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HAZARDOUS AREA TRAINING WORKSHOP

TOOLBOX GUIDE

INSTALLATION, INSPECTION AND MAINTENANCE OF ELECTRICAL INSTALLATIONS IN HAZARDOUS AREAS

NO PART OF THIS TOOLBOX GUIDE MAY BE COPIED OR REPRODUCED IN ANY FORMAT WHATSOEVER. THIS INCLUDES PHOTOCOPYING, SCANNING AND ELECTRONIC STORAGE COPYRIGHT 2008 PETROTEKNO

CONTENTS 1.0 BASIC INFORMATION Prohibited items Environmental conditions Ingress protection Explosive limits ZONES Source of release Grade of release Zones EX Equipment Equipment Groups Gas groups Temperature classification Glands Cables Earthing TYPES OF PROTECTION Exd Exe Exn Exp Exi Additional types of protection Exm, Exo, Exq INSPECTION Grade of inspection Type of inspection STANDARDS European ATEX Directives IEC International standards American NEC standards

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BASIC INFORMATION

COMPETENCY. Technicians need to be competent to work in hazardous areas and one way of proving competence is to attend a hazardous area training programme. PERMITS. A permit to work is required before any work is carried out in a hazardous area. Different companies operate different systems and training must be provided by the employer. SAFE ISOLATION Company policy must be followed to ensure equipment is to be worked on is not LIVE There is one exception to this rule and that is where I.S. intrinsically safe circuits may be worked on live. Always seek advice. TOOLS All tools must be good condition, free from defects and suitable for use in a hazardous area. PROHIBITED ITEMS The following are not permitted in a hazardous area: cigarette lighters matches anything with a battery in it, for example mobile phones, radios, personal CD / MP3 players, car key-rings with central locking remote controls electrical test meters unless intrinsically safe or certified and suitable for the area classification torches, unless intrinsically safe or certified and suitable for the area classification PPE, including boots and coveralls, which could give rise to static

HOT WORK Hot work including welding, burning, drilling, grinding etc. should only be carried out safely under the permit to work system. ENVIRONMENTAL CONDITIONS Electrical equipment can be affected by environmental conditions such as: corrosion ambient temperature water ingress vibration exposure to chemicals accumulation of dust and dirt

INGRESS PROTECTION IP 66 is required for offshore installations. The first number 6 refers to the ingress of matter or particles of dust or dirt and is complete protection against the ingress of dust. (Dust Tight) The second 6 refers to the ingress of liquids and is protection against powerful water jets and conditions on ships decks in heavy seas

This is the IP Table DEGREE OF PROTECTION AGAINST PARTICLES OF MATTER, DUST AND DIRT No protection Protection against particles larger than 50mm diameter Protection against particles larger than 12.5mm diameter Protection against particles larger than 2.5mm diameter Protection against particles larger than 1.0mm diameter Protection against ingress of dust that could interfere with the operation of the equipment (Dust Protected) Complete Protection against the ingress of dust. (Dust Tight) DEGREE OF PROTECTION AGAINST PARTICLES OF LIQUIDS No protection Protection against drops of liquid falling vertically (Drip Proof) Protection against liquid falling at any angle up to 15 from vertical (Shower Proof) Protection against liquid falling from any angle up to 60 from vertical (Shower Proof) Protection against splashing from any direction (Splash Proof) Protection against water projected by nozzle from any direction (Hose Proof) Protection against powerful water jets and conditions on ships decks in heavy seas Protection against temporary immersion in water Protection against total immersion (Submersion) in water to a specific depth for a specific time

0 1 2 3 4 5 6

0 1 2 3 4 5 6 7 8

EXPLOSIVE LIMITS Explosive limits are the upper and lower percentages of gas in air which will burn if ignited. Lower explosive limit (LEL) is the concentration of gas in air below which the mixture is not explosive. Upper explosive limit (UEL) is the concentration of gas in air above which the mixture is not explosive. Between the LEL and UEL the mixture will burn and is explosive. Flash point is the lowest temperature a liquid will give off a vapour that can form an explosive atmosphere. Ignition temperature (auto ignition temperature) is the lowest temperature at which a material will ignite and burn. 2.0 ZONES

Where flammable gases may be present the area must be zoned and shown on hazardous area classification drawings. The basics for establishing zones are to identify the source of release of the flammable gas, vapour or mist and then to determine the grade of release. The source of release is the point from which a flammable gas, vapour or mist can be released into the atmosphere and the grade of release is the expected possibility it may occur. The grade of release is either "continuous", "primary" or "secondary" Continuous Primary Secondary a release which is continuous or is expected to occur frequently or for long periods a release which can be expected to occur periodically or occasionally during normal operation a release which is not expected to occur in normal operation and, if it does occur, is likely to be infrequent and for short periods

ZONE 0 is a place where an explosive atmosphere in the form of gas, vapour or mist is present continuously or for long periods ZONE 1 is a place where an explosive atmosphere in the form of gas, vapour or mist is expected to occur in normal operation ZONE 2 is a place where an explosive atmosphere in the form of gas, vapour or mist is not expected to occur in normal operation but if it does will not last for long. The equivalent zones for dust are: Zone 20 is the same as zone 0 Zone 21 is the same as zone 1 Zone 22 is the same as zone 2 3.0 EX EQUIPMENT

There are two equipment groups: Group I equipment is designed for use in underground mines where methane is present and does not concern us. Group II equipment is designed for use above ground so all electrical equipment data plates on offshore installations will always include the mark II. GAS GROUPS Group II equipment is further divided into 3 gas groups IIA, IIB and IIC

Hazardous Area Classification IIA IIB IIC

Apparatus suitable IIA, IIB or IIC IIB or IIC IIC

TEMPERATURE CLASSIFICATION Temperature classification is based on the maximum surface temperature that can be reached by any part of the equipment that could ignite an explosive atmosphere. The temperature class of the equipment must always be below the ignition temperature of the gas.

Temperature class of apparatus T1 T2 T3 T4 T5 T6

Maximum surface temperature of apparatus C 450 300 200 135 100 85

POTENTIAL SOURCES OF IGNITION FROM ELECTRICAL EQUIPMENT ARCING SPARKING HOT SURFACES Making or breaking of switches, loose contacts and broken wires can all produce arcing Usually associated with rotating equipment such as motors and generators. Motors, transformers and solenoid valves

CERTIFIED ELETRICAL EQUIPMENT will have: a) Type of protection, for example Exd, Exe, Exi

b) Gas group c) Temperature classification

GLANDS Glands may be certified Exe, Exd or dual certified Exde which is suitable for both Exe and Exd. Glands are usually brass but can also be nickel and chromium but never aluminium. Where a deluge seal is included on the gland make sure it is replaced over the gland joint after glanding the cable. Avoid placing any strain on the cable when glanding and finishing off. GLAND MARKINGS W single wire armour Y aluminium strip armour (not suitable for hazardous areas) Z tape armour X braided armour A outer seal B armour lock C equals A + B D inner seal and armour lock E inner seal, outer seal and armour lock BARR inner barrier seal, outer seal and armour lock BARRIER GLAND SELECTION Barrier glands may be required on Exd equipment under certain conditions. A barrier gland used compound filler to prevent the passage of gasses and explosions through the gland. WHEN ARE BARRIER GLANDS REQUIRED? For zone 1 and 2 a) If the cable does not have round, compact, extruded bedding. This means there are no gaps between the cores such as the type where string is used as a filler between cores. b) Where there is an internal source of ignition and the hazardous area classification is gas group IIC.

Also for Zone 1 If there is an internal source of ignition and the internal volume is greater than 2 litres. CABLES All cables must be fitted with circuit identifications. This is to enable safe and effective isolation of the equipment when work is to be carried out. The connection of cables and conduits to the electrical equipment must be made in accordance with the type of protection. Care should be taken that there is no armour visable outside the body of the gland. This is to ensure ingress protection is maintained by clamping the outer seal of the gland to the outer insulation of the cable. Where armour is showing the cable must be reglanded TERMINATING CABLES Crimped terminations should be used as they provide a good connection and there is less risk of loose strands of wire causing short circuits. They are also easy to remove and insert. Hand ratchet type crimping tool must be used to fit crimps and not the simple plier type which often result in bad connections coming loose. TERMINATING UNUSED CORES Unused cores must NOT be left un-terminated. They should be terminated in spare terminals. CABLE MATERIALS Copper conductors may be used in any size required. Aluminium conductors are NOT permitted unless their cross sectional area is greater than 16mm. CABLE CORE COLOURS From 2006 these are the recommended colours for power cables. Phase colours: Brown, Black, Grey Neutral: Blue Protective conductor: Yellow / Green CABLE ARMOUR Galvanised steel wire armour is acceptable for use with mulit core cables Braided armour may be used but if it is aluminium braiding, exposed braiding must be avoided to prevent sparking with rusty or corroded steel. JOINTING Cable runs in hazardous areas should not be jointed whenever possible. Where this is unavoidable, joints must be made in a certified junction box that is suitable for the zone. UNUSED CORES In multi-core cables, the hazardous area end of each unused core shall either be connected to earth or be terminating in spare or unused terminals. Insulation by tape alone is not recommended. CONDUIT SYSTEMS For added protection from mechanical damage, cables may be run in heavy gauge steel conduit. Conduits must be fitted with stopper boxes where it enters or leaves a hazardous area and where it enters flameproof Exd equipment. When conduit contains three or more cables, the total cross-sectional area of the cables shall be not more than 40 % of the cross-sectional area of the conduit. This is to prevent bunching and overheating. EARTHING Earthing on offshore installations refers to an electrically continuous path from a conducting body to the main earth point of the power supply. BONDING Bonding is different and refers to the electrical connection between exposed conductive parts (metal parts of equipment which could become live in the event of a fault)

PROTECTIVE CONDUCTORS

A protective conductor is the main earth conductor from a piece of electrical apparatus in the field back to the main earth at the power supply. Aluminium conductors should not be used. These are the recommended minimum earth conductor sizes according to IEC PHASE CONDUCTOR Up to and including 6mm 16mm 35mm Over 35mm EARTH CONDUCTOR Same as phase conductor but not less than 2.5mm if protected otherwise 4mm 16mm 0.5 X phase conductor size

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TYPES OF PROTECTION TYPE Exd Exe Exn Exp Exi Exm Exo Exq ZONE OF USE Zone 1 & 2 Zone 1 & 2 Zone 2 only Zone 1 & 2 Exia zone 0,1 &2 Exib zone 1 & 2 Zone 1 & 2 Zone 1 & 2 Zone 1 & 2

TYPE OF PROTECTION Flameproof Increased Safety Non sparking Pressurisation Intrinsic Safety Encapsulation Oil Immersed Powder Filling

TYPE OF PROTECTION Exd. Flameproof A type of protection where the enclosure can withstand the effects of an internal explosion without damage. It will also prevent the explosion passing outside and igniting an explosive atmosphere that may be present. PRESSURE PILING Pressure Piling in an Exd enclosure is a result of the ignition of compressed gas. This happens when you have two enclosures joined together by conduit and an explosion takes place in one of the enclosures and the explosion is forced into the other enclosure. This can increase the size of any explosion. SOLID OBSTACLES / SOLID OBSTRUCTION EFFECTS Care should be taken not to obstruct or block the flamepaths. On motors for example, the flanges of the cable connection box should not be located close to walls, steelwork or other equipment. This is because, if the flamepaths are obstructed or blocked, the escaping gas might not be able to escape. The minimum distance of any obstacles or obstructions to a flamepath are stated in the table below. Equipment Group IIA IIB IIC STOP-ENDS Minimum Distance 10mm 30mm 40mm

Sealing plugs or stop-ends for un-used cable entries must be certified Exd GASKETS Must be approved by the manufacturer and made from metallic of non-flammable material. Removing gaskets or changing them for home-made types will invalidate the certificate of conformance. USE OF TAPE Non-hardening textile tape such as DENSO may be used to protect joints, gaps and flanges from water and the weather. This is permitted when the equipment is gas group IIA. When the equipment is IIB advice must be sought from the manufacturer. When the equipment is IIC and the area classification is IIC tape is not permitted but if the area classification is IIA or IIB it is allowed. USE OF PAINT Flamepaths must never be painted before assembly. It is allowed to paint gaps and joints after assembly. Aluminium paint must never be used. USE OF GREASE Flamepaths can be protected from corrosion by use of non-hardening grease. Silicon based grease is permitted but not on gas detectors! Grease may also be used on threads and exposed screws and bolts to protect from corrosion. MODIFICATIONS TO FLAMEPROOF Exd EQUIPMENT Certified equipment must not be changed or modified in any way unless it is mentioned on the manufacturers certificate of conformity. Unauthorised modifications will invalidate the certificate and the equipment will therefore become non-certified. Unauthorised Modifications include: Use of non-certified glands or stop-ends Use of bolts or scews for any other purpose than what they were designed for. This could be using cover bolts for fixing earthing, bonding or brackets for another purpose Drilling Exd equipment Drilling holes to attach cable brackets Use of any gasket other than the one specified in the certificate of conformity or the manufactures information / documentation Use of sealant, grease or tape which hardens Changing the layout of components inside an enclosure Adding components to the inside of an enclosure not mentioned in the certificate GLANDS Glands must be Exd or Exde. There is one occasion where the cable may be indirect entry and the terminal box is Exe, then the gland could be Exe, Exd or Exde. Where the equipment is associated apparatus and is Exd(i) the gland must still be Exd or Exde as above.

TYPE OF PROTECTION Exe. Increased Safety A type of protection where additional measures are applied in the construction, to give increased safety against high temperatures and arcs and sparks. Exe equipment has strict rules for installation that must be followed. These will be stated on the certificate of conformity and in the manufacturers instructions and could include: a specified number of terminals allowed the terminal type the terminal size

cable size maximum current and power ratings

These rules must be strictly followed as they could be vital to the type of protection. INGRESS PROTECTION This is the protection against the ingress of water, dust and dirt. The minimum IP rating for offshore is IP66. To meet the ingress protection requirement on Exe equipment, an IP washer must be fitted between the gland and the body of the enclosure. An IP washer is not required in a threaded entry which has more 5 fully engaged threads or more than 6mm of engaged thread GLANDS Glands must be Exe or Exd. Stop ends and sealing plugs fitted to unused cable entries must be Exe or Exd and be fitted with an IP washer unless there is a minimum 6mm engaged threads the same as for the gland. Where an external earth tag or banjo is fitted it must be fitted after the IP washer. IP washer must be on first. TERMINATIONS More than one conductor is permitted into one terminal if they are the same size and same cross section area. Two wires of different cross section are not permitted into one terminal. CABLE INSULATION Should be maintained right up to the metal of the terminal. JUNCTION BOXES The manufacturers instructions must be followed for terminal type, size and numbers of terminals, conductors size and current ratings. RESISTANCE HEATING DEVICES Also called Trace Heating. Temperature protection devices must be installed to isolate the device. It shall also be the type that has to be manually reset and not automatic. MICC CABLE For MICC cable (mineral insulated copper conductor) Exe certified pots are required to maintain core separation.

TYPE OF PROTECTION Exn. Non sparking or Reduced Risk A type of protection where, in normal operation is not capable of igniting an explosive atmosphere. Exn is divided into five sub-types: nA is for non-sparking nC is for sparking apparatus in which the contacts have extra type of protection nR is for restricted breathing nL is for energy limiting nZ is for enclosures with pressurization. A restricted-breathing enclosure is an enclosure that is designed to restrict the entry of gases but not totally prevent it. Energy-limited apparatus is where the circuits and components are constructed to limit the energy. Hermetically sealed is where sparking contacts are kept away from an explosive atmosphere by means of sealing with either fusion between glass and metal (used on light fittings) soldering, welding or brazing. Enclosed break is a device with electrical contacts that will withstand an internal explosion without suffering damage.

Encapsulated is a device that it is totally immersed in a hard compound so that it is sealed to prevent entry of gas. Electrical connections are usually provided by flying leads. Energy limiting is where the maximum energy contained within a circuit is restricted so it is not capable of causing ignition of an explosive atmosphere. GLANDS Exn does not require certified glands IP WASHERS The same requirements as Exe. Cable entry into an unthreaded holes with Less than 6mm threads required an IP washer.

TYPE OF PROTECTION Exp. Pressurised A type of protection where a positive pressure is maintained inside an enclosure or room to prevent the entry of gasses. Pressure is higher inside than outside. PRESSURISING GAS Nitrogen may be used or air. If air is used it should be drawn from a non hazardous area free from gasses. If nitrogen is used there is a danger of asphyxiation or suffocation. WARNING NOTICES Should be fitted warning personnel not to leave enclosures or doors open that could result in loss of pressure. SPARK ARRESTORS Outlet ducts should be located in a non hazardous areas but where this is not possible, spark or flame arrestors must be fitted. GLANDS Certified glands are not required but care should be taken that the glands maintain the ingress protection and are fitted correctly to prevent the loss of pressure.

TYPE OF PROTECTION Exi. Intrinsic Safety A type of protection where the energy within a circuit is limited to such low levels that ignition of an explosive atmosphere is not possible. SAFETY BARRIERS There are two types of safety barriers, shunt diode (zener) and galvanic isolated and they are located in the safe area. Zener barriers prevent any over voltage or over current getting into the hazardous area by diverting them to earth and blowing fuses. Galvanic barriers allow transfer of energy and signals without any direct wiring. This is achieved by the use of two coils the way a transformer opearates. SEPARATION OF I.S. AND NON I.S. CABLES Intrinsically safe and non-intrinsically safe cables may be run on the same cable tray but should be separated by a minimum of 50mm. In junction boxes and enclosures containing I.S. and non I.S. circuits, the clearance between terminals must be at least 50mm. Clearance between terminals of different I.S. circuits must be at least 6mm. INTRINSICALLY SAFE EARTH This is a dedicated I.S. earth from the zener barrier earth bar to the mains power supply earth.

ASSOCIATED APPARATUS Associated apparatus is apparatus which contains both I.S. and non I.S. circuits and is constructed so that the non I.S. circuits cannot affect the intrinsically safety. It could also be non I.S. equipment located in the safe area but still connected to the I.S. circuit. SIMPLE APPARATUS This is electrical components of simple construction which are compatible with the intrinsic safety of the circuit. The following are considered to be simple apparatus: passive components like switches, junction boxes, resistors and simple semiconductor devices sources of stored energy, for example capacitors or inductors sources of generated energy, for example thermocouples and photocells, which do not generate more than 1,5 V, 100 mA and 25 mW

EARTHING OF SCREENS Screens should be earthed at one end only and usually at the supply end. GLANDS Certified glands are not required on Exi equipment. If the equipment is Exd(i) then the enclosure is Exd and Exd glands are required. INSTALLATION OF INTRINSICALLY SAFE CABLES Cables used for intrinsically safe circuits must be marked to identify them as being intrinsically safe. I.S. cables must be installed so that the intrinsic safety is not affected by other influences such as magnetic fields from power or heavy current-carrying cables. This is normally achieved by the use of screens on the I.S. cables and by keeping the power cables separated by a minimum gap of 50mm. MICC CABLE If mineral insulated copper conductor cable is used, Exe pots are required to maintain core separation. MULTICORE CABLES I.S. and non I.S. circuits must not be run in the same multi-core cable. I.S. MAINTENANCE Some work may be carried out with the equipment LIVE. Work on I.S. equipment in hazardous areas should be limited to adjustment and calibration and taking electrical measurements as long as the test equipment is certified as I.S. or the area is verified as gas free with a hot work permit.

ADDITIONAL TYPES OF PROTECTION ENCAPSULATION. Exm Type of protection where ignition capable parts are enclosed or encased in a hard setting compound so that an explosive atmosphere cannot be ignited. OIL IMMERSION. Exo Type of protection where the electrical parts are immersed in oil so that an explosive atmosphere above the liquid cannot be ignited. Oil level is critical and must be checked regularly. POWDER FILLING Exq Type of protection in which the ignition capable parts are immersed and completely surrounded with a filling material (for example quartz or glass) This quenches any arcs and prevents the ignition of an explosive atmosphere.

INSPECTION Inspection plays a critical part in ensuring safety to personnel, plant and the installation so it is important that EX equipment is inspected regularly. The international standard for inspections is IEC60079-17. The Inspection and Maintenance of Electrical Installations in Hazardous Areas. QUALIFICATION OF PERSONNEL The inspection of EX equipment should only be carried out by experienced personnel, whose training has included instruction on the different types of protection and the rules and regulations of area classification. Continuing education or training must be undertaken by personnel on a regular basis and evidence of experience and training must be available. GRADES OF INSPECTION VISUAL INSPECTION An inspection carried out without the use of step ladders or tools and used to identify defects which are clearly visible such as mechanical damage or missing bolts. CLOSE INSPECTION A close inspection is an external inspection and does not require the equipment to be opened or isolated. Used to identify defects such as loose bolts and loose glands and so tools, steps and ladders may be required. DETAILED INSPECTION This is both external and internal inspection and normally requires electrical isolation. It includes all the close inspection checks and in addition, will identify defects such as loose terminations and water ingress. TYPES OF INSPECTION Initial inspection is for new equipment Periodic inspections are carried at regular intervals or periods Sample inspections are used when there are a large number of items which are all identical. It is an inspection of a percentage of the installed equipment and may be visual, close or detailed.

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STANDARDS

EUROPEAN ATEX DIRECTIVES FOR HAZARDOUS AREAS There are two European Directives: 94/9/EC and 1999/92/EC Directive 94/9/EC (more commonly known as ATEX 95 or the Manufacturers Directive) is intended to assist the free movement of goods throughout Europe. It does this by removing the need for separate testing in each country. Directive 1999/92/EC (more commonly known as ATEX 137 or the Worker Protection Directive) places the responsibility on employers to identify hazardous areas, zones the areas and only use certified equipment in zones. Ex equipment manufactured in Europe will be marked ATEX in the certificate number. For example 04 ATEX 2344. Atex uses categories as well as types of protection. Category 1 Category 2 Category 3 Equipment suitable for use in zone 0 Equipment suitable for use in zone 1 Equipment suitable for use in zone 2

INTERNATIONAL STANDARDS FOR HAZARDOUS AREAS IEC 60079 SERIES OF STANDARDS The IEC 60079 is an international set of standards governing electrical apparatus for explosive gas atmospheres and is created and regularly updated by the International Electrotechnical Commission (IEC). The IEC is a world wide organization responsible for setting the standards for electrical installations in explosive atmospheres. IEC 60079 includes the following parts IEC 60079-1: IEC 60079-2: IEC 60079-5: IEC 60079-6: IEC 60079-7: IEC 60079-10: IEC 60079-11: IEC 60079-14: IEC 60079-15: IEC 60079-17: IEC 60079-18: Flameproof enclosures "d" Pressurized enclosures "p" Powder filling "q" Oil immersion "o" Increased safety "e" Classification of hazardous areas Intrinsic safety "i" Electrical Installations in hazardous areas Type of protection n Inspection and Maintenance of Electrical Installations in hazardous areas Encapsulation "m"

AMERICAN NEC STANDARDS FOR HAZARDOUS AREAS America does not use zones, they use classes and divisions which are basically the same as zones. There are three Classes: Class 1 for flammable gases, vapours, mists and liquids Class 2 for flammable dusts Class 3 for flammable fibres

The only one that concerns us for offshore installations is Class1. America does not use 3 zones. Instead they have 2 divisions. Division 1 and Division 2 usually shown as DIV 1 and DIV 2. DIV 1 is the same as zone 1 and DIV 2 is the same as zone 2 America has four gas groups, A, B, C and D. The following tables shows the differences compared to IEC. NORTH AMERICAN Class 1 DIV 1 Class 1 DIV 2 GAS GROUPS GROUP A GROUP B GROUP C GROUP D IIC IIC IIB IIA IEC Zone 1 Zone 2

AMERICAN TEMPERATURE CLASSIFICATION

The temperature classification used in America is different as well and the following table is a reference guide to the IEC equivalents. NORTH AMERICAN TEMPERATURE CLASSIFICATION T1 T2 T2A T2B T2C T2D T3 T3A T3B T3C 135C T4 120C T4A 100C T5 85C T6 T6 T5 T4 T4 280C 260C 230C 215C 200C 180C 165C 160C T2 T2 T2 T2 T3 T3 T3 T3 IEC EQUIVALENT 450C 300C T1 T2

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