Control Panels Enclosure is purged & pressurized but sealed - - PDF document

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Control Panels Enclosure is purged & pressurized but sealed - - PDF document

Expo Technologies Principle of Operation Pressure Sensor Expo Technologies Ltd Flow Sensor Sunbury-on-Thames, England Expo Technologies, Inc Twinsburg OH, Purge Inlet USA Purge Outlet Representatives & Distributors World Wide Your


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Representatives & Distributors World Wide Expo Technologies Ltd Sunbury-on-Thames, England Expo Technologies, Inc Twinsburg OH, USA

Expo Technologies

Your Support Network

Main Factory Location

Heathrow City Gatwick Sunbury

Applications suitable for Exp

  • Control Panels
  • Switchgear
  • Motors
  • Generators
  • Analysers
  • Rooms/Buildings

Principle of Operation

Flow Sensor Purge Inlet Purge Outlet Pressure Sensor

Minimum Pressures

Standard Minimum Pressure IEC60079-2: 2007 (Zone 1) 50 Pa / 0.5 mbar (0.2” WC) IEC60079-2: 2007 (Zone 2) 25 Pa / 0.25 mbar (0.1 WC) Australia AS2380 Pt 4 50 Pa / 0.5 mbar (0.2” WC) Europe EN 50016 50 Pa / 0.5 mbar (0.2” WC) USA NFPA 496 25 Pa/o.25 mbar (0.1” WC) Measured at the “eye” of the fan

Pressurized Enclosure

PE

Inlet for Protective Gas Purge Outlet Purge Flow Sensor Low Pressure Sensor

FE

Terminology

  • Static Pressurization

– Enclosure is purged & pressurized but sealed

  • Leakage Compensation (LC)

– Enclosure is purge & pressurized – Switches to small flow (tops up any leakages)

  • Continuous Flow (CF)

– Enclosure is purged & pressurized – Purge flow continues (dilutes internal release)

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Basic Build Requirements

  • Flow meter

– monitors purge (and subsequent) flow rate – no over-ride

  • Pressure sensor 1

– monitors minimum required overpressure

Pressure sensor 2

– protection against excessive overpressure

  • Alarm / Isolation of electrical equipment

– if overpressure falls below 0.5mb (Zone 1) System types Equipment being protected Zone 1 Division 1 Zone 2 Division 2

Non-Ex Equipment Auto-Disconnect Auto-Timer Ex px X-Purge Alarm Only Manual Ex pz Z-Purge Ex-Equipment (Ex n / mb) Alarm Only Manual Ex py Y-Purge

Custom Enclosures Motor Purge systems Purge Time

  • IEC Standard

– Equal to 5x enclosure volume

  • NFPA Standard

– Equal to 4x enclosure volume – 10x enclosure + rotor volume (for motors)

  • Practical limit (user-defined?)

– 60 minutes for large motors & compressors – 30 minutes for cabinets – 10 minutes for portable equipment Pneumatic Timer

Based on R – C network

– R = pneumatic restrictor – C = pneumatic reservoir

R C1 C2 C3

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Electronic Timer

  • Accurate & Repeatable

– 1 to 99min (-0/+3 secs)

  • Intrinsically Safe

– Ex ia IIC T6

  • Field-replaceable battery

– 3 year service life – 10 year storage life

  • Global Approvals

– ATEX / IECEx / FM / UL (pending)

  • LED Purge Progress Indicator

Motor Purge Systems Motor Systems G.A. Typical Settings

Pressure Point Pressure Leakage Nl/min Minimum Acceptable Pressure 150Pa, 1.5mbarg Normal Working Pressure 1kPa, 10mbarg Client continuous air usage Relief Valve Lift-off Pressure 3.0kPa, 30mbarg Clients air usage during the purge period Test Pressure (RLV x 1.5) 4.5kPa, 45mbarg Must hold the pressure for 2 minutes without distortion

Witnessed Purge Test required for every motor to ensure compliance with the first motor tested / certified

Typical Motor Purge System

Relief Valve Exe Junction Box D758

Typical Internal

CLAPS: Closed Loop Automatic Pressurization System

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Typical Alarms

  • Loss of Pressurization (Alarm/Shutdown)
  • Intermediate Pressure (Alarm)
  • Permissive Contact (Shutdown)
  • Electronic Options: Ex e or Ex i circuits
  • Pneumatic Options: Pushrod into Ex d box

Expo Motor Systems Coding

5 X LC / ss / ET / OV / PA / PC / D758

System Size

Each number represents a certain amount of air flow (NI/min) 3: 500-1500 5: 2000-6000 7: 7000- 14000

Purge Method

LC: (Leakage Compensation) CF: (Continuous Flow) ET: electronic timer. If it uses a pneumatic timer then this block is not included

Standard Outputs

PA: Power Alarm PO: Pneumatic Output IS: Intrinsically Safe Model variant Many types available, some OEM specific, some general

Hazardous Area Application

X: covers dust and gas protection and has a timer Y: only covers dust protection Z: covers dust and gas protection but is manually timed

Housing ss: stainless steel box

pm: panel mount bp: back plate nm: non metallic co: chassis only

Standard Options

OV: Outlet Valve AO: Alarm Only MO: Manual Override

Non standard output options

AA: Active alarm output fitted AC: Alarm cancellation circuit AS: Alarm ‘Action on pressure of flow failure’ selector valve DS: Door Switch Power interlock fitted DT: Delayed Trip after pressure or flow failure FM: Flow Meter(s) fitted MT: Mechanical Timer OA: On/Off switch controlling protective gas or logic supply OB: On/Off switch controlling logic supply only OC: On/Off switch controlling protective gas only PC: PE pressure control leakage compensation valve SS: Separate supply for protective gas and logic air TW: Twin (or more) outputs for PEs purged in parallel.

Advantages of Ex p for motors

  • Only practical solution for high power units
  • Clean air purge removes environmental

contaminants

  • Easier to achieve IIC compliance
  • High level of security & confidence

– Monitored systems – External alarms – Power interlock Typical Installation – Drillers Console

1ZLC/bp/IS

1ZLC/pm/IS Custom Enclosures - internal

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Custom enclosure - external Typical enclosure systems

Mini-X-Purge Mini-Y-Purge Interface Box

Purge system selection

  • Hazardous Area standards

– ATEX / IECEx / NEC / CSA / INMETRO

  • Zone or Division

– X-purge or Z-purge

  • Enclosure contents

– Ex ratings, power, T rating

  • Enclosure Size / Purge Time

– Determines required air flow capacity Minimum requirements Overpressure test

1.5x manufacturers rating (typically 30–50mbar)

Doors to be opened with tool (Zone 1) IP4X (Zone 1) 7Nm (4Nm on windows) UV resistance test

Standard cabinets pass the above but leak!

Custom Cabinets

Empty cabinet, Manufactured with Exp system Populated cabinet, Expo-inspected, ATEX or IECEx certified assembly

Custom Enclosures

Zone 1 (ATEX Cat 2)

– Pressurized Enclosures

  • Expo PE2

– Increased Safety

  • Expo PE2E

Zone 2 (ATEX Cat 3)

– Pressurized Enclosures

  • Expo PE3

– Increased Safety

  • Expo PE3E
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Custom Enclosures - Zone 1 (ATEX Cat 2)

  • Pressurized Enclosures PE2

– Expo construct OR verify clients assembly

Schedule of Limitations GA drawings & Component List

– 3rd Party Certificate in Expo name:

IECEx: ITS 08.0044X ATEX: ITS10ATEX16944X

  • 20 to +55°C

Ex px IIC T4 Gb Ex p IIIC T135°C

Expo-Intertek Schedule of Limitations 1

Maximum Size * 2100 mm (82.68”) H x 1800 mm (70.87”) W x 1000 mm (39.37”) D Maximum volume = 3780 Litres Purge Time Purge Time must reflect 10 volume changes and be between 10 and 30 minutes Layout * 30% minimum free space, in any cross section of any plane of the enclosure.

* Can be exceeded: requires witnessed purge test

Expo-Intertek Schedule of Limitations 2

Ventilation of Internal Items * Internal closed items require minimum ventilation holes of 1cm²/litre to avoid potential trapped gas. If necessary, increase existing holes to suit or make new/additional holes (min. size 28.2mm2 or 0.043in2) Closed items need ventilation distributed equally at the top and bottom surfaces. Permitted Closed Items Hermetically sealed or potted devices. Allowed if total volume of such sealed items < 1% of the internal free volume of the enclosure, and:

  • the item does not contain any potential source of ignition, or
  • the item is Ex d, Ex e (no batteries), Ex i, Ex m or Ex n

certified

* Can be exceeded: requires witnessed purge test

Expo-Intertek Schedule of Limitations 3

Heat Dissipation Two temperature limiting devices must be used (one can be used to initiate a cooling system). Batteries or Cells The following approved batteries are allowed: CR2032 (VARTA or Panasonic) CR½ AA (VARTA or Sonnenschein) SL-340 (Tadiran or Sonnenschein)

** Non-approved batteries require an Expo “Battery Test”

Fans Maximum airflow permitted: 400 litres/sec (14.125 ft3/sec) Inlet Position > 200 mm (7.78”) from air leakage points, e.g. door gaskets or access plate gaskets.

* Can be exceeded: requires witnessed purge test

Expo-Intertek Schedule of Limitations 4

* Can be exceeded: requires witnessed purge test

Optical Devices Low power communication devices are allowed. Permitted Thru-Wall Components Devices or components mounted through the enclosure wall must have a suitable IP rating for the enclosure and must either be metallic (or if non-metallic, must be Ex rated - demonstrates compliance with UV & Impact specification). Cable Glands, Conduits and Sealing Systems shall be Ex-certified and suitable for use with the cable type and in the required Hazardous Location.

Expo-Intertek Schedule of Limitations 5

Isolation of Electrical Inputs to the Enclosure ALL electrical supplies (power & signals) that enter the enclosure NOT individually protected by another explosion protection technique MUST be automatically isolated following the ALARM signal of the Expo Purge Control system. Hot Internal Components Internal devices with surface temperature above T4 (135 ºC) must be declared, and extra precautions identified and specified. Examples are: filament lamps, power semiconductors, thyristors, heaters, power resistors, etc.

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Achievable certification

Hazardous Area Classification Ex px IIC T4 Maximum range for T

amb = -20ºC to +55ºC

NOTE: fitted certified apparatus with more restrictive classifications (T rating and/or Gas Group) will reduce the

  • verall classification of the PE, and the supplied labelling

will be modified to suit.

What we need

Bill of Materials (BoM) General Assembly Drawings (GA) Circuit Schematics

Power & Signal Isolation design

Data Sheets & Certificates

for hazardous area rated equipment and devices What you get

  • Expo guidance on equipment selection
  • Expo test/verification of content
  • Expo Declaration of Conformity

– IECEx – ATEX – Enclosure labels – Instruction Manual Extra considerations

  • Internal source of release

– Notified Body test – Nitrogen purge

  • Most Ex HMI’s will fail over-pressure test

– Fit into separate inset housing, non-Exp

  • Ex equipment must match overall approval

– ATEX devices must be ATEX marked – IECEx devices must be IECEx marked Purge Flow Monitoring

Orifice Plate (changeable)

Z-Purge CF: Control Unit, Relief Valve

  • SS

Boxed, top or side mounting

  • PM

Panel mounting (inset)

  • BP

Back-plane CF systems include spark arrestor

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Z-Purge LC: Control Unit, Relief Valve

  • SS

Boxed, top or side mounting

  • PM

Panel mounting (inset)

  • BP

Back-plane Purge in Progress indicator

Spark Arrestor flow capacity

Enclosure Volume O/P No. ft3 (4x volume) m3 (5x volume) 1 3.0 0.06 2 8.3 0.15 3 10.5 0.24 4 17.2 0.39 5 24 0.54 6 36 0.81 7 48 1.08 8 60 1.35

Z-Purge

  • Zone 2 / Div 2 use
  • Versions:

– CF Continuous Flow – LC Leakage Compensation

  • Manual operation

– Manual timing – Alarm on loss of pressurization

  • Local indicator
  • Volt-free contact (for wiring by others)

X-Purge Systems X-Purge, direct top mounting Multiple Enclosures

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HMI without Ex approval

  • Window to meet impact test
  • Push-rods operate buttons
  • No product modification

SmartPurge

  • 316 SST

– Enclosure – Pushbuttons – Spark Arrestor

  • IECEx / ATEX
  • Ex [px] IIC T4/T6

– -20 to +60 DegC SmartPurge System

  • Controls up to 540 l/min
  • Switches up to 6A
  • Purge up to 99min
  • Delay up to 99min

SmartPurge accessories

  • I.S. solenoid valve for air inlet
  • Remote panel (50m max)
  • Manual override key switch

SP2- DV SP2- SIU SP2- CF SP2- RP

Ex p systems

  • Simple in principle
  • Solves unique and difficult problems
  • Allows manufacturers to extend their

market application with limited outlay

  • Integrates other protection concepts easily

EXPO: Solution Provider