9.

15 Lightning and surge protection for intrinsically safe circuits

In chemical and petrochemical industrial plants, potentially explosive areas develop frequently during the manufacture, processing, storage, and transportation of flammable materials (e.g. gasoline, alcohol, liquid gas, explosive dust), where any source of ignition must be avoided to prevent explosions. Relevant protective provisions refer to the threat of atmospheric discharges (lightning) to such installations. Here it has to be considered that there is a fire risk and explosion hazard by direct or indirect lightning discharges due to the partially widespread extension of such installations. To achieve necessary plant availability and also the necessary safety of the system, a conceptual action is necessary for protection of process-specific electric and electronic parts of the plant against lightning currents and surges. Lightning Protection Zones Concept Intrinsically safe circuits are often used in areas where explosion hazard may occur. Figure 9.15.1 shows the principal design of such a system and the assignment in lightning protection zones. Due to the necessary, very high availability of the systems and in order to meet the high requirements on safety in the hazardous area, the following areas were divided into lightning protection zone LPZ 1 and lightning protection zone LPZ 2: Electronic evaluation unit in the control room (LPZ 2) Temperature transducer at the tank (LPZ 1) Interior of the tank (LPZ 1) In accordance with the lightning protection zones concept according to IEC 62305-4 (EN 62305-4), all lines at the LPZ boundaries must be equipped with corresponding surge protective devices as described below. External lightning protection The external lightning protection system is the entire equipment installed and existing outside at or in the installation to be protected for interception and conducting the lightning current into the earth-termination system. A lightning protection system for explosive areas corresponds to lightning protection system Class II at normal conditions. In well-founded, individual cases and under special conditions (legal provisions), or by the result of a risk analysis in accordance with IEC 62305-2 (EN 62305-2) it can differ from the standards.

metal container with sufficient material thickness air-termination system

air ventilation

building shield, e.g. steel reinforcement conductor to remote potential

intermeshed equipotential bonding Fig. 9.15.1 Division of a hazardous location into lightning protection zones (LPZ)

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In order to prevent direct lightning strikes to tank facilities they are very often protected by air-termination rods with additional air-termination cables in case of greater distances (Figure 9.15.2). In any case, the following requirements are based on lightning protection system Class II. As with all lightning protection systems, the separation distance must also be maintained here. Lightning equipotential bonding outside the hazardous area The application of surge protective devices in the low voltage installation and for telecommunication lines outside the hazardous area (control room) shows no peculiarities with respect to other applications. In this context it should be noted that the surge protective devices for lines of LPZ 0A to LPZ 1 (Figures 9.15.3 and 9.15.4) must have a lightning current discharge capacity, which is specified in test waveform 10/350 s. The surge protective devices of the different requirement classes must be coordinated among each other. Equipotential bonding In all areas where explosion hazard may occur, a consistent equipotential bonding has to be implemented. Also building supports and parts of the construction, pipelines, containers, etc., must be included in the equipotential bonding so that a voltage difference must not be feared, even in the event of a failure. The connections of the equipotential bonding conductors must be secured against self-loosening. The equipotential bonding must be carefully realised, installed, and tested in compliance with IEC 60364-4-41, IEC 60364-5-54 and IEC 60364-6-61. Using surge protective devices of the BLITZDUCTOR product range, the cross section of the earth conductor for equipotential bonding must be at least 4 mm2 Cu. Surge protection in intrinsically safe circuits Already during the design process, the lightning protection zones and hazardous areas shall be harmonised. The consequence is that the requirements both for use of surge protective devices in hazardous areas and at the LPZ boundaries must be met likewise. Thus, the installation site of the surge protective device was determined precisely. It is located at the boundary of LPZ 0B and LPZ 1. This prevents the penetration of dangerous surges into Ex zone 0 or 20, since the surges are already
Fig. 9.15.2

air-termination conductors

air-termination rod

concrete tub of the tank

Air-termination system for a tank with air-termination rods and conductors

discharged previously. Also, the availability of the temperature transmitter, which is important for the process, is considerably increased in this way. Furthermore, the requirements according to EN 60079-14 must be met (Figure 9.15.5): Use of surge protective devices with a minimum discharge capacity of 10 impulses with 10 kA (8/20 s), each without malfunction or impairment of the surge protective function (Table 9.15.1). Mounting of the surge protective device into a metallic shielded enclosure and earthing with at least 4 mm2 Cu. Installation of the cables between the surge protective device and the equipment in a metal pipe earthed at both ends or the application of shielded cables with a maximum length of 1 m. In accordance with the definition of the protection concept, the programmable controller in the control room is defined as LPZ 2. The intrinsically safe cable leaving the temperature transmitter is also led at the boundary from LPZ 0B to LPZ 1 via a

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lightning equipotential bonding EBB

power supply

water

gas

heating

cathodic protected tank pipe

foundation earth electrode

Fig. 9.15.3

Lightning equipotential bonding according to IEC 62305-3 (EN 62305-3) based on main equipotential bonding according to IEC 60364-4-41 and IEC 60364-5-54

Ex zone 1, 2

BLITZDUCTOR XT
BXT BAS EX, BXT ML4 BD EX 24 / BXT ML4 BC EX 24

protected

BLITZDUCTOR
4 3 4
BXT ML4 BD EX 24

min. 4 mm2

min. 4 mm2

Ex zone 0 cable length max. 1 m

EB Fig. 9.15.4 DEHNventil DV TT 255 in a switchgear cabinet for protection of the power supply system Fig. 9.15.5 Surge protective devices in intrinsically safe circuits

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external lightning protection system

protected
1 2
BXT ML4 BD EX 24

BLITZDUCTOR

Technical data Installation site Type of protection Voltage Current Frequency Immunity Test standards Inner capacitance Ci Inner inductance Li
Table 9.15.1

Measuring transducer TH02 zone 1 ib Ui max. = 29.4 V d.c. Ii max. = 130 mA

Surge protective device BCT MOD MD EX 30 zone 1 ia Uc = 34.8 V d.c. IN = 500 mA

fHart = 2200 Hz fG = 6 MHz frequency-modulated acc. to NE 21, e.g. 0.5 kV line/line ATEX, CE Ci = 15 nF Li = 220 H discharge capacity 10 kA (8/20 s) Y/L SPD T ATEX, CE, IEC 61643-21 Yes negligibly small negligibly small

Isolated from earth 500V Yes

of surge protective devices must not interfere with this isolation from earth. If the transducer has an insulation resistance of < 500 V a.c., the intrinsically safe circuit is regarded as earthed. This requires protective devices, the voltage protection level of which is below the insulation resistance of the earthed transducer (e.g. Up (wire/PG) 35 V) at a nominal discharge current of 10 kA (pulse shape 8/20 s).

Example of a temperature transducer

surge protective device BLITZDUCTOR CT, BCT MOD MD EX 24. This protective device at the other end of the field line between the buildings must have the same discharge capacity as the protective device installed at the tank. After the surge protective device, the intrinsically safe line is led via an isolation amplifier (Figures 9.15.5 and 9.15.6). From there, the shielded cable is laid to the programmable controller in LPZ 2. Because of the twosided earth connection of the cable shield, no protective device is required at boundary LPZ 1 to LPZ 2, since the residual electromagnetic interference still to be expected is strongly attenuated by the cable shield earthed at both ends. Criteria for the choice of surge protective devices in intrinsically safe circuits The example treating a temperature transducer (Table 9.15.1) shows which aspects must be observed for choosing surge protective devices (SPD): Insulation resistance of the equipment In order to prevent measuring errors by compensating currents, the sensor signals from the tank are often isolated electrically. The transducer has an insulation resistance of < 500 V a.c. between the intrinsically safe 4 ... 20 mA current loop and the earthed temperature sensor. Consequently the equipment is considered as floating. The use

Type of protection (explosive atmoshperes): Intrinsic Safety Category ia or ib ? The transducer and the surge protective device are installed in protection zone LPZ 1 so that the category ib is sufficient for the 4 ... 20 mA current loop. The used surge protection fulfils the highest requirements in conformity with certification according to ia and consequently, is also suitable for ib applications.

Fig. 9.15.6

BCT MOD MD EX 24 for intrinsically safe circuits

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short-circuit current Ii (Table 9.15.1). The rated voltage Uc of the protective device must be at least as high as the open-circuit voltage of the supply unit. Also the nominal current of the protective device must be at least as high as the short-circuit current Ii of the transducer to be expected in the event of a failure. If these parameters differ from the basic conditions when choosing the surge arresters, the protective device can be overloaded and, consequently, can fail or the intrinsic safety of the circuit is eliminated by an impermissible increase in temperature at the protective device.
Fig. 9.15.7

Coordination of the surge protective devices with terminal equipment The NAMUR recommendation NE 21 determines the requirements on the immunity against interPermissible maximum values for L0 and C0 ferences for process technology and process conBefore an intrinsically safe circuit is put into operatrol equipment and its general application (e.g. tion, the proof of its intrinsic safety must be protransducers). The signal inputs of such equipment vided. For this purpose, the supply unit, the transmust withstand transient voltages of 0.5 kV ducer, the used cables, as well as the surge protecbetween the wires (differential-mode interfertive devices must fulfil the interconnection condience) and of 1.0 kV between wire and earth (comtions. If necessary, the inductances and capacimon-mode interference). The test arrangement tances of the protective devices must also be taken and the waveform are described in the EN 61000-4-5 into consideration. In accordance with the EC type basic standard. According to the amplitude of the examination certificate (PTB 99 ATEX 2092), the test pulse, a corresponding surge immunity is internal capacitances and inductances are negligiassigned to the terminal equipment. These immuble in the surge protective device type BCT MOD nities of the terminal equipment are documented MD EX 24 of DEHN + SHNE (Figure 9.15.6) and by the surge immunity (1 4). 1 means the lowest need not be taken into account when considering and 4 the highest surge immunity. When there is a the interconnection conditions. risk of lightning and surge effects, the conducted interference pulses (voltage, current and energy) Maximum values for voltage Ui and current Ii must be limited to a value that lies within the According to its technical specifications for intrinsiimmunity of the terminal equipment. The coordically safe circuits, the transducer to be protected nation characteristics Q on the protective has a maximum supply voltage Ui and a maximum devices indicate a direct reference to the test level of Intrinsically SPD type Part No. the terminal equipment. P1 1) safe interface appoved by FISCO describing the requested 0 20 mA, test level of the terminal 4 20 mA BCT MOD MD EX 24 + BCT BAS EX 919 580 + 919 507 equipment and Type 2, the (also with HART) discharge capacity of the BCT MOD MD EX 30 + BCT BAS EX 919 581 + 919 507 protective device of 10 kA Digital I/O DCO RK MD EX 24 919 960 (waveform 8/20 s). NAMUR signal DPI MD EX 24 M 2 929 960 PROFIBUS-PA A threat to chemical and petrochemical installations Foundation Fieldbus PROFIBUS-DP BCT MOD MD HFD EX 6 + BCT BAS EX 919 583 + 919 507 by a lightning discharge and the electromagnetic influ1) FISCO = Fieldbus Intrinsically Safe Concept ence resulting from it, is covered in the relevant Table 9.15.2 Surge protective devices for use in intrinsically safe circuits and bus systems

Surge arrester for field devices DEHNpipe, DPI MD EX 24 M 2

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guidelines. During the realisation of the lightning protection zones concept in design and implementation of such installations, the risks of a sparking by a direct strike or discharging of conducted interference energies can be minimised within a safety-related and also economically justifiable

scope. The used surge arresters must fulfil the requirements of explosion protection, the coordination to the terminal equipment, as well as the requirements from the operational parameters of the measuring and control circuits (Table 9.15.2).

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