Process Instrumentation

Module 5
Lecture -3
Safety Instrumentation
Dr V S Krushnasamy
Dept of EIE
DSCE
 Safety Instrumentation
Introduction
Electrical hazards
Hazardous areas and classification
Non-hazardous areas
Enclosures
NEMA types
Fuses and circuit breakers
Protection methods :Purging, Explosion proofing
and Intrinsic safety
 Introduction
History OF SAFETY & HAZARD :
 In an industrial plant such as a refinery or chemical
process plant, handling of large quantities of
flammable liquids and gases creates a risk of leaks.
 In some cases the gas, ignitable vapor or dust is
present all the time or for long periods.
 Other areas would have a dangerous concentration
of flammable substances only during process upsets,
equipment deterioration between maintenance
periods, or during an incident.
 Refineries and chemical plants are then divided into
areas of risk of release of gas, vapor or dust known
as divisions or zones .
What is an explosion?
What is an explosion?
 What is an explosion?
An explosion is defined as a sudden reaction involving rapid
physical or chemical decay accompanied by an increase in
temperature or pressure or both.
When will an explosion occur?
 The most common types of reaction are between flammable
gases, vapors, or dust with oxygen contained in the surrounding
air.
 As a rule, 3 basic requirements must be met for an explosion to
take place in atmospheric air:
 Flammable substance — needs to be present in sufficient quantity
to produce an ignitable or explosive mixture.
 Oxidizer — must be present in sufficient quantity in combination
with the flammable substance to produce an explosive mixture.
Most common is air [O2].
 Source of ignition — a spark or high heat must be present.
 The presence of these three elements make up the sides of the
ignition triangle. If any one of the three elements is missing, an
explosion will not occur. All three elements must exist
simultaneously for an explosion to occur.
Note:
 In any industrial processes where flammable
materials are handled or stored , any kind of
ignition or spark caused by measurement systems
may give rise to an explosion.
 To protect both plant and personnel and at the
same time carry out measurements , precautions
must be taken to ensure the instrumentation is
intrinsically safe.
 The potentially flammable areas are known as
hazardous areas and the materials involved
include crude oil and its derivatives ,alcohols ,
natural and synthetic process gases , carbon dust
,flour ,starch ,grain , fibers and flying's among
others.
 Hazard
 Hazard can be defined as any condition produced by
or in the industry that may cause harm to property
(plant e machinery, asset), human or environment.
(Or)
 “A hazard is something (e.g., an object, a property
of a substance, a phenomenon, or an activity) that can
cause adverse effects.”
 Center for Chemical Process Safety (CCPS), hazard is
defined as, “an inherent or physical characteristics
that have potential for causing damage to
people,property or environment, it is the
combination of a hazardous material, an operating
environment, and certain unplanned event that
could result an accident.
 NON-HAZARDOUS AREA :

NON-HAZARDOUS AREA :
 An area such as a residence or office would be classed as
Non Hazardous [safe area], where the only risk of a
release of explosive or flammable gas would be such
things as the propellant in an aerosol spray.
 The only explosive or flammable liquid would be paint
and brush cleaner. These are classed as very low risk of
causing an explosion and are more of a fire risk [although
gas explosions in residential buildings do occur].
 Non hazardous areas on chemical and other plant are
present where the hazardous gas is diluted to a
concentration below 25% of its lower flammability limit [or
lower explosive limit [LEL]].
 Electrical hazards
According to OSHA(Occupational Safety and Health
Administration)
An Electrical Hazard can be defined as a serious
workplace hazard that exposes workers to burns,
electrocution, shock, arc flash / arc blast, fire, or
explosions. (Or)
A dangerous condition in which a person may
sustain an injury by making an electrical contact
with an energized equipment.
By identifying these hazards, and understanding
how they happen, we can take steps to protect
ourselves.
 Electrical hazards
What are the hazards of electricity in the
workplace?
Electricity can result in:
 Electric shock,
 Electrocution,
 Burns (electrical or thermal contact),
 Fires,
 Explosions, and
 Indirectly, injury from a fall, from cuts, or from
broken bone
 Electrical hazards
Electric shock
 Electric shock occurs when the body becomes a part of an
electric circuit. The electrical current must enter the body at
one point and leave at another.
 Electric shock normally occurs in 1 of 3 ways. Individuals -
while in contact with the ground - must come in contact with:
i. Both wires of the electric circuit, or
ii. One wire of an energized circuit and the ground, or
iii. A metallic part that has become "hot" by contact with an
energized conductor
Electrocution
It occurs when a person makes a contact with a conductor
carrying a current and simultaneously contacts the ground or
another object that includes a conductive path. to the ground.
 Sources of Electrical Hazards
Equipment failure
Improper insulation
Environmental conditions
Electrostatic hazards
Arc and spark hazards
Combustible and explosive hazards
Sources of Electrical Hazards
Sources of Electrical Hazards
Sources of Electrical Hazards
Sources of Electrical Hazards
 Electrical hazards
What are Examples of Electrical Hazards?
Electrical hazards come in a variety of forms, but all
have the potential to cause serious injury. Common
types of electrical hazard include:
Contact with live wires resulting in electric shock
and burns,
Fires due to faulty wiring,
Exposed electrical parts,
Ignition of fires or explosions due to electrical
contact with potentially flammable or explosive
materials,
 Electrical hazards
 Inadequate wiring,
 Improper grounding, sometimes caused by
workers deliberately removing the ground pin on
an electric plug to fit a two-prong extension cord,
 Interaction with overhead power lines,
 Damaged wire insulation, causing electrical
conductors to make contact with each other,
tools, or a worker’s body,
 Overloaded circuits,
 Wet conditions.
 Effects of Electric Current in the Human Body

Current Reaction

Below 1 milliampere Generally not perceptible

1 milliampere
5 milliamperes
6–25 milliamperes (women)
9–30 milliamperes (men)
50–150 milliamperes
1,000–4,300 milliamperes
10,000 milliamperes
Faint tingle
Slight shock felt; not painful but disturbing. Average
individual can let go. Strong involuntary reactions can lead to
other injuries.
Painful shock, loss of muscular control*
The freezing current or " let-go" range.* Individual cannot let
go, but can be thrown away from the circuit if extensor
muscles are stimulated.
Extreme pain, respiratory arrest, severe muscular
contractions. Death is possible
Rhythmic pumping action of the heart ceases. Muscular
contraction and nerve damage occur; death likely.
Cardiac arrest, severe burns; death probable

* If the extensor muscles are excited by the shock, the person may be thrown away from the
power source.
 Electrical Safety
General electrical safety tips include:
 Treating all electrical wires as if they are live.
 Inspecting electrical cords and plugs for damaged
insulation and broken ground pins before use.
 Reporting all exposed electrical parts, including wires,
terminals, and missing circuit breakers, immediately.
 Checking extension cords ratings to ensure they can
handle the load required by electrical equipment
before use.
 Storing materials and equipment at least ten feet away
from overhead power lines.
 Electrical Safety
 Replacing extension cords and wires with damaged
insulation. Do not use tape to repair the damage.
 Never use nails or sharp objects to hang extension
cords from the ceiling or walls.
 Never run electrical cords through windows or doors.
 Instead of connecting strips or surge protectors to
extension cords, use a three-way extension cord with a
GFCI (a fast-acting circuit breaker)
 Keep floors and work surfaces dry to prevent electricity
from interacting with water or other liquids.
 Regularly inspect electrical tools and equipment for
damage.
 Hazardous areas and classification
Classification Type Criterion
Area Classification Probability of a hazardous
mixture being present

Gas Classification The grouping is done

considering the required
spark ignition energy or
flame propagation aspect

Temperature Classification An ignition may also be

caused by a high surface
temperature
 Who will define classification
IEC – International Electro technical Commission
NEC – National Electrical Code
CENELEC- European Committee for Electro
technical Standardization
NFPA-National Fire protection Association
ANSI-American National Standards Institute
 Hazardous areas and classification

A hazardous location [sometimes abbreviated

to HAZLOC] is defined as a place where
concentrations of flammable gases, vapors, or
dusts occur.
 CLASS classification
 The NFPA Publication 70, NEC, and CEC define
three categories of hazardous materials that have
been designated as Class I, Class II, or Class III.
 The Classes define the type of explosive or
ignitable substances which are present in the
atmosphere such as:
 Class I locations are those in which flammable
vapors and gases may be present.
 Class II locations are those in which combustible
dust may be found.
 Class III locations are those which are hazardous
because of the presence of easily Ignitable fibres
or flyings.
 DIVISION classification
Each of the three Classes, is further subdivided into two
Divisions,Division 1 or Division 2.The Division defines the
likelihood of the hazardous material being present in a
flammable concentration.
Division 1 : In which ignitable concentrations of hazards
exists under normal operation conditions and/or where
hazard is caused by frequent maintenance or repair work or
frequent equipment failure.
Division 2 : In which ignitable concentrations of hazards are
handled, processed or used, but which are normally in closed
containers or closed systems from which they can only
escape through accidental rupture or breakdown of such
containers or systems.
DIVISION classification
ANSI/NFPA AREAS DESCRIPTION :
CLASS I, DIV. 1 : Where ignitable concentrations of flammable gases,
vapors or liquids are present continuously or frequently within the
atmosphere under normal operation conditions.
CLASS I, DIV. 2 : Where ignitable concentrations of flammable gases,
vapors, or liquids are present within the atmosphere under abnormal
operating conditions.
CLASS II, DIV. 1 : Where ignitable concentrations of combustible
dusts are present within the atmosphere under normal operation
conditions.
Class II, Div. 2 : Where ignitable concentrations of combustible dust
are present within the atmosphere under abnormal operating
conditions.
CLASS III, DIV. 1: Where easily ignitable fibers or materials producing
combustible flyings are present within the atmosphere under normal
operation conditions.
CLASS III, DIV. 2: Where easily ignitable fibers or materials producing
combustible flyings are present within the atmosphere under
abnormal operating conditions.
4/11/2020 Dept of Instrumentation Technology 34
 ZONE 0 AREA

ZONE 0 AREA:
 Gas or vapor is present all of the time. An example of this
would be the vapor space above the liquid in the top of a
tank or drum. The ANSI/NEC classification method
consider this environment a Division 1 area. As a guide for
Zone 0, this can be defined as over 1000 hours/year or
>10% of the time.
 Zone 0 place in which an explosive atmosphere consisting
of a mixture with air of flammable substances in the form
of gas, vapour or mist is present continuously or for long
periods or Frequently.
 Flammable atmosphere highly likely to be present - may
be present for long periods or even continuously.
 DIVISION 1 / ZONE 1 AREA

DIVISION 1 / ZONE 1 AREA:

 Gas, vapor or mist will be present or expected to be
present for long periods of time under normal
operating conditions. As a guide for Zone 1, this can be
defined as 10–1000 hours/year or 0.1–10% of the time.
 Zone 1 place in which an explosive atmosphere
consisting of a mixture with air of flammable
substances in the form of gas, vapour or mist is likely to
occur in normal operation occasionally.
 Flammable atmosphere possible but unlikely to be
present for long periods.
 DIVISION 2 / ZONE 2 AREA

DIVISION 2 / ZONE 2 AREA:

 This is a step up from the safe area. In this zone the gas, vapor
or mist would only be present under abnormal conditions [most
often leaks under abnormal conditions]. As a general guide for
Zone 2, unwanted substances should only be present under 10
hours/year or 0–0.1% of the time.
 Zone 2 place in which an explosive atmosphere consisting of a
mixture with air of flammable substances in the form of gas,
vapour or mist is not likely to occur in normal operation but, if it
does occur, will persist for a short period only.
 Flammable atmosphere unlikely to be present except for short
periods of time - typically as a result of a process fault
condition.
Important Note:
It is intended to be applied where there may be an ignition
hazard due to the presence of flammable gas or vapor,
mixed with air under normal atmospheric conditions, but it
does not apply to,

 Mines susceptible to fire damp.

 The processing and manufacture of explosives.
 Areas where a hazard may arise due to the presence of
ignitable dusts or fibres [refer IEC 61241.10/IEC 60079-
10-2].
 Catastrophic failures which are beyond the concept of
abnormality dealt with in this standard.
 Rooms used for medical purposes.
 Domestic premises.
 DUST ZONES

DUST ZONES :
 Flammable dusts when suspended in air can explode. An
old system of area classification to a British standard used a
system of letters to designate the zones. This has been
replaced by a European numerical system, as set out in
directive 1999/92/EU implemented in the UK as the
Dangerous Substances and Explosives Atmospheres
Regulations 2002.

 The boundaries and extent of these three dimensional
zones should be decided by a competent person. There
must be a site plan drawn up of the factory with the zones
marked on.
 DUST ZONES
ZONE 20 :
A place in which an explosive atmosphere in the form of a
cloud of combustible dust in air is present continuously, or for
long periods or frequently(1000hrs per year).
ZONE 21 :
A place in which an explosive atmosphere in the form of a
cloud of combustible dust in air is likely to occur, occasionally,
in normal operation(10-1000hrs per year).
ZONE 22 :
A place in which an explosive atmosphere in the form of a
cloud of combustible dust in air is not likely to occur in normal
operation but, if it does occur, will persist for a short period
only(less than 10hrs per year).
 GAS / VAPOUR GROUPS
 Explosive gases, vapors and dusts have different chemical
properties that affect the likelihood and severity of an
explosion.

 Such properties include flame temperature, minimum ignition

energy, upper and lower explosive limits, and molecular weight.

 Empirical testing is done to determine parameters such as the

maximum experimental safe gap, minimum ignition current,
explosion pressure and time to peak pressure, spontaneous
ignition temperature, and maximum rate of pressure rise.

 Every substance has a differing combination of properties but it

is found that they can be ranked into similar ranges, simplifying
the selection of equipment for hazardous areas.
 GAS / VAPOUR GROUPS
 Flammability of combustible liquids are defined by
their flash-point. The flash-point is the temperature
at which the material will generate sufficient
quantity of vapor to form an ignitable mixture.
 The flash point determines if an area needs to be
classified.
 A material may have a relatively low auto ignition
temperature yet if its flash-point is above the
ambient temperature, then the area may not need
to be classified. Conversely if the same material is
heated and handled above its flash-point, the area
must be classified.
 GAS / VAPOUR GROUPS
Group Representative Gases

I All Underground Coal Mining.

Firedamp (methane)
IIA
Industrial methane, propane, petrol
IIB
Ethylene, coke oven gas and other
industrial gases
IIC Hydrogen, acetylene, carbon disulphide
 GAS / VAPOUR GROUPS
Note:
 Apparatus marked IIB can also be used for IIA gases.
 IIC marked equipment can be used for both IIA and IIB.
 If a piece of equipment has just II and no A, B, or C after
then it is suitable for any gas group.
 A list must be drawn up of every chemical gas or vapor
that is on the refinery/chemical complex and included in
the site plan of the classified areas. The above groups are
formed in order of how volatile the gas or vapour would be
if it was ignited, IIC being the most volatile and IIA being
the least. The groups also indicate how much energy is
required to ignite the gas by spark ignition, Group IIA
requiring the most energy and IIC the least.
 Typical gas hazards are from hydrocarbon compounds, but
hydrogen and ammonia are common industrial gases that
are flammable.
 GAS / VAPOUR GROUPS
Group II is for electrical and mechanical
apparatus used in places other than mines.
Gases of Group II are further divided into sub-
divisions i.e. IIA, IIB and IIC. The sub-divisions
are based on experimental work conducted
with flameproof and intrinsically safe
apparatus.
This sub-division is also called the explosion
group.
 COMMON MATERIALS WITHIN ASSOCIATED CLASS
AND GROUP RATINGS :

 The explosive characteristics of the air mixtures of

gases, vapors, or dusts vary with the specific material
involved.
 Materials have been placed in groups based on their
ignition temperatures and explosion pressures.
 Class I and Class II Divisions are further subdivided into
Groups of hazardous materials. The Groups define
substances by rating their flammable nature in relation
to other known substances.
 Combustible and flammable gases and vapours are
divided into four Groups.
 CLASS I AREAS [FLAMMABLE GASES,
VAPORS OR LIQUIDS] :
Group A: Acetylene
Group B: Hydrogen
Group C: Propane and Ethylene
Group D: Benzene, Butane, Methane and
Propane
 CLASS II AREAS [COMBUSTIBLE
DUSTS]

Group E: Metal Dust

Group F: Carbon and Charcoal
Group G: Flour, Starch, Wood and Plastic.
 TEMPERATURE CLASSIFICATION [AS
PER USA STANDARD] :
 The temperature classes are used to designate the maximum
operating temperatures on the surface of the equipment which
should not exceed the ignition temperature of the
surrounding atmosphere.
 Ignition temperature is the minimum temperature required, at
normal atmospheric pressure in the absence of a spark or
flame, to set afire or cause self sustained combustion
independently of the heating or heated element.
 Another important consideration is the temperature
classification of the electrical equipment. The surface
temperature or any parts of the electrical equipment that may
be exposed to the hazardous atmosphere should be tested
that it does not exceed 80% of the auto-ignition temperature
of the specific gas or vapor in the area where the equipment is
intended to be used.
 Enclosures
 The term enclosure means , a case that is added to an
electrical equipment in such order that it offers a degree of
protection to personal against specific environmental
conditions as well as incidental contact with equipment.
 The IEC developed Ingress Protection(IP) codes while
NEMA (National Electrical Manufacturer’s Association of
USA developed another set of codes.
 The IP code consists of the letters followed by two digits.
 The first digit indicates the degree the degree of protection
provided against the intrusion of solid objects(including
body parts like hands and fingers),while the second digit
indicates the ingress of water in mechanical casings having
electrical enclosures.
 Enclosures

IEC: According to IEC 60529 definitions for

degrees of protection provided by enclosures of
electrical equipment as regards protection
cover:
Access by persons to hazardous parts inside
the enclosure.
Ingress of solid foreign objects.
Harmful effects caused by the ingress of water.
 Enclosures
The standard recommends the necessary measures to
be taken to protect the enclosure and equipment
inside against external influences like:
 Mechanical impact
 Corrosion
 Corrosion solvent
 Fungus
 Vermin
 Solar radiations
 Moisture
 Icing
 Explosive atmospheres
 IP code
 Depending on their potential exposure to foreign
objects, electrical devices (e.g. luminaires, LED
modules and operational equipment) must,
according to IEC 60529, belong to a specific type of
protection.
 The types of protection are also called IP codes. The
abbreviation IP stands for “ingress protection”.
 The IP codes refer only to protection against contact
and the penetration of solid foreign objects and dust
(marked by the first characteristic numeral of the IP
code) and against the damaging ingress of water
(marked by the second characteristic numeral of the
IP code).
 IP code
 The IP codes make no reference to the effect of external
influences.
 In addition, the types of protection must not be confused
with the electrical protection classes that refer to safety
measures aimed at the prevention of electric shock.
 The lowest type of protection is IP00, i.e. the electrical
equipment is neither protected against solid foreign
objects nor against the damaging penetration of water.
 The IP code IPXX means that the type of protection is not
defined because the electrical equipment has not been
subjected to testing.
 If the IP code is not stated, then the electrical equipment is
protected in accordance with IP20.
 NEMA
What Is a NEMA Enclosure?
 NEMA enclosures are versatile protective boxes that
works to shield your sensitive equipment from various
forms of damage.
 The name is directly derived from National Electrical
Manufacturers Association, the association that
standardized the use and ratings of NEMA enclosures.
 There is a wide variety of enclosure types and ratings,
each offering varying levels of protection
and benefits against different dangers and damage
types.
 Which you choose is typically based on where the
equipment will be placed (indoor/outdoor, sheltered
or exposed), the type of equipment in question, and
what types of dangers it could be exposed to.
 Fuses and Circuit Breakers (CB)
Fuses and Circuit Breakers (CB) are used for
the protection of power system. These along
with other protective equipment like relays,
isolater, switches, are collectively called
as switchgear(switching equipment used in
power systems).
The basic function is to break the circuit in
case of faulty conditions so as to protect the
power system equipment and auxiliaries.
 FUSE
FUSE is a low resistance device which is placed
in the circuit for protection.
Under faulty conditions when the current
becomes more than the desired value, then
due to the increase in temperature the fuse
wire melts and breaks, thus breaking the
circuit.
These are used for lower power ratings and can
be used only once, after that it has to be
replaced with a new one.
 CIRCUIT BREAKER
 CIRCUIT BREAKER also solves the same purpose i.e. it breaks
the circuit when the fault occurs.
 These are used for large ratings and in the power systems and
auxiliaries.
 CB also has the capability to re-close after the fault is through
i.e. when the system gets healthy. The CB has two
parts/contacts one is static and the other is moving(the one
responsible for making or breaking the contacts).
 When the contacts of CB separate, then it said to
have tripped.
 Tripping of the circuit breaker has to be very fast so as to
avoid the arc formation between the two contacts, otherwise
it will defeat the purpose of installing the CB. The trip signal is
given to the CB by an other protective device called as
an ELECTRICAL RELAY. CB’s are categorized on the basis of the
power ratings and the medium used to extinguish the arc
formed during the breaking of the contacts.
Fuse and Circuit Breakers
 Fuse and Circuit Breakers
 Fuses and Circuit Breakers both serve the same
purpose – which is to protect electrical circuits by
preventing overloads that can cause fires.
 They both interrupt the flow of electricity, but in
very different ways from each other.
 While a fuse is made of a piece of metal that
melts when overheated, circuit breakers on the
other hand, have internal switch mechanisms
that can be tripped by an unsafe surge of
electricity.
 Purging
 Pressurized apparatus achieves separation of ignition
sources from explosive atmospheres by purging the
atmosphere inside the apparatus with air or an inert
gas and then maintaining a positive pressure inside the
equipment to prevent the ingress of the explosive
atmosphere during operation.
 Failure of the pressurization leads to an alarm
operating or the disconnection of the components
having ignition capability.
 The equipment is designed according to EN 60079-2.
The protection px and py are suitable for equipment
category 2G / equipment protection level [EPL] Gb and
protection pz is suitable for equipment category 3G /
EPL Gc.
Purging
Purging
Purging
Intrinsic Safety
 Intrinsic Safety
Level of protection ia :
 Intrinsically safe circuits in electrical apparatus of category
‘ia’ must not be capable of causing an ignition during
normal operation when two faults occur.
a] in normal operation and with the application of those non-
countable faults which give the most onerous condition;
b] in normal operation and with the application of one
countable fault plus those non-countable faults which give the
most onerous condition;
c] in normal operation and with the application of two
countable faults plus those non-countable faults which give
the most onerous condition.
 Intrinsic Safety
Level of protection ib :
 Intrinsically safe circuits in electrical apparatus of
category ‘ib’ must not be capable of causing an
ignition in each of the following circumstances:
a] in normal operation and with the application of
those non-countable faults which give the most
onerous condition;
b] in normal operation and with the application of
one countable fault plus those non-countable faults
which give the most onerous condition;
 Intrinsic Safety
Level of protection ic :
Intrinsically safe circuits in electrical apparatus
of category ‘ib’ must not be capable of causing
an ignition in normal operation:
a]Where distances are critical for safety, they
shall meet the requirements of IEC 60079-11
 Explosion proofing
 Explosion proof, according to the National Electrical Code,
applies to an apparatus enclosed in a case that is capable
of withstanding a gas or vapor explosion.
 It means that, should there be an explosion, it will be
contained within an enclosure.
 This containment is done through careful design of the
enclosure so that the resulting energy is not only
contained; it is also dissipated through the large surface of
the flanges or threads of the enclosure.
 Consequently, if the integrity of the enclosure is
compromised, either because of a scratch across the flange
face or threads or incomplete tightening of the cover, the
result is a significant increase in the risk of an explosion.
 The net result is that Explosion Proof protection has a
higher level of required maintenance than an Intrinsically
Safe system.
Flame Proof (example 1)
Flame Proof (example 1)
Flame Proof (example 1)
Oil Immersion (Example 2)
Oil Immersion (Example 2)
Oil Immersion (Example 2)
Powder Filling (Example 3)
Powder Filling (Example 3)
Encapsulation (Example 4)
Encapsulation (Example 4)
Encapsulation (Example 4)