Intrinsicsafety 140410014135 Phpapp02

Intrinsic
Safety
& Hazardous
Areas
by
Steve Mackay
1
www.idc-online.com/slideshare TechnologyTraining
Technology Trainingthat
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EIT Micro-Course Series
• Every two weeks we present a 35 to 45
minute interactive course
• Practical, useful with Q & A throughout
• PID loop Tuning / Arc Flash Protection,

Functional Safety, Troubleshooting
conveyors presented so far
• Upcoming:
– Electrical Troubleshooting and much,
much more…..
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Overall Presentation
The focus of this session is the building blocks

of electrical engineering, the fundamentals of
electrical design and integrating electrical
engineering know-how into the other disciplines
within an organisation.
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Objectives
The identification of:
♦ Terminology
♦ Fundamentals of Ex i Protection
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Ex Protection Definition
Explosion Protection:
The measures applied in the construction of

electrical apparatus to prevent ignition of
surrounding explosive atmosphere by such
apparatus.
Need to understand: ‘ignition’
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Inspectorate
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The Fire Triangle
O2
27.2
Air
Fuel
!
with
21% Oxygen Sufficient Vapour
Bang
Source
Sourceof
ofIgnition
Ignition
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Electricity as a Source of Ignition
Electrical Sources
Sparks
Sparks Heat
Heat
Sources
Sourcesof
of Ignition
Ignition
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Ignition Spark Ignition Characteristic
Energy
(milliJoules) Propane-air (1 atmos.)
1.0 Ethylene-air
(1 atmos.)
Hydrogen-air
(1 atmos.)
0.1
Minimum Ignition
Energy (MIE)
Flammable Range
0.01
0 10 20 30 40 50 60 70 80 90 100
Volume
(LEL) (UEL)
Lower Explosive Limit concentration (%) Upper Explosive Limit
Most-easily ignitable mixture

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Explosive limits for materials
Gas/air mixtures are ignitable over a range of concentrations called the
“Flammable Range”
Material Lower Explosive Limit Upper Explosive Limit Minimum
LEL UEL ignition
energy*
Propane 2 % 9.5 % 180µJ
Ethylene 2.7 % 34 % 60µJ
Hydrogen 4 % 76 % 20µJ
* of most easily ignitable mixture (Note: MESG assessed for Ex d)
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Ignition Temperature Definition
Ignition Temperature
The lowest temperature of a flammable gas or vapour at
which ignition occurs.
Sometimes referred to as:
Auto-ignition temperature
Or
Spontaneous ignition temperature
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Flashpoint Definition
Flashpoint
The temperature at which the free surface of a liquid
emits sufficient vapour to be ignited by a small flame
Kerosene:
Flashpoint = 38°C; Ignition Temp. = 210°C)
Only liquids have flashpoints
Operation below Flashpoint constitutes no actual hazard
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Personnel Hazards
For Hydrogen Sulphide, H2S:
a very common danger when dealing with oil products
Volume
Property
Concentration
Smell detection level 0.1 ppm
Safe working level 10
Serious health danger level 50
Lower Flammable Limit 40,000 (4%)
Upper Flammable Limit 460,000 (46%)
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Area Classification
Nature of the Hazard
Locations of hazard
Probability of presence
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Requirement for plant classification
Plant and Installations
are classified according to:-
The nature of the Hazardous Atmosphere

- Gas Classification
- Ignition Temperature
The probability that the Hazardous Atmosphere

will be present
- Area Classification
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Requirement for equipment classification
Equipment
is classified according to:-
The maximum spark energy it can produce

- Apparatus Group
Its maximum surface temperature
- Temperature Classification
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Gas classification: the two main systems
Gas classification
Representative Ignitability
(Test) gas IEC countries
(including Europe) USA & Canada
Acetylene Group IIC Class I, Group A

Hydrogen Group IIC Class I, Group B
Ethylene Group IIB Class I, Group C
Propane Group IIA Class I, Group D
Methane Group I (No classification)

(Mining)
Metal dust Class II, Group E
Carbon dust Class II, Group F More
Flour, starch, (IEC 1241) Class II, Group G easily
Grain ignited
Fibres & Flyings (No classification) Class III
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Temperature classification (IEC/European)
Maximum
Temperature surface
classification temperature
450°C T1
300°C T2 Tamb = 40oC
200°C T3 unless otherwise
stated
135°C T4
Operation above
100°C T5 stated Tamb may
de-rate T Class
85°C T6
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Temperature classification in North America
T class °C
T1 450
T2 300
T2A 280
T2B 260 Apparatus is marked with either T rating
T2C 230 or maximum surface temperature
T2D 215
T3 200
User has responsibility to ensure that the
T3A 180 T-rating is below the Spontaneous
T3B 165 Ignition Temperature ( SIT )
T3C 160
T4 135
T4A 120
T5 100
T6 85
Tamb = 40oC
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Gas/Apparatus compatibility
Ammonia 630
Methane 595 600
Hydrogen 560
500
Propane 470
Gas Ignition Ethylene 425 T1
Apparatus
400
Butane 365 Temperature
Temperature Classification
300 T2
Cyclohexane 259
200 T3
Diethyl Ether 170
T4
Carbon Disulphide 105 100 T5
T6
T4 for apparatus is usually OK o
C
Exception: TAMB=40oC
Carbon Disulphide, requiring T5
Don't confuse T Class with maximum operating temperature!
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Properties of Gases
Compound Vapour LFL UFL Ignition T Apparatus
Density Temp °C Class Group
Acetone 2.00 2.0 13 535 T1 IIA

Ammonia 0.59 15 28 630 T1 IIA
Butane 2.05 1.5 8.5 365 T2 IIA
Carbon Disulphide 2.64 1.0 60 100 T5 IIC
Cyclohexane 2.90 1.2 7.8 259 T3 IIA
Diethyl Ether 2.55 1.7 36 170 T4 IIB
Ethylene 0.97 2.7 34 425 T2 IIB
Hydrogen 0.07 4.0 75.6 560 T1 IIC
Kerosene 0.7 5 210 T3 IIA
Methane 0.55 5.0 15 595 T1 I / IIA
Propane 1.56 2.0 9.5 470 T1 IIA
Extract from IEC79-18
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Area classification in IEC/European countries
Areas classification:
The probability of a potentially explosive atmosphere being present
and
The length of time for which it is likely to exist
Zone 0: in which an explosive gas-air mixture is continuously
present or present for long periods
Zone 1: in which an explosive gas-air mixture is likely to occur in

normal operation
Zone 2: in which an explosive gas-air mixture is not likely occur

in normal operation, and if it occurs it will exist only
for a short time
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Area classification in North America
Zone 0:
Zone 1: Division 1
Hazardous atmosphere is likely to be present in normal operation
Zone 2: Division 2
Hazardous atmosphere is unlikely to be present in normal operation
Div.1 Zone 0 sometimes specified
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Area Classification Example
Tank vents Key
Area Classification Zone 0
for a fixed-roof tank
with Zone 1
heavier than air Liquid surface
vapour Zone 2
Bund wall
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Typical Area Classification Plan Drawing
IIB T3 Hazard 4 Flow Valves
Zone 2 Radius Zone 1: in pipe B
4.5 metres trench 1.75 o
T4 metres wide
across CL u
d
T1-4
Zone 2: 3 metres a
Tanks
T1 across CL r
y
Zone 1 Radius
to bund wall F
2.5 metres
e
n
c
T2 T3 e
N
Name and Location of Company
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Thermocouple in a hazardous are
Outside of pipe
Zone 2 Zone 1 Zone 0
Inside of pipe or
process vessel
Division 1
Division 2
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Why Area Classify?
Probability of Probability of
Gas/Air Mixture
being present X Source of
Ignition = Acceptable
Risk
Matched to
Type of Nothing is
Zone 0,1,2 Protection 100% Safe
d, i, q, o,
p, m, e, n, s
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Methods of Explosion Protection
E Technique: IEC Description: Zone: Application:
x 79-
p Separation (Gas) 2 Pressurisation 1,2 Control rooms, analysers
o (Liquid) 6 Oil-filling 2 Transformers switchgear
q (Semi-solid) 5 Quartz/Sand 2 Instrumentation
m (Solid) 18 Encapsulation 1,2 Instrumentation, control gear
n Construction 15 Non-incendive 2 Transformers, switchgear
e Construction 7 Increased Safety 1,2 Motors, lighting, boxes (Draft)
d Containment 1 Flameproof 1,2 Switchgear, motors, pumps
i Electrical design 11 Intrinsic Safety 0,1,2 Instrumentation, control gear
s Special Special 0,1,2 Gas detection
0 General
Requirements
Ex s Not adopted
Zones are ‘permitted Zone of use’
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Intrinsic Safety
Ex i
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Definition of ‘intrinsic’
Intrinsic:
“in-built”
or
“of its nature”
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Definition
Intrinsically Safe Circuit

“A circuit in which no spark or
thermal effect in any part of
the circuit intended for use in
a hazardous area is capable
of causing ignition.”
IEC79-11
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V & I Limiting Network
Current limiting
resistor
RCLR
VZ Vinput
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Energy limiting arrangement
Infallible Components
Current limiting
resistor FUSE
RCLR
Hazardous VZ Safe Area

Area Vinput Circuit
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Intrinsic safety categories
Countable Faults: Faults in infallible components
Ex ia Ex ib
Intrinsically safe Intrinsically safe
with with
two countable faults one countable fault
Zones 0, 1 and 2 Zones 1 and 2
Intrinsic safety is the only protection concept which

considers failure of the field wiring
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System
Hazardous Fault 1
+
RELAY
- Fault 2
E N L
Note! Earth Connection
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Current Limiting from C V Supply
Hazardous Barrier Relay
+
Supply
Supply
N L E
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Component Failure
Infallible Components
Current limiting
resistor FUSE
RCLR
Hazardous area VZ Vinput

Safe area
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Thank You For Your Interest
If you are interested in further training, please visit:
http://www.idc-online.com/slideshare
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Intrinsic

• Practical, useful with Q & A throughout

• PID loop Tuning / Arc Flash Protection,

• You get the recording and slides

The focus of this session is the building blocks

The measures applied in the construction of

Need to understand: ‘ignition’

21% Oxygen Sufficient Vapour

Most-easily ignitable mixture

* of most easily ignitable mixture (Note: MESG assessed for Ex d)

Sometimes referred to as:

Spontaneous ignition temperature

Only liquids have flashpoints

Operation below Flashpoint constitutes no actual hazard

Safe working level 10

Serious health danger level 50

Lower Flammable Limit 40,000 (4%)

Upper Flammable Limit 460,000 (46%)

Nature of the Hazard

The nature of the Hazardous Atmosphere

The probability that the Hazardous Atmosphere

The maximum spark energy it can produce

Its maximum surface temperature

Acetylene Group IIC Class I, Group A

Methane Group I (No classification)

Fibres & Flyings (No classification) Class III

Acetone 2.00 2.0 13 535 T1 IIA

Extract from IEC79-18

Zone 1: in which an explosive gas-air mixture is likely to occur in

Zone 2: in which an explosive gas-air mixture is not likely occur

Div.1 Zone 0 sometimes specified

Zone 2 Zone 1 Zone 0

Intrinsically Safe Circuit

Hazardous VZ Safe Area

Zones 0, 1 and 2 Zones 1 and 2

Intrinsic safety is the only protection concept which

Hazardous area VZ Vinput

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