within a flameproof enclosure may be used (Exe.d) TYPE D CHEMICAL CARRIERS The products catried in these vessels may produce explosive gas-air mixtures and can also be intensely corrosive. Jn cases like this electricat equipment must not only be explosive protected but also designed to withstand corrosion These products are categorised as follows ia arder ta give euidance on the electrical equipment which would he suitable TYPE OF CHEMICAL PRODUCT Products which have similar properties to those carried by vessel types A. B and C The recommendations given for those vessels would apply. Products which are considered to be more hazardous than those in 1 The extent of dangerous arcas is increased from 3m to 4.5m, Products which are susceptible to chemical instability which creates flammable eases. Special arrangements would be required for this type of product. Products which will damage any clectrical equipment with which they come inte contact, Materials and enclosures must resist the corrosive effect of these products Hazardous zones Hazardous areas are classified into *ZONES' which indicate the probability of an explosive gas-air mixture being present and, therefore, the likelihood of an explosion occurring. Zone 0 Zone 1 Zone 2 In which an explosive gas-air mixture is continuously present, or present for long periods. te which an explosive gas-air mixture is likely to occur in normal operation In which an explosive gas-air mixture is not likely t@ occur in normal operation and, if it occurs, will exist far anly a short time An area which is not classified Zone 0. 1 or2 is assumed 10 be a non-hazardous or ‘yale’ area, Examples of this zoning applied to ships could be: ZONE 0 Interior spaces of oil cargo tanks. pipes. pumps. ete. ZONE 1 Enclosed or semi-enclosed spaces on the deck of tanker, the boiler firing area on a yas carrier using methane boil-offas 3 fuel and battery rooms. ZONE 2 Open spaces on the deck of a tanker The cargo pump rooms of tankers are. at present. considered 2s falling somewhere between ZONE 0 and ZONE 1 Electeical ignition of gas Gases can be ignited by heat generated from various electrical sources when concentrated above the Lower Explosive Limit (LEL), e.g “i ay (iii) fv) wy (vi) (vii) Arcing between switch contacts ‘Accing between a live conductor and earth An internal arcing fault within an electrical enclosure ‘Overheating causing “hot spots Anelectrostatic spark discharge between charged bodies or between a charged body and earth Chemical action Lightning strikes. Apparatus gas groups The flammable gases in which explosion protected elecirieah equipment may have 1 operate are grouped according to the amount of electrical energy, in the form of an are, which is needed Gases associated with the mining industry a to ignite the gas. Jassed as GROUP 1. all other industrial gases are classed as GROUP II in tour sub-groups according to their ease of ignition. 6/4 ENCLOSURE GROUPS BS4683 PART 2 1971 [Group of Enclosare[Gas or Vapor — [__T__|Methane (Firedamp) [-——1a-—“Tamonia Industrial methane Blast furnace gas ‘Carbon monoxide Propane Butane Pentane |Hexane Heptane iso Octane Decane Benzene Xylene {Cyclohexane |Acetone Ethyl methyl ketone Methyl acetate Ethyl acetate n-Propyl acetate Butyl acetate Amyl acetate Chloroethylene IMethanut Ethanol iso Butanol n-Butanol Amyl alcohol Eshy) nitrite 118 Buta-T. 3 diene Ethylene Diethylether Ethylene oxide It should be noted that equipment certified for use in GROUP LIC may also be used for HA and IB Equipment certified for IB may be used for A. Equipment certified for HA may be used with no other group. ‘The gas grouping ean affect the design and construction of some types of explosion protected equipment (Exd and Ex). Temperature class This detines the maximum surtace temperature of the components in the electrical equipment under normal and fault conditions. This maximum surface temperature must not exceed the {as ignition temperature The Cemperature class is stated with reference 10 maximum ambient temperature of 40°C, should any other reference temperature be adopted, regulations require that this temperature be shown on the equipment Ueisimportant to note that the apparatus ges grouping and temperature class are not related For instance. hydrogen requires very little spark energy to ignite. but the surface temperature necessaey for igcition is verw high (SOFC). 6/5 ‘The following table relates the temperature class to the maximum surface temperature under fault conditions. “Temperature Class] Maximum surface temperature] T BUC 300°C 200°C | 35°C Jone 85°C For example, an electric motor may have @ maximum sprface temperature of 120°C and would be classed as T4. Temperature Classifications and Apparatus Groups for all Group II gases can be found in BS $345 Part I, 1976 Types of explosion protection There are a number of different constructional techniques employed in preventing electrical equipment causing explosions in hazardous areas. Some techniques, such as flameproof enclosures, have long been established but others, such as intrinsic safety and increased safety, are the result of more recem developments in clectronics and materials. {t has been internationally agreed that explosion protected equipment be identified by the symbol ‘Ex’ followed by a letter indicating the type of protection employed. ‘The following table Tists the types of protection and their symbols Type of Protection | Mlaméproof enclosure intrinsic safety incensed satery | ‘non-sparking { | powder fitea oil immersed pressurisation special protection ‘Some equipment may use more than one of these types of protection in its construction. {5 this case, the primary type of protection is quoted first, For example, un increased safety motor with a fameproof terminal box would be marked Exe.d. Ex'd’ Flameproof Enclosure ‘A flameproof enclosure is one which will withstand, without damage. an explosion of the flammable gas within itself, and will prevent transmission of the flame which could ignite the gas in the surrounding atmosphere FS EBa ae aN 9 NN RY 6/6 Ee Eee sero Flameproof enclosures are of heavy construction and access to them is by means of covers which fit onto wide, machined flanges, and are secured by a large number of bolts. ‘The pressure set up by the internal explosion is released through the small gap between the wide, machined flanges, and this cools the rush of gas sufficiently to prevent it from igniting any external flammable gas. ‘The width of flange and the maximum allowable gap depends on the type of gas present (gas roupins Standard lect! equipment can be used wih his eypeof enclosure screwed int {(ehown in heevy tin oth length ‘QUESTION A ship's battery locker is fitted with a flameproof luminaire marked Exd Ile T4. Is this luminaire certified for use in the battery room? ANSWER Yes - The hazard is hydrogen gas from the batteries which requires apparatus designed for use in apparatus gas group Ile. The ignition temperature of hydrogen is 560°C and the temperature classification ofthe fuminaire is T4. This means that it's surface temperature will not exceed 135°C. so the temperature classification is OK. Ex‘? intrinsic safety ‘These are circuits in which no spark nor any thermal effect produced under prescribed test conditions (which include normal operation and specified fault conditions) is capable of ‘causing ignition of a given explosive atmosphere. Generally. this means limiting the circuit conditionsto less than 30V and SOmA. Naturally. this restricts the use of Exi protection to low power instrumentation, alarm and communication circuits. The design of the circuit will depend on the type of gas present (gas grouping), In the UK two grades of Intrinsic Safety are recognised based on the safety factor of the

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