NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION GES L.35 ELECTRICAL EQUIPMENT IN HAZARDOUS AREAS

Rev 0

Date 1999

Description Issued for Implementation

Checked DL

Approved

Compiled by Teknica (UK) Ltd

GENERAL ENGINEERING SPECIFICATION ELECTRICAL EQUIPMENT IN HAZARDOUS AREAS

INDEX SEC 1.0 1.1 1.2 2.0 2.1 2.2 2.3 3.0 3.1 3.2 4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 5.0 5.1 5.2 5.3 5.4 5.5 6.0 6.1 6.2 6.3 6.4 TITLE SCOPE OF SPECIFICATION Introduction Other NOC Specifications DEFINITIONS Technical Terms Contractual Terms Codes and Standards PROTECTION PHILOSOPHY Principles of Hazard Reduction Area Classification PROTECTION METHODS AND CONSTRUCTION Explosion Proof - Ex "d" Increased Safety - Ex "e" Intrinsic Safety - Ex "i" Encapsulation/Sealing - Ex "m" Non-Sparking - Ex "n" Oil Immersion - Ex "o" Purged or Pressurised - Ex "p" Powder Fillings - Ex "q" Special - Ex "s" Construction Temperature Classification CERTIFICATION AND APPROVAL General IEC CENELEC UL/FM CSA NORTH AMERICAN/EUROPEAN DIFFERENCES General Explosionproof and Flameproof Purging and Pressurisation Intrinsic Safety

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GENERAL ENGINEERING SPECIFICATION ELECTRICAL EQUIPMENT IN HAZARDOUS AREAS

INDEX SEC 7.0 8.0 8.1 8.2 8.3 8.4 9.0 9.1 TITLE EQUIPMENT MARKING INSTALLATION General Explosionproof and Flameproof Purged\Pressurised Systems Intrinsically Safe DOCUMENTATION Introduction

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FIGURE 1 - Selecting a Zener Barrier

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1.0 1.1 1.1.1 1.1.2 1.1.3 SCOPE OF SPECIFICATION Introduction

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This specification covers the general guidelines for the selection requirements for electrical equipment and instrumentation in hazardous areas. It is the responsibility of the Vendor/Contractor and the Owner to make sure that the selected equipment is suitable and safe in its design and installation in hazardous areas. This specification is generally based on ANSI/NEMA standards. The Vendor/Contractor shall comply fully with the provisions laid down in this specification. Any exception must be clearly stated and be authorised in writing by the Owner as failure to do so shall indicate full compliance; any remedial work then necessary shall be at the Vendor/Contractor's expense. In the event of any conflict between this specification and the Data Sheets, or with any of the applicable codes and standards, the Vendor/Contractor shall inform the Owner in writing and receive written clarification from the Owner before proceeding with the work. Exclusions: Analyzer enclosures or houses are not within the scope of this document; refer to GES B.04.

1.1.4

1.2

Other NOC Specifications The following NOC General Engineering Specification is an integral part of this specification and any exceptions shall be approved in advance by the Owner. GES B.04 GES L.31 Process Analyser Houses Area Classification.

2.0 2.1

DEFINITIONS Technical Terms The technical terms used in this Specification are defined as follows: Combustible/Gas or Vapour Any substance that exists in the gaseous or vapour mixture state at normal atmospheric temperature and pressure, that is capable of being ignited when mixed with air. Ignition (Auto-ignition) Temperature The minimum temperature required at normal atmospheric pressure, to initiate or cause self sustained combustion of a flammable mixture independent of any external source of ignition. Intrinsically Safe Circuit A circuit in which any spark or thermal effect is incapable of causing ignition of a flammable mixture under test conditions specified by UL 913. Pressure Piling

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The increase pressure in that occurs as the ignition of flammable gas at one end of a passageway forces unburnt gas/air to travel through the passageway, so compressing it before the flame front. the higher compression ratio produces an increased explosion pressure. This effect is critically dependant on the passageway geometry and dimensions. FM Factory Mutual 2.2 Contractual The commercial terms used in this specification are defined as follows: Owner The oil or gas company, an associate or subsidiary, who is the end user of the equipment and facilities. Vendor The company supplying the equipment and material. Contractor The main contractor for a defined piece of work. Sub-Contractor A company awarded a contract by a contractor to do part of the work awarded to the contractor. Inspection Authority The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and facilities have been designed, constructed, inspected and tested in accordance with the requirements of this specification and the Purchase Order/Contract. Inspector A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority, who verifies that the equipment and facilities have been designed, constructed, inspected and tested in accordance with the requirements of this specification and the Purchase Order/Contract. 2.3 2.3.1 Codes and Standards General In general, the requirements specified herein are based on the ANSI/NEMA and other American Codes and Standards, the most important of which are listed below. Wherever applicable, equipment and materials shall comply with these Codes and Standards. Unless specified in the Purchase Order/Contract, the current editions of the codes and standards at the time of order shall be used. The Vendor/Contractor shall operate and supply certification for a Quality System complying with the requirements of ASQ Q9000 Series or BS EN ISO 9000, Part 1 (Design) Part 2 (Production) and Part 3 (Test and Inspection). 2.3.2 US Codes and Standards

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ANSI C39.5 ASQ Q9000 CSA 22.2 No. 30 FM Class 3615 ISA-RP 12.1 ISA-RP 12.6 Safety Requirements. Quality Management and Quality Assurance

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Explosion-proof Enclosures for use in Class I Hazardous Locations. I.S. Apparatus and Associated Apparatus for use in Class I, II and III, Division 1 Hazardous Locations. Electrical Instruments in Hazardous Atmospheres. Intrinsically Safe Instrumentation in Class I Hazardous Locations.

ISA-S 12.12 Electrical Equipment for use in Class I Division 2 Hazardous Locations. NEMA 250 NFPA-70 (Art.500) NFPA 493 NFPA 496 NFPA 497B UL 698 UL 886 UL 1203 2.3.3 Enclosures for Electrical Equipment. Hazardous (Classified) Locations. Intrinsically Safe Process Control Equipment for use in Hazardous Locations. Purged and Pressurised Enclosures for Electrical Equipment. Recommended Practice for the Classification of Class II Hazardous (Classified) Locations. Industrial Control Equipment for use in Hazardous (Classified) Locations. Outlet Boxes and Fittings for use in Hazardous (Classified) Locations. Explosion-proof and Dust-ignition-proof Electrical Equipment for use in Hazardous (Classified) Locations.

IEC and Other Recommendations When appropriate, equivalent International Standards which may be used as alternatives, are listed below and may be used with the prior approval of the Owner. Equipment and materials complying with IEC Recommendations shall be at least equal to the requirements of this specification. The Vendor/Contractor shall advise full details of any deviations to these requirements in his offer if IEC based standards are utilised. BS 5345: Parts 1-7 BS 6121 BS 6941 Code of Practise for Selection, Installation and Maintenance of Electrical Apparatus in Explosive Atmospheres. Mechanical Cable Glands for Elastomer and Plastic Insulated Cables. Specifications for Electrical Apparatus for Explosive Atmospheres

Electrical Apparatus for Potentially Explosive Atmospheres as follows: BS EN 50014 BS EN 50015 BS EN 50016 - General Requirements. - Oil Immersion "o". - Pressurised Apparatus "p".

GENERAL ENGINEERING SPECIFICATION ELECTRICAL EQUIPMENT IN HAZARDOUS AREAS

BS EN 50017 BS EN 50018 BS EN 50019 BS EN 50020 BS EN 50028 BS EN 50039 IEC 34-5 IEC 79: Parts 1-15 IEC 79: Part 18 IEC 60529 - Powder Filling "q". - Flame Proof Enclosures "d". - Increased Safety "e". - Intrinsic Safety "i". - Encapsulation "m". Specification for intrinsically safe electrical systems "i".

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Rotating Electrical Machines. Degrees of Protection by Enclosures for Rotating Machinery. Electrical Apparatus for Explosive Atmospheres. Electrical Apparatus for Explosive Gas Atmospheres Encapsulation 'm'. Degrees of Protection Provided by Enclosures (IP).

3.0 3.1

PROTECTION PHILOSOPHY Principles of Hazard Reduction The aim of regulations and standards for the use of electrical equipment in hazardous areas, is to ensure that the use of electrical equipment does not significantly increase the probability of loss of life or property damage due to a fire or explosion. The method of hazard reduction is based on the fact that for a fire or explosion to occur, both combustible material and a source of ignition must be simultaneously present. If either is absent, or if the probability of both occurring simultaneously is low, then little or no hazard exists. The probability of a source of ignition being present at a location is dependant on the selection, design and installation of the electrical equipment installed at that location. The probability of combustible material being present at a location is dependant on the design and operation of the process plant.

3.2

Area Classification The process known as Area Classification subdivides plants into areas based on the probability of combustible materials being present. The process is codified in national and international standards such as the NEC, CSA, IEC or CENELEC. Codes of Practice giving practical guidance on Area Classification are issued by user bodies such as the American Petroleum Institute, Instrument Society of America, or the Institute of Petroleum (U.K.). Refer to GES L.31 for full details.

4.0 4.1 4.1.1

PROTECTION METHODS AND CONSTRUCTION Explosion Proof/Flameproof (applicable to both North American and European practices) General This important type of protection is applied to instrument and electrical equipment. Explosion/Flameproof enclosures do not seek to exclude flammable gases and vapours from the interior

GENERAL ENGINEERING SPECIFICATION ELECTRICAL EQUIPMENT IN HAZARDOUS AREAS

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of the enclosure, and therefore the possibility of internal explosions occurring in the enclosure is accepted. The enclosure has sufficient mechanical strength to withstand the force of an internal explosion, and is constructed so that the products of the explosion are relieved via the enclosure entries. 4.1.2 Explosion/Flameproof Housings Explosion/Flameproof housings are characterised by rugged and heavy construction and wide flanges. The design of an Explosion proof housing in particular the flange gap is dependant on the specific gas group(s) and an enclosure designed and tested for one gas group would not necessarily be suitable for another gas group. Enclosures designed for hydrogen require much wider flanges and extremely narrow flange gaps. For this reason, particularly in European equipment, design tends to favour screwed joints. The flanges, conduit/cable entries and case construction of an Explosionproof housing are correctly designed for application in accordance with the certification. No modification such as the insertion of unspecified gaskets, the drilling of the case for the addition of labels, or addition, deletion or modification to the internal components are permitted. Explosion/Flameproof housings are suitable for Division 1 or Zone 1 locations but not Zone 0. Explosion/Flameproof enclosures are not necessarily "weatherproof", unless so stated by the Vendor/Contractor. Where no weatherproof certified enclosures are available the gaps may be enclosed or sealed by the use of suitable methods. 4.1.3 Cable Entries In the United States, conduit systems must be used for Class 1 Division 1 areas. Cables, other than mineral insulated cable, and cable for intrinsically safe systems, are not permitted (NEC Article 501-4). CSA and CENELEC\IEC allows the use of direct and indirect entry by armoured and metal sheathed cable with matching cable glands. The cable glands must be tested to an approved standard e.g. CSA Standard C22.2 No 174 or BS 6121 and must be of the "barrier" type unless the cable is adequately constructed with a filler and cable entry is indirect. Refer to BS 5345: Part 3: New Figure 1 Selection Chart for direct entry of cables into the flame proof enclosure. Most explosionproof boxes "breathe". Under conditions of high humidity water can accumulate in the bottom of the enclosure. Suitable explosion-proof drains shall be fitted to allow periodic draining of the enclosure. Explosion/Flameproof enclosures are not generally proof against the effects of electrical faults within the enclosure, e.g. short circuits. It is important, therefore, that all circuits supplying explosion/flameproof enclosures be equipped with electrical protection that cuts off the power in as short a time as possible. Fuses are often used for protection since they act quicker than circuit breakers where ground fault protection is not used. Care must be taken not to alter the internal airway dimensions of any Explosion/Flameproof apparatus to larger than the design figure. e.g. when skimming the rotor of a motor. The effects of "pressure piling" are significant and may be considerably affected by modifications. 4.2 4.2.1 Increased Safety - Ex "e" (European use only) General This important type of protection is normally applied to electrical equipment or parts of apparatus that do not produce sparks or dangerous temperatures in normal service e.g squirrel cage motors,

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transformers, some lighting fittings etc. The technique is not normally applied to instrumentation other than cable terminations and junction boxes. In addition to normal, sound construction practices additional measures are adopted to reduce the possibility of failure, and hence arcing or sparking of the normally non-sparking parts. These measures include: the use of insulation materials with a high degree of integrity; the temperature derating of insulation materials; enhanced creepage and clearance distances; particular attention to terminal design; protection against the ingress of solids and liquids; impact test requirements for the enclosure; the control of maximum temperatures (mainly applicable for equipment such as motors) in the case of motors control of air gaps and running clearances (fans etc.)

In addition measures shall be taken to ensure that no surface (internal or external) exceeds the maximum temperature associated with the temperature class for the equipment. Equipment with this type of protection is suitable for use in Zone 1 locations, and is increasingly being used instead of Explosion/Flameproof constructions. The protection concept is not recognised in North America, and therefore no guidelines exist for its use in Division 1 locations. The normal methods of construction to Ex 'e' standards require locking devices in terminals, minimum clearance on terminals and creepage distances on insulating materials, sealed cable entries with packing glands, robust enclosures which can withstand specified impact tests, and sealing to prevent the ingress of dust or moisture. Components such as terminals are often de-rated from their standard industrial current rating to limit any possible temperature rise. 4.2.2 Terminations and Junction Boxes Termination or junction boxes certified to an Ex 'e' standard can accommodate a differing number of terminals of various sizes. Each Ex 'e' box is given an enclosure factor or load limit which allows the user to calculate the number of terminals that can be fitted. Each terminal is allocated a maximum current rating, and the sum of the current ratings must be less than the load factor for the box. The certification applies only to apparatus assembled in the works by the Vendor/Contractor and Owner modification is not allowed. The Owner may drill cable entry holes in an enclosure to suit the installation. Variations have been approved by certifying authorities which allow for the derating of the terminal currents when used, for example, with thermocouples. The normal ingress protection (as defined in IEC standard 60529) is a minimum of IP65 but more typically IP66. 4.2.3 Motors Increased safety motors are more liberally designed than motors of normal construction in that they can, for example, be stalled at working temperatures for at least 5 seconds without any part of them, including the rotor, exceeding the temperature classification for the motor. The temperature on starting is also limited depending on the class of insulation. These restrictions frequently result in Increased Safety motors having a larger frame size than standard motors. The motor protection equipment is an integral part of the protection concept and the overload and overcurrent settings on the motor protection must be as specified in the certification.

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A critical parameter in the design and selection of Increased Safety motors is the "tE" time. This is defined as the time taken to reach a limiting temperature from the temperature reached in rated service. The motor protection device, if of the current dependant type should switch off the motor in the "tE" time appropriate to the temperature time. The majority of applications of Increased Safety motors are for continuous running duty. The selection of the motor is initially dependant on the maximum temperature that is allowed in accordance with the gas group or the maximum temperature of the insulation. 4.3 Intrinsic Safety Ex "i" (applicable to North American and European practices) This important type of protection is normally applied to instrument applications and is the only technique that may be used in Zone 0 applications. 4.3.1 General The term intrinsically safe properly applies to complete systems or equipment and wiring rather than the individual devices that make up a system. No single device or wiring is intrinsically safe by itself (except for battery operated equipment such as portable pagers, gas detectors, portable corrosion monitors etc). All standards define intrinsic safety with words similar to:"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 hazardous atmospheric mixture in its most easily ignited concentration". All intrinsically safe systems are therefore based on limiting the amount of energy available, under fault or normal conditions, to generate sparks or heat a component or surface. The energy required to generate a spark is related to the type of gas hazard present. The North American Intrinsically Safe systems are evaluated to the same fault conditions as the CENELEC/IEC "ia" category i.e. to include the two fault conditions. The CENELEC/IEC codes specify two types of Intrinsically Safe systems, one type "ia" suitable for Zone 0 applications and the other "ib" suitable for Zone 1 applications. The main difference between "ia" and "ib" is that the former is evaluated under normal, single-fault and two-fault conditions whilst the latter is restricted to normal and single-fault conditions. Under these definitions external wiring faults such as short circuits, open circuits and earth faults are considered to be part of "normal" operation. However, under the North American Codes, only one criteria exists for intrinsically safe systems suitable for Division 1 applications. For all practical purposes the "ia" type of intrinsically safe system may be considered to be interchangeable with the North American Intrinsically Safe Apparatus. Type "ib" intrinsically safe systems should not be used in Division 1 applications. Intrinsically Safe systems must refer specifically to the gas groups with which they can be safely used. The surface temperature must also be specified. The limiting of the electrical energy available under fault conditions to a safe level may be done by using intrinsically safe interfaces (associated apparatus) which have been approved or certified to have inherent energy limitations, or by interposing certified energy limiting equipment (barriers) between the unclassified area power source and the intrinsically safe devices in the hazardous areas. Certifying Authorities now adopt a modular approach to intrinsic safety which allows the user to assemble simple intrinsically safe systems on his own, using equipment from any Vendor/Contractor provided that it is electrically compatible and certified to the same standard. The Owner must ensure

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that the installation conforms to the assumptions made by the Vendor/Contractor and the Certifying Authorities when certification is issued. A combination of independently certified devices to form an Intrinsically Safe system is possible only if sufficient information exists to prove without doubt that the combination of devices into a system is intrinsically safe. The design, assessment and certification of intrinsically safe devices for use in hazardous areas is carried out by the Vendor/Contractor and Certifying Authorities and with the exception of cables, does not involve the Owner. The Owner, however, has the responsibility of ensuring that the system as a whole complies with the requirements for intrinsically safe systems. 4.3.2 I.S. Equipment located in Hazardous Areas The apparatus certificate will specify the maximum voltage, current and power that can safely be applied to the apparatus, and also the capacitance and inductance that the apparatus will add to the system. The information will allow the use of the apparatus as one of the blocks in an intrinsically safe circuit. Simple Apparatus, known in North America as "non-voltage" producing e.g such as thermocouples, resistive sensors, LED's and switches may be used in a hazardous area without certification. These do not generate sufficient power nor store enough energy to jeopardise the concept of Intrinsic Safety. CENELEC standard EN 50 014 states that "Devices in which, according to the manufacturer's specification, none of the values 1.2V, 0.1A, 20J or 25 mW is exceeded need not be certified or marked". This definition has also been accepted by Factory Mutual. There is no hard boundary between simple apparatus and certified apparatus because of the inductance and capacitance of simple apparatus. There are few guidelines but BASEEFA states that simple apparatus should not have an inductance exceeding 5% of the permissible cable inductance. No guidance is given on capacitance but the lower the operating voltage the better; for example barriers below 5v have no restriction on the capacitance which can be added to them. As a general rule the residual cable capacitance should be greater than 0.1F for 1500 ft (457 metres) of typical cable, after subtracting the sum of all the capacitance in the hazardous area. No concern need exist over normal simple apparatus such as switches, thermocouples, resistance thermometers etc. Simple apparatus can be added to certified systems without invalidating the system certificate. No limits are stated on the number of 'Simple Apparatus' that may be added but normally it is obvious when a system remains safe. For example an infinite number of switches or terminals would not alter the safety of a loop where a large number of thermocouples could generate more than 1V and would not be acceptable. If there is any doubt a specialist Vendor/Contractor should be consulted. When a switch has multiple contacts connected to both Intrinsically Safe and non-Intrinsically Safe circuits then adequate segregation must be allowed between the two circuits irrespective of the location of the switch i.e a clearance of 2 inches (50 mm) or an earthed metallic barrier is required between the field terminals. 4.3.3 I.S. Apparatus located in Non-Hazardous Areas Such apparatus is an integral part of Intrinsically Safe system and is normally the source of power for the hazardous area equipment. The maximum permitted voltage permitted with certified equipment or equipment utilising intrinsically safe interfaces is 250V. However, quite frequently visual display units or other equipment using cathode ray tubes operating at

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voltage levels considerably in excess of 250V are used in non-hazardous area systems forming part of an Intrinsically Safe system. It is accepted that under normal configurations it would require a multiplicity of failures for the high voltage of the CRT to break through to the hazardous area terminals and that therefore no significant risk occurs. The safety document supplied by the Vendor/Contractor should include a statement that the high voltage is adequately segregated or made safe by the use of surge suppressors. 4.3.4 Certified equipment (Associated Equipment) Where a loop is relatively simple and self contained it is usual for the non-hazardous area equipment to be certified as meeting the requirements for connection to the hazardous area equipment. The basic criteria for associated equipment is: Segregation of the hazardous area terminals from dangerous voltages and currents, from mains supplies. This refers to the signal paths as well as the power supplies. Limitation of voltage available to the hazardous area. Limitation of current available to the hazardous area terminals. particularly

The associated apparatus must match the requirements of the hazardous area equipment in all respects including the level of intrinsic safety and gas group. There is no temperature classification for this equipment because it is not exposed to flammable gases or vapours. 4.3.5 Intrinsically Safe Interfaces (Barriers) Where certified safe area equipment cannot be obtained the problem may be overcome by the use of intrinsically safe interfaces which limit a dangerous level of energy to the hazardous area. Shunt diode barrier connections to barrier earth must be secure and effective. The Intrinsically Safe Earth should be an insulated and identified earth conductor having not more than 1 ohm resistance to the neutral earthing system of the main electrical power system. The circuits on each side of the barrier must be free from any other connection to earth. It is also important that all hazardous area conductors and equipment are suitably insulated from earth. CENELEC standards require that the entire hazardous area circuit connected to a shunt diode barrier should be capable of withstanding a test voltage of 500V rms to earth and that the wiring should be insulated to a minimum of 0.008 inches (0.2mm) to withstand abrasion. Shunt diode barrier power supplies must be derived via a double insulated isolating transformer to avoid multiple earthing. The constraints, particularly in earthing, associated with the shunt diode, can be overcome by the use of more expensive galvanically isolated barriers. These are not referenced to earth via the barrier. The use of these barriers allows considerable operational flexibility in that systems such as earth leakage detection, or earthing either connection to produce a preferred mode of failure, i.e. "fail safe" circuits can be implemented. An isolating transformer is not required with isolating barriers. Appendix A outlines the procedure for selecting the correct IS. barrier type. inductance and capacitance these can store energy and can discharge. 4.3.6 Intrinsically Safe Cables An associated apparatus and intrinsically safe interfaces should specify the total capacitance and Since cables have

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inductance that may be connected. If the capacitance and inductance of the apparatus in the hazardous area is subtracted from this figure, the balance gives the maximum allowable for the cable. Normally, cable capacitance is a problem only with higher voltage sources and with gas groups B (II C) (hydrogen) and cable lengths exceeding 1500 ft (457 metres). It is worth noting that cable parameters for gas groups D(IIA) and C(IIB) are 3 and 8 times those for B (IIC) respectively. Cable capacitance and inductance will not normally require consideration with hazardous area cable sum of less than 3000 feet (914 metres). Intrinsically safe circuits should not be wired using cores in different cables. There are two ways of deciding as to whether a cable is safe from a stored inductive energy viewpoint: To keep the inductance below the specified level by knowing the cable length and its inductance per unit length (commonly less than 0.02 microhenries per foot). This is especially important in low voltage circuits. By assessing the value of the L/R ratio. The effect of resistance on inductive stored energy is significant since the maximum stored energy occurs when the line resistance matches the source resistance. Where this is less than the energy permitted in a pure inductor, the line is always safe. Where the L/R ratio is less than that specified in the cable certificate, the cable is safe irrespective of cable length.

In general, it is only in exceptional circumstances that the stored energy of cables presents a problem, especially if the cable is specified to standards such as BS 5308 in which both the capacitance and L/R ratio are specified. But the worst case loop calculations should be performed and results recorded.

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4.4 Encapsulation/ Sealing - Ex "m"

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Encapsulation, sealing or potting is the embedment of a component or assembly in a solid or semisolid medium such as plastic, ceramic, tar or grease. There may or may not be an additional enclosure surrounding the solid medium. This technique is normally considered to be suitable for Div 2/Zone 2 applications. It may however be combined with other techniques to give suitable protection for Div 1/Zone 1 applications. Solenoid valves are commonly protected by encapsulation, with the wire leads being made off in explosion proof or Ex e (increased safety) junction boxes. 4.5 Non-Sparking Ex "N" This important protection technique, which is suitable only for Div. 2 or Zone 2 applications, is based on the use of good quality industrial, weatherproof housings containing non-sparking or energy limited or protected sparking components. The requirements for type N apparatus are more stringent than those for "Division 2 approved" apparatus and hence the former should be used in preference to the latter (Refer to BS 5345: Part 7: Section 7). The technique is characterised by the following general requirements: Industrial apparatus which does not spark or become hot in normal service and is constructed to a minimum standard of reliability. Apparatus which does spark or get hot where the parts which spark or get hot are protected in some way, e.g. by encapsulation, by hermetic sealing, by use of a restricted breathing enclosure, or by being shown to be non-ignition capable.

Restricted breathing enclosures use gaskets and sealing devices to prevent the ingress of flammable material into the enclosure. It should be noted that the use of restriction breathing apparatus is prohibited in areas of limited natural ventilation. It is also prohibited in areas where gases having high diffusion rates or low flammable limits are present. Examples of such gases are hydrogen, acetylene, carbon disulphide, isopentane and isoprene. No modification may be carried out to type Ex'n' apparatus unless it can be verified that such changes do not invalidate the certification. All Ex'n' enclosures shall be marked with the temperature class. Ex'n' type protection is largely a British concept, and whilst widely accepted around the world is not currently covered by CENELEC standards. The current standards for Ex'n' are BS 6941, and IEC 79 Part 15. 4.6 Oil Immersion - Ex "o" A similar technique to powder filling in that a protective liquid restricts the flow of flammable gas to the equipment and quenches any arcing. This protective liquid is normally mineral oil conforming to IEC 296 (BS EN 50015) states constructional requirements for other liquids as well as verification tests for overpressure in both the sealed and unsealed enclosure. This technique is more commonly associated with power electrical equipment, but may occasionally be encountered for instrument applications. One such example is a data acquisition system employed in

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the off-shore wellhead area. This type of protection is normally suitable for Zone 2 only. 4.7 4.7.1 Purged or Pressurised - Ex "p" General Purging and pressurisation systems reduce the concentration of any flammable gas or vapour to an acceptably safe level by initially purging the enclosure with clean air or gas and then preventing a flammable atmosphere from entering the enclosure by maintaining a small positive pressure inside the enclosure. Pressurised enclosures having an internal source of flammable gas or vapour, e.g analyzer enclosures are not included within this specification. Purging and pressurization protection may be used in either Zone 1 or Zone 2 and Division 1 or Division 2. Different actions are required on detection of a failure of the purge or pressurising system depending on the classification of the location of application. Pressurisation/purging can be applied for the protection of any electrical equipment contained in an enclosure. Pressurisation/purging may be the only practical method for installing some equipment in Group A or Group B hazardous locations since the safe gap for gases such as acetylene and hydrogen is so small that large explosion/flameproof housings are impractical. 4.7.2 Enclosures The protected enclosure, including windows, shall be of substantial construction, so that it is not likely to suffer damage during shipping, erection, and operation. Windows should be inch (6 mm) tempered glass, shatterproof glass or other shatterproof material suitable for the environment and conditions of use. Enclosures containing power equipment shall be of substantially non-combustible construction. General purpose ingress protection e.g. to IP 54 may not be suitable for sealing a pressurised enclosure because the seal acts in the reverse direction; i.e. is not intended to retain internal pressure. The Vendor/Contractor's standard sealing should be used. The enclosure working pressure shall be 0.2 inches water gauge (0.05 kPa). The North American standard differs from the IEC\CENELEC requirement, being 0.1 inches water gauge (0.025 kPa). The more stringent standard may be selected. The enclosure, ducts, and connecting parts shall be able to withstand an overpressure equal to 1.5 times the maximum overpressure specified in normal service with a minimum of 0.8 inches water gauge (0.08 kPa). The protecting devices and the protective gas ducting shall be designed to prevent the escape of sparks or burning material. Doors and covers which can be opened without the use of a special purpose tool shall be interlocked with the electrical supply so that the supply is disconnected automatically when they are opened and so that the supply cannot be restored until they are closed.

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4.7.3 Pressuring System

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The protective gas used for purging and pressurisation should be non-combustible. Air is normally used, although an inert gas such as nitrogen may be used. The gas should not contain more oxygen by volume than that normally present in air. Where air is used, the source shall be located in an un-classified area usually in such a position as to reduce the risk of contamination. Instrument air is commonly used provided that the air consumption of the purge system(s) does not impose a significant demand on the instrument air system. An automatic device, e.g. pressure switch, shall be provided to operate when the overpressure falls below the minimum working value. The device shall generate an alarm or shall automatically remove power from ignition capable devices, if positive pressure is not maintained. The alarm actuator shall take its signal from the protected enclosure and shall not be installed between the enclosure and the protective gas supply. No valve shall be installed between the alarm actuator and the enclosure. Conduit used to provide mechanical protection for wiring to a system may also be used to supply protective gas to an enclosure. Care must be taken that the conduit sealing requirements do not affect the flow of protective gas. Where several pressurised enclosures are purged and pressurised from a common source of protective gas care must be taken that the pressures in the protected enclosures do not fall below the minimum acceptable over pressure when it is necessary to purge one or more enclosures. For this reason individual regulators for each enclosure are preferred. 4.7.4 Purging System Pressurised enclosures should be purged before switching on the electrical supply both during the initial commissioning period and when recommissioning after loss of protective gas or after the enclosure has been opened. At least 5 volume changes are required for small enclosures but a minimum of 10 volume changes shall be required for electric motors and large enclosures of the order of 10 ft3 (0.3m3). If the ratio of maximum internal dimensions to the minimum exceeds 10 to 1 multiple purge gas inlets should be considered to eliminate any possible pockets of combustible material. Where the density of the combustible gas is lighter than the protective gas, the protective gas inlet should be at the bottom of the enclosure and the purging outlet(s) at the top. Where the density of the combustible gas is heavier than the protective gas, the protective gas inlet should be at the top of the enclosure and the purging outlet(s) at the bottom. 4.7.5 Safety Devices Safety devices should be installed to monitor both the purge and pressurisation of an enclosure. The purge monitoring devices should monitor a positive purge flow and also the time of purge flow. Automatic systems for operating the purge vents may be included in the purge monitoring system. Any device used to monitor the closing of enclosure doors or covers should be additional to devices used to monitor over-pressure. All monitoring devices, including timers etc shall be suitable for the area classification, and gas group and be independent of the protection offered by the pressurised enclosure. Intrinsically safe systems are suitable for these functions and are frequently used. The action following the detection of an underpressure is dependant on the application and the applicable codes:

GENERAL ENGINEERING SPECIFICATION ELECTRICAL EQUIPMENT IN HAZARDOUS AREAS

Under the North American codes (NFPA 496) three types of protection are defined:Type X Type Y

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Reduces the classification within an enclosure from Division 1 to un-classified. Reduces the classification within an enclosure from Division 1 to Division 2, which permits the use equipment suitable for installation in Division 2 areas inside the enclosure. Reduces the classification within an enclosure from Division 2 to un-classified.

Type Z

CENELEC standard EN 50 016 and IEC 79-2 only specify one level of protection and it is left to the user to decide as to whether the failure of the enclosure over-pressure should generate an alarm or the removal of power supplies. In practice no real conflict exists between these documents, and the North American requirements are therefore regarded as typical. Type X protection allows the use of un-certified ignition capable equipment within an enclosure located in an area where the atmosphere is presumed to be frequently flammable. Because the pressurisation/purge is the only safeguard its failure must automatically remove power from all circuits that are not suitable for Division 1. The door or cover must be fitted with an automatic disconnect switch. A purge timer should also be included. Type Y protection requires the equipment installed in the enclosure to be suitable for operation in Division 2 locations. No interlocks are required, because an explosion can only occur after the pressurisation/purge and the equipment has failed. A protection failure alarm is required. The unit shall be fused so that in the event of a wire arcing to the case, the arc will not burn through the case or raise the external surface temperature to 80% of the ignition temperature of the gas or vapour involved. The relationship between the maximum fuse size, case thickness, and the gas or vapour expected outside the enclosure is given in ISA S12.4. Type Z protection does not require any interlocks but does require protection failure alarms. 4.7.6 Temperature The temperature number (T number) shall be the highest of the following:The hottest enclosure surface temperature; The hottest internal component surface; The temperature of the protective gas leaving the enclosure.

The casing temperature of Type Z enclosures should not exceed 80% of the ignition temperature of the gas or vapour when the equipment is operated at 125% of the rated voltage. If any internal surface temperature might exceed 80% of the ignition temperature of the gas or vapour, then warning plates must fixed to the exterior of the enclosure that a delay of "x" minutes must be allowed to elapse after power removal to allow the unit to cool to a safe temperature. 4.8 Powder Fillings - Ex "q" Powder filling using quartz or glass particles is applicable only to apparatus without moving parts in contact with the filling material. Note that this type of protection does not prevent the surrounding explosive atmosphere from entering the apparatus and Ex components. The concept relies on two factors to achieve safety; the small free volume in the filling material and the short flame path in the filling material. Together, these two factors help to prevent an external explosion. The enclosure is normally required to have a degree of protection to IP54 as defined in EN 60529. Enclosures with the degree of protection IP55 or higher are provided with a breathing device but are

GENERAL ENGINEERING SPECIFICATION ELECTRICAL EQUIPMENT IN HAZARDOUS AREAS

still required to comply with the degree of protection IP54.

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Enclosures with an "X" in their certification are normally intended for use in clean dry rooms and the degree of protection offered by such enclosure is IP43. All apparatus bearing the letter "X" need to be closely checked for their conditions of use and installation. Powder filling is not usual under the North American system, and is rarely used for instrumentation. It is normally considered suitable only for Zone 2 applications. 4.9 Special - Ex "s" This type of protection applies new protection techniques or a combination of existing techniques which do not meet the requirements of the recognised types of protection, but which can be shown by test or otherwise to be suitable for use in classified areas. The general requirements are set out in SFA 3009 and include encapsulation and hermetic sealing requirements etc. The relevant Code of Practice is BS 5345, Part 8. In theory, the UK Code of Practice and other documents permit the use of type "S" apparatus, specifically certified for Zone 0. In practice, however, the application of this concept is very much limited. 4.10 4.10.1 4.10.1.1 Construction Electrical Protection Methods General (a) The philosophies controlling the use of electrical equipment in hazardous areas is not an exercise in absolutes but rather in low probabilities. The installations should not increase the probability of fire or explosion above that which existed before the equipment was installed.

(b) Two basic methods of construction are employed: - To allow ignition, but to control it in such a way that combustion does not cause damage e.g. explosion proof. - To eliminate the source of ignition by either ensuring that no source is capable of imparting sufficient energy to the flammable material to cause ignition e.g. intrinsically safe, or by controlling the atmosphere at an ignition source e.g pressurised equipment and encapsulation. (c) The probability of fire or an explosion occurring is the product of the individual probabilities of the flammable material and source of ignition being present. It follows therefore that equipment designed for use in Div 1 (or Zone 0/1) areas should have a lower probability of being the source of ignition than equipment for use in Div 2 (or Zone 2) areas. This is recognised worldwide and has led to systems of protection method approval and equipment certification which are based on the area classification of the location of use and the materials (gas) groups. Equipment suitable for the more restrictive Divisions (or Zones), is of course automatically suitable for the less restrictive Divisions (or Zones).

4.11

Temperature Classification (a) Flammable mixtures may be ignited by hot surfaces, and therefore the maximum temperatures of surfaces to which the flammable gas has access is of importance in the selection of equipment for

GENERAL ENGINEERING SPECIFICATION ELECTRICAL EQUIPMENT IN HAZARDOUS AREAS

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use in hazardous areas. Where the enclosure forms part of the protection, e.g. explosion proof, only the temperature of the enclosure needs to be considered, but where the flammable atmosphere is deemed capable of penetration, e.g, Intrinsically Safe (I.S)., the temperature of all components within the enclosure has to be taken into account. (b) Internationally recognised temperature codes for the marking of electrical equipment for use in hazardous areas are given in Table 3 above. These codes assume an ambient temperature not exceeding 104F (40C). Where ambient temperatures in excess of 104F (40C) are encountered the Vendor/Contractor should confirm the suitability of the equipment for the application. Under the North American system, enclosures containing equipment of the non-heat producing type, e.g. junction boxes, conduit and fittings, and other equipment of heat producing types, such as instrument transmitters and transducers having a maximum temperature of not more than 212F (100C) need not be marked. In Europe, junction boxes are frequently awarded T6 = 185F (85C) since they do not contain heat dissipating components. In practice, a rating of T4 = 275F (135C) covers most application encountered in the oil and gas industries, since only two little used chemicals - carbon disulphide and ethyl nitrate - have ignition temperatures requiring a temperature classification lower than this.

GENERAL ENGINEERING SPECIFICATION ELECTRICAL EQUIPMENT IN HAZARDOUS AREAS

Table 4 - Gas Groups and "T" Rating Material Ignition Temp F (C) 581 (305) 869 (465) 928 (498) 928 (498) 550 (288) 1121 (605) 216 (102) 499 (260) 959 (515) 1040 (560) 518 (270) 464 (240) 1103 (595) 878 (470) 536 (280) 469 (243) 410 (210) 896 (480) 869 (465) Gas Group North American A D D D D D B D D B C D D D D D D D D Gas Group IEC/Cenelec IIC IIA IIA IIA IIA IIA IIC IIA IIA IIC IIB IIA IIA IIA IIA IIA IIA IIA IIA

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"T" Rating

Acetylene Acetone Ammonia Benzene Butane Carbon Monoxide Carbon Disulphide Cyclo-Hexane Ethane Hydrogen Hydrogen Sulphide Hexane Methane Propane Gasoline (60 Octane) Pentane Kerosene Toluene Xylene Notes 1.

T2 T1 T1 T1 T2 T1 T1 T1 T1 T1 T3 T3 T1 T1 T3 T3 T3 T1 T1

These values have been taken from NFPA 497M and BS 5345 Pt 1 (IEC79). There are differences in some of the ignition temperatures between the two standards because of the differing test methods. Where this has occurred the lower of the two values has been used. It is important to be aware that there is no correlation between the ease of ignition by hot surfaces and by sparks; the two mechanisms of ignition being entirely different. For example hydrogen is much more easily ignited by a spark (20J) than acetaldehyde (150J), but has a high ignition temperature of 968F (520C) compared to 284F (140C) for acetaldehyde. Information on the ignition temperature of a number of gases is given in NFPA 497-M-1991, NFPA 325M-1991, (BS 5345 Part 1 and IEC 79-12). A list of the properties of some gases/vapours and the corresponding gas groups and temperature classification is given in Table 4 above. Note that natural gas is normally assumed to be close to methane for gas grouping purposes.

5.0

CERTIFICATION AND APPROVAL

GENERAL ENGINEERING SPECIFICATION ELECTRICAL EQUIPMENT IN HAZARDOUS AREAS

5.1 General

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The certification of electrical equipment for use in hazardous areas is a significant aid to plant designers and users. Most countries require that employers provide a safe workplace, and the use of certified equipment is accepted as an important demonstration of the owners intention to comply with that requirement. For the certification to have any validity, it must be carried out to standards and the testing must be carried by agencies who have the facilities and technical capabilities to implement the requirements of the standards. In most countries the standard setting bodies are not the same as the testing and certification bodies e.g. in the U.K. the standard setting body is the British Standards Institute, whilst the recognised testing and certification body is BASEEFA. In Canada on the other hand, CSA is both a standard setting and testing body. The CSA will also allow other certifying bodies, e.g. BASEEFA to test and certify to CSA standards. In the USA, both FM (Factory Mutual) and UL (Underwriters Laboratories) are both standard setting and testing bodies. They do not allow other testing bodies to test and certify instruments to their standards. Some international bodies exist which are attempting to harmonise various national standards. The most prominent of these are the International Electrotechnical Commission (IEC) and CENELEC. 5.2 IEC The IEC is the official international organisation for the electrotechnical standardisation in the field of international commerce. It is affiliated to the International Organisation for Standardisation, but has autonomy. The objective of the IEC is to ensure that all member countries have identical standards. Most national bodies are represented on the IEC technical committees, and are recommended to adopt the texts of the standards as far as national conditions permit. The IEC specifications covering the use of instruments in hazardous areas form part of the IEC 79 series. 5.3 CENELEC CENELEC (Centres European Des Normes Electrique) has the task of harmonising the electrical standards of its member countries. CENELEC standards are then adopted as national standards without modification. It could use IEC standards without change and may do in the future, but at present develops its own using an IEC standards as its basis. It is an European concept derived from the wish to eliminate non-tariff barriers to trade within Europe. There are, at present, seventeen member countries, comprising the European Community member states and Norway and Switzerland. CENELEC is a standards writing authority not a certifying authority. Equipment may be certified to CENELEC standards by the national testing bodies. Equipment certified to CENELEC standards are denoted as EEx. 5.4 UL/FM In the United States the largest and most widely recognised certification agencies are the Underwriters Laboratories (UL) and Factory Mutual (FM). In addition to certification, both organisations prepare

GENERAL ENGINEERING SPECIFICATION ELECTRICAL EQUIPMENT IN HAZARDOUS AREAS

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standards which are substantially based on the requirements of the National Electrical Code. The NEC frequently refers to approval by the "code enforcing authority" who may be a local inspector, an insurance representative, or a municipal authority such as a fire marshall. Certifications by UL and FM are recognised in most jurisdictions, although in some particular locations, e.g. Chicago, FM certification does not appear to be recognised. 5.5 CSA In Canada the Canadian Electrical Code, similar in content and format to the National Electrical Code, is the reference for electrical equipment installations. Both the writing of standards and the certification of equipment is carried out by the Canadian Standards Association (CSA). Certifications by CSA are subject to acceptance by an Approvals Council representing all ten provinces and the cities. Certifications by the CSA are recognised nationally. CSA certification is not necessarily acceptable in the USA.

6.0 6.1

NORTH AMERICAN/EUROPEAN DIFFERENCES General The protection concepts specified under the North American and IEC/CENELEC systems are similar in concept but differences in standards, test methods and the area classification system have resulted in differing design features. Components certified under one system may not be interchangeable or equivalent to components circuits under the other. The protection concept is not recognised in North America, and therefore no guidelines exist for its use in Division 1 locations. Statutory requirements vary and do not normally refer to specific standards. The normal statutory requirement is that all reasonable steps are taken to make an installation safe. In general users should use components that conform to a to a common certification standard. Where components certified under differing systems are intermixed, the responsibility lies with the Owner to ensure the safety of the total installation. In North America the accepted additional protection methods are encapsulation (sealing), hermetically sealing, oil immersion and non-incentive. The additional methods are not covered by North American standards other than ISA -S12.12 and CSA C22.1 (CEC Part 1) C22.2-157 and C22.2-213 which cover non-incentive equipment. Their use under the North American system is generally limited to Division 2 locations. Standardisation under the CENELEC\IEC is more comprehensive, and standards exist for the aforementioned protection methods together with other concepts not included in the North American system e.g. Ex'e' (increased safety) and Ex 's' (special precautions)

6.2

Explosionproof and Flameproof In practice, explosionproof enclosures certified to North American standards may be regarded as being interchangeable with flameproof enclosures certified to IEC/CENELEC standards, but some differences exist as given below. In the United States, conduit systems must be used for Class 1 Div 1 areas. Cables, other than mineral

GENERAL ENGINEERING SPECIFICATION ELECTRICAL EQUIPMENT IN HAZARDOUS AREAS

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insulated cable, and cable for intrinsically safe systems, are not permitted (NEC Article 501-4). Canadian and the IEC/CENELEC regulations allow the use of direct entry by armoured and metal sheathed cable with matching cable glands.(Tested to the requirements of CSA Standard C22.2 No 174 for Canada). It is a requirement in the USA and Canada that seals be used in all conduit leaving a hazardous areas within 18 inches (450 mm) of the enclosure. Testing and certification of the enclosures is based on this requirement. This is not a requirement for IEC/CENELEC so it is recommended that, where conduit is used with flameproof enclosures to IEC/CENELEC standards, conduit seals are placed at the entry to the enclosure. In the USA enclosures must be of metallic construction. Canada and IEC/CENELEC standards allow the use of small volume non-metallic enclosures. IEC/CENELEC recommendations do not allow the use of flameproof enclosures alone as being suitable for ZONE 0 applications, since it does not provide for the possibility of two independent faults. Under the North American system explosion proof enclosures are allowed for use in Div 1 which embraces Zone 0 and Zone 1. It is unlikely however that explosionproof housings would be used in a Div 1 area in which an explosive atmosphere would constantly be present (e.g. inside a tank) without some additional protection. 6.3 Purging and Pressurisation No practical differences other than the working pressure and purge time. The working pressure under the North American system is 0.1 inches of water (0. 25 mbar) whilst in the CENELEC\IEC system it is 0.2 inches of water (0.5 m bar). The purge time under the North American system allows for four enclosure volumes, whilst under CENELEC\IEC it is the time for five volumes. EN 50016 (BS 5501 Part 8) makes an additional requirement that the enclosure shall have a degree of ingress protection in accordance with at least IP 40 of IEC 144. The differences in action following failure of pressurisation, between the two systems (Section 4.7.5) should be noted. 6.4 Intrinsic Safety Differences exist in the design and testing procedures for IS devices and systems because of the differing requirements under North American and IEC/CENELEC standards. These differences do not, with one exception, have a significant impact on the user. The main difference, as far as the user is concerned is a consequence of the differences in the systems of area classification. Under the IEC/CENELEC rules, IS systems for use in Zone 0 and Zone 1 have differing and specific criteria for certification. For Zone 0 applications the fault criteria is normal operation and two independent faults and the type designation is "EExia". For Zone 1 applications the specification is less stringent, the fault criteria being normal operation and one fault. The type designation is "EExib" . The North American criteria for Div 1 application is similar to that for ZONE 0, i.e. normal operation and two faults, since Div 1 is the equivalent to Zone 0 and Zone 1 and the more stringent condition must apply. since this is the equivalent of both Zone 0 and Zone 1. It follows that only CENELEC/IEC "EExia" certified devices or systems may be used in Div 1 Classified Areas.

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7.0

EQUIPMENT MARKING All electrical equipment for use in hazardous areas must be marked in a legible and durable way and in a visible position. In Europe, the marking must include the manufacturer's name and trade mark, the Class and Group for which approved, the protection technique employed e.g Explosionproof or Ex"d", The ambient temperature rating, the testing standard, certificate number and the certification authority, and the temperature classification. The letter "E" is used to certify that the equipment is suitable for use in hazardous areas. If the equipment has been certified to a CENELEC standard an additional "E" is added. Typical European marking for equipment installed in a classified area and certified to a CENELEC standard would be :EExd IIB T5 BS 5501 Part 5, EN50.018 BASEEFA No Ex811077x. Certified associated equipment, even though installed in an un-classified area will have a marking which indicates compliance with a standard e.g (EEx ib) IIC indicates compliance with a CENELEC standard for use with intrinsically safe equipment located in a Zone 1, Gas group IIC area. The North American marking system is different from the system used in Europe in that the protection technique need not be included. The marking will however include the hazardous area classification in which the equipment can be used. The marking must include the vendor's name, trademark, electrical ratings, ambient temperature, and the maximum operating temperature or temperature code. In addition the enclosure must include a nameplate with the following or equivalent statement: "CAUTION. To prevent ignition of hazardous atmospheres, disconnect the device from the supply circuit before opening. Keep assembly tightly closed when in operation". Typical North American would be:Division 1, Class 1, Group C & D, Temperature Class T3A.

Pressurised/purged enclosures shall additionally give the following information: The internal free volume. The type of protective gas (where air is not used). If an inert gas is used which could lead to a risk of asphyxiation, a suitable warning label shall be fixed to the enclosure. The minimum quantity of gas required to purge the enclosure. The permissible overpressure. The cooling down period (if applicable) necessary before opening the enclosure after removal of the power supplies.

8.0 8.1

INSTALLATION General Any apparatus which includes the capital letter "X" in its certification, should be closely scrutinized for its conditions of use as some of these conditions are likely to be of special nature e.g. special cable used in an I.S system.

GENERAL ENGINEERING SPECIFICATION ELECTRICAL EQUIPMENT IN HAZARDOUS AREAS

8.1.1 Explosionproof and Flameproof

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Installation, inspection and maintenance for CENELEC equipment shall be to BS 5345, Part. Table 1 lists the inspection requirements. 8.2 Enclosure All unused openings must be closed so that the explosion/flameproof properties are maintained. The closing devices shall not easily be removed from the outside, and shall either have either an internal retaining device, or need special tools for their removal, or be secured by means of special fasteners. The use of gaskets is not allowed unless certified by the Vendor/Contractor as part of the equipment. Suitable sealing methods are non-setting greases and approved anti-corrosive agents. Tape may be used with Group D (IIA) apparatus, but not C (IIB), B (IIC) or A (IIC). Flange gaps or screw threads shall not be painted after installation. Gaps should be free of corrosion, dirt and paint. Breathing and draining devices may be fitted but must be explosion/flameproof and incapable of incorrect assembly. Fixing holes must not breach the wall of the enclosure and must only be present as included by the Vendor/Contractor. Confining bolts should be complete and tight. Other equipment close to the apparatus should have adequate clearance. 8.2.1 Conduit and Cables The cable entry, whether conduit or cable gland, is required to preserve the integrity of the enclosure which it enters. In the USA NEC Article 501-4 requires the use of conduit or mineral-insulated cables for all applications in Class I Div 1 areas. CSA and IEC\CENELEC standards additionally allow armoured cable. The requirements for conduit under the North American and IEC/CENELEC systems are similar except for the positioning of conduit seals. NEC (and CSA) requires that seals be placed in conduits within 18 inches (450 mm) of enclosures. The equivalent enclosures certified under the IEC/CENELEC systems assume that seals are installed immediately at the point of entry of the conduit into the enclosure. There shall be no union, coupling box, or fitting between the seal fitting and the point at which the conduit leaves a classified area and an area of lower classification. Conduit must be installed so as to prevent water accumulation. In Div 1 locations the entire conduit system should be explosionproof whereas in Div 2 locations the conduit system need only be explosionproof between the enclosure and the sealing fittings. Sealing fittings must be accessible and mounted in the orientation for which they were designed. The pouring hub should be above the sealing cavity. Sealing compounds shall not be moisture absorbing materials. No splices, joints or taps are allowed in sealing fittings. Barrier glands, approved in accordance with the area classification, shall generally be used for direct

GENERAL ENGINEERING SPECIFICATION ELECTRICAL EQUIPMENT IN HAZARDOUS AREAS

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cable entry to Flameproof enclosures. Refer to BS 5345, Part 3, New figure 1 - Selection Chart for direct entry of cables into flameproof enclosures. Barrier glands shall include an epoxy putty to form a solid seal around the cable cores and should be filled to the top. Glands shall be correctly sized for the enclosure screw thread and cable dimensions. Gland adaptors should not be used since the extended length will be unlikely to comply with the impact test requirements. All conduit connections must be designed to ensure five full thread engagement of rigid conduit. All unused openings must be plugged with plugs having not less than five thread engagement. Under the North American codes it is required that approved sealing devices be used in all conduit, within 18 inches (450 mm) of the enclosures. Seals are also required in all conduit leaving DIV 1 areas, and in all conduit 8.0 2 inches (50 mm) or larger entering junction boxes with splices or terminals. The IEC\CENELEC codes also require seals to be fitted in conduit but specifies them to be fitted at the point of entry to the enclosure. 8.2.2 Earthing Metal enclosures for instruments shall include an earthing terminal both inside and outside the enclosure. The external terminal shall be sized for a minimum of 2 AWG (35 mm) conductors, whilst the internal terminal shall be sized for a minimum of 12 AWG (4mm) conductors. The electrical continuity of earth paths through joints between armoured cable and an enclosure, between two parts of conduit etc should be ensured by the joint itself. Locknut bushings should additionally have bonding jumpers to ensure good earthing. Flexible metal conduit must not be used as an earthing bond but must have independent earthing conductors. The use of thread tape for glands or conduit shall not be allowed since it may defeat the integrity of the earth bonding.

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8.2.3 Isolation

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Means shall be provided to isolate all conductors, including the neutral, from all electrical supplies. It shall be possible to lock the isolator(s) in the off position to prevent the restoration of supply when the enclosure is open to a flammable atmosphere. 8.3 8.3.1 Purged\Pressurised Systems Enclosure The enclosure shall be able to withstand an overpressure of at least 50% greater than the maximum overpressure specified for normal service. Suitable safety devices shall be fitted if an overpressure can occur in service that may cause any dangerous deformation of the enclosure or ducts. The enclosure shall be protected against the ingress of liquids. The protection shall not rely on the overpressure within the enclosure. The enclosure materials shall be suitable for the environment in which it is installed, and should be located in an area where it is unlikely to suffer physical damage. 8.3.2 Conduit and Cables Conduit may be used to supply the protective gas in addition to mechanically protecting the wiring. Care must be taken that cable seals do not affect the flow of protective gas. The temperature of the protective gas shall normally not exceed 104F (40C) at the inlet to the enclosure. Where this temperature is exceeded, it shall be marked on the enclosure. Where the density of the combustible gas is lighter than the protective gas the protective gas inlet should be at the bottom of the enclosure and the purging outlet(s) at the top. Where the density of the combustible gas is heavier than the protective gas the protective gas inlet should be at the top of the enclosure and the purging outlet(s) at the bottom. Electrical devices for the operation of purge vents shall be suitable for application in accordance with the area classification. Any automatic timing systems (for the purge sequence) and any electrical door interlocks shall be suitable for application in accordance with the area classification. The protective gas shall, as far as is reasonably practicable, be free from any foreign materials and flammable gas or vapours. Normally instrument air shall be the purge medium but nitrogen or other nonflammable gas may be used. Where double pressurisation is used, e.g. an enclosure containing ignition capable devices inside another enclosure in a Div 1 area, the protective gas supplies shall be independent. No modification shall be carried out to the enclosure sealing since this may alter the purge/pressurisation characteristics of the enclosure. 8.4 8.4.1 Intrinsically Safe Intrinsically Safe Systems The most important requirement for the installation of an intrinsically safe system is to ensure that the installation conforms to the requirements of the Vendor/Contractor and the certification. The selection of cable and system design should ensure that the parameters or certification documents and Vendor/Contractor's instructions are not exceeded. All such calculations should be recorded.

GENERAL ENGINEERING SPECIFICATION ELECTRICAL EQUIPMENT IN HAZARDOUS AREAS

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During the life cycle of the plant, the I.S. systems must be properly maintained, faults reported and modifications recorded. For example, instrument technicians must be fully trained in the installation and maintenance aspects of the I.S. systems. Since the technique of intrinsic safety relies on the limitation of energy to the classified area, most of the installation requirements reflect the need to avoid invasion from high energy sources. 8.4.2 Cabling\Wiring The wiring/cabling of an intrinsically safe circuit should not exceed the surface temperature appropriate to the temperature classification of the system. Assuming that the wiring is based on copper conductors, then temperature class T4 will be achieved if the current is related to the conductor cross-section as follows:Table 2. Maximum Cable Currents Wire Gauge 24 12 Cross Sectional Area (mm2) 0.2 3.3 Maximum Current (amps) 5 8

The conductors of cabling shall have a minimum radial insulation thickness of 0.012 inches (0.3 mm) or be mineral insulated. The cable should be capable of withstanding a test voltage of 500 v rms between any core and the rest of the cable. Screens shall be insulated from the armouring or any other metalwork external to the cable. Intrinsically safe systems which have different earth references or are derived from differing power sources, or which are certified for use in different groups should not be mixed in a single cable. Intrinsically safe wiring should be separated from other wiring by the use of separate raceways, conduit, cable trays etc. If this is not practical the intrinsically safe wiring should be separated from the nonintrinsically safe wiring by partitions or a spacing of 2 inches (50mm). Where intrinsically safe cabling is used for Zone 0 applications or Div 1 areas where flammable gases or vapours are frequently expected to be present, then interconnecting cables containing more than one intrinsically safe circuit should not be used unless it can be shown that no combination of faults between the circuits in the cable can lead to an unsafe condition. The method of cable entry to apparatus should be such as to minimise the risk of mechanical damage to the cable. In practice this means that a cable gland should always be used. Intrinsically safe cabling should be clearly identified as such preferably by the use of a light blue sheath. In the absence of suitably sheathed cable it shall be identified at labels or light blue tape at junction boxes, marshalling cabinets etc.. 8.4.3 Junction Boxes and Marshalling Cabinets Junction boxes do not require specific approval for use in intrinsically safe systems provided that the enclosure provides a degree of environmental protection appropriate to the location. However, Ex"e" certified junction boxes are normally used. Some Ex"e" terminals are made out of brittle material and these shall be avoided. The terminals in a junction box should have a clearance between terminals of separate circuits or between terminals and earth of at least inch (6mm).

GENERAL ENGINEERING SPECIFICATION ELECTRICAL EQUIPMENT IN HAZARDOUS AREAS

GES L.35 Page 29 of 30 Rev 0 1999

In general separate junction boxes should be used for intrinsically safe and non intrinsically safe circuits. Where the connection of intrinsically safe and non-intrinsically safe circuits in the same junction box is unavoidable, then they shall be separated by at least 2 inches (50 mm) either directly or around an insulating or earthed metal barrier. All spare conductors shall be shorted and connected to the I.S. earth. It is advisable that blue terminals be used in the junction boxes. All I.S. Junction boxes should be clearly marked as such by means of a stainless steel label. 8.4.4 Earthing Intrinsically safe systems should be earthed at the I.S. bar only, and should be insulated from all other earths. The Intrinsically safe earth should have a minimum isolation of 1 Megohm from other earths at 500V rms with the I.S. earth bar disconnected from the main electrical power earthing system. The cross section area of I.S. earth conductor must be greater than 12 AWG (4mm2). Earthing cable should be duplicated in order to facilitate periodic impedance testing. Barrier earth bar to main power system earth (at the neutral point) resistance must not exceed 1 ohm. The I.S. earthing cable should carry a warning label repeated every 3 feet (1 metre) with the warning "Intrinsically Safe Earthing Cable - Do Not Disconnect". 8.4.5 Selecting a Zener Barrier (See Figure 1 - Page 31) Care needs to be taken when reading Zener barrier specifications. In a barrier described as 28V, 300 ohm, 93mA: 28 V is the maximum open circuit voltage, 300 ohm is the minimum value of the terminating resistor and 39 mA is the resulting maximum short circuit current Thus the zener barrier specification is purely an indication of the potential fault energy which can be transmitted to the hazardous area. It neither refers to the working voltage of the device nor does it indicate its end to end resistance. End to end resistance is the resistance between both ends of a barrier; this being the sum total of resistance value of the resistors and the fuse. 9.0 9.1 9.1.1 9.1.2

DOCUMENTATION Introduction This section covers the documentation required for the design, selection, fabrication, inspection and testing for all the equipment, components and services to be provided against this specification. The detailed list of documents that are required is included with the Purchase Order/Contract, and reference shall be made to the relevant GES equipment specification.
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