Process Measurement Instruments – Flow, Temperature, Level & Pressure Measurement
KROHNE Flow Meters
Process Instrumentation for Industrial, Hazardous Area & Explosive Atmopheres
Ultrasonic Flow Measurement
KROHNE flowmeters and measurement instruments provide accurate and reliable measurement of industrial liquids, gases and other media (including emulsions, corrosive liquids and gases) with a range of low/high flow rates.
KROHNE is a world-leading manufacturer and supplier of solutions in industrial and explosive atmosphere process instrumentation – with over 30 worldwide approvals for hazardous area gas and dust Zones including ATEX, IECEx, usFMc, NEPSI, INMETRO, KGS, GOST-R and PESO/CCOE. The range of flowmeters manufactured by KROHNE incorporates multiple explosion proof and protection concepts – including IS (Intrinsically Safe) and Ex d (Flameproof) for flow measurement and metering in the hazardous area industries.
Flowmeters by KROHNE | the world-leading manufacturer and supplier of solutions in industrial and hazardous area process instrumentation: flow meters, level meters, temperature meters and pressure measurement.
Background
SC Klaipedos Nafta is one of the largest oil ports on the Baltic coast in Lithuania. Crude oil and oil products are delivered by ships and freight trains and then loaded for further transport onto tank lorries and ships. Tank ships with a shipping volume of up to 100000Â t can dock and the port capacity is 500Â rail cars.
The storage volume is approx. 400000 m3. A new filling system suitable for custody transfer was necessary in order to increase the capacity for light oil products when loading tank lorries from tank cars.
Flow Measurement requirements
The new loading system for tank lorries had to be suitable for custody transfer and able to generate all financial data. Additional requirements included: simple installation, superior accuracy and smooth integration of the new system into the existing SCADA and filling control and control system. Measurements must be based on the European MID in accordance with MI-005 and API 5.5 Level A.
Product benzene EÂ 95 ( = 95Â %Â ethanol + 5Â %Â benzene ):
- Density: 741…791 kg/m3
- Flow rate: 20…100 m3/h
- Viscosity: 0,45…1,5 mPa•s
- Operating pressure: 4Â bar
- Operating temperature: -29…+35 °C/84.2…95 °F
KROHNE Solution
For this application KROHNE supplied 5 OPTIMASS 7300 C mass flowmeters and 2 SUMMIT 8800 digital flow computers. It is very easy to install the OPTIMASS measuring devices in the pipelines as there are no installation requirements.
Pipeline vibrations have no impact on the highly accurate measurements. The compact designs of the measuring devices make the electrical connection easier. The devices come equipped with density and temperature measurement as standard.
The devices can be started up and operated without any special knowledge. The SUMMITÂ 8800 is a digital flow computer featuring a large, easy-to-read colour display with multi-colour light control and touchscreen operation. The completely redundant Ethernet is suitable for WLAN when using all common protocols. The SUMMITÂ 8800 can be used for many different types of measurement.
KROHNE Flowmeters
Customer benefits
OPTIMASS mass flowmeters from KROHNE offer many advantages such as excellent long-term stability and repeatability, guaranteeing precise measuring results. The devices work extremely reliably. Because OPTIMASSÂ 7300Â C measuring devices can measure the mass flow directly, recalibration becomes unnecessary, even with varying process parameters. There is virtually no additional pressure loss due to the single straight measuring tube design of the mass flowmeters. This means that the required pump output is minimal.
- Equipping a loading system for tank lorries with Coriolis mass flowmeters
- Simple integration into existing SCADA, filling control and control system
- Custody transfer measurement in accordance with MID MI-005 and API 5.5 Level A
KROHNE Flowmeters Used
OPTISONIC 7300 flowMeter
Hazardous Area Process Instrumentation, Meters & Measurement – KROHNE OPTISONIC 7300
The OPTISONIC 7300 is a universal 2-path ultrasonic gas flowmeter for process and utility gas measurements in oil and gas refineries or the chemical or petrochemical industries.
It is also suitable for non-custody transfer natural gas applications or applications with (compressed) air, mixed or flue gases (up to +180°C / +356°F). Using the transit time differential measuring principle, the OPTISONIC 7300 delivers high performance over a wide flow range (up to DN600 / 24″, turndown ratio: 100:1).
The flowmeters patented titanium transducers are perfectly focused, equalizing process fluctuations and avoiding acoustic feedback.
- Bi-directional flow measurement over a wide dynamic range (turndown ratio: 100:1)
- Integrated volume correction to standard conditions (using pressure and temperature measurement)
- With current inputs for external pressure and temperature sensors
- NACE-approved grade 29 titanium transducers for maximum corrosion resistance
- Largely independent of gas density and composition
- Full bore design: No moving parts, no wear, no pressure loss
- Compact or field-mounted version
Hazardous Area Process Instrumentation, Meters & Measurement – KROHNE SUMMIT 800
SUMMIT 880 Meter
The SUMMITÂ 8800 is a digital flow computer for custody transfer (CT) measurement. Its state of the art full colour graphical touch screen allows a graphical representation of the measurement process, with all measured values shown in real time; Up to 5 different types of meters combined in one flow computer, with CT measurements still being processed within 0.25s.
The SUMMITÂ 8800 communicates via digital, analogue, serial and Ethernet interfaces to obtain the measurement and diagnostics from the field converters and analysers. All calculated values (densities, flow rates, totals, etc.) are available in Modbus format which can be read by any PLC, SCADA, accounting system etc.
- Compliant with all main international standards, such as OIML, ISO, API, AGA, GOST
- Fully digital; no loss on accuracy due to analogue to digital conversions
- Enhanced diagnostics with logging of preselected measured parameters
- Modbus mapping & system compatibility (DCSs, PLCs, Supervisory, SCADA, HMI)
- Advanced system integration incl. eReporting push, web interfacing and remote monitoring
- Very short cycle time: down to 0.25 sec
- Redundant operation in duty-standby configuration
- Up to 8 non-CT multi product liquid applications per flow computer
Explosive Atmosphere Experts
Thorne & Derrick are Specialist Distributors of Hazardous Area Electrical, HVAC & Process Instrumentation Equipment with IECEx & ATEX Certifications to the onshore and offshore oil, gas, petrochemicals and process industries.
We supply major UK and international infrastructure projects and also MRO (Maintenance, Repair, Operations) requirements for both planned and unplanned plant shutdowns – we react with a rapid response to customer demand to ensure downtime is minimised and reliable Power, Light & Heat is restored or provided.
We distribute Innovative products to manage the planned replacement of legacy equipment conformant with international classifications including ATEX and IECEx.
Key Product Categories: Control Panels | Plugs & Sockets | Isolators | Enclosures & Junction Boxes | Lighting | Control Stations | Motor Starters | Heat Trace Cables & Systems | Gas Detection & Detectors | Fire Detection & Detectors | Heat Detectors | Electrical Heating & HeatersÂ
➡ Also Process Instrumentation Products: Ashcroft Pressure Gauges | ASCO Valves | Katronic Flow Meters | KROHNE Flow Meters | VEGA Level Sensors | Rotronic Temperature & Humidity Sensors
Process Measurement Instruments – Flow, Temperature, Level & Pressure Measurement
KROHNE Flow Meters
Process Instrumentation for Industrial, Hazardous Area & Explosive Atmopheres
Ultrasonic Flow Measurement
KROHNE flowmeters and measurement instruments provide accurate and reliable measurement of industrial liquids, gases and other media (including emulsions, corrosive liquids and gases) with a range of low/high flow rates.
KROHNE is a world-leading manufacturer and supplier of solutions in industrial and explosive atmosphere process instrumentation – with over 30 worldwide approvals for hazardous area gas and dust Zones including ATEX, IECEx, usFMc, NEPSI, INMETRO, KGS, GOST-R and PESO/CCOE. The range of flowmeters manufactured by KROHNE incorporates multiple explosion proof and protection concepts – including IS (Intrinsically Safe) and Ex d (Flameproof) for flow measurement and metering in the hazardous area industries.
Flowmeters by KROHNE | the world-leading manufacturer and supplier of solutions in industrial and hazardous area process instrumentation: flow meters, level meters, temperature meters and pressure measurement.
Background
The JSC Mozyr oil refinery refines crude oil and other fuels in Belarus. The crude oil for refining is imported from Russia and Venezuela via the Ukraine.
The main products include fuels such as petrol, jet fuel, diesel fuel and domestic heating fuel.
A variety of bitumen products for road building, for roofing felt and other applications are also manufactured.
In addition, the refinery also produces liquefied gases including hydrocarbon fuel gases, butane and other products such as vacuum gasoil for export, commercial sulphur, lamp oil and gasoline-pyrolysis feedstock.
Flow Measurement requirements
The first mass flowmeter is required to measure the flow of crude oil in the supply pipe to the primary oil refining. The mass flow rate here is 1600Â t/h.
The second meter is used to measure black oil in the pipeline to the Commodity and Raw Materials Park.
Additionally the customer required simple installation, high accuracy and smooth integration of the new meters into existing systems.
KROHNE Solution
For this application, KROHNE supplied 2Â OPTIMASSÂ 2300Â C mass flowmeters, size SÂ 250Â s / 10Â inch. It is extremely easy to install these OPTIMASS meters in existing pipelines as there are no restrictions on installation. Vibrations in the pipeline have no influence on the very precise measurements.
The compact design of the meters simplifies the electrical connection and the meters come equipped with density and temperature measurement as standard. The meters can be commissioned and operated without any special knowledge.
KROHNE Flowmeters
Customer benefits
OPTIMASS mass flowmeters from KROHNE offer many advantages. Excellent long-term stability and repeatability ensure exact measuring results with the OPTIMASSÂ 2300Â C.
This mass flowmeter measures mass directly, eliminating the need for recalibration, even when process parameters vary. Extensive diagnostic functions facilitate self-monitoring of the systems and give prompt indication of possible errors in the system.
- Mass flow measurement of crude oil products
- Easy integration into existing systems
- Bulk mass flow measurement
Explosive Atmosphere Experts
Thorne & Derrick are Specialist Distributors of Hazardous Area Electrical, HVAC & Process Instrumentation Equipment with IECEx & ATEX Certifications to the onshore and offshore oil, gas, petrochemicals and process industries.
We supply major UK and international infrastructure projects and also MRO (Maintenance, Repair, Operations) requirements for both planned and unplanned plant shutdowns – we react with a rapid response to customer demand to ensure downtime is minimised and reliable Power, Light & Heat is restored or provided.
We distribute Innovative products to manage the planned replacement of legacy equipment conformant with international classifications including ATEX and IECEx.
Key Product Categories: Control Panels | Plugs & Sockets | Isolators | Enclosures & Junction Boxes | Lighting | Control Stations | Motor Starters | Heat Trace Cables & Systems | Gas Detection & Detectors | Fire Detection & Detectors | Heat Detectors | Electrical Heating & HeatersÂ
➡ Also Process Instrumentation Products: Ashcroft Pressure Gauges | ASCO Valves | Katronic Flow Meters | KROHNE Flow Meters | VEGA Level Sensors | Rotronic Temperature & Humidity Sensors
Process Measurement Instruments – Flow, Temperature, Level & Pressure Measurement
KROHNE Flow Meters
Process Instrumentation for Industrial, Hazardous Area & Explosive Atmopheres
Ultrasonic Flow Measurement
KROHNE flowmeters and measurement instruments provide accurate and reliable measurement of industrial liquids, gases and other media (including emulsions, corrosive liquids and gases) with a range of low/high flow rates.
KROHNE is a world-leading manufacturer and supplier of solutions in industrial and explosive atmosphere process instrumentation – with over 30 worldwide approvals for hazardous area gas and dust Zones including ATEX, IECEx, usFMc, NEPSI, INMETRO, KGS, GOST-R and PESO/CCOE. The range of flowmeters manufactured by KROHNE incorporates multiple explosion proof and protection concepts – including IS (Intrinsically Safe) and Ex d (Flameproof) for flow measurement and metering in the hazardous area industries.
Flowmeters by KROHNE | the world-leading manufacturer and supplier of solutions in industrial and hazardous area process instrumentation: flow meters, level meters, temperature meters and pressure measurement.
Background
The Berre Petrochemical Cluster is a complex covering almost 1000 hectares located 30 km / 18.6 miles from Marseille, France, on the Étang de Berre lagoon. The site consists of a steam cracker as well as large-scale polypropylene and polyethylene plants.
The polyolefin plants produce polypropylene and polyethylene, the majority of which is used for consumer and industrial applications. Also located on the site are chemical plants and logistics facilities such as port facilities, pipelines, storage terminals and transhipment facilities.
Flow Measurement requirements
One of the producers requires the continuous flow measurement of hydrogen. The customer was looking for custody transfer flow measurement that would be in line with the internal procedure followed in compliance with the Sarbanes-Oxley Act (SOX).
The main objective of the act is to oblige the companies in question to develop and implement their own control procedures used to detect cases of fraud and/or errors in the financial management of the company. This ensures that the financial data disclosed by the company is both accurate and applicable, preventing false reports from influencing prices on the stock market.
It is important for the customer to accurately determine and invoice the hydrogen flow. The volume flow varies from 100…400 kg/h / 3.67…14.7 lb/min, the pressure from 9…15.7 bar / 130.5…227.6 psi and the temperature from 0…+20°C / +32…+68°F.
The producer required a pressure and temperature-compensated flow measurement (standard volume flow measurement) in custody transfer as per MID MI-002 and in accordance with the internal SOX procedure. To this end, the customer was looking for a reliable and accurate comprehensive flowmeter system that would comply with both the MID requirements and the company’s own procedures (accuracy, control, approval, documentation, certifications etc.).
These flow measurements allow the customer to invoice hydrogen consumption and guarantee income. Previously, the company had used an orifice plate (not MID compliant). The MID MI-002 approved equipment must also comply with ATEX Ex d.
KROHNE Solution
KROHNE provided a measuring system complete with the ALTOSONIC V12 ultrasonic gas flowmeter (DN 100, ASME Cl 300 flange) and the SUMMIT 8800 flow computer. The ultrasonic flowmeter was installed in a horizontal stainless steel pipe with straight inlet and outlet runs.
The measuring system complies with MIDÂ MI-002. In addition, KROHNE offered the “KROHNE Care” expert system, providing diagnostic functions for the ALTOSONICÂ V12 ultrasonic gas flowmeter.
Based on diagnostic parameters, this system interprets the functionality and accuracy of the measuring device around the clock. The 12-beam measuring device features a vertical diagnostic path that detects contamination on the bottom of the measuring tube.
KROHNE also offered to commission the system and train personnel in the use of the two measuring devices. The system had to feature integrated pressure and temperature sensors for custody transfer measurements. KROHNE prepared the documents for custody transfer including calibration certificates, MID certificates, technical documentation etc.
KROHNE Flowmeters
Customer benefits
The reliable and accurate measurement in accordance with MID is a clear benefit for the customer. The customer can now create invoices covered by MID approval that also comply with the internal SOX procedure.
Thanks to the “KROHNE Care” diagnostic system and the diagnostic path to detect contamination, this reliable and accurate measuring system featuring self-monitoring made process optimisation possible. As a result, production increased and the producer recorded increased revenue.
- Reliable and highly accurate measuring system
- Comprehensive solution in accordance with MIDÂ MI-002
- Self-monitoring of the measuring system for process optimisation
KROHNE Flowmeters Used
ALTOSONIC V12 Meter
Hazardous Area Process Instrumentation, Meters & Measurement – KROHNE ALTOSONIC V12
The ALTOSONIC V12 is a 12-chord ultrasonic custody transfer (CT) flowmeter for natural gas. It has been designed to offer the best possible measurement accuracy, not only during calibration under ideal conditions but also during less ideal conditions in the field. As a result, ALTOSONIC V12 is the first ultrasonic flowmeter that was certified to OIML R137 class 0.5 by NMi.
Due to its design with 12 acoustic chords a flow conditioner is no longer required; standards such as AGA9, ISO 17089 and MID are met with just 5D straight inlet piping. CBM flowmeter diagnostics are standard and give an exact picture of what is happening inside the flowmeter.
With the optional KROHNE Care diagnostic expert system an integrated web server becomes available that presents the results as an easy to access webpage – in plain language.
- Complete product family for widest application range
- 12 acoustic chords for excellent swirl immunity and built-in redundancy
- Dedicated diagnostic path for deposits, dirt or changes in surface roughness
- No flow conditioner required
- Just 5D straight inlet piping required to comply to AGA9, ISO 17089 and MID
- First ever ultrasonic flowmeter to receive OIML R137 class 0.5 approval by NMi
- Free of charge condition-based monitoring (CBM)
- Optional with KROHNE Care system for 24/7 evaluation of meter health and accuracy
Hazardous Area Process Instrumentation, Meters & Measurement – KROHNE SUMMIT 800
SUMMIT 880 Meter
The SUMMITÂ 8800 is a digital flow computer for custody transfer (CT) measurement. Its state of the art full colour graphical touch screen allows a graphical representation of the measurement process, with all measured values shown in real time; Up to 5 different types of meters combined in one flow computer, with CT measurements still being processed within 0.25s.
The SUMMITÂ 8800 communicates via digital, analogue, serial and Ethernet interfaces to obtain the measurement and diagnostics from the field converters and analysers. All calculated values (densities, flow rates, totals, etc.) are available in Modbus format which can be read by any PLC, SCADA, accounting system etc.
- Compliant with all main international standards, such as OIML, ISO, API, AGA, GOST
- Fully digital; no loss on accuracy due to analogue to digital conversions
- Enhanced diagnostics with logging of preselected measured parameters
- Modbus mapping & system compatibility (DCSs, PLCs, Supervisory, SCADA, HMI)
- Advanced system integration incl. eReporting push, web interfacing and remote monitoring
- Very short cycle time: down to 0.25 sec
- Redundant operation in duty-standby configuration
- Up to 8 non-CT multi product liquid applications per flow computer
Explosive Atmosphere Experts
Thorne & Derrick are Specialist Distributors of Hazardous Area Electrical, HVAC & Process Instrumentation Equipment with IECEx & ATEX Certifications to the onshore and offshore oil, gas, petrochemicals and process industries.
We supply major UK and international infrastructure projects and also MRO (Maintenance, Repair, Operations) requirements for both planned and unplanned plant shutdowns – we react with a rapid response to customer demand to ensure downtime is minimised and reliable Power, Light & Heat is restored or provided.
We distribute Innovative products to manage the planned replacement of legacy equipment conformant with international classifications including ATEX and IECEx.
Key Product Categories: Control Panels | Plugs & Sockets | Isolators | Enclosures & Junction Boxes | Lighting | Control Stations | Motor Starters | Heat Trace Cables & Systems | Gas Detection & Detectors | Fire Detection & Detectors | Heat Detectors | Electrical Heating & HeatersÂ
➡ Also Process Instrumentation Products: Ashcroft Pressure Gauges | ASCO Valves | Katronic Flow Meters | KROHNE Flow Meters | VEGA Level Sensors | Rotronic Temperature & Humidity Sensors
Process Measurement Instruments – Flow, Temperature, Level & Pressure Measurement
KROHNE Flow Meters
Process Instrumentation for Industrial, Hazardous Area & Explosive Atmopheres
Ultrasonic Flow Measurement
KROHNE flowmeters and measurement instruments provide accurate and reliable measurement of industrial liquids, gases and other media (including emulsions, corrosive liquids and gases) with a range of low/high flow rates.
KROHNE is a world-leading manufacturer and supplier of solutions in industrial and explosive atmosphere process instrumentation – with over 30 worldwide approvals for hazardous area gas and dust Zones including ATEX, IECEx, usFMc, NEPSI, INMETRO, KGS, GOST-R and PESO/CCOE. The range of flowmeters manufactured by KROHNE incorporates multiple explosion proof and protection concepts – including IS (Intrinsically Safe) and Ex d (Flameproof) for flow measurement and metering in the hazardous area industries.
Flowmeters by KROHNE | the world-leading manufacturer and supplier of solutions in industrial and hazardous area process instrumentation: flow meters, level meters, temperature meters and pressure measurement.
Background
TIGF, headquartered in Pau, France, is one of the main operators of the French natural gas transport network and specialises in natural gas storage. After it is extracted, the gas is processed and then transported either via gas pipeline or in liquefied form.
When transporting in liquid form, the gas is loaded into liquefied natural gas tankers and taken to the designated receiving terminal. The gas is then processed, stored and gasified once again before being fed into the network and delivered to end consumers.
Flow Measurement requirements
The customer must measure the stored, compressed and transported natural gas. Measuring the transported product volume requires a great deal of accuracy.
Depending on the measuring point, the natural gas temperature may vary between 10…50 °C / 50…122 °F, the pressure may be between 30…85 bar / 435…1232.5 psi and the flow rate between 0…30 m/s / 0…98.5 ft/s.
A measurement of the gross volume flow is the starting point and the pressure and temperature compensation (in other words the conversion to standard volume) takes place automatically.
Measuring accuracy is extremely important for TIGF as they need to be able to control the internal process from the storage facilities to the transport arteries at any time.
The gas goes through various processing steps in the process. The company was thus looking to improve its internal gas measurements.
The customer had previously used orifice plates or outdated ultrasonic flowmeters and was looking for a more reliable measuring solution from KROHNE.
The customer specified the need for flowmeters with ATEX approval (Ex d), ASME flanges (Cl 600) and sealing rings. The instrumentation needed to be temperature resistant to -29 °C / -20.2 °F (the steel needed increased resistance in case of sudden decompression). It was also necessary for the flowmeter to be unsusceptible to any moisture occurring in the gas.
KROHNE Solution
A total of 14 OPTISONIC 7300 ultrasonic flowmeters and 3 ALTOSONIC V12 ultrasonic gas flowmeters were installed.
The nominal sizes of the flowmeters ranged from 8…24″, with ASME  RTJ flanges (Cl 600) and sealing rings, and were installed into mainly horizontal pipelines. However, two of the installations were in fall pipes with the appropriate inlet runs (10 D/5 D).
KROHNE Flowmeters
Customer benefits
IGF standardised its equipment fleet park with reliable and accurate instrumentation. The customer benefits from a reliable overview of the gas flow and now has better control over its facilities as a result of the improved management of the internal gas metering.
- Flow measurement of natural gas at a storage facility
- Increased requirements for measuring accuracy
- Improved management of internal gas measurements
Explosive Atmosphere Experts
Thorne & Derrick are Specialist Distributors of Hazardous Area Electrical, HVAC & Process Instrumentation Equipment with IECEx & ATEX Certifications to the onshore and offshore oil, gas, petrochemicals and process industries.
We supply major UK and international infrastructure projects and also MRO (Maintenance, Repair, Operations) requirements for both planned and unplanned plant shutdowns – we react with a rapid response to customer demand to ensure downtime is minimised and reliable Power, Light & Heat is restored or provided.
We distribute Innovative products to manage the planned replacement of legacy equipment conformant with international classifications including ATEX and IECEx.
Key Product Categories: Control Panels | Plugs & Sockets | Isolators | Enclosures & Junction Boxes | Lighting | Control Stations | Motor Starters | Heat Trace Cables & Systems | Gas Detection & Detectors | Fire Detection & Detectors | Heat Detectors | Electrical Heating & HeatersÂ
➡ Also Process Instrumentation Products: Ashcroft Pressure Gauges | ASCO Valves | Katronic Flow Meters | KROHNE Flow Meters | VEGA Level Sensors | Rotronic Temperature & Humidity Sensors
Estellito Rangel Jr.
Thorne & Derrick, The Experts in Equipment for Explosive Atmospheres, are privileged to have received permission from Estellito Ranel Jr. to republish this article.
Estellito was the first Brazilian national expert accepted at IEC Technical Committee 31 to provide consultation on the elaboration of the IEC Standards for explosive atmospheres.
The scope of TC31 is to prepare and maintain international standards relating to equipment, such as lighting systems, for use where there is a hazard due to the possible presence of explosive atmospheres of gases, vapours, mists or combustible dusts.
Estellio has over 3 decades industry experience exployed by Petrobras, the Brazilian state owned oil company, working in the following Departments: Engineering, Offshore Platform Utilities Management, Maintenance, Offshore Platform Technical Support, Refinery Electrical Systems Design and E&P Workers’ Safety.
Hazardous Area Locations
Safety In Electrical Installations
The electrical installation in classified locations has additional requirements than those defined for ordinary locations in order to offer no ignition risks for an occasional explosive atmosphere. Electrical and electronic equipment suitable for use in such locations, must have a “Certificate of Conformity” issued by a certification Body duly accredited.
However, in the audits we do in many industries, we still find a large number of non-conformities, originated as in the assembly stage as in maintenance activities.
As such non-conformities affect the safety of the plant (as if their integrity is compromised, electrical equipment can act as source of ignition), we will highlight some points that need special attention.
1. Signage
A worrying factor is the absence of particular signalization in industrial plants.
The directive is: “Safety signs should be clear to all professionals involved in services on classified areas, providing information on the zone classification, the gas group (for flammable gas and also for combustible dust atmospheres) and the allowed temperature class.”
Unfortunately, it can be found in internet many plates that do not comply with ISO requirements. The IEC 61892-7:2014 (a voluntary standard applied only on offshore units), suggested a model for an Ex sign – as shown in Figure 1 – but it has lack of information, as explained below:
Fig 1: A poor model of an Ex sign.
The suggestion above provides only incomplete information for safety, because the essential items for specification of the adequate equipment to be used there, are missed, as:
- Redundancy: The yellow triangle with “Ex” inside, already means “hazardous area”;
- Sometimes the word “danger” is also included, but the meaning of “possibility of an explosive atmosphere” is closer to a “hazard” (risk), than a “danger”;
- Texts require to be written in different languages, in order to be read by foreign workers at a given site;
- No information on the Zone of the location;
- No information on the gas group;
- No information on the temperature class allowed for the location.
So, in order to provide safety, a comprehensive sign is required, that also includes the classification area drawing number, facilitating the worker to get more details, as Fig 2:
Fig 2: An effective sign model that meets all safety recommendations for signage of hazardous locations, and that was already adopted by many companies, as Petrobras. The red background allows a quick alert and it is recommended by many safety documents.
2. Training the workforce
It is very common to see a lack of specialized professional training on installations in hazardous locations, as contracting companies usually hire electricians with experience on commercial and industrial installations, but without a sound knowledge on requirements for installations in hazardous locations.
And a concern arose in the market since IEC 60079-14:2013 included in its “normative” annex A4 that “The competency of responsible persons, operatives and designers shall be verified and attributed at intervals…” , because at first sight it suggests an association with “personnel certification” and, consequently, with the IECEx Scheme (a commercial branch of the IEC, dedicated to Certification of products, companies, persons and services, based solely on IEC standards, and receiving royalties from each certificate issued).
It is not difficult to find in the internet some misguided information that the “United Nations recommends that scheme“, but in fact, the organization that proposed such recommendation was the UNECE – United Nations Economic Commission for Europe (an UN commission focused on the European economic affairs). The document ECE/TRADE/391 explains the topic at the UNECE website.
In Brazil, some organizations started to offer Ex personnel certification under similar structure to that offered by the IECEx Scheme, but their certificates can’t show that logo if the certification body is not member of the Scheme. As only certifications on the Ex 000 and Ex 001 units are being offered (December 2017), they can’t be considered as “Ex personal certification“, because they are based only on multiple choice tests, without any practical activity assessment.
For example, an Ex installer will need to pass on the units Ex 001, Ex 003, Ex 006 and Ex 008 to be certified, what means that this is an expensive process. In short: companies should invest in effective training of the workforce, because the competence certificates based solely on units Ex 000 and/or Ex 001 by multiple choice tests, do not guarantee that the worker performs his tasks on Ex installations in the proper way.
Photo 1: The “hands-on” training: the effective way to teach the workers on Ex installations.
3. Changes in installations and Ex equipment
The explosion-proof boxes (Ex d) are designed in a way that the gases resulting from any internal explosion are driven to the outside through adequately designed joints. And it is up to the user to make sure that these joints are at a minimum distance from any solid obstacle, according to the table 13 of IEC 60079-14.
The non-conformity that we will highlight here in Ex d boxes, although allowed by the standard, is a “greased tape” wrapped around the flanged joints, as shown in Photo 2. This practice, according to the CEPEL report DLA 43410/2011, raises at 16% the internal pressure in the propagation test, denoting a risk that was not evaluated in the original Certificate of Conformity of the junction box, and therefore invalidates it! It is clear that changes in equipment and installations can affect the safety of installations and people.
Photo 2: Non-conformity in Ex installations, especially those that violate the provisions of the equipment Conformity Certificate, affects the safety of the industrial plant!
Conclusions
It is essential for all companies that process, store and transport flammable or combustible products, to go beyond the standards’ requirements, prioritizing updated training given by experienced consultants, because training deficiencies lead to non-conformities that cause risks (explosions) with potential to cause damage to workers, installations and neighbouring communities, what may even lead to ceasing the company activities!
References
[1] Electrical installations in hazardous locations: Tackling some controversial IEC recommendations, Estellito Rangel Jr. Electrical Business Magazine
[2] The importance of inspections on electrical installations in hazardous locations, Estellito Rangel Jr., Alan S. Queiroz and MaurÃcio de Oliveira. IEEE paper
[3] Brazil moves from divisions to zones [hazardous location safety], Estellito Rangel Jr. IEEE paper
EXPERTS IN EQUIPMENT FOR EXPLOSIVE ATMOSPHERES
leaders in ATEX Innovation To The Hazardous Area Industries
Thorne & Derrick are leaders in the development and distribution of Product Innovations that deliver significant improvements to clients plant, people and operational safety in the explosive atmosphere industries.
Your proactive problem solvers experienced in succession planning for the replacement of obsolete, non-conformant and legacy equipment in hazardous areas.
Your first-choice provider of innovative and competitive solutions to ensure ATEX & IECEx Compliance for Hazardous Area Electrical, HVAC & Process Instrumentation Equipment to UK and international projects.
Control Panels | Plugs | Isolators | Enclosures & Junction Boxes | Lighting | Control Stations | Motor Starters | Heat Trace | Gas Detection | Flame Detection | Process Instrumentation | Process Heating | Ventilation Fans | Security Access ControlÂ
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