The Future Looks Brighter with Intrinsically Safe Lighting Solutions

If your work environment has you in hazard area locations day in and day out, one tool that is essential is a reliable Class I, Division 1 flashlight or headlamp for your hard hat. Make sure your device is providing you the best lighting possible with an LED bulb, 32 hours of sustained operation and a 500' range on the optics. Technology for 3 of the best performers on the market are now offered in the smallest and most efficient form factor in it's class. No more two handed operation to turn the light on and off, with a single tail switch and ergonomic design these are the best solutions available today. Because they all use new Compound Path Optics (CPO) you have the brightest LED lights for the toughest jobs you do. Go ahead, Brighten Your Future with an intrinsically safe flashlight.

Defining Misperceptions on Intrinsically Safe and Nonincendive Equipment

Voodoo Science Nonincendive Circuits are better than Intrinsically Safe Circuits (NOT TRUE)

This misconception is mainly because nonincendive circuits employ the same basic rationale for reducing the risk of ignition of a hazardous atmosphere both rely on energy limitation.  Also the sound of the word itself nonincendive is part of the voodoo.  The word nonincendive strongly sounds to a layman like something simple that will not (Lite, Ignite or set A Fire) any atmosphere. On the other hand the word Intrinsic itself which sounds foreign, mysterious, microscopically looked at in detail.  The word Intrinsic sounds complicated must be thoroughly looked at in detail if not it will (Lite Ignite or set A Fire) any atmosphere at the smallest quantity.  This is reversed rationale and logic otherwise we can call it voodoo science.

The important differences nonincendive circuits are permitted in Division 2 and Zone 2 classified locations only. Intrinsically safe circuits on the other hand, are suitable for use in Division 1 and 2, and Zone 0, 1 and 2 classified locations. The main difference between the two types of equipment is that nonincendive circuits are evaluated for ignition capability under normal operating conditions, while intrinsically safe circuits are evaluated under fault conditions. During an evaluation of an intrinsically safe circuit, it is allowed to introduce up to two independent faults per the requirements in the applicable product standard in an attempt to increase the energy available in the circuit. Under these conditions, the circuit must still be incapable of causing ignition of the specified gas either by introduction of a spark (shorting of two points in the circuit) or by thermal effects of individual components within the circuit.

Therefore Intrinsically Safe Circuits are better than Nonincendive circuits (THIS IS TRUE)

Intrinsic safety and nonincendive equipment and wiring methods are practices where apparatus is designed with low power levels and low stored energy, so that an arc produced during normal functioning of the equipment or as the result of equipment failure has insufficient energy to initiate ignition of the explosive mixture. Equipment enclosures can be pressurized with clean air or inert gas and designed with various controls to remove power or provide notification in case of supply or pressure loss of such gases. Arc-producing elements of the equipment can also be isolated from the surrounding atmosphere by encapsulation, immersion in oil, sand, etc. Heat producing elements such as motor winding, electrical heaters, including heat tracing and lighting fixtures are often designed to limit their maximum temperature below the auto-ignition temperature of the material involved. Both external and internal temperatures are taken into consideration.

Section 500.7(F) of the National Electrical Code explains that it is a protection technique for equipment installed in Class I, Division 2, hazardous (classified) locations. With the advent of more stringent environmental regulations, intentional release of flammable materials is greatly restricted and, with the resulting changes in containment techniques, many areas that previously were classified as Division 1 (continuously flammable) have been reclassified as Division 2 (infrequently within the flammable range).

This allows the installation of nonincendive equipment in applications previously limited to Division 1 protection techniques, such as explosion proof or intrinsic safety. Nonincendive equipment tends to be less costly and less complicated to maintain than Division 1 equipment. The obvious economic benefits will mean that this protection technique will see an expanded usage in the years to come.

The same concept can be applied in Class II and Class III, Division 2, locations; but, in those locations, the enclosures of the nonincendive equipment must also prevent the entrance of dust.

In an industrial plant such as a refinery or chemical process plant, handling of large quantities of flammable liquids and gases creates a risk of leaks. In some cases the gas, ignitable vapor or dust is present all the time or for long periods. Other areas would have a dangerous concentration of flammable substances only during process upsets, equipment deterioration between maintenance periods, or during an incident. Refineries and chemical plants are then divided into areas of risk of release of gas, vapor or dust known as divisions or zones. The process of determining the type and size of these hazardous areas is called area classification. Guidance on assessing the extent of the hazard is given in the NFPA 497 Standard, or API 500 and according to their adaptation by other areas gas zones is given in the current edition of IEC 60079.10. For hazardous dusts, the guiding standard is IEC 61421.10.

Typical gas hazards are from hydrocarbon compounds.

Safe area

An area such as a residence or office would be classed as safe area, where the only risk of a release of explosive or flammable gas would be such things as the propellant in an aerosol spray. The only explosive or flammable liquid would be paint and brush cleaner. These are classed as very low risk of causing an explosion and are more of a fire risk (although gas explosions in residential buildings do occur). Safe area on chemical and other plant are present where the hazardous gas is diluted to a concentration below 25% of its lower flammability limit (or lower explosive limit (LEL)).

      Division 2 or Zone 2 area

This is a step up from the safe area. In this zone the gas, vapor or mist would only be present under abnormal conditions (most often leaks under abnormal conditions). As a general guide, unwanted substances should only be present under 10 hours/year or 0–0.1% of the time.

Division 1 or Zone 1 area

Gas, vapor or mist will be present or expected to be present for long periods of time under normal running. As a guide this can be defined as 10–1000 hours/year or 0.1–10% of the time.

Zone 0 area

Gas or vapor is present all of the time. An example of this would be the vapor space above the liquid in the top of a tank or drum. The ANSI/NEC classification method considers this environment a Division 1 area. As a guide this can be defined as over 1000 hours/year or >10% of the time.

In the case of dusts there is still a chance of explosion. An old system of area classification to a British standard used a system of letters to designate the zones. This has been replaced by a European numerical system, as set out in directive 1999/92/EU implemented in the UK as the Dangerous Substances and Explosives Atmospheres Regulations 2002

The boundaries and extent of these three dimensional zones should be decided by a competent person. There must be a site plan drawn up of the factory with the zones marked on.

The zone definitions are:

            Zone 20

A place in which an explosive atmosphere in the form of a cloud of combustible dust in air is present continuously, or for long periods or frequently.

      Zone 21

A place in which an explosive atmosphere in the form of a cloud of combustible dust in air is likely to occur, occasionally, in normal operation.

Zone 22

A place in which an explosive atmosphere in the form of a cloud of combustible dust in air is not likely to occur in normal operation but, if it does occur, will persist for a short period only.

The Value of 'Fully Rugged vs. Non-Rugged'

As with all major Fortune 500 companies that have large field workforces, the on-going debate is always having a fully rugged solution deployed over a non-rugged device. Organizations that have mission critical applications understand the true total cost of ownership along with the reliability and
up-time of these devices. There is only one mobile computing solution with a 'bumber to bumper' 5 year warranty. This fully rugged device vs a commercial grade pc with only a 12 month warrranty along with the philosophy of buy 'em cheap and stack 'em deep is extremely flawed. Especially from an IT support and maintenance level not to mention having field personnel that routinely experience down-time with commercial grade laptops. Talk about making it very hard for companies to justify operational efficiency without the correct mobile devices deployed or even provided. Now add the fact that you're world operates in an explosion hazard area where a certified device is mandatory. ATEX, NEC and IECEx devices are far and few between, be sure your vendor/supplier has all the world certifications. Thus allowing an employee to operate globally,  whether he's offshore in Louisiana one day or Nigeria the next.

Noise Induced Hearing Loss #1 Occupational Illiness

The other day while gaining access to a plant in Texas I was offered the standard safety orientation. Normally, I carry my own hard-hat and safety goggles but rarely think about hearing protection.

A great business colleague, Pam Cheesman, Sensear - Southwest  Account Executive provided the following;  "Noise Induced Hearing Loss is the number one occupational illness in the world. Communication in high noise is also a big issue, especially in the Oil & Gas industry, due to the high noise throughout the plants. As a result, workers remove their hearing protection to try and hear communication or they have to constantly step away from the noisy area to be able to hear their 2-way radio or cell phone call. The Intrinsically Safe certified headsets (ATEX, IECEx, Class 1/Div 1) are allowing Sensear to provide solutions for this issue globally. In two recent surveys, the results showed that at least 40% of workers lose over 30 minutes a day trying to communicate in high-noise environments."

She further stated, "Our clients that have adopted Sensear into their environment, have seen a huge difference. Workers that used to scream at each other, use hand signals or just not communicate at all until they were in a quieter area, are now communicating much more efficiently, without any delay and in a much safer environment because of the situational awareness that the Sensear headset provides."

When you consider your work environment, especially when exposed to any type of industry manufacturing where high noise is constant, hearing protection should be first and foremost.

Cell Phone Results in Fire and Personal Injury

  Recently, a flash fire occurred on a platform in the Gulf of Mexico OCS Region while a contract panel specialist was working on an open panel that used supply gas for the instrumentation. The contractor was carrying an uncertified cellular phone that was turned on and rang while working on the panel. When the employee flipped the bottom piece of the phone to answer the call, a flash fire occurred causing second degree burns on his forearms and face.

 If your company personnel conduct routine work in explosion hazard areas you have to consider the safety and compliance of those employees within Refineries, Petrochemical, Oil & Gas both Upstream and Downstream, Pipelines, Mining & Pharmaceutical locations. Now that a Class I, Division 1 cell phone is offered on a GSM network along with Global certifications including; ATEX, NEC, IECEx these types of accidents to loss of life and assets don't have to occur.