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AFPC Electrical Procedures

The document provides recommendations for operating diesel engines safely in hazardous zones. It outlines acceptable protection methods for different ignition hazards, such as using non-electric starters, flameproof electrical equipment, and flame traps on exhaust systems. It also provides maximum surface temperature limits and requirements for cooling jackets, temperature sensors and high temperature cut-outs. The recommendations aim to minimize risks of sparks, static discharge, overheating and overspeeding that could cause fires or explosions in hazardous zones.

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332 views

AFPC Electrical Procedures

The document provides recommendations for operating diesel engines safely in hazardous zones. It outlines acceptable protection methods for different ignition hazards, such as using non-electric starters, flameproof electrical equipment, and flame traps on exhaust systems. It also provides maximum surface temperature limits and requirements for cooling jackets, temperature sensors and high temperature cut-outs. The recommendations aim to minimize risks of sparks, static discharge, overheating and overspeeding that could cause fires or explosions in hazardous zones.

Uploaded by

api-3697472
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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EP 95-0210

5.2.2 Operation of diesel engines in hazardous zones

The Shell standard reference used for operating diesel engines in


hazardous zones is contained in the 'Recommendations for the
Protection of Diesel Engines Operating in Hazardous Areas'
(Ref. ) published on behalf of the Institute of Petroleum. The
recommendations contained in this document were formulated
to provide for the protection of diesel engines when used in
potentially hazardous zones within the petroleum and
petrochemical industries. Details are provided in Appendix V

5.2.3 Electrical safety in hazardous zones


There are many different systems of electrical equipment classification and certification. For the
purpose of uniformity and standardisation the European (CENELEC), UK (BSI) and international
(IEC) are used as the main references for electrical equipment specifications for use in hazardous
zones.

Electrical equipment for use in hazardous zones shall be selected in accordance with the
following criteria:
• the type of protection shall be compatible with the hazardous zone classification
• the surface temperatures of the apparatus shall be lower than the ignition temperature of the
gas and vapours that will be encountered
• the apparatus construction shall be able to withstand the environmental conditions.
APPENDIX V
Operation of Diesel Engines in Hazardous Areas
The following data is taken from the document' Recommendations for the Protection of Diesel
Engines Operating in Hazardous Areas' (Ref. )

V.1 Introduction
There are considerable problems in providing assured protection to diesel engines for use in
hazardous Zones 0, 1 and to a certain extent in zone 2 as defined by the document 'Electrical
Safety' (Ref. ) and by 'Code of Practice for Selection, Installation and Maintenance of Electrical
Apparatus for Use in Potentially Explosive Atmospheres' (Ref. ).

The use of permanently installed diesel engines in Zone 0 is unacceptable, and the use of
permanently installed diesel engines in Zones 1 and 2 should be avoided wherever possible.

Note: The effectiveness of protective devices is dependent upon a high standard of maintenance
and inspection of the equipment; certain items need to be checked regularly.

Table V.1 Recommendations for protection of diesel engines on drilling rigs which are
permanently installed in hazardous Zones 1 and 2

Nature of Hazard Zones 1 and 2


Discharge of sparks from electrical The starter shall be of the following non-electric types: pneumatic,
equipment hydraulic, spring recoil, inertia or hand start.
Any other electrical equipment associated with the engine shall be
flame proof as defined in BS 4683 'Specification for electrical
apparatus for explosive atmospheres', or intrinsically safe as defined in
BS 1259 'Intrinsically safe electrical apparatus and circuits for use in
explosive atmospheres' (see also BS 5345 Part 1: Selection, installation
and maintenance of electrical apparatus for use in potentially explosive
atmospheres).
Electrical equipment shall be effectively earthed and bonded to the
main engine frame.
Discharge of sparks from mechanical Cooling fan blades shall be made from non-metallic materials.
causes
Generation and discharge of static All belts shall be of antistatic fire-resistant type.
from belt drives
Discharge of sparks or flames from the A gas conditioner box and a flame trap shall be installed. Alternatively,
exhaust system the exhaust should be designed to discharge to a location within a 'safe'
zone.
Flashback through induction system Wherever possible, air intakes for engines shall be located in a 'safe'
zone as defined by the Institute of Petroleum Electrical Safety Code.
Alternatively, a flame trap should be provided (Barber valve).
Overheating due to failure of cooling Alarms or automatic shutdown devices shall be provided, actioned by
water system or loss of lube oil excessive water temperature and low lube oil pressure.
pressure
Table V.1 Recommendations for protection of diesel engines on drilling rigs which are
permanently installed in hazardous Zones 1 and 2 (continued)

Nature of Hazard Zones 1 and 2

Excessive engine vibration A system using an alarm or trip device to protect the engine from
excessive vibration should be considered.

Explosions in engine crankcase; An engine having a crankcase volume of over 0.5 m3 shall be provided
discharge from crankcase and cylinder with relief devices. Relief valves, preferably of BICERI design, or
head relief valves and breathers breathers on engines shall be fitted with flame traps or alternatively
discharge into the induction system downstream of the flame trap, if
fitted, and upstream of the shut-off valve, if fitted. Dipsticks and/or
filler caps should be screwed or effectively secured by other means.

Explosions in intake or exhaust Intake and exhaust systems shall be designed in accordance with
systems Appendix 3.3 of the OCMA MEC-1 document.

Flame transmission to atmosphere by Decompression systems should not normally be provided. However, if
opening of decompression pots they are essential, then the decompression ports should be provided
with flame traps and ducted away to a safe zone.

Reverse running of engine The fuel injection pump and governor where fitted should be so
designed that reverse running of the engine is not possible.

Excessive temperature of exhaust The surface temperature of the engine and exhaust system shall not
gases and excessive surface exceed 250°C when tested under full load conditions. In some
temperature of engine and exhaust situations cooling of the exhaust manifold and piping may be
system necessary, using water jacketing or finned coolers and/or high
temperature cut-outs or alarms should be provided.
In this connection it should be noted that air cooled or supercharged
diesel engines generally have significantly higher exhaust temperatures
than water cooled engines.
Conversely, engines operated below their maximum power rating will
have correspondingly lower exhaust gas and surface temperatures.
Given conditions of normal operation, for the majority of refinery and
petrochemical flammables in the regions of natural convection
surrounding the hot surfaces of diesel engines, surface temperatures of
250°C are acceptable.
Exceptions are:
• when free movement of air is restricted by thermal or acoustic
shielding
• when the auto-ignition temperature of the flammable, determined
by ASTM test D2155-66 is below 200oC.
If either of these two conditions exists, no engine exposed surface
temperature shall exceed that determined for the flammable by the
ASTM test.
Note: The IP Code indicates that where the principal mobile
combustible fluid is known to be methane gas, then higher engine
surface temperatures (e.g. 500oC) may be considered acceptable.
Overspeeding of the engine due to A means shall be provided to stop the engine when flammable gas or
induction of flammable gas or vapour vapour in the atmosphere can cause the engine to overspeed.

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