Professional Documents
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SIS Intrinsic Safety
SIS Intrinsic Safety
SAFETY
THE ART
OF
INTRINSIC SAFETY
Contents
1. Combustion Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Area Classification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Explosion Prevention Methods . . . . . . . . . . . . . . . . . . . . . 5
4. Ignition Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5. How Intrinsic Safety Works . . . . . . . . . . . . . . . . . . . . . . . 11
6. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7. Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8. Definition of Barrier Terms . . . . . . . . . . . . . . . . . . . . . . . 18
9. Barrier Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
10. Advanced Barrier Selection. . . . . . . . . . . . . . . . . . . . . . . . 22
11. Ronan’s Philosophy on the Intrinsic Safety Barrier . . . . 24
Appendix A: Ignition Graphs . . . . . . . . . . . . . . . . . . . . . . 26
1
Combustion Theory
We need to start our discussion on
Intrinsic Safety with some background Fuel
about ignition, combustion, and explo- Gas, Vapors,
sions. Since our goal is to prevent an explo- or Powder
sion, we first need to know how an
explosion can occur.
An explosion requires the proper
environment in order to exist. By eliminat-
ing those conditions an explosion is
impossible! COMBUSTION
The three ingredients necessary for an
explosion (fuel, oxidizer and ignition
source) make up the Ignition Triangle (see Oxidizer Ignition Source
Figure 1-1). All of the triangle’s compo- Air or Thermal or
Oxygen Electric
nents must be present in the correct pro-
portions for ignition to occur.
Once ignition occurs, if the conditions
are right, a combustion wave can grow Figure 1-1: The Ignition Triangle
In order for an explosion to occur, the ignition triangle
from the ignition. An explosion is any un- must have all the ingredients in the correct proportions.
controlled combustion wave.
Initially, most of the energy is supplied by
THE COMBUSTION PROCESS the spark. If more energy is supplied by
An explosion starts when the fuel and the spark (through the combustion zone)
oxidizer are present in the correct propor- than is lost to the surrounding gas, the
tions, and an ignition source (i.e. spark) flame sphere will grow. As the diameter of
occurs. Energy then proceeds along a nar- the sphere increases, the wave begins to
row combustion zone, and is conducted to resemble a planar wave. Eventually, the
unburnt gas ahead of the flame front as amount of energy produced by combustion
well as to burnt gas behind the flame. is sufficient to continually supply energy
2
to the unburnt gas ahead of the flame,
thereby causing the wave to self propa-
gate. Figure 1-2 shows the beginning
stages of combustion. The larger the in-
Propane-Air
itial spark is, the easier it is for the wave at 1 ATM
3
Area Classification
Class III - Fibers or Flyings (particles Note: Since 1974, a dividing line of 100
normally suspended in air). kohms/cm separates groups E & G.
DIVISIONS
CLASS I: GASES AND VAPORS Locations are classified by division ac-
Materials are grouped according to their cording to the probability that an explo-
level of explosion hazard. The following sive concentration of hazardous material
groups are listed in order of the most to may be present.
the least easily ignited. Division 1 - defines locations where
Group A - Acetylene (has a tendency to there lies a high probability that an ex-
form copperacetylides which are easily plosive concentration is present during
ignited by friction). normal operation. To be classified Divi-
sion 1, there has to be a minimum of
Group B - 100 hours/year, or 1% probability that
Hydrogen, an explosive material is present. In
Hydrogen Europe, Division 1 is subdivided into
Mixtures. Zone 0 and Zone 1. Zone 0 has the high-
est probability of an explosive concen-
Group C - tration being present (greater than
Ethylene, most 10% probability). Zone classifications
Ethers, some are not presently made in North Amer-
Aldehydes. ica, but may be in the future.
Group D - Alkanes (Butane, Ethane,
Division 2 - defines locations where
Methane, Octane, Propane), Hydrocarbon
there lies a low probability that an ex-
Mixtures (Diesel Oil, Kerosene, Petro-
plosive mixture is present during nor-
leum, Gasoline), Alcohols, Ketones, Esters,
mal operation (10 hours/year, or 0.1%
Amines, Alkenes, Benzenoids.
of the time).
4
Explosion Prevention Methods
ELIMINATE THE IGNITION
There are three different philosophies or SOURCE
approaches which have been used to pre-
vent explosions. All deal with the ignition The simplest method! Since all three ele-
triangle (Figure 1-1) differently. ments of the Ignition Triangle are neces-
sary for an explosion, why not eliminate
PERMIT IGNITION one or more of the elements?
This method allows all three elements of By the very nature of a hazardous proc-
the ignition triangle to be present, but con- ess, the fuel can not be removed. Notice
trols the location of the flame or explosion. that in a general purpose environment,
Examples of this include a pilot light on a the fuel is the absent element, with oxi-
gas stove, a flare stack, and an explosion- dizer and ignition source safely present.
proof housing. The key safety feature here Rarely is the oxidizer (air) removed. The
is the physical device which controls or halon fire extinguisher is an example of an
limits the explosion location. Permitting absent oxidizer. It works by replacing oxy-
ignition is normally costly and requires gen with halon, thereby suffocating the
high maintenance. fire.
The ignition source can be removed. By
CONTROL ATMOSPHERE inserting an energy limiting barrier, any
This method segregates the hazardous potential ignition source can be elimi-
fuel/air mixture from the ignition source. nated. This method is the only true com-
If you have a hazardous mixture in one bustion prevention method. The other
room, you can put your potential ignition possible solutions are actually combustion
sources in another room. The key safety protection.
feature here is the physical device which METHODS FOR SAFE CONTROL IN
controls the segregation. See Figure 3-1
HAZARDOUS AREAS
for one example. Another more common
example is purging or pressurization. Con- Taking these three explosion preven-
trolling the atmosphere can be a very com- tion philosophies and implementing them
plex and costly procedure. produces a variety of techniques. These
include:
Figure 3-1: One way to separate the fuel/air mixture from the ignition source.
5
◆ Pneumatic (Air)
◆ Fiber Optics (Light)
◆ Explosion-Proof Enclosures (Electric)
◆ Purging or Pressurization (Electric)
◆ Encapsulation (Electric)
◆ Oil Immersion or Powder Filling
(Electric)
◆ Intrinsic Safety (Electric)
Let’s review each of these in a little
detail.
PNUEMATIC SYSTEM
Pnuematic systems are a safe means of Figure 3-2: Explosion Proof Enclosure.
combustion control because they are pow-
ered by air. This type of system is practi- sures available. Both types do not allow
cal in operations where clean compressed the explosive energy to completely escape
air is available. A typical pneumatic field the enclosure.
device is a control valve. Pneumatics can Care must be taken not to mar the
be used in only a limited number of opera- flanged surfaces. Also, all bolts must be
tions, for limited distances and have a torqued down correctly. One missing or
slow reaction time. loose bolt or scratched surface could pro-
vide a path for the explosion to reach the
FIBER OPTICS OR PHOTOVOLTAICS outside world. Explosion-proof enclosures
Photovoltaic loops provide a safe means are designed to resist the excess pressure
of control because they are powered by created by an internal explosion. They are
light. A light beam goes out to the hazar- built with a variety of materials, including
dous area and is either reflected back to cast aluminum, cast iron, welded steel and
the safe area or is interrupted. This has stainless steel.
limited distance capabilities, is affected by PURGING (PRESSURIZATION)
dust or mist, and is limited to contact sens-
ing applications. Purging prevents explosions by main-
Fiber-optic loops are also a safe means of taining a protective inert gas within the
control because they are powered by light. enclosure at a pressure that is greater
When the light reaches the instrument than the external atmosphere. This
however, it will probably need to be con- method prevents the dangerous air/gas
verted to electricity. In these cases, the mixture from entering the enclosure. Pres-
electrical safety methods discussed next sure may be preserved with or without a
must be used. Fiber optics has some poten- continuous flow of the inert gas. Pressure
tial for contact sensing but special con- loss or opening of enclosure cause the sys-
tacts need to be used, and are not yet
readily available.
EXPLOSION PROOF ENCLOSURES
The use of explosion-proof enclosures is
a method which allows ignition to occur,
but prevents any significant damaging
results from the ignition.
The explosion-proof enclosure contains
the explosion so that it does not spread to
the surroundings and cause damage to the
plant and the personnel. There are bolt-on
enclosures (shown) and screw-on enclo-
Figure 3-3: Purging.
6
tem to alarm or power down depending on
the type of purge.
There are three types of purging
methods, each of which reduce the area
classification within an enclosure. Type X
reduces classification from Division 1 to
Non-Hazardous. Type Y reduces classifica-
tion from Division 1 to Division 2. Type Z
reduces classification from Division 2 to
Non-Hazardous.
Certain criteria must be met in order for
a purging process to get rated as Type X,
Y or Z (and thereby reduce the area
classification accordingly). These criteria
are listed in Figure 3-4. Figure 3-5: Encapsulation.
ENCAPSULATION
The encapsulation method encloses the ever, let’s review a few miscellaneous
hazardous operation with a resin potting protection methods. These methods are
material that prevents accidental shorting not used very often, but they provide an in-
of electrical components. This method of- teresting insight to explosion prevention.
fers effective mechanical protection that Oil Immersion - A piece of equipment
works well as a complement to other pre- is immersed in oil. A spark can not pass
vention processes. If a spark does occur, it through the oil covering to ignite the sur-
can not escape through the potting mater- rounding atmosphere. This method is
ial into the hazardous environment. sometimes used for large electrical
apparatus such as transformers. The
MISCELLANEOUS electrical apparatus may even have
PROTECTION METHODS moving parts since the oil will not impede
The intent of this chapter is to give the the movement.
reader a background of all the various ex- Powder Filling - An enclosure con-
plosion prevention methods available. The taining electronics is filled with quartz
most popular methods are: explosion proof powder. The level and granulometry of the
housing, purging, and intrinsic safety. The powder is specified by an approval agency
rest of this book will concentrate only on (CENELEC). A spark can not pass
intrinsic safety. Before we do that, how- through the quartz powder and ignite the
7
Figure 3-6: Intrinsic Safety removes the ignition source from the ignition triangle. The official definition is as follows:
Intrinsically safe equipment and wiring shall not be capable of releasing sufficient electrical or thermal energy under
normal or abnormal conditions to cause ignition of a specific atmospheric mixture in its most easily ignited concentration.
surrounding atmosphere. No moving parts tightened so gas accumulation does not in-
are possible. crease above lower explosive level (see fig-
Non-Incendive - Also called Simpli- ure 1-3) for a period longer than the
fied Protection Method in Europe, it is presumed presence of the hazardous gas/
widely used in England. This protection dust.
method does not consider fault conditions.
It assures you can not ignite a hazardous
INTRINSIC SAFETY
air/gas mixture during normal function-
ing. Devices which may spark during nor- Intrinsic Safety (I.S.) removes the igni-
mal operation such as relays and switches tion source from the ignition triangle. The
must be hermetically sealed. This safety official definition is as follows: Intrinsi-
method only applies to Division 2 areas. cally safe equipment and wiring shall not
Increased Safety - Developed in Ger- be capable of releasing sufficient electrical
many. Recognized by CENELEC. Takes or thermal energy under normal or abnor-
into account connections, wiring, compo- mal conditions to cause ignition of a spe-
nents, distances and temperature changes. cific atmospheric mixture in its most
Sealing (Limited Breathing) - Uses easily ignited concentration.
seals and gaskets. The enclosure is
8
Ignition Mechanisms
Ronan’s Series X57 Intrinsic Safety Bar- IGNITION BY SPARK
riers eliminate the ignition source from The second type of ignition source is the
the ignition triangle, thereby preventing spark. Matches and cigarette lighters fall
combustion. There are two basic types of into this category. Many chemical plants
ignition sources. place containers at the entrance where
THERMAL IGNITION people must put their matches or lighters
The first type of ignition source is ther- before entering.
mal. A hot surface can cause ignition by A spark can also be produced electroni-
spontaneous combustion. This is why cally. Any electronic device which stores or
every hazardous area has a temperature produces energy can cause a spark. Let’s
classification (see Table 4-1 for a full list- discuss three different electronic ignition
mechanisms in more detail.
ing of all the temperature classifications).
Let’s take one example of how tempera- CLOSING OF CONTACTS
ture classification works. A hazardous IN CAPACITIVE CIRCUITS
area classified as T4 risks explosion if any
A capacitor stores energy in the electri-
surface gets hotter than 135°C (275°F).
cal field between its plates, and this en-
Faulty motor windings, for example, can
ergy can present itself as a spark in the
create such a high temperature very
hazardous area.
quickly. Any piece of equipment used in-
When the switch in Figure 4-2 is open in
side this particular hazardous area must
a capacitive circuit, the capacitor charges
not be capable of generating a tempera-
to a voltage “V”, and accumulates an
ture greater than 135°C. Only equipment
energy equal to one-half the capacitance
rated at T4, T5, or T6 would be allowed in
(C) times the square of the voltage.
this hazardous area.
E = 1/2 CV2
Maximum Surface Temperature When the contacts close in a capacitive
USA/
Fahrenheit Centigrade Europe Canada
circuit to discharge a capacitor, a spark
can form just before the contacts touch. Be-
842 450 T1 T1 cause the contacts are almost touching,
572 300 T2 T2 the size of the spark is small.
The switch shown in this example can
536 280 T2A
also represent field wiring which is acci-
500 260 T2B dently shorted.
446 230 T2C Figure A-1, in Appendix A, compares the
ignition voltage to capacitance.
420 215 T2D
392 200 T3 T3
356 180 T3A
329 165 T3B
320 160 T3C
275 135 T4 T4
248 120 T4A
212 100 T5 T5
185 85 T6 T6
Figure 4-1: Temperature Classifications. Figure 4-2: Closing of contacts in capacitive circuits.
9
instant the switch is opened. If the induc-
tance is large, then the voltage developed
(which is equal to L * di / dt) is large, and
a spark could appear between the two
electrodes formed by the switch opening.
The switch shown in this example can
also represent field wiring which is acci-
dently cut.
Figure A-2, in Appendix A, compares
ignition current to inductance.
OPENING AND CLOSING OF
CONTACTS IN RESISTIVE CIRCUITS
In this instance, shown in Figure 4-4,
Figure 4-3: Opening contacts in inductive circuits.
the ability to ignite the hazardous atmos-
phere depends on the open circuit voltage
OPENING CONTACTS (V = VOC), and the short circuit current (ISC
IN INDUCTIVE CIRCUITS = V/R). Energy from the power supply could
The energy stored in the magnetic field be released in the form of a spark at the
of an inductor can be released in the form point of the circuit opening or shorting.
of a spark in the hazardous area. Figure A-3, in Appendix A, compares the
With the switch in Figure 4-3 closed, ignition current to voltage for resistive
the inductor L stores an energy equal to circuits.
one-half the inductance times the square
of the current.
E = 1/2 Li2
When the switch opens, the inductor
“tries” to keep current flowing from A to B
as it had been before the switch was
opened. The voltage which attempts to con-
tinue this current flow is determined by
the equation
V = L(di/dt)
The term “di/dt” is the change in cur-
rent with respect to time. This number
can be very large because the current will Figure 4-4: Opening and closing of contacts in resistive
circuits.
change from its previous value to zero, the
10
How Intrinsic Safety Works
Figure 5-1: The Intrinsic Safety Barrier. Notice the intrinsic safety barrier is always located in the safe area.
11
Figure 5-2: Zener Barrier Fault Path.
There are two basic varieties of intrinsic diodes for redundancy. The series resistor
safety barriers: the zener barrier and the limits current to the hazardous area, and
active barrier. Let’s review each of them in is considered an infallible component. The
a little detail. arrow in Figure 5-2 shows the resultant
path if excess current enters the barrier as
ZENER BARRIER a result of excess voltage input from the in-
The zener diode barrier works by di- strument.
verting potentially dangerous energy to Since a zener barrier is powered by the
ground before it can reach the hazardous loop and it has a current limiting resistor,
area. it has a voltage drop across it. This bar-
The zener diodes limit the fault voltage rier, in addition to protecting against
to the hazardous area. There are two such
Figure 5-3: Will the resistance of a zener barrier adversely affect this 24 V, 4-20 mA transmitter loop? Not if it is less
than 340Ω.
12
Figure 5-4: Active Barrier. An active barrier is sometimes called a galvanically isolated barrier.
13
Installation
14
field exceeds the maximum allowed for ◆ Since zener diode barriers work by di-
connecting to the I.S. barrier. The same verting fault currents, they must have a
principle applies to the inductance. good quality ground.
◆ The impedance of the conductor from
GROUNDING the barrier ground bus to the ground con-
nection should be less than 1 ohm.
When using zener barriers, the danger-
ous energy is diverted to ground. There- ◆ Follow local codes.
fore, it is important to ensure a high ◆ Ground cables should be insulated.
quality intrinsic safety ground. In fact,
because this grounding is so critical, two ◆ Ground cables should be protected me-
separate ground connections from each chanically if there is a risk of damage.
barrier are recommended, each with a re- ◆ Ground cable should be an uninterupted
sistance of less than 1 ohm. run to the nearest high integrity earth
The following rules should be adhered to point.
for I.S. grounding: ◆ Redundant cables are advisable.
15
Certification
16
Electrical Code, section 504, also discusses Factory Mutual Standard for Electrical
I.S. installation. Utilization Equipment. This ensures a
In Canada, I.S. product approvals are piece of equipment is not a shock or fire
obtained through the Canadian Standard hazard.
Association (CSA). This group develops When someone specifies FM approval,
the standard and also certifies devices to they should specify which type of FM
the standard. approval they require. If it is general
When obtaining FM and CSA approv- purpose (G.P.) approval, a device which is
als for intrinsic safety, the equipment approved for I.S. or G.P. can be used. If
must also meet the requirements for gen- the approval is for I.S., only I.S. approved
eral purpose use. For FM, this means you devices may be used.
must also meet the requirements of the
17
Definition of Barrier Terms
VOLTAGE I.S. barrier term should not be confused
with the VMAX entity parameter of a field
Open Circuit Voltage (VOC) - The maxi-
device.
mum voltage a barrier can deliver to the
hazardous area in the case of a fault. This RESISTANCE
value is assigned by Factory Mutual
based on the configuration of the barrier Basic Safety Specifications (Ohms) -
application. This entity parameter is The value of the terminating resistor.
tested and assigned by Factory Mutual. This resistor performs the current-limit-
ing function, and is a wire wound (infal-
Basic Safety Specification (V) -
lible) resistor.
Approximate maximum voltage a barrier
can deliver to the hazardous area. The Maximum End-to-End Resistance
design engineer will want to use VOC in- (Ohms) - The total resistance of the bar-
stead of this term. rier between the safe and the hazardous
area connection terminals, including all
Working Voltage (VWK) - The maximum
resistors and fuses.
dc voltage (or peak ac voltage) that can be
connected between the safe area ter- CURRENT
minals and ground, with the hazardous
area terminals open circuited. This is the Short Circuit Current (ISC) - The maxi-
maximum voltage the barrier can safely mum current a barrier can deliver to the
pass with no (or very little) leakage cur- hazardous area in a fault situation. It is
rent through the zener diodes to ground. based on the configuration of the barrier
application. This entity parameter is
Maximum Voltage (VMAX) - The maxi-
tested and assigned by Factory Mutual.
mum peak voltage which can be sustained
without opening the fuse. The hazardous Basic Safety Specification (mA) - The
area terminals are open circuited for this approximate maximum short circuit cur-
measurement. If they are not, then this rent available in the hazardous area
current will reduce VMAX. This is a under fault conditions. This value is calcu-
measure of zener diode breakdown lated from the basic safety specifications
tolerance, and fuse characteristics. This for voltage and resistance (V/R).
18
Barrier Selection
Intrinsically safe barriers are designed
to be application oriented. If you want a
barrier for any application, an RTD, for ex-
ample, you can select one of the few barri-
ers a company has designed for RTD’s.
You may have a choice of a zener barrier
to work with a two wire RTD, another
zener barrier to work with a three wire
RTD, and yet another zener barrier to
work with a four wire RTD. You may also
have a choice of an isolating active barrier
and even a barrier which takes a three
wire RTD input, performs signal condition-
ing, and gives an isolated, linearized, 4-20
mA output.
In general, once you know the applica-
tion, you can choose from a small subset
of a manufacturers’ large variety of bar-
riers. There are certain steps that you
need to go through to select the proper
barrier.
current passes through the barrier resis-
We are now ready to go through the
tance. This must be considered, because
process of selecting an I.S. barrier for an
during normal operating conditions, we do
application. We will go through all the
not want the voltage drop across the bar-
steps required so you can become familiar
rier to adversely affect the circuit. This
with them. Two examples follow, both
will not affect the safety of the loop, it will
with the same application.
just not allow the loop to function prop-
The first example is basic barrier selec-
erly. These examples do not attempt to
tion. It takes into account voltage and cur-
choose between an active or a zener bar-
rent. The second example is advanced
rier. The benefits of each were discussed
barrier selection and is shown in Chapter
earlier. The examples work equally well
10. In this example, we take the basic bar-
for both active and zener barriers.
rier selection and expand it to include
Lastly, these examples do not consider
capacitance and inductance. These four
multiple channel barriers, connecting mul-
parameters: voltage, current, capacitance,
tiple field devices to one barrier, or con-
and inductance help form the entity con-
necting multiple barriers to one field
cept which allows users to safely “mix and
device. This gets a little more complicated.
match” barriers and field devices from dif-
Any barrier must have an approved instal-
ferent manufacturers.
lation drawing showing that it is ap-
These examples show two considera-
proved for the particular connection you
tions the user needs to look at when select-
are considering.
ing a barrier. The first is that the barrier
allows the loop to function during normal BASIC BARRIER SELECTION
operating conditions. The second is that
the loop is safe during fault conditions. In When selecting a barrier, you must ask
order to impress certain points, these ex- the following questions:
amples do not review the voltage drop ◆ What is the hazardous area classifica-
that will occur across the barrier when tion?
19
Figure 9-1: Basic Barrier Selection. In order to simplify the understanding of barrier selection, we will not consider the
capacitance or inductance of the field wiring and the field device in the basic example. We will add this to the advanced
example. The basic barrier selection example satisfies the three equations, therefore it is an approved loop. In addition to
the three equations, the field device must be approved for use in that particular hazardous area (CL1, DIV1, GPC, T4).
The barrier must also be approved for connection to that hazardous area (CL1, DIV1, GPC). All the critical safety ap-
proval parameters can be found in the installation drawings done by the manufacturer of the barrier and the field device.
◆ What is the input voltage to the barrier Figure 9-1 shows a barrier connected be-
with respect to ground (AC, +DC, or -DC)? tween an instrument in the safe area and
This is called VLOOP. an I.S. approved field device. The barrier
◆What is the maximum voltage and cur- can be safely used here and has full ap-
rent which can be applied to the field proval. During normal operating condi-
device (VMAX and IMAX)? These are the tions, this instrument loop operates at
entity parameters of the field device +24 Vdc. The zener diodes in the barrier
assigned by FM. do not start to conduct any voltage to
ground until that voltage reaches +25.5
You will want to follow these guidelines Vdc. Thus, under normal operating condi-
when selecting a barrier: tions, the barrier is transparent to the
◆ Select a barrier that is approved for use loop.
in the hazardous area where it will be During fault conditions, the maximum
installed. voltage the barrier can ever deliver to the
◆ VLOOP VWKG (barrier) hazardous area is 31.2 V. The field device
is approved safe for that hazardous area if
◆ VOC (barrier) ≤ VOC it never receives more than 35 V. The bar-
◆ ISC (barrier) ≤ IMAX rier ensures this. The barrier can never
VWKG = working voltage deliver more than 90 mA to the hazardous
VOC = max voltage delivered to the hazardous area area during fault conditions. The field
ISC = max current delivered to the hazardous area
device is safe as long as it never receives
VMAX = max voltage which can safely be applied to the field device
IMAX= max current the field device can safely draw
more than 110 mA. The barrier ensures
this as well. Therefore, because the volt-
age and current entity parameters match
20
up correctly, this loop is approved intrinsi-
cally safe.
This was a little bit simplified, and did
not consider the capacitance and induc-
tance entity parameters. In reality, all the
entity parameters (voltage, current,
capacitance and inductance) must match
up correctly in order for the loop to be
approved intrisically safe. The entity
parameters are all given by the approval
agency and obtained through the manufac-
turer. These are shown in an installation
drawing. There is one installation draw-
ing from the barrier manufacturer and
one from the I.S. field device manufac-
turer. Both of these should be obtained by
the user to ensure correct design. And
keep in mind, just because the loop is safe
does not mean that it works!
The normal operating conditions are
given by the manufacturer and are not
subject to approvals.
Let’s take the next step and discuss
capacitance and inductance.
CABLE CAPACITANCE
AND INDUCTANCE
A cable (or wire) is an energy storing
device. A cable stores capacitive energy
and inductive energy. From an intrinsic
safety standpoint, this cabling needs to be Figure 9-2: Cable Capacitance and Inductance.
analyzed to ensure safety at the system
level. What good does it do to limit the
amount of energy which can be passed The maximum inductive energy which
through the barrier if potentially is stored in the cable is related to the ratio
dangerous energy can be stored in the L/R, and is independent of the cable
cable? length.
Figure 9-2 diagrams the relationship of The L/R parameter is the unit induc-
capacitive energy to cable length and of in- tance of the cable divided by the unit resis-
ductive energy to cable length. Capacitive tance of the cable. This parameter is used
energy stored in cabling increases as cable in the example in Chapter 10.
length increases.
21
Advanced Barrier Selection
(Includes Cabling)
Let’s go through our first example a u For the cables: What is the
second time, taking into consideration capacitance and inductance of the cable
capacitance and inductance. In addition to used [CCABLE (in pF/ft.), and LCABLE (in
the questions asked in the basic selection, µΗ/ft.)]? The L/R ratio of the cable can be
we need to ask the following: used instead of the inductance/ft.,
u For the field device: What is the simplifying the calculations.
value of the capacitance and inductance u For the barrier: What is the amount
appearing at its terminals? (This is called of capacitance and inductance which may
CEQ and LEQ and is specified by FM.) be safely connected to it? This is called
CA and LA and is specified by FM.)
Figure 10-1: Advance Barrier Selection. In this example, we take the basic example and also consider the capacitance
and inductance of the field wiring and the field device.
22
The following simple equations need to Since capacitive energy increases per
be satisfied: unit length, 5000 ft. is the max. cable
length permitted due to capacitive energy.
CEQ + CCABLE ≤ CA
However, inductive energy calculations
LEQ + LCABLE ≤ LA result in a maximum length of 2667 ft.
Figure 10-1 illustrates the previous ex- The ideal intrinsic safety system
ample with capacitance and inductance designer takes the capacitance and
taken into consideration. The maximum inductance into account at the beginning
allowable cable capacitance, and therefore of the design, not as an afterthought to
maximum allowable cable length is calcu- verify safety.
lated as follows: The designer can calculate that capaci-
tance and inductance allowed in the cable.
CEQ + CCABLE ≤ CA Next, knowing his longest cable length,
CCABLE = CA - CEQ he can calculate some cable requirements.
The values used in the above example
= 0.4 µF - 0.2 µF
(40 pF/ft. and 0.3 µH/ft.) are typical
= 0.2 µF max parameters and are usually not exceeded
Length = 0.2 µF / 40 pF / ft in instrumentation cable. By defining
= 5000 ft max maximum cable parameters, the designer
Due to Capacitive Energy is leaving nothing to chance.
LEQ + LCABLE ≤ LA
LCABLE = LA - LEQ
= 2.9 mH - 2.1 mH
= 0.8 mH max
Length = 0.8 mH / 0.3 µH / ft
= 2667 ft max
Due to Inductive Energy
23
Ronan’s Philosophy on
the Intrinsic Safety Barrier
Before designing the X57 Series, Ronan Several factors involved meeting the
investigated many different factors that requirements of the various approval
should go into the design of an intrinsic agencies. In the development of the I.S.
safety barrier. approval standards, these agencies took
24
extra safety precautions with each step. “Should a safety barrier require removal
Some of these measures include: assum- from the intrinsically safe circuit please fol-
ing any mixture present is at its most low these guidelines.
easily ignited concentration, 1.5 safety fac- Disconnect the wiring from the safety
tor on the maximum current allowed, two barrier’s nonhazardous terminals prior
ground wires for redundancy, and two to disconnecting wires from the intrinsi-
zener diodes required per channel. cally safe terminals.
When these safety standards were re-
leased, an alarming fact was discovered. Cover bare wire ends with tape or other
Although no explosions have occurred insulating material, especially those
with intrinsic safety barriers properly in- conductors that are towards the hazard-
stalled, explosions have resulted from ous (classified) location.
faulty installations. Disconnect the safety barrier from
Further research and customer feed- ground. In most cases this step will
back illustrated a major need for easy in- also remove the safety barrier from the
stallation, low maintenance and safety mounting hardware.
assurance. Observation of I.S. loops in the Reverse this procedure to mount the
field showed additional areas where im- new barrier."
provement was needed.
Taking all of these factors into account, Obviously these guidelines leave much
Ronan developed a chassis-based design to be desired.
with modular (plug-in) barriers. All u The chassis is easily installed and
wiring connects directly to the chassis, not ready to use, unlike the flimsy “do-it-your-
to the individual barriers. Also, a metal self” mounting arrangements available
cover plate is provided to insulate the blue elsewhere.
hazardous area terminal blocks. This u The zener barriers, which require
gives additional protection for the intrin- ground, all connect to an FM approved in-
sically safe wiring. These design features ternal I.S. ground bus. This bus connects
have many advantages: to two external mounting studs which the
u The chassis has FM, CSA, and user connects to I.S. ground. In a typical
BASEEFA (CENELEC) approvals. 20 position chassis, this reduces the num-
ber of crucial ground connections by 95%.
u Users wire up their system and can
verify wiring accuracy before inserting u The active barriers, which require 24
any barriers in the loop. This minimizes Vdc to operate, all connect to an internal
the risk of losing any barriers during power bus. This reduces the number of
start up. power connections by up to 95%.
uIf a barrier needs to be removed or u Any barrier can connect to any position
replaced, wire removal is not necessary. in any chassis.
The old barrier snaps out easily and the Keying of barrier and chassis positions
new one snaps in. is available in order to prevent putting a
This eliminates a major cause of intrin- barrier in the wrong position.
sic safety problems: maintenance. Most In short, Ronan took an acceptable
manufacturers of barriers do not provide standard and went the extra mile to make
additional safety in their mounting pack- it better, developing a design strategy
age to reduce installation and main- that does not rely on ideal situations.
tenance errors. Here’s a direct quote from Ronan I.S. Barriers provide safety along
another manufacturer of barriers concern- with ease of installation and maintenance
ing replacement of intrinsic safety in the real world.
barriers.
25
Appendix: Ignition Graphs
The following are some of
the many graphs which an
intrinsic safety approval
agency uses when certify- COMPARISON OF
ing a field device for use in IGNITION VOLTAGE
a particular hazardous TO CAPACITANCE
area. These are the actual FOR CIRCUITS
IN HYDROGEN
ignition graphs for the ENVIRONMENTS
various gases. They repre-
sent the amount of electri-
cal energy required to cause
the combustion of an
air/gas mixture at its most
easily ignited concentra-
tion. The area under the
curves represents an en-
ergy which is too small to
cause an explosion.
Figure A-1 applies to
resistance-capacitance cir-
cuits only. This graph com-
pares the ignition voltage to C
capacitance for a Group B
gas at its most easily
ignited concentration.
Various current limiting
resistors are added in
series to the discharge path
of the capacitance. This is
shown to lower the effective
capacitance.
26
Figure A-2 applies to resistance-induc- safety factor of 1.5 is applied to the igni-
tance circuits only. This graph compares tion current allowed.
the ignition current to voltage for specific The approval agencies apply safety fac-
values of inductance. The curves repre- tors when using these graphs. You are not
sent the inductive energy required to allowed to have a circuit which operates
cause the combustion of a Group B gas at just below the ignition energy required for
its most easily ignited concentration. a particular gas. This would be too close to
Figure A-3 applies to resistive circuits a potentially dangerous situation.
only and shows the combinations of volt- The selection of which intrinsic safety
age and current which will ignite air/gas barrier to use for a particular application
mixtures for groups A, B, C and D. When does not entail the use of these graphs
designing intrinsically safe products, a
COMPARISON OF
IGNITION CURRENT TO
VOLTAGE FOR
Minimum Value of ISC for Ignition (Amps)
VARIOUS INDUCTANCE
CIRCUITS IN GROUP B
27
COMPARISON OF
IGNITION CURRENT
TO VOLTAGE FOR
RESISTANCE CIRCUITS
28