Intrinsic Safety

Training Development and Delivery
Hazardous area
Non Hazardous area
1. Principles of Intrinsic Safety 2. Application of Intrinsic Safety 3. Installation 4. Inspection
THE IGNITION TRIANGLE

Fuel
Note : Air has approximately 21% oxygen
EXPLOSION
IGNITION SOURCE
OXygen
Plant is classified according to :
the probability that the Hazardous Atmosphere will be present
AREA CLASSIFICATION
( in the UK these are Zone 0, 1 & 2 )
the nature of the Hazardous Atmosphere GAS GROUPING

( IIA , IIB and IIC )
Representative Gas for Sub-Division of Groups IIA , IIB and IIC
Group IIA Group IIB Group IIC
Propane Ethylene Hydrogen
Energy level for Ignition Energy level for Ignition Energy level for Ignition
160mJ 95mJ 20mJ
Area Classification - Recap
Probability of Gas/Air Mixture being present
Probability of source of ignition
Acceptable Risk
Matched to
Type of Protection
d , e ,n, I
Nothing is 100% safe
Zone 0,1, 2
Intrinsically Safe System

A system, comprising apparatus and interconnecting wiring, in which any spark or thermal effect in any part of the system intended for use in hazardous areas is incapable of causing ignition.
By Electrical Design
Power supply
Conventional Power Circuits
What happens when a fault occurs?
Training Development and Delivery Training Development and Delivery
conductor resistance 0.5 W
12V Car Battery
12V headlamp Short circuit fault
I = V/R I = 12/1 I = 12 A
P=VxI P = 12 x12 P = 144W
Energy W = P x t
Energy W= 144 x 0.01

Energy W = 1.44 Joules
conductor resistance 5 W
12V Car Battery
12V headlamp Short circuit fault
I = V/R I = 12/10 I = 1. 2 A
P=VxI
Energy W = P x t Energy W = 14. 4 x 0.01 Energy W = 0.144 Joules
P = 12 x1.2
P = 14. 4W
Energy W = 144mJ
Current limiter of 20k W
12V supply
Load Transd ucer P=VxI P = 12 x 0.00072 P= 0.0072W P = 7.2mW Energy W = P x t Energy W = 0.0072 x 0.01 Energy W = 0.000072 Joules Energy W = 72mJ
I = V/R
I= 12/20000
I= 0.00072 A I = 0.72mA
How can the principles of Intrinsic Safety be achieved ? Careful design of circuits which limit the amount of available electrical energy Where can the principles of Intrinsic Safety be applied ? Due to the small levels of available energy , this method of protection is only suitable for instrumentation or control circuits How can the principles of Intrinsic Safety be maintained ? By regular planned inspection and maintenance
For a 28V Zener with a 300 ohmn resistor for use in a IIC area Apply a 10% safety factor for zener voltage =30.8V 28V/0.093mA = 300 ohms Barrier is suitable for maintaining the integrity of the IS circuit in a IIC hazard
140mA . Applying a safety factor Of 1.5 , gives approx 93mA
Approx . 140mA
Hazardous area
I = V/R I = 12/400 I = 0.03A I = 30mA
12 V
240V
PSU
Relay 12 V 400 W
What if the relay coil inductance created a spark at the contacts capable of causing ignition?
Low power circuit - IS or non - IS ?
Limiting network 12 V
Hazardous area
240V
PSU
Relay 12 V 400 W
Low power circuit - Insertion of an energy limiting network
Limit Voltage Limit Current
Limit stored electrical energy
Ex ia Intrinsically safe with two faults Zones 0, 1 and 2
Ex ib Intrinsically safe with one fault Zones 1 and 2
"Faults"
are those in components upon which the safety of the installation depends Intrinsic Safety is the only protection concept which considers failure of the field wiring
AND THEIR APPLICATION

A Forward current
Negative
SILICON DIODE CHARACTERISTICS
Forward Bias
Reverse voltage ( Volts )
Forward voltage ( Volts )
Positive
800
700
600
500
400
300
200
100
0.6 0.7 0.8
Positive
Reverse Bias Forward bias conducting voltage of 0.6V
Negative
mA Reverse current
Fuse
Hazardous area connection

Vz
Non Hazardous area connection
Any load connected in parallel with the Zener Diode will maintain the same potential Resistors are usually wire wound and are assumed to fail open circuit
Fuse
Vz
Using 2 diodes in this example indicates that the device is safe with one fault A device like this would have the category ?
ib
Fuse

Vz
Using 3 diodes in this example indicates that the device is safe with 2 faults A device like this would have the category ?
ia
Fuse
Fuse rating is chosen to protect the diodes and is not directly related to the barrier short circuit current CENELEC and other standards require the fuse to be encapsulated within the barrier so that the fuse is not replaceable
Fuse
Secondary replaceable fuse versions of barriers are available. These are useful where there is a possibility of faults occurring during commissioning which would otherwise blow the barriers' internal safety fuses. One secondary replaceable fuse for each barrier channel is provided and is lower in value than the related safety fuse. Fuses are packaged in small mouldings which can be latched in a 'disconnect' position to break the safe and hazardous areas during commissioning, maintenance or fault finding, avoiding the need for additional disconnect terminals.
Fuse
Vz
If the barrier is used the wrong way round, then the fuse will no longer protect the Zener.
Fuse
1 Vz 2
Barriers are usually described in terms of their safety parameters: 28V 93mA 300 W is a common barrier safety description
Where Vz = 28 V
R = 300 W
28 V is the maximum OPEN Circuit voltage available at the hazardous area terminals and 93 mA is the maximum short circuit current available.

Recap Questions 1
Q1. A safety factor of 1.5 is applied to components designed to be used for Intrinsically safe devices . True / False.
Q2. An intrinsically safe system identified as ( ib ) will remain safe with 2 faults . True / False.
Q3. The fuse encapsulated within a zener barrier is designed in relation to the barrier short circuit current . True / False .
Q4. An Intrinsically safe instrument designed for operation in the field would be connected to terminals 1 and 2 of a zener barrier . True / False.
Non-hazardous area
Associated Associated Electrical Apparatus Apparatus
Hazardous area
Intrinsically Safe Safe Intrinsically Electrical Electrical Apparatus Apparatus
Field wiring
Intrinsically Safe Circuit
Intrinsically Safe System

Note:
An intrinsically safe circuit consists of all the intrinsically safe apparatus in the loop PLUS the cable
The Entity Concept

In the entity concept each item possesses its own certificate of conformity that provides sufficient information to enable end users to assemble intrinsically safe systems.
Safe area limitations
Requirements
Suitably fused double wound mains transformer
Instrument Electronics
Power supply
250 V RMS. max.

N
Should not be fed from or contain voltages greater than 250V rms.
Uncertified instrument
Intrinsically safe systems

Hazardous area Non Hazardous area
Certified hazardous area apparatus
Certified interface remote from the uncertified safe area apparatus
Uncertified safe area apparatus
Intrinsically safe systems - typical installation

Hazardous area
Non Hazardous area
Certified interface
Junction Box Field Apparatus Uncertified safe area apparatus
Intrinsically safe systems

Hazardous area Non Hazardous area
Simple Apparatus
Certified interface
Hazardous area equipment in an intrinsically safe loop is either

Certified
or
energy storing instruments etc.
Simple apparatus
non-energy storing devices
Simple apparatus: Devices in which, according to the manufacturer's specifications, none of the values 1.5V, 100mA, or 25 mW is exceeded, need not be certified or marked
1.2 V
Piezo device
Piezoelectric device limited to 1.2 V output Does this still meet the simple apparatus criteria?
1.2 V
Piezo device
Simple apparatus has to be inherently simple. You cannot make apparatus simple by the addition of a limiting device, which could fail.
Hazardous (Classified) Location
Non-Hazardous Location
Monitoring
Thermocouple
Normal Operation mV
Instrumentation
110 V
Monitoring Thermocouple Bad Day 110 V Instrumentation
110 V
Intrinsically safe systems ( REMINDER )

hazardous area Non Hazardous area
Non-Certified
hazardous area
Simple apparatus
Certified interface
Thermocouple mV
Intrinsically safe interface device
Monitoring
Instrumentation
110 V
Hazardous Location
Associated Apparatus
Simple apparatus Thermocouples Photocells RTDs
Zener Barrier OPTO Isolator
Intrinsically safe interface Intrinsically safe apparatus Transmitters Solenoid Valves
Control room equipment
Barriers are required to be connected to the main system electrical earth with a resistance of less than one Ohm Main electrical system earth point is usually the neutral star point
The important resistance is between the barrier earth rail and the main earth busbar connection point
Minimum CSA of conductor is 4mm2 copper . However ,standards indicate that TWO copper conductors of 1.5mm2 can also be used.
Barrier Fuse
Safe area Equipment Distribution transformer
For safety reasons the connection to the neutral star point must be of low resistance and secure
ONE 4mm2 conductor or TWO 1.5mm2 parallel conductors
IS earth (<1 W)
Shunt-diode safety barrier installation
Fault
Safe area Equipment Distribution transformer
For safety reasons the connection to the neutral star point must be of low resistance and secure
IS earth (<1 W)
Shunt-diode safety barrier under safe area mains fault
Apparatus
Intrinsically Safe Hazardous Area apparatus falls into one of two categories Portable Apparatus Field Mounted Apparatus
Equipment of this nature is typically marked EEx ia IIC T4
PORTABLE APPARATUS The Intrinsically Safe Continuity and Insulation Resistance Tester METROHM
Apparatus
Intrinsically Safe Non Hazardous Area Apparatus
Equipment of this nature is typically marked [EEx ia] IIC
Certificate of Conformity
Applies to APPARATUS certified by an EC approved test Authority to a CENELEC standard recognised by the EC Directives Will Include the EEC Distinctive Community Mark Approved code will be EEx
Example Z barrier CE II 1 GD CE ll 3 G [EEx ia] IIC EExn A ll T4
Fault
Safe area Equipment Raised potential
JB
Distribution transformer
Plant earth Shunt-diode safety barrier under hazardous area mains fault

Recap Questions 2
Q1. A device marked EEx ib IIB T4 is suitable for mounting in a Zone 1 hazardous area where Ethylene gas is being processed . True / False. Q2. The minimum size of earthing lead permitted for the connection from plant earth to the I.S. earth is a 6.00 mm2 copper conductor. True / False . Q3. It is permitted for the resistance / impedance of the earthing lead to be greater than 1W. True / False.
(L & C parameters) Assume an interface of 28V 300 ohms resistance Maxm source current = 28/300 = 93.33 A (IIC gas area) Apply safety factor of 1.5 Maxm source current = 140 ma From ignition curves the maximum safe inductance for Group llC is found to be 4.0 mH For Capacitive circuits apply safety factor of 1.5 to the zener barrier voltage of 28V = 42V For a IIC gas the maximum safe capacitance is 0.08 microFarads
Segrataion of IS and non Is circuits in hazardous areas is essential to avoid the possibility of higher voltages invading EExi circuits Cable screens should be earthed at one point only (zener barrier)
Cable marking ---Marking of Is cables is not necessary if either the Is or non-Is cables are armoured, screened or metal sheathed
Is and non Is circuits must not be run in the same multi -core cable
Multi core cables must be capable of withstanding a 750V dc IR test
Installation must comply with system documentation and the manufacturer's recommendations
Location of the interfaces should be permanently marked to show the correct type of replacement barrier in each position Barriers are normally mounted in the safe area at the nearest convenient point to the hazardous/safe area boundary Hazardous area mounting is permissible if the appropriate type of protection is provided for the barriers and cabling : Zone 1 : Flameproof (Ex d) enclosure Zone 2 : Type n enclosure
The cable must:
Be capable of withstanding a 500 V insulation test to earth for 1 minute Conform to the cable parameter requirements
Be clearly identified as carrying intrinsically safe circuits by the use of Blue cable Blue tape
Be suitable for environmental conditions
Mechanical protection not necessary for safety purposes
Multicore Cables are permitted in IS systems but IS and non-IS circuits must not be contained in the same multicore Multicores
should be run where the risk of mechanical damage is slight should be fixed throughout their length each IS circuit to occupy adjacent cores no voltage should exceed 60V peak
Outer sheaths need not necessarily be blue for IS systems but easy identification of IS cables is required.
NON - HAZARDOUS AREA
HAZARDOUS AREA
Connected to plant earth via gland at enclosure Cable Screen Earthing Requirements I.S. earth terminal R
CPC
Connected to plant earth via gland at detector Screen , insulated and left to float in detector box
CPC
Screen connected to plant earth at detector
R
SPARK
X
Break in screen when carrying earth leakage current
SCREEN EARTHING ARRANGEMENT
BARRIER ENCLOSURE
Screen connected to barrier busbar
NON-HAZARDOUS AREA IS Earth ( Min csa 4.00mm2 )
CPC connected via gland body
0 0
0 0
HAZARDOUS AREA
Screen connected to through terminal . Isolated from plant earth. Screen insulated and left to float in enclosure
JOINT BOX
TRANSDUCER
IS Circuits
non-IS Circuits
Separate cable trays. Partition must be earthed.
IS Circuits
non-IS Circuits
IS and non-IS circuits can be in the same tray so long as at least one cable is armoured or has a metal sheath.
Earthing
where fault currents are caused to flow via a dedicated return path (backed up by connection to physical ground) in such a way as to operate a protective device in an appropriately short time.
Bonding
where voltage difference between parts of plant, handrails etc., are eliminated by physical crossconnection ( i.e. common potential )
The length of the cable in the hazardous area is the only crucial factor when using simple apparatus and an approved safety barrier
Hazardous area 4 - 20 mA
Non Hazardous area
Safety barrier Certified system

Safety description
EEx ia IIC T4 Ex94C2053
31/2 digit Indicator MTL 633B
Input terminals: non-energy storing apparatus; can be connected without further certification into any IS loop
Least expensive
no requirement for lockable fused isolators, protected cable, special glands
Simple apparatus
permits the use of normal industrial devices if they are non-energy storing
IS is the only technique which remains safe after faults develop in cables and fallible components
Fault Tolerant
Live maintenance
IS is the only technique which permits live working without gas clearance certificates
Unarmoured cables System is electrically, not mechanically protected Safe for personnel extra low voltage and currents
Recap Questions 3
Q1. Cable screens should be insulated and left to float in the enclosure of a transducer in the hazardous area . True / False .
Q2. Intrinsically safe circuit cables should be tested with a potential of 500V to determine if the insulation has been damaged . True / False .
Q3. 6mm is the minimum clearance between similar I.S. circuits . True / False .
Q4. 100mm is the minimum distance for segregation between I.S. and Non I.S circuits . True / False .
Inspection
Screens are to be connected to earth at one point only, usually the same point as the barriers Barriers are the correct type and firmly fixed to earth bar Record results by an effective and verifiable means
Inspection
Apparatus must be installed in accordance with drawings and schedules, fully labeled and undamaged Segregation of IS and non-IS cable should be adequately maintained
Creepage and clearance distances must be acceptable where cable cores enter terminal blocks
IS earth connection must be separate from plant earth and other electrical earths, except at one point - the main electrical system earth point
Where screens are used in IS cables then they should be earthed at one point only, usually at the same point as the interface devices are earthed. In the field, screens should be isolated from earth and each other .
Cable armour or metal shields should be solidly earthed to the plant structure
Electrical inspection
Insulation testing (hazardous area)
Resistance of core to core and core to screen, typically

Pass > 10MW Fail < 1 MW
Despite the fact that these are low current devices, they still generate 500V dc ( 500V rms ). If the cable has sufficient capacitance it has the potential to store enough energy to provide an incendive spark.
Read the manual
Don't bridge the interface
Simple test on barrier
Zener Diode Barrier
Non-IS meter
You may
Work Live
You must
Use the correct tools to avoid possible damage to enclosures etc.
Use certified test equipment
You must not
Interfere with the process without authorisation Compromise the safety of the loop by : bridging the interface interconnecting separate loops incorrect substitution of interfaces invade IS circuits with unrestricted power
Short circuit wiring on one loop at a time Open-circuit wiring on one loop Claim simple apparatus for: wire links as switches resisters as loads
Use barriers for measurements with uncertified equipment
Perform measurements through barriers
Multiple Choice Questions on the topic of
Intrinsic Safety
The standards indicate that a limitation is placed on the input voltage when supplying an instrument system via a zener barrier. The level stated in the standards is : ( a ) 55V ( b ) 110 V ( c ) 250V ( d ) 440V
When a screened cable is used to supply an intrinsically safe transducer , as part of an emergency shut - down system , it is recommended that the screen be terminated : ( a ) at one end only ( c ) to the plant earth at both ends ( b ) at both ends ( d ) isolated at both ends
A suitable instrument for measuring the resistive value of the copper protective conductor when used for intrinsic safety is : (a ) an insulation tester ( c ) an audible continuity tester ( b ) an ohmmeter ( d ) a neon test screwdriver
Intrinsic Safety
The correct clearance distance between an IS circuit and earth , operating at a potential of 65V would be : ( a ) 1.5mm ( b ) 3mm ( c ) 4mm ( d ) 6mm
It is a recommendation that the unused cores of an instrument cable supplying intrinsically safe circuits , when terminated in a control panel containing zener barriers be : ( a ) left to float in the enclosure until required ( c ) terminated in a connector and left to float until required ( b ) connected together and terminated to the plant earth ( d ) connected together and terminated to the intrinsically safe earth
An example of Simple Apparatus as defined in the standards would be : (a ) a transducer producing an output of 120mA ( c ) a light emitting diode ( b ) a transducer producing an output of 2V ( d ) a capacitor capable of storing 30mJ
Intrinsic Safety
The minimum CSA of the protective conductor required for a circuit using a zener barrier to maintain the intrinsic safety would be : ( a ) 1.5mm2 ( b ) 2.5mm2 ( c ) 4.00mm2 ( d ) 6.00mm2
Intrinsically safe and non - intrinsically safe circuits are permitted in the same enclosure provided that : ( a ) the cables have the same thickness of insulation ( c ) the cables are bound together in the same cable loom ( b ) the cables are made by the same manufacturer ( d ) the correct clearance is applied
Intrinsically safe components , circuits and systems are categorised as ia and i b . A device which is identified as that with the category ia indicates that it will remain safe with :
(a ) no faults ( c ) 2 faults ( b ) 1 fault ( d ) 3 faults
PORTABLE APPARATUS
Simple apparatus or any approved intrinsically safe apparatus with entity parameters
R&H Model 728+

I.S. Ground
Entity Concept parameters
Vt 29.2V It 297mA Group IIC IIB C (mF) 0.11 0.33 L (mH) 4 12
Vmax 30V
Imax 350mA Ci + Ccable 0.02F Li + Lcable 0.07mH
Notes
The barrier must not be connected to any device which uses or generates in excess of 250Volts RMS or DC unless it has been determined that the voltage has been adequately isolated from the barrier The barrier must be connected to a suitable ground electrode. The resistance of the ground electrode must be less than 1 Ohm.
Hazardous area
Non Hazardous area
Approved barrier
24V
Approved apparatus Max. Voltage Max. Current Internal Capacitance Internal Inductance Va Ia Ca La
250 W
Barrier Parameters O/C voltage Vb S/C current Ib Capacitance Cb Inductance Lb
For this example Va , Ia Ca and La relate to the Apparatus . Likewise , Vb , Ib , Cb and Lb relate to the Barrier

Intrinsic Safety

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Intrinsic Safety

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Training Development and Delivery

Non Hazardous area

Training Development and Delivery

1. Principles of Intrinsic Safety 2. Application of Intrinsic Safety 3. Installation 4. Inspection

Training Development and Delivery

THE IGNITION TRIANGLE

Note : Air has approximately 21% oxygen

Training Development and Delivery

Plant is classified according to :

the probability that the Hazardous Atmosphere will be present

( in the UK these are Zone 0, 1 & 2 )

the nature of the Hazardous Atmosphere GAS GROUPING

Training Development and Delivery

Representative Gas for Sub-Division of Groups IIA , IIB and IIC

Group IIA Group IIB Group IIC

Propane Ethylene Hydrogen

160mJ 95mJ 20mJ

Training Development and Delivery

Area Classification - Recap

Probability of Gas/Air Mixture being present

Probability of source of ignition

Nothing is 100% safe

Training Development and Delivery

Intrinsically Safe System

Training Development and Delivery

Conventional Power Circuits

What happens when a fault occurs?

Training Development and Delivery Training Development and Delivery

conductor resistance 0.5 W

12V Car Battery

12V headlamp Short circuit fault

P=VxI P = 12 x12 P = 144W

Energy W= 144 x 0.01

Training Development and Delivery Training Development and Delivery

12V Car Battery

12V headlamp Short circuit fault

Energy W = P x t Energy W = 14. 4 x 0.01 Energy W = 0.144 Joules

Training Development and Delivery Training Development and Delivery

Current limiter of 20k W

Training Development and Delivery

Training Development and Delivery

140mA . Applying a safety factor Of 1.5 , gives approx 93mA

Training Development and Delivery

Low power circuit - IS or non - IS ?

Training Development and Delivery

Low power circuit - Insertion of an energy limiting network

Training Development and Delivery

Limit Voltage Limit Current

Limit stored electrical energy

Training Development and Delivery

Ex ia Intrinsically safe with two faults Zones 0, 1 and 2

Ex ib Intrinsically safe with one fault Zones 1 and 2

Training Development and Delivery

AND THEIR APPLICATION

Training Development and Delivery

SILICON DIODE CHARACTERISTICS

Reverse voltage ( Volts )

Forward voltage ( Volts )

0.6 0.7 0.8

Reverse Bias Forward bias conducting voltage of 0.6V

Training Development and Delivery

Training Development and Delivery

Hazardous area connection