Documente Academic
Documente Profesional
Documente Cultură
Atmosphere Course
Hazardous Area and Explosive
Atmosphere Course
Macaé, RJ
ÍNDICE
1. HAZARDOUS AREA ............................................................................ 10
1.1. EXPLOSIVE ATMOSPHERE ............................................................. 10
1.2. COMBUSTION OR FIRE ................................................................. 12
1.2.1. FIRE TETRAHEDRON ................................................................ 13
1.2.2. OXIDIZER .............................................................................. 13
1.2.3. FUEL ..................................................................................... 14
1.2.4. COMBUSTIBLE SUBSTANCES .................................................... 14
1.2.5. IGNITION .............................................................................. 17
1.2.6. CHAIN REACTION ................................................................... 29
1.2.7. PROPAGATION ........................................................................ 29
1.3. FLASH POINT .............................................................................. 32
1.4. POINT OF COMBUSTION ............................................................... 33
1.5. AUTO-IGNITION TEMPERATURE ..................................................... 33
2. PROCESS EQUIPMENT ....................................................................... 35
2.1. TANKS ........................................................................................ 35
2.2. PRESSURE VESSELS ..................................................................... 36
2.3. REACTORS .................................................................................. 36
2.4. BOILERS ..................................................................................... 37
2.5. SILOS ......................................................................................... 37
3. RISK MANAGEMENT .......................................................................... 38
3.1. DANGER ..................................................................................... 39
3.2. RISK .......................................................................................... 39
3.2.1. ACCIDENT RISKS .................................................................... 40
3.2.2. ERGONOMIC RISKS ................................................................. 40
3.2.3. PHYSICAL RISKS .................................................................... 41
3.2.4. CHEMICAL RISKS .................................................................... 41
3.2.5. BIOLOGICAL RISKS ................................................................. 41
3.3. PREVENTIVE MEASURES ............................................................... 42
3.4. RISK ANALYSIS ........................................................................... 43
3.5. HANDLING OF FLAMMABLE LIQUIDS .............................................. 43
3.6. MINIMUM RECOMMENDED PREVENTIVE ACTIONS ............................ 44
3.7. HOW DO I MANAGE RISKS? .......................................................... 45
3.7.1. RISK OF EXPLOSION ............................................................... 46
4. STANDARDIZATION AND LEGISLATION ............................................... 50
4.1. PENATIES ................................................................................... 53
4.2. LIABILITIES ................................................................................ 53
5. AREA CLASSIFICATION ...................................................................... 56
5.1. AREA CLASSIFICATION PROCEDURES............................................. 57
5.1.1. IDENTIFICATION OF SOURCE (POINTS) ..................................... 57
5.2. FLAMMABLE AND COMBUSTIBLE LIQUIDS: CHARACTERISTICS,
PROPERTIES, DANGERS AND RISKS ......................................................... 58
5.3. FLAMMABILITY LIMIT.................................................................... 59
5.4. INERTING ................................................................................... 61
5.5. AIR DENSITY ............................................................................... 61
5.5.1. RELATIVE GAS OR VAPOR DENSITY........................................... 62
5.6. VOLATILITY ................................................................................. 63
5.7. MINIMUM IGNITION ENERGY (MIE) ................................................ 64
5.8. DUST AND FIBERS – PARAMETERS FOR CLASSIFICATION ................. 66
5.8.1. MAXIMUM SURFACE TEMPERATURE ........................................... 67
5.9. TEMPERATURE CLASSIFICATION .................................................... 68
5.10. MAXIMUM TEMPERATURE FOR DUST AND FIBERS ............................ 69
5.11. EXPLOSION GROUPS .................................................................... 70
5.12. CLASSIFICATION BY ZONES .......................................................... 71
5.12.1. CONTINUOUS RELEASE SOURCE ............................................... 72
5.12.2. PRIMARY RELEASE SOURCE ..................................................... 72
5.12.3. SECONDARY RELEASE SOURCE ................................................ 73
5.13. VENTILATION .............................................................................. 75
5.13.1. NATURAL VENTILATION ........................................................... 75
5.13.2. ARTIFITIAL VENTILATION ........................................................ 76
5.13.3. DEGREE OF VENTILATION ........................................................ 76
6. ELECTRICAL EQUIPMENT FOR CLASSIFIED AREAS ................................ 78
6.1. TYPES OF PROTECTION EQUIPMENT ............................................... 80
6.1.1. INTRINSEC SAFETY – (EX-I) ..................................................... 80
6.1.2. EXPLOSION PROOF – (EX-D) .................................................... 84
6.1.3. NON-INCENDIVE – (EX-N) ....................................................... 92
6.1.4. TYPES OF PRESSURIZATION .................................................... 96
6.1.5. INCREASED SAFETY – (EX-E) ................................................... 98
6.1.6. IMMERSION IN OIL – (EX-O) ...................................................100
6.1.7. IMMERSION IN SAND – (EX-Q) ................................................102
6.1.8. ENCLOSED – (EX-M) ..............................................................104
6.1.9. PROTECTION BY CASING – (EX-T) ...........................................105
6.1.10. SPECIAL PROTECTION – (EX-S) ...............................................106
6.2. TABLES AS PER TYPE OF PROTECTION...........................................107
6.2.1. GASES AND VAPORS – NBR IEC 600.79-0 .................................107
6.2.2. DUST AND FIBERS – NBR IEC 600.79-0 ....................................107
6.3. CASINGS ...................................................................................108
6.4. SPECIFICATION ON CONVENTIONAL POWER EQUIPMENT ................108
6.5. SPECIFICATION ON EX EQUIPMENT...............................................108
6.6. LEVEL OF PROTECTION - EPL........................................................109
6.6.1. GROUP I – COAL MINES..........................................................110
6.6.2. GROUP II – GASES, VAPORS AND MISTS ..................................111
6.6.3. GROUP III – DUST AND FIBERS ...............................................112
6.7. IP PROTECTION LEVEL .................................................................114
6.7.1. DEFINITION OF ADDITIONAL LETTER FOR PROTECTION GRADES TO
AVOID THE ACCESS TO DANGEROUS PARTS ..........................................117
6.7.2. SUPPLEMENTARY LETTERS ......................................................117
6.8. IK PROTECTION GRADE ...............................................................118
7. POWER EQUIPMENT CERTIFICATE ......................................................119
8. INSPECTION ....................................................................................128
9. REPAIR OF EQUIPMENT .....................................................................130
10. MARKING ON EX EQUIPMENT ............................................................134
11. ELECTRICAL EQUIPMENT ATMOSPHERES ............................................142
RULES
FALCK RULES
Loose clothes, jewelry, piercings, etc. must not be used during practical
exercises;
Do not walk through training areas without permission. Use the Personal
The trainees are responsible for their belongings. Lockers with padlocks and
keys are available and they shall be used when instructed. Falck Safety Services
is not responsible for any loss or damage;
Every trainee is responsible for ensuring the training safety under the best
possible conditions. Unsafe acts or conditions must be immediately reported to
the instructors;
Pregnant women cannot carry out training due to the practical exercises;
If an absence during the training period is inevitable, request the specific
form for a permission to leave. Your employer will be informed about it, and if it
exceeds 10% of the discipline hours you won't be able to continue the training;
Falck Safety Services ensures the trainee’s safe transport during their stay
in the Company in its selected vehicles. The Company is not responsible by
transport in private vehicles;
If the student does not meet the conditions described in the paragraphs
above, he will fail the assessment.
Hazardous Areas and Explosive Atmosphere Course
1. HAZARDOUS AREA
A Hazardous Area is the area in which there is a probability of formation or
the existence of an explosive atmosphere. It can be understood as an open or
closed location, where there exists a possibility that an explosive atmosphere will
form. The Area is Classified by Zones, Explosion Groups and Temperature
Classifications.
Petrochemical industry;
Chemical industry;
Pharmaceutical industry;
Food industry;
Cosmetic industry;
Steel industry;
Coal mines;
Refineries;
Gas stations;
Textile industry;
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Asphalt is also used for paving roads. It is estimated that there are
around 18 million kilometers of paved roads worldwide;
In the food industry they are used directly (in dyes, flavoring and
preservatives) or indirectly (in fertilizers and pesticides);
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1.2.2. OXIDIZER
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1.2.3. FUEL
Fuel is any substance that reacts to the oxygen (or other oxidizer),
releasing energy, in the form of heat, flames and gases. Examples: Diesel,
Biodiesel, Gasoline, Ethanol, etc.
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Flammable Gas
According to NR-20:
Combustible liquid is any liquid that has a flash point between 60ºC
and 90ºC.
When they settle, under their own weight, may burn or glow in the
air.
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The standard measure for classifying dust is around 63 microns and for
fibers, above 500 microns. Most organic material powders and fibers have a
minimum explosive concentration, typically ranging from about 20 grams up to
several kilograms per cubic meter.
Operations for loading and unloading grains in silos and warehouses may
generate dust, and this may accumulate on the ground or remain suspended. The
contact of this dust cloud with the air and a simple spark from common sockets
and switches or with the heated surface of a piece of equipment, could produce a
risk of explosion.
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1.2.5. IGNITION
Eddy currents;
Open flames;
Atmospheric discharges;
Radiant heat;
Lit cigarettes;
Spontaneous ignition;
Static electricity;
Electrical;
Electronic;
Atmospheric discharges;
Electrostatic;
Thermal;
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Mechanical;
Chemical;
Cathodic protection;
Radiant energy;
Electrical
Electrical equipment may generate sparks, short circuits, electrical arcs and
static electricity. The occurrence of fires and explosions due to the formation of
electrical arcs and short circuits is common in electrical installations. In
hazardous areas it is very important to have the correct sizing, installation and
maintenance of the grounding, since it is one of the main pieces of protective
equipment. The grounding is a low resistance connection to the ground,
discharging faults, short circuits and static electricity to earth. The hot surface of
electrical equipment may contribute to the ignition of combustible substances.
The sparks from outlets, switches and other electrical equipment can activate the
ignition of combustible gases, vapors,
dust and fibers.
Explosion of a 17500-Volt
breaker at the Urgezes Power Plant, in
Guimarães.
Electronic
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Atmospheric Discharges
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Electrostatic
Thermal
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Mechanical
In industrial plants where products are process in the form of grains, during
the processing, dust may form due to the friction between them. If the grains
have combustible properties, this dust can remain suspended or settle on
structures or locations that are difficult to access, and, when it mixes with the air
in the presence of an ignition source, this may contribute to the formation of an
explosive atmosphere. For fires to occur, it is necessary that the amount of
combustible material is significant and the particles have a small amount of space
between them, hindering direct and abundant contact with the oxygen in the air.
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Therefore, the burning takes place in layers, in locations where the dust
settles throughout the workday, or in one of the following ways:
Piled up;
Stored in a granary;
Deposits;
Others.
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Chemical
Dangerous chemical reactions may occur not only exothermically, but may
also cause the release of dangerous products, phenomena that often occur
simultaneously. To prevent risks due to the chemical nature of products, we must
understand the list of chemical substances that are incompatible and used
frequently in laboratories in order to use special care when stocking, handling
and discarding them.
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Cathodic Protection
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The amount of current supplied to the structure is limited by the very low
difference in potential, between the anodes and the structure. Furthermore, the
protection will be must easier if the electrical resistivity of the medium at the
location is not low enough.
In this process, the current flow provided comes from the electromotive
force from a source that generates a continuous electrical current, and the
rectifiers that, fed by an alternating current, are widely used in the process to
provide the continuous electrical current necessary to protect the metallic
structure. For the dispersion of this electrical current in the electrolyte, special,
inert anodes are used, i.e., anodes that have very low wear. The biggest
advantage of the impressed current method consists of the fact that a generator
source (current rectifier) can have the necessary power and output voltage.
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And therefore, be applied to any medium, even those whose electrolyte has
a high electrical resistivity, Furthermore, this method may be applied,
economically, for the protection of large metal installations.
Radiating Energy
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The radiant energy is able to cross the vacuum perfectly. Almost all the
energy that we get from the sun, reaches our plane in the form of radiant
energy, distributed in a wide range of frequencies. This range includes the visible
range in the region with the highest energy density, with the various colors
(violet, blue, green, yellow, orange and red) that we are able to see, being
particularly intense on the SOLAR SPECTRUM. However, scientists use radio
telescopes to observe the cosmos in wavelengths that we cannot see, from radio
waves to X-rays, and even cosmic rays.
Gamma rays have frequencies that are much higher than visible light.
Radio waves have a frequency that is much lower than the lowest frequency that
our eyes are able to see. Among the other forms of irradiation that we are unable
to see, we have infrared radiation and ultraviolet radiation.
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1.2.7. PROPAGATION
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Whenever the speed of a gas is greater than the speed of sound, a shock
wave forms in it. When an airplane reaches the speed of sound, the sound waves
emitted by it condense in front of it because they are spreading at the same
speed.
The speed of sound is much higher in liquids and solids where the
molecules are closer to each other than they are in a gas. In water, the speed of
sound is around 4 times its speed in air; at a temperature of 25ºC, it is
approximately 1500 m/s. In steel, the speed is around 5 times greater, able to
reach 5000 m/s.
According to the speed that pressure waves spread (waves that spread due
to a variation of the pressure), the explosions are classified as:
Deflagration;
Explosion;
Detonation.
Speed of Propagation
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Deflagration
Explosions that cause subsonic pressure waves, meaning, below the speed
of sound. The speed of propagation is cm/s. The pressure waves have a slight
increase and cause a faint sound.
Explosion
Detonation
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The flash point is not applicable to flammable gases. The lower the flash
point of a combustible substance is, the greater the extent of the Hazardous Area
may be.
Example: Isopropyl alcohol has a flash point of 11ºC and the temperature
of the liquid is 5ºC. When the temperature of the liquid reaches a temperature
equal to its flash point, in the presence of a lit match, we have a combustion that
does not sustain itself, since the vapors do not hold the flame.
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The storage and use conditions allowed are different for products with a
flash point lower than 23ºC, between 23ºC and 66ºC and above 66ºC.
Fuels with a flash point that is lower than 23ºC are considered, for
transport and storage purposes, as DANGEROUS and HIGHLY FLAMMABLE.
Fuel oils that typically have a flash point that is above 66ºC are considered
safe.
FLASH POINT
SUBSTANCE
(°C)
GASOLINE -48
CYCLOHEXANE -18
ANHYDROUS ETHANOL 12
STYRENE 30
ACETIC ACID 40
AMYL METHYL KETONE 49
BUNKER FUEL OIL 66
The lowest temperature at which the mixture of vapor with the air ignited
by an external ignition source continues to burn continuously above the surface
of the liquid, even if the heat source is removed.
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AUTO-IGNITION
SUBSTANCE
TEMPERATURE
ACETONE 535°C
GASOLINE 280°C
PENTANE 285°C
KEROSENE 210°C
XYLENE 464°C
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2. PROCESS EQUIPMENT
Some process equipment such as tanks, pressure vessels, reactors, boilers
and silos may contribute to the formation of explosive atmospheres, since they
are pieces of equipment that operate at high temperatures, pressures and may
contribute to the accumulation of electric charges (static energy), such as silos
during the operations for loading and unloading grains in the agricultural area.
2.1. TANKS
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The pressure vessels may contain liquids, gases or a mixture thereof. Some
applications are: final or intermediary storage, pulsation dampening, heat
exchange, containment of reactions, filtration, distillation, fluid separation,
cryogenics, etc.
2.3. REACTORS
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2.4. BOILERS
2.5. SILOS
Silos are structures used for the storage of heavy materials. Silos are used
in agriculture for storing grains and fermented foodstuffs. They are most
commonly used to store grains such as: coal, cement, black carbon, food
products and wood fibers.
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3. RISK MANAGEMENT
According to the definition from HOPE (2002), being able to manage risk
means “trying to prevent losses, trying to decrease the frequency or severity of
losses or paying for the losses of all efforts to the contrary.” Frequency of losses
is a reference to the number of times that the loss occurs, while severity would
be the total damage caused by the loss and how much this damage will cost.
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3.1. DANGER
3.2. RISK
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Any factor that puts the worker in a vulnerable situation and may affect his
or her integrity and physical or mental well-being.
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These are considered the various forms of energy to which the workers
may be exposed, such as: noise, heat, cold, pressure, humidity, and non-ionizing
ionizing radiation, vibration, etc.
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Preventative measures are actions that must be taken for the purpose of
preventing unwanted events (accidents) from occurring.
To limit the area across which the liquid released can spread.
In the figure below, the black arrow indicates the safety valve (relief). The
yellow arrow indicates grounding between the drum and the security container.
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A systematic method for examining and evaluating all the steps and
elements to identify:
Make sure that tools, if needed, are suitable and are available;
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Connect the equipment’s plugs, verifying their correct fitting into the
socket;
Verify that the openings on floors, walls, doors and drains were
closed, covered or protected;
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The goal is to identify equipment and areas where there exists the
possibility that explosive atmospheres may occur, which should be represented in
the Area Classification Design.
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The aforementioned measures are preventative, but they may fail and an
accident may occur. Therefore, it is important to plan measures for mitigation
(reduction) of the damages that may occur, such as, for example, emergency
plans of action, separation of buildings, explosion relief windows, etc.
NOTE: The pressure relief windows are used in facilities for storing grains,
where a bucket elevator or pneumatic conveyer is used to transport grains from a
lower level and deposit them into a storage structure or silo. Large elevators with
quick conveyer belts generally produce a lot of vibration, which may stress the
relief windows, causing premature faults.
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Below are some examples of explosions that occurred in the oil sector.
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A gas leak would have produced a fire in two of the facility’s tanks. 26
workers were killed and 80 were wounded. The accident occurred on August 25,
2012.
P-36 PLATFORM
The accident occurred on March 15, 2001, in the Campos Basin, 130 Km off
the coast of Rio de Janeiro. There were two explosions in one of the platform’s
pillars, destabilizing the structure, which became titled. 11 workers died in the
accident.
The P-36 platform was the largest production platform in the world,
producing 84.1 thousand barrels of oil
per day. After investigations, the National
Petroleum, Natural Gas and Biofuel
Agency (ANP) (Agência Nacional de
Petróleo e Gás Natural e Biocombustíveis)
concluded that the accident occurred due
to “non-compliance with the operating
procedures, maintenance and design.”
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DEEPWATER HORIZON
The accident occurred on April 20, 2010, in the Gulf of Mexico. The
platform suffered a massive explosion in one of its two support towers. The tower
was in the final stages of drilling a well. This process is delicate, because there is
a possibility that the fluids in the well will be uncontrollably released. In this
accident, 17 workers were wounded and 11 were killed.
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Initially, most of the equipment manufactured in Brazil was copied and did
not go through evaluations that ensured the effectiveness of its protection.
Certification was based on type testing (model 3), however, the only
laboratory available was the IEE-USP, which operated on a limited scale, due to a
lack of structure.
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In Brazil we have the NBR IEC 600.79 series for Hazardous Areas due to
gases and vapors.
INMETRO Ordinance No. 89, from February 23, 2012, in force, altered
INMETRO) Ordinance No. 179, from May 18, 2010, regarding electrical equipment
for explosive atmospheres, in the conditions of flammable vapors and gases and
combustible dust.
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4.1. PENATIES
3) Civil and criminal liabilities - All the standards are considered laws
4.2. LIABILITIES
Process;
Operation;
Area Classification;
Designs;
Installation;
Maintenance;
Ex equipment manufacturing;
Trainings;
Designated authorities;
Insurance companies.
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5. AREA CLASSIFICATION
In various types of industrial plants we can find the presence of flammable
substances such as gases, vapors, dusts and fibers in sufficient quantities to form
an explosive atmosphere, as in the petrochemical, chemical, pharmaceutical,
textile, pulp and paper, paints and varnishes industries and sugarcane mills, etc.
In these facilities the Area Classification is a very important activity for the
identification of sources of release of explosive atmospheres, the frequency at
which they occur, the identification of the presence of oxidization and ignition
sources, so that the equipment can be specified and installed in such
environments so as not to cause possible sources of ignition.
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This classification aims to avoid contact between ignition sources and the
explosive atmosphere and serves as a reference for the choice of electrical
equipment, such as motors, lamps, sockets, switches, panels, speakers, etc.
Good work (design) within area classification is the most powerful tool of
economy, bringing the following benefits:
Optimization of investments;
Optimization of maintenance;
Optimization of procedures;
Optimization of insurance.
Source Of Release
This is a point from which the product can be released into the atmosphere
so that an explosive atmosphere can be formed.
Permanent;
Normal;
Abnormal.
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Documentation
In plans;
In cross-sections.
MSDS: The material safety data sheet, also known as MSDS, is the main
source of information about the explosiveness of the combustible substance. The
values determined by the MSDS related to the following atmospheric conditions:
Accident Insurance).
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There is a large amount of gases and vapors that are capable of reacting
with the oxygen present in the air. Gases that do not burn are called inert gases,
such as nitrogen, helium, carbon dioxide, water vapor and carbon tetrachloride.
All gases, flammable liquids and fuels may enter ignition when heat above
their flash point. For combustion to occur, it is necessary for there to be a
minimum and maximum concentration of substances that are combustible with
air (oxygen) or another type of oxidant. The minimum concentration at which the
mixture becomes flammable is called the LOWER FLAMMABILITY LIMIT and the
maximum concentration at which the mixture becomes flammable is called the
UPPER FLAMMABILITY LIMIT.
The Flammable Range covers the lower limit to the upper limit. The
substances with very broad flammability ranges present a higher level of risk
when compared to substances with lower flammability ranges.
Oxygen concentration;
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One of the methods used for the purpose of reducing and eliminating the
ability of gases to cause an explosion or combustion is dilution of the gas with an
inert gas. This may be obtained using the following procedures:
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5.4. INERTING
This is the ratio of the mass per unit of volume of the Earth's atmosphere.
The density and air pressure reduce with increases in altitude. This also changes
with temperature variations, composition of dry air or humidity. The air density
may change depending on your heating and cooling when heated the air density
decreases and this tends to rise when cold air increases density and this
downward trend.
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The relative density of a gas or vapor is the ratio between the gas density
in relation to air, based on an air density equal to 1. The IEC standard considers
that if the density of the product is between 0.8 and 1.2 it should be dealt with as
if it had the same density as air. The molecular mass of air is approximately 29g,
corresponding to a relative density of 1. The gases with molecular masses lower
than 29 have relative density less than 1 and are lighter than air.
The density of the substance may vary depending on the temperature and
pressure, thus to specify the density of a gas or vapor it is necessary to specify
the temperature and pressure at which the density was determined.
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PRODUCT DENSITY
HYDROGEN 0.07
METHAN 0.55
E
ETHYL 0.97
ENE
ETHANO 1.59
L
CYCLOHEXANE 2.90
5.6. VOLATILITY
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VOLATILE FUELS: are those whose molecules become detached from its
natural form (solid or liquid) without the need of temperature or pressure
variations, such as gasoline, naphtha, ether, hexane, toluene, benzene, etc. All
products emitting vapors at room temperature are called light products.
This is the lowest electrical energy value sufficient for the ignition of an
explosive atmosphere of the substance concerned, for certain specified test
conditions. At this point the maximum power is developed, that is, the explosion
is greater. Gases, vapors and dusts are usually classified according to their
minimum ignition energy (MIE). These values are obtained through a spark gap,
supplying a parameter of how the substance may ignite easily due to sparks.
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The circuit components and the location of the electrodes between the
generated sparks are the main differences between the methods.
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20ºC and +40ºC. If the ambient temperature range is outside this range,
or if any influence due to other factors, such as process temperature and
exposure to solar radiation, the effect on the equipment should be considered
and the measures taken should be documented. In this case, the equipment
manufacturer must be informed of the ambient temperature conditions to which
the equipment will be submitted.The indication of the maximum surface
temperature classification of the electric equipment, determined during
certification tests and indicated on the certificate of conformity should be
indicated in the markings on the electrical equipment.
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This should always be less than the auto ignition temperature of the
flammable products.
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The standard ABNT NBR IEC 60079-14 defines the calculations to be used
to define the maximum surface temperature of the equipment enclosure that will
be installed in areas classified as Group III (combustible dust or fibers) in the
form layers or clouds of combustible dust
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The maximum surface temperature is the lowest of the values obtained for
dust clouds or dust layers, determining the maximum surface temperature for the
equipment to be used. In locations where the dust thickness cannot be controlled
to a maximum of 5mm, considerations should be made with the manufacturer. If
there is a lack of product information, the Tmax may be obtained in a
conservative form using the NEC standard.
Flammable substances in the form of gas and vapor are classified into 03
groups according to the IEC: IIA, IIB and IIC according to their dangerousness.
This classification is made according to experimental procedures and based on
the MIC (Minimum Ignition Current) and MESG (Maximum Experimental Safe
Gap).
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Note: The electrical equipment certified as group IIC is adequate for IIB
and IIC. The electrical equipment certified as group IIC is adequate for groups
IIIA and IIIB.
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This is a point from which release occurs continuously laid for long periods
of time or frequently.
Examples for dust and fibers: inside silos, bag filters, etc.
ZONE 0
ZONE 20
This is a point from which release will possibly occur during normal
operation.
Examples for dust and fibers: transfer points, open sacks, etc.
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ZONE 1
ZONE 21
This is a point from which the release during normal operation is not
predicted and, if it occurs, is likely to be only occasionally, and only for short
periods of time.
ZONE 2
ZONE 22
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Time of presence of
% time of
ZONE Explosive Atmosphere per
presence per year
year (about 10,000 hours)
Zone 0 1000 hours or more per year ˃ 10%
Zone 1 10 < hours per year < 1000 0.1% to 10%
Zone 2 1 < hours per year < 10 0.01% to 0.1%
Non-
Less than 1 hours per year < 0.01%
hazardous
areas
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5.13. VENTILATION
To obtain good ventilation of the area, the conditions of the facilities should
be assessed, and the maximum amount of flammable vapor or gas that could be
released.
When the facility is in the open air, i.e. there are no obstacles that
characterize a confined environment. This type of ventilation is obtained through
the movement of air caused by wind and/or temperature gradients. In open
environments, the air speed is generally higher than 2 m/s and rarely below 0.5
m/s.
Outdoor situations, typical of the chemical and oil industries, such as:
open structures, pipe supports, pumping stations and suchlike;
A building that is not open, but that has a natural ventilation provided
with permanent openings, built with the objective of ventilation.
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The area classification inside the exhaust system should be taken into
consideration, immediately to the external side of its point of
discharge, and other openings in this exhaust system.
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The Degree of Ventilation depends on the wind speed and number of air
changes per unit of time.
Ventilation may be divided into three levels: low, medium and high.
High Ventilation
Average Ventilation
Low Ventilation
The concentration cannot be controlled while the leak occurs and/or the
unsuitable persistence of an explosive gas atmosphere, after the leak stops.
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The standard ABNT NBR IEC 60079-0/13 defines two types of certification:
This condition is indicated using the symbol "U" as a suffix for the number
of the certificate.
Confinement;
Isolation or;
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Confinement
The components that could cause ignition are installed in enclosures that
can withstand the pressure developed during an internal explosion of an
explosive mixture and prevent the transmission of this to the atmosphere around
the enclosure.
Isolation
The components that could cause ignition are isolated from the surrounding
explosive atmosphere through an insulating medium, which may be protective
gas, oil, sand, or resin.
Dilution
Limitation
Suppression
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All mixtures have a minimum ignition energy (MIE), and below this value it
is impossible to cause detonation, depending on the concentration of the mixture,
i.e. the amount of fuel in relation to the amount of air.
The intrinsic safety circuits always manipulate and store energy, below the
minimum explosive limits of gases representative of each family, considering the
most dangerous concentrations. Thus even in abnormal operating conditions in
the equipment, Intrinsic Safety circuits do not cause ignition, as they do not have
enough energy for such, making the installation safe and allowing assemblies
even in Zone 0.
Below are some of the terms of most importance for understanding intrinsic
safety:
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Zener Barrier
The function of the energy barrier is to limit the power delivered to the
hazardous area through the safe area, by limiting the current and voltage.
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The type of protection in which the parts that could cause ignition are
installed in enclosures that can withstand the pressure developed during an
internal explosion of an explosive mixture and prevent the transmission of this to
the atmosphere around the enclosure.
Explosion proof enclosures are not used in high risk zones (zone 0) as the
integrity of this level of protection depends on correct installation and
maintenance. This protection method is confinement, and may be used in zone 1.
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Joints
Generally, explosion proof enclosure has joints for reducing the high
pressure gas that is generated due to possible ignition in the enclosure. These
joints have tow main functions: reducing the pressure generated and reducing
the temperature of the gas from the explosion released through the joint,
preventing the exterior atmosphere from suffering the ignition process.
Sealing Units
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This system using the sealing unit has the disadvantage of being a
physically rigid and sealed system, with a loss of material due to impregnation in
the event of maintenance. The passage of gas or vapor and propagation of
flames may occur through interstices between the wires of which the flexible
cables with a gauge of more than 35 mm2 are composed. In these cases, special
constructions for these conductors become necessary, with the use of individual
sealing units or cable fittings.
The mixture used in the sealing is relatively porous, so that some gases,
particularly under pressure and with very small molecules, such as hydrogen, can
very slowly pass through the sealer mixture. Furthermore, sealing is undertaken
around the external insulating layer of the conductor, leaving minimum spaces
inside the conductor (interstices) without the due protection.
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The figure below shows a cross-section of a cable fitting, with a quick and
easy installation system, however attention is required on the use of suitable
cable fittings appropriate to the cable size, avoiding gaps that could compromise
the set as a whole, in the same way as a very large cable would not allow it to
grip to body, which can compromise the system with protection type Ex.
CCM “Ex” with “traditional" flat joint metal enclosure and sealing units Ex d.
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Explosion proof cable fittings and Increased Safety for unshielded cables
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In the design and technical specification phases for the "E" electrical
equipment and instrumentation, for cases in which the specification of metal
explosion proof enclosure is inevitable, preference should always be given to
equipment with threaded covers and indirect cable intakes to inside the Ex "d"
enclosure.
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In this method the equipment does not have enough energy to cause
detonation of the explosive atmosphere, like Intrinsic Safety, but does not
forecast any fault or defect condition .
Non-Sparking – (Ex-nA)
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Distribution board with the markings Ex of IIc T6 EPL Gc and Light Fixture
Ex nA EPL Gc.
Dry type transformer for areas classified with the markings BR-Ex nA II T4
IP55.
These are electrical devices which contain both circuits with limited energy
and parts with the presence of unlimited energy.
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These should not interference with the operation of each other. Equipment
with associated energy limitation may be:
Hermetically sealed device - the device that prevents contact with the
explosive mixture present outside the enclosure (welding, brazing, or
glass-metal fusion);
Encapsulated device.
Pressurization – (Ex-p)
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In this case, the alarm system should be based on the relative amount of
protective gas in the atmosphere, also acting in the de-energizing of the power
supply.
This protection method is isolation, and may be used in zone 1 and zone 2.
This technique is also known as "Continuous Dilution" and can be applied to
electrical boards and especially as a solution for control rooms, which can be
mounted near risk areas.
The source of air or inert gas used should be free of flammable gases and
should be reliable. It may be necessary to clean or dry the air or gas before use
in pressurization, with the most common inert gas being nitrogen.
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EXTERNAL INTERNAL
EPL TYPE
CLASSIFICAT CLASSIFICATION WITH
ION PRESSURIZATION
px Type Protection
py Type Protection
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pz Type Protection
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Induction motors;
Light fixtures (provided the power and the type of lamp does not
generate a high temperature), for example, fluorescent lamps;
Valves, solenoids,
Control buttons;
Measurement instruments;
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In this type of protection, the oil used must be of a mineral origin, in the
event that another liquid is used, it should meet the following requirements:
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The principal guidelines that must be met when the Ex-o type protection
equipment is designed, are:
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Warning to turn off the feed equipment before opening the box.
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The casing, or the parts of it that are filled with material, must have an
IP54 minimum degree of protection, in the event that the degree of protection is
greater than or equal to IP55, the casing must be equipped with a vent, and in
this case, the equipment must be IP54. In the event that the casing is designed
and specified for installation in a sheltered, clean and dry environment only, it
should have a an IP43 minimum degree of protection, since various factors are
limited, the protection may have a lesser degree.
The casing of equipment filled with sand or another material with similar
characteristics or EX components filled shall be sealed during the manufacture
phase, and it shall not permit to open the casing without destroying the closing
seal, thus ensuring the original sealing.
Filling with sand or little balls of glass shall comply with the minimal
size specification for the particles;
The filling material cannot be withdrawn off of the box during the
normal operation or occurrence of any event (short circuit);
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Type of protection where the parts that might ignite inside an explosive
atmosphere, by spark or heat, are enclosed in a compound in such way the
explosive atmosphere cannot be ignited in operation conditions.
The compound (resin) used to enclose shall have the full description of
composition aiming to assess the temperature conditions and the temperature
rate, which shall be defined together with the maximum operation temperature.
The casing shall be tested in a way to ensure the insulation, mechanical
resistance and the resistance for water absorption conditions, being the last one
specific for devices exposed to humid environments.
The casing shall be performed without any voids; voids are allowed only in
cases of compounds that need to move, as relays, but in these cases, the free
volume shall be 100 cm3 maximum for "ma"-type protection, and 10 cm3
maximum for "mb"-type. In case there is devices with contacts, it shall be
predicted an additional casing that allows the mechanical movement of the
component.
Open spaces smaller than 100 cm3 for "ma" protection, and 10 cm3
for "mb" protection;
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Material used for filling the casing shall not react with possible
chemicals that may arise from the local where the equipment or
device shall be installed;
Relays and limited power circuit breakers (with movable parts inside
the casing volume);
Proximity sensors;
On Zener barriers;
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It allows the equipment accreditation that did not contribute with the
formation of any explosive atmosphere when tested and experimented. This
rating is an open door for standards aiming the manufacturer's technological
innovation.
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The tables that list the type of protection as per area rating per zones are
as follows.
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6.3. CASINGS
The casing of a power equipment is the set of walls that involve the living
parts of a power equipment, including doors, lids and cable inlets, axles, rods and
support.
Nominal features;
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On historical basis, we know that not all types of protection provide the
same level of protection against the possibility of an ignition condition to occur.
ABNT, IEC and NFPA standards establish specific types of protection for specific
zones, considering the more likely or frequent is the occurrence of an explosive
atmosphere, the higher the required protection level for the equipment shall be.
Rated areas (except coal mines – due to firedamp) are divided in zones.
The equipment is measured for a certain type of zone according to the type of
protection it has. In certain situations, this type of protection can be divided in
different levels of more specific protections, which are related to zones. Example:
the protection of equipment by Ex-i intrinsic safety is divided by "ia", "ib" and "ic"
protection levels.
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EPL Ma
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EPL Mb
EPL Ga
EPL Gb
EPL Gc
Example: in case a light bulb fails; in this case, the device is required to
have an Ex-n type of protection.
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EPL Da
EPL Db
EPL Dc
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For equipment that does not have any type of protection, the specified
marking related to a characteristic numbering shall be replaced by "X" letter,
which means "XX" shall indicate that both numbers were omitted.
If the industry requires any special conditions for the equipment casing
where it is installed and needs a special protection, different from dust or water,
the user shall include the "W" letter before the two numbers or after the
supplementary letter when specifying the IP protection grade, besides the normal
conditions (solid objects and water); such additional measures are resulted from
the agreement between the equipment and the final client.
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1 Protected against solid objects larger than 50 A large surface of the body, like the hand.
mm Solid objects whose lower dimension is above 50 mm.
2 Protected against solid objects larger than 12 Fingers or objects with a similar length below 80 mm. solid object whose
mm lower dimension is above 12 mm.
3 Protected against solid objects larger than 2,5 Tools, wires, etc. with a diameter or thickness above 2.5 mm. Solid
mm objects whose lower dimension is above 2.5 mm.
4 Protected against solid objects larger than 1,0 Wires or tapes with length above 1.0 mm. Solid objects whose lower
mm dimension is above 1.0 mm.
5 Protected against dust It is not totally sealed against dust entry; the dust, however, shall not enter
in a quantity able to impair the equipment’s operation.
1 Protected against vertical raindrops (Vertical) water falls shall not have harmful effects.
2 Protected against water drops that fall with a Vertical water falls shall not have harmful effects when the casing has a
maximum slope of 15º 15º slope for any side from their normal position.
3 Protected against water sprinklers Water sprinkled from a 60º vertical angle shall not have harmful effects.
4 Protected against water projections Water projected from any direction against the casing shall not have
harmful effects.
5 Protected against water jet Water projected from any direction by a nozzle against the casing shall not
have harmful effects.
6 Protected against sea waves Water from sea waves or projected via powerful jets shall not enter the
casing in harmful quantities.
7 Protected against immersion It shall not be possible the water entry in harmful quantities inside the
casing immersed in water under conditions specified – from time to
pressure.
8 Protected against submersion The equipment is suitable for continuous submersion in water under
conditions specified by the manufacturer.
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ABNT NBR IEC 62262 standard defines the protection grade against
mechanical impacts indicated by the IK letters and followed by a number.
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Currently, INMETRO Ordinance No. 179, of May 18, 2010 requires the
identification of certificate as per Brazilian System on Conformity Assessment
(SBAC – Sistema Brasileiro de Avaliação da Conformidade).
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Whereas the products certified by Inmetro Ordinance No. 179, of May 18,
2010, published by the Federal Official Gazette on May 20, 2010, section 01,
page 76, intended to explosive atmospheres under conditions of flammable gases
and vapors and combustible dust are subjects regulated by the Ministry of Labor
as per item 10.9.2 of NR-10 - Power Installation and Services, approved by
Ordinance No. 598, of December 7, 2004, published by the Federal Official
Gazette on September 8, 2004;
Whereas Inmetro Ordinance No. 270 of June 21, 2011, published by the
Federal Official Gazette of June 24, 2011, section 01, pages 98 and 99, which
emends the articles of Inmetro Ordinance No. 179/2010, Power Equipment to
Explosive Atmospheres;
“Art. 7 To establish that up to thirty six (36) months from the publication
date of this Ordinance, the Power Equipment for Explosive Atmospheres, under
conditions of Combustible Dust shall be sold by the local market only in
compliance with the Requirements previously approved.” (N.R.)
“Art. 8 To establish that up to twenty four (24) months from the publication
date of this Ordinance, the Power Equipment for Explosive Atmospheres, under
conditions of Combustible Dust shall be manufactured and imported only in
compliance with the Requirements previously approved.” (NR)
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“Art. 7 To establish that up to thirty six (36) months from the publication
date of this Ordinance, the Power Equipment for Explosive Atmospheres, under
conditions of Flammable Gases and Vapors shall be sold by the local market only
in compliance with the Requirements previously approved.” (NR)
"Art. 8 To establish that up to thirty six (36) months after the effective
dates established by articles 6 and 8, the Power Equipment for Explosive
Atmospheres, under conditions of Flammable Gases and Vapors and Combustible
Dust shall be manufactured and imported in accordance with the publication of
the current version of the Standards related to Requirements previously
approved.”
§2 The due date established by the caption shall enable the manufacture
process of this equipment in compliance with the updated Standards." (NR)
"Art. 12 To establish that up to forty eight (48) months after the effective
dates established by articles 7 and 9, the Power Equipment for Explosive
Atmospheres, under conditions of Flammable Gases and Vapors and Combustible
Dust shall be sold on the local market in accordance with the publication of the
new version in force of the Standards related to Requirements previously
approved.” (NR)
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Art. 7 To be aware that sub items 6.1.2.3 and 6.3.2.1, paragraph “d” of sub
item 6.3.2.2.1 and paragraphs “d”, “l” and “g” of sub item 6.3.4.5 of Conformity
Assessment Requirements for Power Equipment for Explosive Atmospheres,
under conditions of Flammable Gases and Vapors and Combustible Dust,
approved by Inmetro Ordinance No. 179/2010, shall be in force with the following
wording:
"6.3.2.1 The solicitant shall forward a formal request to OCP, which shall
have the denomination, product's characteristics together with the related
descriptive brief, installation manual and instructions for safe use of the
equipment attached, in (Brazilian) Portuguese, and other complimentary
documents that OCP deems necessary. If the solicitant is the user him/herself,
the presentation of instructions for safe use of the equipment in (Brazilian)
Portuguese is not necessary." (NR)
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“6.3.2.2.1
(...)
“6.3.4.5
(...)
“6.3.4.5
(...)
“6.3.4.5
(...)
"The first audit shall be performed by OCP, which shall grant the conformity
certificate to verify, besides the technical requirements, the following
requirements:
a)conformity marking,
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“6.1.1.5.5
(...)
“6.2.1.4.5
(...)
“6.3.4.5
(...)
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For single packages of products, it shall use the full template of seal. But
when there is no space to apply the full seal or the application is via direct
printing on the package, the use of a "compact" seal that complies with the
minimal dimension of the seal with 11 mm of width shall be accepted.
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Legend:
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For Ex equipment;
The certification of shops for repair and revision services aims to ensure the
product reliability that continues to comply with the certificate requirements after
repair and revision.
Repair;
Revision;
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8. INSPECTION
ABNT NBR IEC 60079-17 standard – Inspection and maintenance of power
installations is about factors directly related to inspection and maintenance of
power installations in rated areas only, where the risk can be caused by
flammable gas, vapors, mists, dust or particulate matter.
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VISUAL NO NO
ACCURATE YES NO
DETAILED YES YES
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9. REPAIR OF EQUIPMENT
After repairing, the power engine shall, on a mandatory basis, receive a
marking indicating it was repaired. In 2008 a ABNT NBR IEC 60079-19 standard
was published: Repair, revision and recovery of equipment; this standard
provides information on repair, revision, and recovery and change on equipment
designed to be used inside explosive atmospheres. This standard was regulated
by INMETRO via Ordinance 179 of May, 2010. This ordinance states that repair
services on Ex equipment shall be mandatorily rendered by companies that are in
compliance with the standard as from May, 2013.
There are two types of marking indicated by ABNT NBR IEC 60079-19
standard:
If the repaired engine does not meet the requirements of ABNT NBR IEC
60079-19 standard and the standards regarding the types of protection, it is not
suitable to operate in an explosion risk area; in this case, the engine shall not
receive the expected marking of repair. The user is responsible for keeping filed
all documents regarding the engine, such as: copy of certificates, drawings and
history of reports from previous repairs.
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B.1 – Scope
Responsible persons for the process involved with revision, repair and
recovery of specific types of protection of equipment for explosive atmospheres,
which shall have at least the following knowledge:
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B.2.2 – Performers
Performers shall have, up to the required level for performing their tasks,
the following knowledge:
B.3 – Competencies
B.3.1 - General
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B.3.3 – Performers
Can work in total compliance with the specified rate of activities; and
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In Section 29 (Marking) of ABNT NBR IEC 60079-0 are presented the new
requirements and marking examples, including the equipment protection levels.
The marking system indicated shall be applied in power equipment or "Ex"
components in compliance with the applicable standards for the types of
protection presented by the standard.
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This part of the ABNT NBR IEC 60079 Standard contains the specific
requirements for the electrical installations project, selection and building in gas
explosive atmosphere.
Following are some items from the ABNT NBR IEC 60079-14 standard.
Portable equipment must be used in classified areas only when such use
cannot be avoided.
This item still makes some references to portable equipment, such as:
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Note: Where the ground resistivity is high, such systems may not be acceptable.
Note: In the absence of Statics Electricity Protection IEC Standards, national standards or
other must be followed.
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The subsection 12.3 of ABNT NBR IEC 60079-14 gives details of lightning
protection for equipment Ex "ia" installed in zone 0.
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Note: Precautions must be taken to avoid damages to the cover or PVC cable insulation
materials, when they were installed in temperatures under -5ºC.
Such precautions must involve sealing of tube bundles, ducts or piping. For
piping, the proper ventilation or filling with sand may be done. Conduits and, in
special cases, cables (example, where differential pressure exists), must be
sealed, if necessary, in order to avoid the passage of liquid or gases.
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Note: When cables, not selected for high temperature, are selected and installed
according to the manufacturer recommendations, the cable surface temperature must not
normally exceed the T4 temperature class, and in practice is uncommon to exceed the T6
temperature class.
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Note: In the absence of IEC standards for cables, references must be made to the
national standard or others.
Note: Equipment compliant with IEC 60079-1 shall be marked as group IIA, IIB, IIB + H2
or IIC. Equipment marked with "IIB + H2" must be installed with IIC equipment.
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IIA 10
IIB 30
IIC 40
It is essential that cable inputs are in compliance with all the requirements
of the proper equipment standards, maintaining the respective protection type,
which the input are adequate to the cable type used, and are in compliance with
section 9.
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When the cables get directly inside explosion-proof equipment, the cabling
system must be according to 10.4.2.
The cable input system must be according to one of the following criteria:
The cable input device in compliance with IEC 60079-1 and certified as part
of the equipment when tested with a sample of the specific cable type.
Note: If it is noticed that the use of a certain type of cable with a cable inlet
as per IEC 60079-1, by aggregating an O-ring does not cause an ignition due to
an external damage to the cable (caused by flame erosion) when subject to
repeated ignitions of flammable gas inside the casing, so the full compliance with
figure 1 may not be necessary.
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The conduit shall have at least five threaded wires to allow the connection
of five threaded wires between the conduit and the explosion-proof casing, or the
conduit and the coupling. The tolerance class of the conduit thread shall be 6q.
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BIBLIOGRAPHY
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catodica.pdf
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http://educador.brasilescola.com/estrategias-ensino/evidencias-ocorrencia-
reacoes-quimicas.htm
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artigos-e-materias-relacionadas/149-vestimenta-de-protecao-contra-
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http://nrfacil.com.br/blog/?p=3543
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mortos,67ea9c01358da310VgnCLD200000bbcceb0aRCRD.html
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http://www.inmetro.gov.br/painelsetorial/palestras/IECEx.pdf
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artigos-e-materias-relacionadas/96-a-importancia-das-adequacoes-em-uma-
area-classificada.html
http://www.eidos.com.br/areas-de-atuacao/atmosfera-
explosiva/inspecao%C2%A0de%C2%A0area%C2%A0classificada
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http://www.osetoreletrico.com.br/web/documentos/fasciculos/ed.40_instal
acoes_eletricas_e_de_instrumentacao_para_areas_classificadas.pdf
http://www.osetoreletrico.com.br/web/documentos/fasciculos/ed38_instala
coes_eletricas_de_-instrumentacao_para_areas_classificadas.pdf
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abencoados-antes-de-
lancamento.bf0805c32935b310VgnCLD200000bbcceb0aRDRD.html
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QUESTIONS
d) How the zoning are defined in an area rating (gas and vapor)
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x) Which are the factors that can influence the delimitation of an Rated
Area?
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