‘Scanned by CamScannerMINAR PROCEEDINGS TECEX 2003 Fire / Explosion Triangle ri A ignition | Flammable / ‘ Substance / __\ The first two components must be present in sufficient quantities to form a potentially explosive atmosphere. Oxygen These oxidation reactions normally involve the release of heat and pressure, which are the major criteria of an explosion. A LPG gas stove provides the 4 simplest example of a small explosion. When the knob is operated, jet within the bummer releases.a small amount of flammable gas, which mixes with the immediately surrounding atmospheric air and comes out of bumer as a flammable gas air mixture. Spark from the gas lighter ignites it and it bums. The quantity of release being controlled and small the flame is limited to immediate vicinity of burner. However, when there is no control either on quantity, rate of release of flammable media and source of ignition, then this may lead to explosion instead of controlled flame. The quantity and rate of flammable media, even with best of design & operational precautions can be minimized but cannot be eliminated and hence lead to flammable atmosphere in Industry. In gassy coalmines this occurs naturally. In view of this the control of source of ignition becomes very critical. n this particular paper, we shall restrict ourselves to the source of ignition from current carrying equipments popularly known as Ex equipments. FLAMMABLE SUBSTANCES, Flammable substances may be gaseous, liquid or solid. {A Flammable gas such as hydrogen reacts with oxygen with very litle external energy. Flammable gases are often hydrocarbons and require very little energy to react with atmospheric oxygen. | Flammable liquids such as ether, acetone and lighter fuel evaporate even at room temperature in sufficient quantities to form flammable atmosphere. Other liquids need higher temperatures for this to occur. The lowest temperature at ‘ which a sufficient quantity of vapour will arise from liquid so as to permit its | ignition under laboratory condition is defined as flash point. The flash poi is ‘an important factor in the classification of hazardous areas. 75 ‘Scanned by CamScannerFlammable solids in the form of dust, fibers and fluff may react with the atmosph ae it 0 Cause explosions in presence of source of ignition. Dust is a Yen ditferent matter. Layers of dust on hot surfaces can begin to smoulder and dust clouds can start ex, ‘plosions after coming into contact with hot surfaces or other sources of energy. LOWER EXPLOSIVE LIMIT (LEL) / UPPER EXPLOSIVE LIMIT (UEL) When the quantity of available atmospheric oxygen is more or less sufficient for the combustion of the quantity of flammable material present, the effect of an explosion - temperature and pressure -is most violent. If the quantity of flammable material is too small, combustion will spread with dificulty or will cease altogether. ‘The same applies if the quantity of flammable material is too great for the available oxygen Flammable materials each have an upper and lower explosion limit above which or below which no explosion will take place MINIMUM IGNITION CURRENT (MIC) A reference figure based on a standard circuit is used to graduate ignition in. an EY apparatus conforming to IEC. This reference figure is known as the minimum ‘gnition current MIC. This enables the gases and vapours in explosion hazard group Il to be subdivided into subgroups A, B and C. MAXIMUM EXPERIMENTAL SAFE GAP (MESG) 'EC 60079-1A stipulates an apparatus consisting of two hemispheres with a 25 mm wide flange which enclose a volume of 20 cm3. This sphere is placed in a larger vessel and both filled by the mixture to be used for determining the safe gap. The gap between the 25 mm flange at which 10 ignitions within the sphere just fail to ignite the mixture in the outer vessel is a value specific to the mixture in question @nd is designated maximum experimental safe gap (MESG), Subdivision of the gases and vapours by MESG results in approximately the same classification as that obtained with minimum ignition current. IEC 60079. 12 provides an overview of classification by the MESG and MIC procedures, Gas Group | Represenatve Gas WA | _ Propane 209 ie ~ Ethylene 3051009 ic Hydrogen <05 ‘Scanned by CamScannerTECEX 2003 - SEMINAR PROCEEDINGS AUTO IGNITION TEMPERATURE Beis: The auto ignition temperature is temperature at which any flammable substance: shall ignite spontaneously without any source of ignition. AREA CLASSIFICATION There are two major classifications prevalent worldwide * As per NEC (National Electrical Code) of USA. © As per IEC (International Electro technical Commission) AREA CLASSIFICATION AS PER NEC * NEC classification is prevalent in American continent for areas other than mines. * MSHA (Mine safety & health administration) covers mines area in American continent NEC 500 CLASSIFIES COMBUSTIBLE MEDIA AS UNDER © Class 1: Flammable Gases, Vapors & Liquids © Class 2: Combustible Dusts © Class 3: Ignitable Fibers & Flyings Mining (Methane- Fire Damp) is not covered under NEC Code but comes under MSHA GROUPS UNDER CLASS 1 (FLAMMABLE GASES, VAPORS & LIQUIDS) © Group A: Acetylene © Group B: Hydrogen ¢ Group @ Ethylene © Group D: Propane Group A gases being most hazardous & Group D gases being least hazardous GROUPS UNDER CLASS 2 (COMBUSTIBLE DUS © Group E: Combustible metal dust ar other © Group F: Combustible dust having volatile Scanned by CamScannerchar oal, Coal or coke dust Group G: Othe; ; up G: Other Combustible dust having higher resistivity than Group G ae UNDER CLASS 3 (IGNITABLE FIBERS & FLYINGS) lone NEC 500 DEFINES EXTENT OF HAZARD AS UNDER ‘* Division 1: Hazardous media can exist under normal operating condition or due to repair & maintenance or due to leakage caused by faulty operation or break down * Division 2: Hazardous media will exist only under abnormal circumstances due to accidental failures TEMPERATURE CLASSIFICATION AS PER NEC 500 FOR CLASS 1&1 APPARATUS Identification Degrees C Number (Max) 1 450 TarT2aT2B/T2C/T2D 300/280/260/230/215 T3/T3AT3B/T3C 200/180/165/160 TaT4a 135/120, | 15 100 16 85 TEMPERATURE CLASSIFICATION AS PER NEC 503 FOR CLASS. @ APPARATUS, ¢ Maximum 165 Degree C for apparatus not subject to overloading ¢ Maximum 120 Degree C for apparatus subject to overloading HARMONIZATION OF NEC CODES WITH IEC © NEC has a separate Code NEC 505 for classification identical to IEC. © This code was introduced with a view to allow harmonization of IEC & NEC Codes. ‘Scanned by CamScanner— SEMINAR PROCEEDINGS TECEX 2003 AREA CLASSIFICATION AS PER IEC cae © [EC classification is prevalentin Europe & most ofthe coun ms! @ CENELEC (Comite Europeen de Normalisation Electrotec! en European Committee for Electrotechnical Standardisation at IEC classification same «Area classification as per BIS (Bureau of Indian Standard) is also as IEC IEC CLASSIFIES COMBUSTIBLE MEDIA AS UNDER © Group 1: Mining (Methane — Fire Damp) © Group 2: Other than Mining (Gases & Vapors) GAS GROUPS * Group A: Propane © Group B: Ethylene ‘© Group C: Acetylene, Hydrogen & Carbon Di sulphide '* Group C gases being most hazardous & Group A gases being least hazardous EXTENT OF HAZARD IS DEFINED BY ZONE © Zone O: Hazardous media is frequently present © Zone 1: Hazardous media can exist under normal operating condition or due to repair & maintenance or due to leakage caused by faulty operation or break down © Zone 2: Hazardous media will exist only under abnormal circumstances due to atcidental failures IEC 60079-10 lays down guideline for extent of Zone, which depend on many parameters like frequency and duration of release, the release rate, concentration, velocity, ventilation, geometty of the source of release, volatility of flammable liquid, liquid temperature, Lower explosive limit, relative density of the gas or vapour, climatic conditions & topography etc. It also allows use of industry specific data to be taken from related industry codes like API 505 or IP 4 ‘Scanned by CamScanner_ (0 be noted that statutory authorities (Chiat Controlor of Explosive Director C ‘of Mines Satety) in Indla have laid down certain guidelinds for c ation vide Petroloum Rules 2002, Coal Mines regulation 1957, Oi tion 1984 and DGMS circular there under, This has to be taken inte TEMPERATURE CLASSIFICATION AS PER IEC Identification Number Degrees © (Max) \ } YPES OF PROTECTION Special protection (Ex 8) | Note : Refer to enclosed table for various international codes & other relevant fe type of protections Scanned by CamScannerROCEEDINGS TECEX 2003 - SEMINAR FI ection primarly uses following four techniques: ur inside enclosure but prever tof prot cc nt its spread ‘¢ Allow the explosion to ocet outside. © Eliminate arc, spark & hot surfaces s* E present © Limit energy of spark so that itis incapable of ignition. © Keep the flammable media out of enclosure. TYPE EXPLOSION PROOF OR FLAMEPROOF (Ex d) 10 that source of ignition is not Performance requirements ‘* These enclosures allow explosion to take place inside the enclosure but do not allow explosion to permeate to surrounding hazardous area. © They are capable of withstanding the internal explosion & their mechanical integrity remains unaffected ‘* The surface temperature of enclosures does not exceed auto ignition } temperature of surrounding flammable gases. Construction features © Flame path (length & clearance) is ensured as per code requirement * Openings & entries are as per code requirements ‘© Material of construction is chosen to avoid frictional sparks Applications ‘© Equipments such as Control & Power panels’ etc. having arcing devices such as fuses and switchgears ete TYPE INCREASED SAFETY (Ex e) Performance requirements Explosion inside enclosure is prevented by ensuring that ignition of flammable gases do not take place by eliminating all contributory factors like arc, spark and hot surfaces. The surface temperature of enclosures or components mounted inside does not exceed auto ignition temperature of surrounding flammable gases. 8 ‘Scanned by CamScannerThese enclosures are not capable of withstanding explosion inside the enclosure. These enclosures should have minimum ingress protection of IP 54 Construction features * No arcing devices such as fuse & switchgears are used. © Ignition is prevented by use of non-sparking & components with thermal rating with higher safety margins to prevent sparks & rise in temperature ¢ High impact resistant materials like FRP or GRP not holding static charge or metals are used © Clearance and creepage distances are maintained as per code requirement ‘© Anti loosening & vibration proof terminals are used. Applications Terminal housing, luminaries and motors, TYPE INTRINSICALLY SAFE (Ex i) Performance requirements Explosion is prevented by ensuring that sufficient energy for ignition of flammable gases is not available. ‘The surface temperature of enclosures or components mounted inside does not exceed auto ignition temperature of surrounding flammable gases intrinsically safe circuits can be mounted in enclosures having minimum ingress protection of IP 20 ‘ Construction features These equipment are primatily low energy electronic devices To eliminate risk of explosion these devices operate at lower voltage & ‘amperage to ensure that during fault condition sufficient energy is not available for ignition All he components / PCB track / wire cross section are chosen with a ae Scanned by CamScannerremperature rise under fault condition high safety margins to prevent t thus preventing ignition. ‘* In addition with many devices safety barriers ar devices under fault condition 1¢ used to isolate field Application Various Instruments, communication equipments etc. TYPE PURGE PROTECTION (Ex p) Performance requirements © Explosion inside enclosure is prevented by purging flammable media and ensuring non-ingress of flammable media by keeping positive pressure of uncontaminated purge media. ‘© The surface temperature of enclosures does not exceed auto ignition temperature of surrounding flammable gases These enclosures are not capable of withstanding explosion inside the enclosure. Construction features ‘¢ Under this type of protection component & devices are installed inside a purge panel. A positive pressure of uncontaminated air or other neutral gas is maintained inside panel so as to exclude surrounding flammable media thus eliminating risk of explosion © Normally two types of purge panels are used. In first type purge media does not vent during normal operation, it vents only during initial purge cycle i.e. at initiation of proggss cycle. In other type of panel, purge media vents through out the normal operationsat desired rate to prevent ingress of surrounding flammable gases. The rate of venting is much lower in comparison to high venting rate for initial purge cycle. ‘¢ Flammable media is purged from the panels and then only these are energized. «Incase of failure of overpressure in purge panel, the alarm is initiated and in oritical condition the apparatus is de-energized. 83 ‘Scanned by CamScanneree Applications . Electrical equipment whose normal operation involves sparks, arcing of hot components and complex assemblies like large motors, Switchgear and control cabinets and analysis devices TYPE ENCAPSULATED (Ex m) Performance requirements * Ensuring exclusion of flammable substance coming in contact with source of ignition by encapsulation prevents explosion ‘* The surface temperature of enclosures or components mounted inside does not exceed auto ignition temperature of surrounding flammable gases. Construction features © Either potting with resin or hermetically sealing achieves encapsulation * By encapsulation ingress of surrounding ambient is prevented. © This is prevalent for small devices & electronic components Applications © Static coils in ballast, solenoid valves or motors, relays and other control gear of limited power and complete PCBs with electronic circuits. © Control Components like indicating lamps, push button elements and control switches etc TYPE NON-SPARKING (Ex n) Performance requirements © Explosionginside enclosure is prevented by ensuring that ignition of flammable gases do not take place by eliminating all contributory factors like arc, spark and hot surfaces. ‘© The surface temperature of enclosures or components mounted inside does not exceed auto ignition temperature of surrounding flammable gases. * These enclosures are not capable of withstanding explosion inside the enclosure. Scanned by CamScannerTECEX 2003 - SEMINAR PROCEEDINGS Construction features © In these types of equipments, only such components Or parcel are used, which are incapable of producing sparks thus eli 9 | source of ignition, Application Motors, luminaries, terminal housing ete TYPE OIL FILLED (Ex 0) Performance requirements * Ensuring exclusion of flammable substance coming in contact with source of ignition by submerging arcing or sparking components in oil Prevents explosion. ! The surface temperature of enclosures or components mounted inside does not exceed auto ignition temperature of surrounding flammable gases due to cooling by oil Construction features * Oilhaving high dielectric strength & good thermal conductivity are very good media for spark/ are quenching | * They are in use since very long in High Rating Power Electrical j equipments like Circuit Breakers. They are also in use in transformers for cooling © However they have negative aspect of flammability & forming carbon particle during arc quenching. . ‘* In spite of these negative aspect they remain a good source for arc quenching & thus used to exclude source of ignition in Hazardous area in Oil quenched equipments Applications © Large transformers, switchgear, starting resistors and complete starting controllers. ‘Scanned by CamScanner—D TYPE SAND FILLED (Ex q) Performance requirements & construction features * Quartz grade sand is a very good media to suppress arc! sparks & is used in sand filled equipments to prevent explosion hazard by isolating spark from surrounding hazardous gases. Applications ‘© Capacitors, electronic sub-assemblies or transformers etc SPECIAL PROTECTION (Ex s) Performance requirements & construction features ‘This category comprises all such methods not covered under other types of protection discussed but may be used. The criteria being that either the source of ignition be eliminated or contained or excluded from surrounding hazardous ambient. Author is Area Manager, Ex-Protecta, Consultant to IFMA, President-ISA-Patalganga Section & Member ET 22 & 24 ¢ munities of BIS. «e-mail : b_gupta@ysnl.com. ‘Scanned by CamScannerLozozt vsiue pases us paseg| Lozozi vsiue pesea| 207! 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