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Summary of Topics
1. Explosion basic knowledge
2. Explosion groups
3. Zone classification
4. Explosion-proof electrical apparatus design standards
5. Explosion-proof mark of different countries
6. Explosion-proof type of electrical apparatus
7. The basic principles of the intrinsically explosion-proof technology
8. The feature of the intrinsically explosion-proof technology
9. Intrinsically safety apparatus and associated apparatus
10. Intrinsic safety electrical apparatus type
11. Marking of apparatus
12. The basic components of intrinsically safe explosion-proof system
13. Safety barrier
14. Guidelines for use of devices with intrinsically safe circuits
Page
1
1
2
3
3
3
4
4
5
5
6
7
9
11
component
interpretation
Fuels (flammable
substances)
Oxidizers
air (21 % Oxygen), pure Oxygen, oxygen releasing compounds (i.e. potassium
manganate)
Possible sources
of ignition
Explosive limits
2. Explosion groups
GB3836-2000 ordains that combustible materials are divided into the following classes in accordance with
the degree of the inflammable hierarchy.
Factory type
Classification
of the gases
Representative
gases
Inflammable
hierarchy
Methane
0.280mJ
Propane
0.180mJ
Difficultly
Page 1 of 12
Ethylene
0.060mJ
Hydrogen,
acetylene
0.019mJ
easily
The United States of America and Canada (NEC500) divide the explosive objects spreading in the air into
three classes firstly. The CLASS are gas and vapour. The CLASS is dust. The CLASS is
fiber. Then divide the gas and vapour into Group:
Class
CLASS
CLASS
CLASS
group
Representative gases or
dusts
Acetylene
C (Hydrogen, Acetylene)
Hydrogen
C (Hydrogen, Acetylene)
Ethylene
B (Ethylene)
Methane
A (Propane)
Metal dusts
(Methane)
Coal dusts
Grain dusts
No grouping
To be determined()
3. Zone classification
According to EN 60079-10 and EN 1127-1 explosion hazardous areas are divided into zones such as
flammables gases, vapours, mists and combustible dust. The classification is based on the likelihood that a
dangerous explosive atmosphere occurs. The ATEX directive has re-defined the zone division as follows:
China
IEC
European
Union
Likelihood of an
explosive
atmosphere:
occasionally
Likelihood of an
explosive
atmosphere: unlikely
or infrequently - for a
short period only
European
Union
constant or long
term corresponds
to > 1000 h/year
occasionally
corresponds to
10...1000 h/year
gases and
vapours
zone 0
zone 1
zone 2
dusts
zone 20
zone 21
zone 22
Description
Zone
classification
North
America
China
Likelihood of an
explosive
atmosphere :
occasionally
continuously, for
long periods or
frequently
Description
Page 2 of 12
abnormal operate
occasionally.
Zone classification (gases
and dusts)
Div.1
Div.2
Standards Code
Standards Name
GB3836.1-2000
GB3836.4-2000
Country Standards
IEC60079-0:1998
IEC
IEC60079-11:1999
EN 50020
NEC500
Intrinsic safety
signification
Ex
EEx
AD
Italy
MSAE
France
FLP
Great Britain
ULFM
America
Germany \IEC
China National Quality Supervision and Test Centre for Explosion Protected Electrical Products (CQST):
CQST is one of the China famous professional testing and certification authorities and engages in safety
test, examination and evaluation of Ex electrical products. CQST has made deep research and obtained
extensive experience in the field of explosion protection electric safety technique and has a high reputation
in the word.
CQST has signed the cooperation agreements of mutual acceptance of test results separately with more
than ten international wellknown Ex scientific research and test bodies, such as UL (U.S.A.), FM (U.S.A.),
PTB (Germany), NEMKO (Norway), testsafe (Australia), CCVE (Russia) and LCIE (France).These
cooperation have promoted the international exchange of Ex technique and offered convenient services for
sino-foreign Ex product entering into opposing side market.
6. Explosion-proof type of electrical apparatus
GB3836-2000 (Electrical apparatus for explosive gas atmospheres) defines as follows:
Page 3 of 12
code
type
standards
explosion-proof measure
flameproof
GB3836.2
Isolate the
existing
increased safety
GB3836.3
Zone1,Zone2
ia
intrinsic safe
GB3836.4
Zone0-2
ib
intrinsic safe
GB3836.4
Zone1,Zone2
Pressurized
GB3836.5
Zone1,Zone2
jelly filled
GB3836.6
Zone1,Zone2
sand filled
GB3836.7
Zone1,Zone2
non-sparking
GB3836.8
Zone2
pour enveloping
GB3836.9
Zone1,Zone2
hermetically sealed
GB3836.10
Zone1,Zone2
ignition
application zone
source
Zone1,Zone2
For automatic control and instrumentation, intrinsic safe, flameproof and increased safety types are used
commonly.
7. The basic principles of the intrinsically explosion-proof technology
In electrical apparatus, electric spark and thermal effect is the main ignition sources that set danger
explosive gas off. The intrinsic safety methods are considered protection devices and their function is to
avoid possible errors and faults by preventing the transfer of unsafe levels of energy to the hazardous area.
Possible faults are: 1) Excessive voltage in the hazardous area. 2) High current levels in the hazardous area
(short-circuit).
The intrinsic safety method of explosion protection always relates to intrinsically safe circuitry that
comprises an intrinsically safe apparatus, an appropriate electrical power source and the connecting cables.
In intrinsically safe circuits, an explosive environment cannot be ignited by sparking or a thermal effect
when operating normally under prescribed fault conditions. In an intrinsically safe circuit for categroy ia, 2
calculable faults (see definition EN 50020) must not cause an ignition and in category ib only 1 such fault
is permissible.
Limiting the power supply, total inductance and total capacitance within the intrinsically safe circuitry is
the basic principle of the intrinsically safe explosion protection method. The project manager or user has to
compare the permissible internal limit values for intrinsically safe electrical apparatus with the permissible
connection values of the associated electrical apparatus.
8. The feature of the intrinsically explosion-proof technology
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Intrinsically safe explosion-proof technology is actually a low-power design technology. It is a very good
apparatus for the design of industrial automation instrument. Compared with other explosion-proof type,
using the explosion-proof electrical technology has following characteristics:
1. Intrinsically electrical apparatus have simple structure, small size, light weight.
2. Installation and maintenance can be with power input.
3. High security and reliability. Do not reduce the security and reliability of the electrical apparatus for
outside structural damage.
4. Applicable range is wide range. It is the only explosion-proof technology that can be applied in the
zone 0.
9. Intrinsically safety apparatus and associated apparatus
a. Intrinsically safety apparatus
In the conditions of the national standards, any spark and thermal effects produced by this electric
apparatus can not ignite the explosive gas environment It can be used in hazardous area.
It can be divided into general electrical apparatus and simple electrical apparatus.
General electrical apparatus: Has the energy storage element, need explosion-protection
authentication. Such as intrinsically transmitter, approach switch, and so on.
Simple electrical apparatus:If Voltage is lower than 1.2V, current is lower than 0.1A,energy is lower
than 20uJ or power is lower than 25mW, it is considered as simple electrical apparatus . Do not need
explosion-protection authentication, can directly access to the intrinsically explosion-protection
system. Typical feature as followers: Internal equivalent inductance Li = 0, Internal equivalent
capacitance Ci = 0. Common simple apparatuses are: thermocouples, thermal resistors, resistor, light
emitting diode, contact switch, and so on.
b. Associated apparatus (safety barrier)
It is an apparatus installed in a safety area, connecting the intrinsically electric apparatus and
non-intrinsically electric apparatus. Safety barrier limit the energy get in to the hazardous area in the
safety rang and ensure that the field equipment, personnel and production are safety.
10. Intrinsic safety electrical apparatus type
a. Apparatus groups
According to the principle of GB3836-2000, intrinsic safety electrical apparatus has 2 types as
follows:
Group
interpretation
Device Group I
Device Group II
For all other locations in which a potentially explosive atmosphere exists. There
are three class of A, B and C
b. Apparatus Category
Intrinsic safety electrical apparatus and associated apparatus can be divided into ia class and ib class
according to the places used or connected and the safety standards.
Code
Page 5 of 12
interpretation
ia
Very high level of safety: devices featuring two independent means of protection;
even in the event of rare device disturbances, the device remains functional and
maintains the requisite level of protection. It can be used in the hazardous areas of
zone0, zone1 and zone2.
ib
High level of safety: devices featuring one means of protection. Even in the event of
frequently occurring device disturbances or equipment faults which normally have to
be taken into account the device provides the requisite level of safety. It can be used
in the hazardous areas of zone1 and zone2.
Maximum surface
temperature
ignition
temperatures of
flammable materials
T1
450
450
Hydrogen, acrylonitrile,
etc. (46 kinds)
T2
300
300
T3
200
200
Petrol, crotonaldehyde ,
etc. (36 kinds)
T4
135
135
Acetaldehyde,
tetrafluoroethylene, etc.
(6 kinds)
T5
100
100
carbon disulfide
T6
85
85
Electrical
safety
Low
High
Intrinsically safe equipment for direct installation in hazardous areas requires temperature
classification. For associated apparatus temperature classification is not needed.
11. Marking of apparatus
Equipment for explosion protected areas must be clearly marked. There are two different types of marking.
According to CENELEC marking of an apparatus conforming to EN 50014/20 must provide the following
information:
Manufacturers name or trademark
Part number
EEx-symbol
Ignition category (e. g. ia)
Designated group together with the respective subdivision (e. g. IIC)
Temperature class or maximum surface temperature (for group II devices only)
Page 6 of 12
Ex ia C T6
temperature class
explosion group
type of protection
conform to IEC or chian standard
[Ex ia]C
explosion group
type of protection
conform to IEC or chian standard
Intrinsically
Safety
apparatus
cable
Safe Area
Associated
apparatus
(safety
barrier)
Centralized
Control
System/
PLC/
Operation
Terminal
Maximum internal Equivalent Capacitance (Ci): Total equivalent capacitance inductance appearing by
the intrinsically safety apparatus.
Maximum internal Equivalent Inductance (Li): Total equivalent internal inductance appearing by the
intrinsically safety apparatus.
Intrinsically performance certification parameter of associated apparatus (safety barrier):
Maximal Voltage (AC RMS or DC Um):The maximal voltage put on the associated apparatus (safety
barrier), and can not lead to the intrinsically performance failure
Maximum Output Voltage (Uo):The maximum Output Voltage that may appear in the intrinsically
current when open circuit and the intrinsically safety apparatus voltage (including the Um and Ui ) is
maximal (AC peak or DC).
Maximum Output Current (Io):The intrinsically current maximum current that come from the
intrinsically safety apparatus (AC peak or DC).
Maximum Output Power (Po):The intrinsically current maximum power that can from the intrinsically
safety apparatus.
Maximum external Capacitance (Co):The intrinsically current maximum capacitance that can connects
to the intrinsically safety apparatus and do not lead to the intrinsically performances failure.
Maximum external Inductance (Lo):The intrinsically current maximum inductance that can connects to
the intrinsically safety apparatus and do not lead to the intrinsically performances failure.
Patch cable:Intrinsically cable is a low capacitance and low inductance cable. Compared with other cable
has excellent shielding and anti-interference performance. It suits for explosion hazardous area and having
high explosion-proof security requirement. Its intrinsically performance as follows:
Maximum distribution capacitance that the cable allow: Cc = Ck * L
Maximum distribution inductance that the cable allow: Lc = Lk * L
Ck Distributed capacitance per unit length of the cable
Lk Distributed inductance per unit length of the cable
L The actual length of the cable
The various configuration of the intrinsically explosion-protection system must meet the following
conditions:
1. The explosion-protection mark class of the intrinsically safety apparatus can not higher than the
associated apparatus (safety barrier).
2. Authentication parameters have to satisfy the following inequality between the associated apparatus,
intrinsically safety apparatus and the cable.
Associated
apparatus
Demonstration of intrinsic
safety apparatus
Intrinsically safe
apparatus + cable
Uo
Ui
Io
Ii
Po
Pi
Co
Ci + Cc
Lo
Li + Lc
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Safe
Area
Zener safety barrier have simple principle. Its current can achieve easily and the price is cheap. But the
Page 9 of 12
application reliability is affected greatly for its principle defect and this limits its application range. The
reason as follows:
a. Installation location must have reliable ground system, and the ground must be less than 1,
otherwise it would lose the explosion-protection performance and reduce signal anti-interference
capacity directly, affect the stability of the system.
b. The instrument from hazardous area must is isolation type, or the signal connected to the ground by
the ground terminal of the zener safety barrier can not transmit correctly, and because of signal
grounding, it will reduce signal anti-interference capacity directly, affect the stability of the system.
c. Zener safety barrier has greater impact on the power supply, at the same time it can be damaged
easily for the instability of the power supply.
d. Using zener safety barrier, signal negative pole all need to the intrinsically ground, it will reduce
signal anti-interference capacity directly, affect the stability of the system., the impact on the DCS
system is sharp prominent.
. Isolation safety barrier
Isolation safety barrier is composed of limiting energy unit, isolation unit, signal process unit, power
supply unit, etc. The principle as follows:
Safe
Area
Hazardous
Area
limiting
energy
unit
Isolation
unit
signal
process
unit
Isolation safety barrier not only has limiting energy function, but also has isolation function, at the same
time in accordance with intrinsically limiting energy requirements. Compared to zener safety barrier,
although the price is slightly higher, but its others outstanding advantage give more benefits to user.
a. Transformer isolated barriers do not require grounding, because the transformer in the barrier
galvanically isolates the hazardous area from the safe area.
b. Transformer isolated barriers have an internal voltage regulator. The function necessary to the
application is thereby assured.A regulated power supply is only necessary for Zener barriers. If the
power supply for Zener barriers is too low, the field device can no longer operate. The same applies to:
If the power supply becomes too high, the Zener diodes divert the current and the fuse blows when
the current exceeds its maximum rating.
c. Any process monitoring signal circuit (mA- or mV-signal) that is connected to a transformer isolated
barrier is not grounded. In contrast to this, Zener barriers require a suitable ground. From an
instrumentation point of view this is best achieved through a quasi ungrounded system.
d. Transformer isolated barriers from MORNSUN can be repaired; Zener barriers cannot, because they
are filled with an epoxy resin.
e. Transformer isolated barriers have an internal current limit. The fuse is not activated if there is a short
circuit at the exterminal.
f. Instead of using diagrams and Ohm's Law to determine the proper barrier, each transformer isolated
barrier is designed for special applications (i. e. 4 mA~20 mA amplifier, thermocouple amplifier,
solenoid drivers, etc.)
Page 10 of 12
According to the function, the types of safety barrier commonly used are as follows: switch safety
barrier, analog safety barrier, digital safety barrier, resistance thermometry safety barrier, thermocouple
safety barrier, frequency safety barrier, and so on.
14. Guidelines for use of devices with intrinsically safe circuits
The principle of selecting the intrinsic safety electrical apparatus
Simple electrical apparatus:
According to the principle of GB3836.4-2000 about explosion-protection standards, if voltage is lower than
1.2V, current is lower than 0.1A, energy is lower than 20uJ or power is lower than 25mW, it is considered
as simple electrical apparatus. Typical feature as followers: Internal equivalent inductance Li = 0, Internal
equivalent capacitance Ci = 0. Common simple apparatuses are: thermocouples, thermal resistors, pH
electrode, strain gauge, switch, and so on.
General electrical apparatus:
a. The design whether or not in accordance with the GB3836.1-2000 and GB3836.4-2000 requirements and
if the electrical apparatus had been approved by the explosion-proof inspection agency which was
authorized by the national.
b. If the explosion-proof mark class is applicable to the safety requirements of the hazardous area.
c. Clear the authentication parameters of Ui, Ii, Pi, Ci and Li.
d. If intrinsically safety current ground or if it is isolated effectively between the grounding intrinsically
current and the safety barrier interface current.
e. What is the method of the signal transmission?
f. Clear the minimum operating voltage and loop normal operating current of the intrinsically electrical
apparatus.
The principle of selecting the safety barrier
a. Safety barriers explosion-proof mark class is not lower than the class of the intrinsically field apparatus.
b. Make sure the end and circuit resistances can meet the minimum operating voltage of the intrinsically
field apparatus.
c. Safety barriers safety parameters of the intrinsically port can conform to UoUi, IoIi, CoCi+Cc,
LoLi+Lc.
d. The safety and the signal transmission mode between the safety barrier and the intrinsically field
instrument must be best match.
e. Do protection well. Avoid leakage current of the safety barrier affects the normal operation of the
field intrinsically safety apparatus.
f. Safety barrier have two types: one is zener safety barrier, the other is isolation safety barrier.
The principle of selecting the cables
The governing regulations cover installation of intrinsically safe circuits, mounting to external connections,
cable characteristics and cable installation. Cables and terminals with intrinsically safe circuits must be
marked and separated from nonintrinsically safe circuits or feature appropriate isolation (> 1.500 VAC).
Following an excerpt from the requirements according to EN 60079-14:
a. Protection against external electrical or magnetic fields (e.g. power current cables).
b. Prevent conductor splicing of fine wires through wire sleeves.
c. Min. cross section of 0.1 mm (also single wires of a conductor).
d. Protection against damaging (mechanical, chemical, thermic...)
e. Armouring, metal cladding, shielding of cables and lines
Page 11 of 12
f. Common use of single-core nonsheathed cables of intrinsically and nonsafe circuits in one line is not
permitted.
g. Separate error assessment when using multi-conductor cables and lines.
h. When marking cables by colour, light-blue must be used.
Installation of cables
Electrical cables are the connection between field and interface devices and are important functional
components of an automation system. Therefore it is advisable to observe some frame conditions when
installing cables. Cables must be protected against negative environmental influences.
Chemical resistance, temperature rating, resistance against ultraviolet radiation and applicable operation
standards are just some of the parameters which should be taken into account.
By choosing an appropriate installation method it is possible to prevent damages, e.g. through vehicles.
When connected to field devices, the cable should be routed in a conduit. If connected to vibrating
machines or moving parts, some extra cable should be added as a reserve. The minimum bending radius
must also be observed. Cable manufacturers provide information on cable installation and valuable
installation hints. Data integrity and reliability depend strongly on the cable types and installation methods.
Sensor cables should always be installed separately from the power cables. Electromagnetic interferences
must also be avoided. Cable connections to motors which are controlled via frequency converters should be
protected according to the manufacturers safety specifications. If long cables are needed, it is
recommended to use shielded and earthed cables. The line resistance of sensors may not exceed 50 (EN
60947-5-6); the maximum cable length is determined by the cable' cross-section:
L=
R = line resistance []
S = cable cross-section [mm2]
= resistivity [mm2/m]
L = cable length [m]
Page 12 of 12
R S