A technical seminar
on
Intrinsic Safety
Introduction
A1
The Flammable Facts
Gas, Temperature and Area
Classification
Introduction
Section A A2
Source of
Ignition
Spark
Heat Spark
Hazardous
location
Gas Air
Introduction
Explosion A3
Plant and Installations
are classified according to:-
The nature of the Hazardous Atmosphere
- Gas Classification
- Ignition Temperature
The probability that the Hazardous Atmosphere
will be present
- Area Classification
Introduction
Requirem A4
ent for
Equipment
is classified according to:-
The maximum spark energy it can produce
- Apparatus Group
Its maximum surface temperature
- Temperature Classification
Introduction
Requirem A5
ent for
Propane-air (1 atmos.)
1.0 Ethylene-air
(1 atmos.)
Ignition Energy
(milli Joules)
Hydrogen-air
(1 atmos.)
0.1
Minimum Ignition
Energy (MIE)
Flammable Range
0.01
0 10 20 30 40 50 60 70 80 90 100
Lower Explosive Limit (LEL) Volume concentration (%) (UEL) Upper Explosive Limit
Introduction
Spark Ignition Characteristic A6
Gas/air mixtures are ignitable over a range of concentrations called the
Flammable Range
Material Lower explosive limit Upper explosive limit Minimum *
LEL UEL ignition energy
propane 2% 9.5 % 180µJ
ethylene 2.7 % 34 % 60µJ
hydrogen 4% 76 % 20µJ
* of most easily ignitable mixture
Introduction
Explosiv A7
EXPLOSIVE LIMITS (% gas in air by volume)
GAS 0 10 20 30 40 50 60 70 80 90 100
Methane
Propane
Ethylene
Hydrogen
Introduction
Flammable Range A8
Gas classification
Representative Ignitability
(test) gas IEC countries
(including Europe) USA & Canada
Acetylene Group IIC Class I, Group A
Hydrogen Group IIC Class I, Group B
Ethylene Group IIB Class I, Group C More
Propane Group IIA Class I, Group D easily
ignited
Methane Group I (mining) (No classification)
Metal dust (Dusts not Class II, Group E
Carbon dust classified) Class II, Group F
Flour, starch, Discussions and Class II, Group G
grain draft documents
in circulation
Fibres & flyings Class III
Introduction
Gas classification: the two main systems A9
Flammable materials have a temperature at which ignition
will take place, even in the absence of an external source
This temperature is called the
Ignition Temperature
of that material
Apparatus must be selected such that it will not expose the
gas-air mixture to a temperature exceeding the ignition
temperature Introduction
Temper A10
ature
Maximum Tamb = 40oC
Temperature surface unless otherwise
classification temperature
stated
Operation above
stated Tamb will
o
T1 450 C
require re-assessment
o
T2 300 C
o
T3 200 C
o Better
T4 135 C Apparatus
o
T5 100 oC
T6 85 C
Introduction
Tempera A11
ture
T class °C
T1 450
T2 300
T2A 280
T2B 260 Apparatus is marked with either T rating
or maximum surface temperature
T2C 230
T2D 215
T3 200 User has responsibility to ensure that the
T3A 180 T-rating is below the Spontaneous
T3B
Ignition Temperature ( SIT )
165
T3C 160
T4 135
T4A 120
T5 100
Tamb = 40oC
T6 85
Introduction
Tempera A12
ture
700
Gas Ignition Apparatus
Ammonia 630
Temperature Hydrogen 560 600 Temperature
Methane 537 Classification
500
Propane 470 T1
Ethylene 425
400
Butane 365
300 T2
Cyclohexane 259
200 T3
Diethyl Ether 170
T4
Carbon Disulphide 95 100 T5
T6
Introduction
Gas/equipment compatibility A13
T4 for apparatus is usually OK
Exception:
Carbon Disulphide,CS2 requiring T6
Don't confuse T Class with maximum operating
temperature!
Introduction
Gas Ignition Temperature A14
Flashpoint
The flashpoint of a flammable liquid
is defined as the temperature at which the free
surface of the liquid emits sufficient vapour
to be ignited by a small flame
Note: Don’t confuse Flashpoint with Ignition Temperature
(eg for kerosene, Flashpoint = 38°C; Ignition Temp. = 210°C)
Introduction
Flashpoint Definition A15
Compound Vapour LFL UFL Ignition T Apparatus
Density Temp C Class Group
Acetone 2.00 2.0 13 535 T1 IIA
Ammonia 0.59 15 28 630 T1 IIA
Butane 2.05 1.5 8.5 372 T2 IIA
Carbon Disulphide 2.64 1.0 60 95 T6 IIC
Cyclohexane 2.90 1.2 7.8 259 T3 IIA
Diethyl Ether 2.55 1.7 36 160 T4 IIB
Ethylene 0.97 2.7 34 425 T2 IIB
Hydrogen 0.07 4.0 75.6 560 T1 IIC
Kerosene 0.7 5 210 T3 IIA
Methane 0.55 5.0 15 537 T1 I / IIA
Propane 1.56 2.0 9.5 470 T1 IIA
Taken
Extract from BS.5345
from IEC 79-10:1995
Part 1
Introduction
Properties of Gases A16
Probability of Probability of
Acceptable
Gas/Air Mixture
being present
X Source of
Ignition
= Risk
Reasoning : The higher the probability of the gas/air mixture being present demands a lower
probability of having a source of ignition and vice versa. Hence in Zone 0 we use IS;
in Zone 2 we perhaps use Type N or Exq,Exo,Exm, etc
Introduction
Why Area Classify? A17
Areas are classified with regard to the probability of a potentially
explosive atmosphere being present and the length of time
for which it is likely to exist
Zone 0: in which an explosive gas-air mixture is continuously
present or present for long periods
Zone 1: in which an explosive gas-air mixture is likely to occur
in normal operation
Zone 2: in which an explosive gas-air mixture is not likely occur
in normal operation, and if it occurs it will exist only
for a short time
Introduction
Area A18
classifica
Division 1
Hazardous atmosphere is likely to be present in normal operation
Division 2
Hazardous atmosphere is unlikely to be present in normal operation
Introduction
Area A19
classification
Why area Classify ?
• Why go to all the trouble with areas & equipment?
• If we know the probability of hazardous area & probability
of source of ignition , we know whether we are taking an
acceptable risk.
• Eg. Probability of flammable atmosphere = high
• If apparatus insures never sparks = acceptable risk
Introduction
A20
For Hydrogen Sulphide, H2S:
a very common danger when dealing with oil products
Property Volume
Concentration
Smell detection level 0.1 ppm
Safe working level 10
Serious health danger level 50
Lower Flammable Limit 40,000 (4%)
Upper Flammable Limit 460,000 (46%)
Note! Figures for safe working levels vary, the above are from a
Middle East location. Introduction
Personnel Hazards A21
Tank vents Key
Area Classification Zone 0
for a fixed-roof tank
with heavier than air Zone 1
vapour
Liquid surface Zone 2
Bund wall
Introduction
Area Classification Example A22
Outside of pipe
Zone 2 Zone 1 Zone 0
Inside of pipe or
process vessel
Division 1
Division 2
Introduction
Thermocouple in a hazardous area A23
Within UK, BS EN60079-10 : 1996
IEC79 - 10 : 1995
Book; -
Classification of hazardous locations
by A.W. Cox, F.P. Lees, and M.L. Ang
Published by IChemE ISBN 0 85295 2589
Introduction
Which documents A24
About 70% of dusts occuring in
Is the dust flammable? industry are flammable.
Dusts need milliJoules Dusts and powders typically require
mJ of spark energy for ignition,
of spark energy to ignite so a more likely mechanism is hot
surface ignition.
Whereas the majority of flammable
What is its ignition gases have ignition temperatures
o
temperature? above 350o C, some dusts ignite at
150 - 200 C.
Ingress protection alone Ingress protection alone for
is not enough equipment is not enough: must
protect
against ignition by raised
temperatures of enclosures.
Introduction
Explosion protection for dusts A25
Ignition Temperature Minimum Spark Energy Minimum Explosive
Type of Dust required for ignition concentration
of dust cloud (oC)
of cloud ( milli-Joules ) ( gms / cu.metre )
Aluminium, 550 15 35
milled
Zinc 600 650 385
Polystyrene 490 15 12
Urea resin 450 80 55
Cocoa 420 100 35
Coffee 410 160 70
Cotton seed 470 80 45
Grain dust 430 30 45
Sugar 350 30 30
Coal 610 60 45
Cork 470 45 30
Sulphur 190 15 30
Wood flour 430 20 35
Introduction
Ignition Properties of Dusts A26
Following the introduction of new European Directives a group of new
Standards are being prepared.
Two standards have been published, they are;
EN 50281-1-1 : 1998 Electrical apparatus protected by enclosures
- Construction and testing
EN 50281-2-1 : 1998 Test methods for determining the minimum
ignition temperatures of dust
In draft stage are;
prEN 50281-1-3 Classification of areas where combustible dust
are or may be present
IEC are working alongside the European Standards committee
Introduction
IEC/European Dust Standards A27
Grade of release BS6467 IEC 1241 DIN VDE
1988 ATEX 137 0165: 1991
Continuous 20
Primary Z 21 10
Secondary Y 22 11
Area classification of dusts and powders must be treated differently
from gases and vapours:
Dusts don’t disperse with time
Ventilation can convert layers into clouds
Introduction
Comparison of dust classification A28
systems
Zone Z An area in which combustible dust is, or may be, present
as a cloud during normal processing, handling or cleaning
operations in sufficient quantity to be capable of producing
an explosive concentration of combustible or ignitable dust
in a mixture with air.
Zone Y An area not classified as Zone Z, in which accumulations
or layers of combustible or ignitable dust may be present
under
under abnormal
abnormal conditions
conditions and give rise to ignitable
mixtures of dust and air.
Definitions taken from
British Standard 6467: Part 2: 1988
Introduction
Area Classification - Dusts A29
Relevant Standards for Dusts
BS 6467 "Electrical Apparatus with protection by
enclosure for use in the presence of
combustible dusts"
Part 1 (1985) "Specification for apparatus"
Part 2 " Guide to selection, installation and
maintenance"
ISA-S12.10 Area classification in hazardous dust locations
BS 7535 : 1992 Guide to the use of electrical apparatus
complying with BS 5501 or BS 6941 in the
presence of combustible dusts
Introduction
Dust Hazards A30
Hazardous Area Suitable apparatus
Intrinsically safe with
Zone Z degree of protection
at least IP6X *
Intrinsically safe with
Zone Y degree of protection
at least IP5X *
Source: BS 7535 : 1992; Clause 2.7
* Note: do not confuse with NEMA categories
Introduction
Intrinsic safety and dust hazards A31
Source of
Ignition
Spark
Heat Spark
Hazardous
location
Gas Air
Introduction
Explosion Triangle A32
