Transcript Hazardous Locations Overview

The world leader in serving science
Antaris EX and
Hazardous Locations
Overview
Matt Ebersole
August 13, 2007
Hazardous Locations Defined
 The National Electrical Code (NEC)
defines hazardous locations as those
areas "where fire or explosion hazards
may exist due to flammable gases or
vapors, flammable liquids, combustible
dust, or ignitable fibers or flyings."
 These areas are also called:
• Classified Locations
• Explosive Atmospheres (ATEX)
• HazLoc
 NEC gives as an example: “drying
rooms for the evaporation of flammable
solvents” (Article 500).
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Pharmaceutical Dryer
Hazardous Locations Defined
 Equipment for these locations are
referred to as:
• Listed
• Classified
• Labeled
 Why talk about this?
• Some models of the Antaris EX are rated for
hazardous locations
• Antaris Target Blend Analyzer is being tested for
future hazardous locations ratings
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Worldwide Standards
The governing codes are:
 United States
• National Electric Code (NFPA 70) Article 500
• National Electric Code (NFPA 70) Article 505, since 1996
• NFPA codes
 Canada
• Canadian Electric Code
(CEC)
• CSA 60079
 Europe – Directive 94/9/EC
• EN 60079
 Other –
• IECEx Scheme, slowly being
• accepted
• May accept US or European rating
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Hazardous Area Classification
 These areas are divided into three classes:
• Class I: Flammable Gases or Vapors
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Antaris EX-Z1
& EX-Z2
Pharmaceutical plants
Refineries and chemical plants
Some food processing
Gas stations, aircraft hangers and fueling, paint/spray areas, sewage treatment
facilities, natural gas handling, printing presses
• Class II: Combustible Dusts
• Grain storage, flour and feed mills, metal grinding, pharmaceutical plants, producers
of: plastics, fireworks, starch, candies, sugar, cocoa, spices, coal
• Class III: Ignitable Fibers & Flyings
• Textile, mattress, cotton mills, wool processing, wood cutting
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Hazardous Area Classification
 European standards (94/9/EC) instead divide hazardous
locations into:
• Group
• Group I: Mining, underground, firedamp
• Group II: All other installations
Antaris EX-Z1
& EX-Z2
• Type of hazard
Antaris EX-Z1
& EX-Z2
• G: gases, vapors, or mists
• D: dusts
• Both
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Hazardous Area Classification
 Divisions, Zones, and Categories
• NEC Code 500
• Division 1
Antaris EX-Z1
 exists under normal operating conditions
 or may exist frequently due to repair, maintenance, or leakage
• Division 2
Antaris EX-Z2
 only in accidental rupture or breakdown or abnormal operation
 only in breakdown of ventilation system
 adjacent to C1D1 location
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Hazardous Area Classification
 NEC Code 505 – since 1996, and IEC60079
• Zone 0
 gases present continuously or for long periods of time
• Zone 1
Antaris EX-Z1
 gases likely to exist under normal conditions
 or frequently for maintenance or leakage
 adjacent to Zone 0
• Zone 2
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Antaris EX-Z2
gases not likely to exist in normal operation, and if they do only for a short time
only due to breakdown or abnormal operation
only due to ventilation failure
Adjacent to Zone 1
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Hazardous Area Classification
 Europe 94/9/EC
• Category 1
 explosive atmosphere present continuously, for long periods, or frequently
• Category 2
Antaris EX-Z1
 explosive atmospheres likely to occur occasionally
• Category 3
Antaris EX-Z2
 explosive atmospheres unlikely to occur, and if they do, only infrequently and for a short period
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Hazardous Area Classification
Class I, or Equipment Group 1 Comparison:
NEC500
Division 1
Unrated
EX-Z1 North Amer
Division 2
EX-Z2
N. Amer
NEC505
IECEx
Zone 0
Zone 1
Zone 2
Unrated
EX-Z1
Intl
EX-Z2
Intl
Europe
94/9/EC
Category 1
Category 2
Category 3
Unrated
Continuously
Occasionally
Unlikely
Never
More dangerous
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EX-IP
Hazardous Area Classification
How would you classify these areas? The mixing tank
is open and contains volatile materials. A hood is
provided over the tank. There is a valve to empty the
tank. Fresh air comes in through the vents. More
volatile product is stored in the walled-off, separately
ventilated area.
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Hazardous Area Classification
(2) = Zone 0 (hazard continuously present)
(3) = Zone 1 (only intermittent hazard)
(4) = Zone 2 (only abnormal hazard, such as barrel spill)
(5) = Non-Hazardous
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Hazardous Area Classification
• Equipment is also classified by groups
• Some gases, such as Hydrogen, have higher explosive pressures
and are harder to contain.
• Antaris EX-Z2 North America covers groups A, B, C, and D.
• Antaris EX-Z2 International covers group IIC (and all lesser groups).
• Antaris EX-Z1 North America covers groups C and D.
• Check labeling of system to be sure.
More
dangerous
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Hazardous Area Classification
 Temperature Class
• Equipment is rated by the
hottest surface temperature on
or in the enclosure.
• This must be less than the
ignition temperature of the gas
the area is rated for.
• Antaris EX-Z2 and EX-Z1 are
rated T4. Check labeling of
system to be sure.
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Hazardous Area Classification
 Ambient Temperature
• Standard operating
temperature range for
equipment in hazardous
locations is -20°C to 40°C.
• All versions of the Antaris
EX are rated for -20°C to
40°C.
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Markings
 A note about different standards:
• Factory Mutual Approval
• We do not carry FM approval. They are a certification body, just like UL, or others. We
use Intertek, which is a notified body in Europe and an OSHA approved NRTL for the
US.
• CENELEC Approval
• “CENELEC approved” is the old term for ATEX. The ATEX directive, 94/9/EC, became
mandatory July 1, 2003, repealing the old method (76/117/EEC, 79/196/EEC, and
82/130/EEC). While the CENELEC standards body still creates the standards used for
all European regulatory approvals, ATEX is the new approval method.
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Working in Hazardous Locations
 Some review on working in Hazardous Locations:
• Static electricity: sparks can set off explosions. Typically, ESD protection is
used (straps, jackets, etc).
• Ordinary location electrical equipment is not allowed in the hazardous
location (e.g. cell phones, meters, oscilloscopes, laptop computers, etc).
Also, the enclosures cannot be opened to access the equipment being
serviced while it is powered up.
• The above can often be overcome with a “hot work permit” or “safe work
permit”. In Zone 1 and 2, where the hazard is intermittent, the atmosphere
can be tested for the hazard, and then work can commence.
• The safe environment window for service can be very specific and very
small.
• There may be on-site training required before you can enter.
• Always consult the local facility’s safety engineer or officer and
strictly comply with his or her guidance and all local safety rules.
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Protection Techniques
 The equipment needs to use one or more of the defined protection
techniques.
Protection Technique
Principle
Intrinsic Safety (ia)
Limit Energy
Flameproof (d)
Contain the Explosion
Purged and Pressurized (p)
Keep Flammable Gas Out
Oil Immersion (o)
Keep Flammable Gas Out
Increased Safety (e)
No arcs, sparks, or hot surfaces
Encapsulation (m)
Keep Flammable Gas Out
Powder Filling (q)
Contain the Explosion
Type ‘n’, non-sparking (nA, nC, nR)
No arcs, sparks, or hot surfaces
 Antaris EX-Z1 and EX-Z2 use a combination of some of these, but
primarily type ‘p,’ purged and pressurized.
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Antaris EX Product Overview
 Common Specifications:
• Antaris FT-NIR Fiber Optic Analyzer
• A rated enclosure containing essentially an Antaris MX spectrometer
• 4 channels with internal reference, sampled simultaneously
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Hose washable, corrosion resistant, stainless steel
Optional Integrated Computer with full-size keyboard and pointing device
Optional PLC Accessory
Ambient Temperature of -20°C to 40°C
Humidity of 0 to 100% condensing
Able to be wall mounted or stand mounted. EX-IP able to be cart mounted.
All of the enclosure models are very heavy. They require mechanical lifting.
They must be anchored securely according to the instruction manual.
• Key access to enclosure for safety reasons.
• Foam insulated for stability, noise, and temperature reasons.
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Antaris EX Product Overview
 8 different systems:
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EX-IP Integrated Computer
EX-IP Remote Computer
EX-Z2 North America Integrated Computer
EX-Z2 North America Remote Computer
EX-Z2 International Remote Computer
EX-Z1 North America Integrated Computer
EX-Z1 North America Remote Computer
EX-Z1 International Remote Computer
Note: No integrated computer available internationally for EX-Z1 or EX-Z2
Note: North America system is approved for US and Canada. It can be sold
outside of Europe to any country accepting the ETL mark. International is
approved for Europe. It can be sold to any country accepting the European
ATEX certification.
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Antaris EX Product Overview
 Antaris EX-IP
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Rated IP65 per IEC 60529
Hose down environment
Also protected against dust
Thermo Electric Cooler (runs from
electrical supply) with closed loop
control
Can be purged, but not necessary
(similar to standard Antaris)
110V OR 220V
Only this system has a cart option.
This system allows you to take an
Antaris MX into an industrial
environment. It is well suited for a
loading dock where the temperature
can be more extreme, or an area
where there is dripping of material.
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Antaris EX Product Overview
 Antaris EX-IP Concerns
• Use caution when rolling cart down ramps.
• Use caution when working inside the enclosure as there is hazardous voltage
present.
• The enclosure may be purged with Nitrogen. Use caution when opening.
Turn off the Nitrogen and allow the air to clear before putting your head
inside.
• Power plug must be into an outlet rated for the area. The power cord comes
with a normal plug on the end. If the area is washed down then the cord
should go through a gland into an outlet box. The plug can also be removed
for direct wiring into a junction box.
• Keep vents of cooler clear.
• System is not universal voltage. It is ordered for 110V or 220V based on the
power cord selected. The cooler is the only part that is voltage specific.
• If the system is to be installed on a cart, then the service engineer may be
unpacking the enclosure for installation.
• Keep all 4 door latches closed.
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Antaris EX Product Overview
 Antaris EX-Z2
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Rated for Division 2 or Zone 2
Must be ordered for North America or International
Hose down environment
Vortex Cooler (runs from purge supply) with closed loop control
Universal input voltage
Type ‘Z’ purge system
Tested to NFPA 496 or IEC 60079-0 and 60079-2
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Antaris EX Product Overview
 Antaris EX-Z2 Theory of Operation
• The enclosure is sealed, but because the sealing is not perfect the enclosure
is pressurized at least 0.1 inches of water above ambient to keep out
dangerous gases.
• After the door has been opened or the purge gas has been off, the enclosure
must go through a purge cycle. A high flow of gas is pushed through for a
certain amount of time to clear out any dangerous gases. Only after this is
complete can the enclosure be powered on.
• The timing of the purge cycle is done manually. Connecting and
disconnecting power is done manually.
• The system has an alarm available. These are contacts that open when the
system is not pressurized.
• Because of hot components inside (source, etc.) that could ignite gases, it is
not necessarily safe to open the door when the power is off. Only open the
door if the area is known to be non-hazardous.
• If present, the keyboard is protected by “non-incendiary” design. It is certified
to not product sparks that could ignite gases.
• See the manual for operating instructions. Read the warning labels.
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Antaris EX Product Overview
 Antaris EX-Z2 Concerns
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Cooler is loud.
Outside of cooler is very hot.
Use caution when working inside the enclosure as there is hazardous voltage present.
The enclosure may be purged with Nitrogen. Use caution when opening. Turn off the
Nitrogen and allow the air to clear before putting your head inside.
Do not open door unless the area is known to be non-hazardous.
Do not power up system unless the purge cycle has been completed.
Ordinary plant compressed air is not suitable as purge gas due to contaminants. We
specify our usual purge gas guidelines.
Electrical wiring inside enclosure will be required. Customer must supply means to
cycle power to the system.
Purge must be filtered well.
Keep relief valve area clear.
Keep all 4 door latches closed.
Test the purge system after every service procedure.
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Antaris EX Product Overview
 Antaris EX-Z1
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Rated for Division 1 or Zone 1
Must be ordered for North America or International
Hose down environment
Vortex Cooler (runs from purge supply) with closed loop control
Universal input voltage
Type ‘X’ purge system
Tested to NFPA 496 or IEC 60079-0 and 60079-2
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Antaris EX Product Overview
 Antaris EX-Z1 Theory of Operation
• The enclosure is sealed, but because the sealing is not perfect the enclosure
is pressurized at least 0.2 inches of water above ambient to keep out
dangerous gases (higher pressure than Z2).
• After the door has been opened or the purge gas has been off, the enclosure
must go through a purge cycle. A high flow of gas is pushed through for a
certain amount of time to clear out any dangerous gases. Only after this is
completed is the enclosure powered on.
• The timing of the purge cycle is automatic. Connecting and disconnecting
power is automatic. When the pressure falls, all power and I/O signals are
cut.
• There is a service bypass that will bypass the purge system and apply power
immediately. It is designed so that it cannot accidentally be left in the system.
• The switches to cut the power are located inside an explosion proof box on
top of the enclosure. This is designed to keep out that gases, but if there is a
leak it will contain any explosion that may occur.
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Antaris EX Product Overview
 Antaris EX-Z1 Theory of Operation
• The system has an alarm available. These are contacts that open when the
system is not pressurized.
• Because of hot components inside (source, etc.) that could ignite gases, it is
not necessarily safe to open the door when the power is off. Only open the
door if the area is known to be non-hazardous.
• If present, the keyboard is protected by “intrinsically safe” design. “Barriers”
inside the enclosure limit current and voltage to prevent energy that is large
enough to ignite gases from passing out to the keyboard.
• See the manual for operating instructions. Read the warning labels.
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Antaris EX Product Overview
 Antaris EX-Z1 Concerns
• Cooler is loud.
• Outside of cooler is very hot.
• Use caution when working inside the enclosure as there is hazardous voltage
present.
• The enclosure may be purged with Nitrogen. Use caution when opening.
Turn off the Nitrogen and allow the air to clear before putting your head
inside.
• Do not open door unless the area is known to be non-hazardous.
• Do not power up system unless the purge cycle has been completed.
• Do not open the explosion proof box unless the area is known to be nonhazardous.
• Make sure the explosion proof box is sealed correctly and all of its ports are
plugged.
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Antaris EX Product Overview
 Antaris EX-Z1 Concerns
• Ordinary plant compressed air is not suitable as purge gas due to
contaminants. We specify our usual purge gas guidelines.
• Electrical wiring inside enclosure will be required. Customer must supply
means to cycle power to the system.
• Purge must be filtered well.
• Keep relief valve area clear.
• Keep all 4 door latches closed.
• Test the purge system after every service procedure.
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Antaris EX Product Overview
 Antaris EX Vents
• The spectrometer has vents in its sidewalls on 3 sides.
• In the EX-Z1 and EX-Z2, these prevent pockets of gas from forming inside
the spectrometer. They must not be covered up!
• In the EX-IP, these vents are covered up to improve spectrometer stability.
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Antaris EX Installation Process
 2 Palettes, one with enclosure, one with spectrometer
• “Do not open” sticker on spectrometer box
 Simple Antaris EX-IP installations (cart or table top mounting, not direct
wired but plugged into wall outlet)
• Service engineer will install entire system
• Customer will need to help with moving the heavy enclosure into place
 All other installations:
• Customer will:
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Unpack enclosure
Mount enclosure
Connect power into enclosure
Run fiber optics into enclosure
Connect purge supplies to enclosure
Complete pre-commissioning form
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Check mounting, wiring, fiber optic routing
Complete wiring connections inside enclosure
Unpack spectrometer
Install spectrometer
Complete fiber optic connections inside enclosure
Test spectrometer
Help customer with I/O connections
Test purge system (EX-Z1 and EX-Z2 only)
Documentation
 Our systems will include:
• Antaris EX Site, Safety and Installation Manual
• Schematic Packet specific to the system (5 different versions: EX-IP,
EX-Z2 NA, EX-Z2 Intl, EX-Z1 NA, EX-Z1 Intl)
• Customer Installation Drawing
 Shows mounting information, locations for connections
• Block Diagram
 Informational only
• Enclosure Wiring Diagram (EX-Z2, EX-Z1)
 Shows DIN rail wiring connections with options
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Purge Interface Unit Wiring Diagram (EX-Z1)
Declaration of Conformity (EX-IP, EX-Z2 Intl, EX-Z1 Intl)
ATEX Certificate (EX-Z2 Intl, EX-Z1 Intl)
Schedule drawing showing all regulatory items (EX-Z2, EX-Z1)
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Antaris EX I/O Options
 Antaris EX-IP with Integrated Computer
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Power in
2 USB ports to computer (for USB key, drives, printer, etc.)
Ethernet to computer
Ethernet to optional PLC
2 gland holes for customer connections to optional PLC
• Holes come with removable plugs
• 2 glands provided with system
• Make connections directly into PLC
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Antaris EX I/O Options
 Antaris EX-IP with Remote Computer
• Power in
• No USB ports provided
• CAT-5 plug for spectrometer connection
• This must be a dedicated CAT-5 cable that goes straight to the receiver at the controlling computer
• The receiver at the computer requires AC power. It connects to the computer through the provided
USB cable.
• 50 meters maximum
• Ethernet to optional PLC
• 2 gland holes for customer connections to optional PLC
• Holes come with removable plugs
• 2 glands provided with system
• Make connections directly into PLC
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Antaris EX I/O Options
 Antaris EX-Z2 wiring connections
• All wiring must be through conduit or armored cable. If using cable, then
glands are required that are RATED for the hazardous environment and
installed according to the manufacturer’s directions. The gland or the conduit
entries will have epoxy packed around the wires to prevent gas from traveling
through the cable.
• 5 holes with removable plugs are provided
• No glands provided with system
• Make connections to DIN rail terminal blocks or directly to optional PLC
• One Ethernet interface is provided on the DIN rail.
• 8 I/O wires plus ground are provided on the DIN rail. They can be connected to the
optional PLC I/Os.
• See more information below
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Antaris EX I/O Options
 Antaris EX-Z2 with Integrated Computer
• Power in
• Connect to DIN rail terminal blocks
• Ethernet to computer
• Connect to DIN rail terminal blocks, plug Ethernet cable into computer
• Ethernet to optional PLC
• Connect to DIN rail terminal blocks, plug Ethernet cable into PLC. If both Ethernets are required, plug
Ethernet cable into computer and run an additional Ethernet directly to the PLC, bypassing the
terminal blocks.
• Customer connections to optional PLC
• Connect to DIN rail terminal blocks. Make appropriate connections at the PLC. If additional I/O lines
are required, connect directly to the PLC, bypassing the terminal blocks.
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Antaris EX I/O Options
 Antaris EX-Z2 with Remote Computer
• Power in
• CAT-5 wiring for spectrometer connection
• This must be a dedicated CAT-5 cable that goes straight to the receiver at the controlling computer
• The receiver at the computer requires AC power. It connects to the computer through the provided
USB cable.
• The receiver must be located in the non-hazardous area.
• 50 meters maximum
• Connect to DIN rail terminal blocks. Leave Ethernet cable plugged into USB receiver.
• Ethernet to optional PLC
• Connect Ethernet directly to the PLC, bypassing the terminal blocks.
• Customer connections to optional PLC
• Connect to DIN rail terminal blocks. Make appropriate connections at the PLC. If additional I/O lines
are required, connect directly to the PLC, bypassing the terminal blocks.
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Antaris EX I/O Options
 Antaris EX-Z1 wiring connections
• All wiring must be through conduit or armored cable. If using cable, then
glands are required that are RATED for the hazardous environment and
installed according to the manufacturer’s directions. The gland or the conduit
entries will have epoxy packed around the wires to prevent gas from traveling
through the cable.
• All power and I/O wiring must be disconnected automatically when the pressure inside
the enclosure falls.
• All connections are to the explosion-proof box, not to the enclosure
• Five holes with removable plugs are provided
• No glands provided with system
• Make connections to relay terminals.
• Only 8 I/O wires are available
• See more information below
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Antaris EX I/O Options
 Antaris EX-Z1 with Integrated Computer
• Power in
• Connect to large relay
• There are only 8 wires so options are limited (each Ethernet is 4 wires, the
PLC is an option):
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Computer Ethernet, PLC Ethernet – connect Ethernet to computer, I/O cable to PLC Ethernet
Computer Ethernet, 4 PLC I/Os – connect Ethernet to computer, I/O cable to PLC I/Os
PLC Ethernet, 4 PLC I/Os - connect Ethernet to PLC, I/O cable to PLC I/Os
8 PLC I/Os – connect I/O cable to PLC I/Os
Make connections to relay terminals. Connect wires inside enclosure as stated above.
Connect 8-wire cable from explosion-proof box to appropriate terminal blocks on the DIN rail
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Antaris EX I/O Options
 Antaris EX-Z1 with Remote Computer
• Power in
• Connect to large relay
• The PLC is not an option on this system. All 8 wires are used for
spectrometer communication.
• Make connections to relay terminals. Inside enclosure, leave all 8 wires connected to the Ethernet
terminal blocks on the DIN rail. Leave Ethernet cable connected to the USB receiver.
• Connect a dedicated CAT-5 cable from the relay terminals inside the explosion-proof box straight to
the receiver at the controlling computer
• The receiver at the computer requires AC power. It connects to the computer through the provided
USB cable.
• The receiver must be located in the non-hazardous area.
• 50 meters maximum
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Antaris EX Fiber Optic Installation
 Fiber optic probes require SMA connectors on the end.
 Leave 1m of fiber inside enclosure for connection.
 EX-IP
• Install through 2 existing holes, or add additional holes in gland plate.
 EX-Z2
• Install through 5 existing holes, or add additional holes in gland plate.
 EX-Z1 North America
• Install through 3 existing holes, or add additional holes in gland plate
 EX-Z1 International
• Install through 3 existing holes, or add additional holes in gland plate
 Glands are required that maintain the waterproof nature of the enclosure.
 For fiber optics with metal sheathing installed into hazardous locations,
then glands are required that are RATED for the hazardous environment
and installed according to the manufacturer’s directions. The gland or the
conduit entries will have epoxy packed around the fiber optic to prevent
gas from traveling through the cable.
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Wrap Up
 The EX is a complicated mix of certification options.
 There are important safety considerations throughout the sales,
installation, commissioning, and servicing process.
 Think carefully about how your actions affect safety. Is it safe to open
the enclosure now?
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Questions
 Time for questions!
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