CABLE ENTRIES IN HAZARDOUS AREAS CORRECT SELECTION, INSTALLATION AND MAINTENANCE
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1 CABLE ENTRIES IN HAZARDOUS AREAS CORRECT SELECTION, INSTALLATION AND MAINTENANCE Compiled by: Arthur Cameron
2 NOT SO CORRECT SELECTION AND INSTALLATION OF CABLE GLANDS AND JUNCTION BOXES IN HAZARDOUS AREAS
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9 INCORRECT INSTALLATION AND MAINTENANCE
10 INCORRECT INSTALLATION AND MAINTENANCE
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13 HREAD SELECTION NPT METRIC
14 THREAD DIMENSION CHART
15 SELECTION Factors to consider when selecting cable glands: Dimensional, Mechanical, Constructional, Environmental factors. Cable: Type of cable, armoured or unarmoured? Sizing over the inner sheath and outer sheath. Shape and construction of the cable. Is the cable round, filled and non hydroscopic?
16 IEC SELECTION OF CABLE GLANDS START YES Does the hazardous gas require IIC apparatus? YES NO Does this enclosure contain an internal source of ignition? NO Use a suitable flameproof cable entry device with a sealing ring. (Gland with Elastomeric Seals) Apply YES Is the area of installation Zone 1? NO d) or e) YES Is the volume of the enclosure greater than 2dm 3? NO
17 IEC SELECTION OF CABLE GLANDS d) flameproof sealing device (for example a sealing chamber) specified in the equipment documentation or complying with IEC and employing a cable gland appropriate to the cables used. The sealing device shall incorporate compound or other appropriate seals which permit stopping around individual cores. The sealing device shall be fitted at the point of entry of cables to the equipment; e) flameproof cable gland, specified in the equipment documentation or complying with IEC , incorporating compound filled seals or elastomeric seals that seal around the individual cores or other equivalent sealing arrangements;
18 Problems With Cable Construction: In order to comply with the installation codes of practice, cable glands using elastomeric sealing rings should only be used on cables that are substantially round, compact with an extruded bedding and have non hygroscopic fillers such as Figure 1. However this cable construction is not always possible especially when it comes to multi core cables. Figures 2 and 3 show cables that should not be used with glands with elastomeric sealing rings. Interstices Figure 1 Figure 2 Square not round Figure 3
19 roblems With Cable Construction: Has extruded bedding but not filled Extruded bedding and filled
20 Selection IEC Section 9.3 States: NOTE: Where enclosures are likely to be subjected to large variations in ambient and/or service temperature conditions, a pumping action can transfer the fluids from the hazardous atmosphere through cables which are not substantially compact. Similarly cables with non filled interstices or with hygroscopic fillers (e.g. fiber fillers), may transmit flammable fluids through the interstitial spaces of the cable under capillary or hygroscopic action with sufficient partial pressure to exit the cable termination at the extremities of the cable. Particular caution is drawn to the use of electro-pneumatic transducers and the like which employ natural gas as their pneumatic medium. When such cables link between a hazardous and non-hazardous area this may result in a flammable atmosphere being transported to the inside of, for example, control room equipment. The situation is likely to be most acute with equipment installed in a Zone 0 or Zone 1 location (where the presence of a hazardous atmosphere has a greater likelihood and duration). If these conditions are likely to apply, a cable sealing device (which seals between the inner sheath and the individual conductors) should be used. Therefore it has been established that if unfilled cable is used explosive gases or liquids can migrate down the interstices of a cable from a hazardous area into a safe area.
21 An explosion in the Ex d enclosure can propagate down the interstices of the cable causing damage to the cable as well as forcing pressure into a non certified enclosure. Hazardous Area Zone-1 Safe Area Exd
22 Barrier Gland Construction ENTRY THREAD COMPOUND SLEEVE/ CHAMBER CABLE ARMOUR CLAMP OUTER IP SEAL
23 hen To Use Barrier Glands? ere cables enter into Ex d equipment directly, the cable system shall comply with e standard goes on to say in note 2 under 10.4 as or vapour migration and propagation of flame may occur through the interstices between the strands of standard stranded conductors, or between individual cores of a cable. Special cable construction can be employed as means of reducing migration and preventing the propagation of flame. Examples include compacted strands, sealing of the individual strands, and extruded bedding..4.2 outlines the selection process for cable gland for Exd equipment as follows:.4.2 Selection of cable glands e cable entry system shall comply with one of the following: Cable glands in compliance with AS/NZS and certified as part of the equipment when tested with a sample of the particular type of cable; where a cable has thermoplastic, thermosetting or elastomeric insulation and is substantially compact and circular with extruded bedding and fillers that are non-hydroscopic; a flameproof cable gland, in compliance with AS/NZS , may be utilized, providing this incorporates a sealing ring and is selected in accordance with Figure 2
24 Gas Explosion incident : At 8pm on monday12 January 2004, the South East Australian Sea Gas System Control centre received an alarm. A water heater installed at the Torrens Island facility had failed. Investigations revealed that a gas explosion had taken place inside the heater control panel located outside of the classified area. HOW COULD THIS HAPPEN?
25 Gas Explosion Incident: Buckled enclosure door and broken latches due to explosive forces. Further investigation revealed that gas had migrated along the cables from field instruments in the classified area and significantly also passed through the epoxy filled barrier glands and accumulated inside the control panel. This gas was ignited when the cooling fan inside the panel activated, thus causing the explosion.
26 The Cause: Badly Installed Barrier Glands: Barrier compound installed incorrectly Compound hasn t bonded to the cable insulation leaving voids for gas to pass through.
27 ime taken and Risks of Installing Epoxy Putty Barrier lands: For a number of years installers in hazardous areas have been relying on barrier glands with two part epoxy based putty as a way of effectively stopping explosive gasses and liquids from diffusing down unfilled cables. Whilst effective once properly installed, the problems with the two part putty based compound have always been the time taken to mix the putty and then insert and pack between the cables voids and into the barrier gland chamber. The mixing process can take several minutes depending on the volume of putty required and has always been subjective as the putty is only properly mixed when the two parts are hand moulded into an even colour.?
28 Time taken and Risks Of Installing Epoxy Putty Barrier Glands: The insertion of the putty between the individual cores of multi core cable is not only time consuming but there could be additional risks in that the putty may not have been inserted and packed correctly which results in the potential of voids and gaps for gas or liquids to migrate through. In addition once the putty has been inserted between the cable cores and the barrier chamber, the time taken for the putty to harden can be up to several hours. Because of these installation problems barrier glands have always required special skills from the installers and particular attention from inspectors.
29 100% Effective Gas Barrier :
30 Installation Codes and Standards Environmental Conditions and Risks. Equipment Construction and Protection Techniques Cable Type and Size Entry Size and Thread form of the Equipment.
31 INSPECTION and MAINTENANCE Surface Industry: (a) Initial Inspections:- These inspections are directly related to required inspections before equipment will be commissioned for the first time e.g. on cable glands checking that the marking and certification is correct, checking tightness and that all components have been correctly fitted and not left out. (b) Periodic Inspections:- It stipulates that the interval between periodic inspections shall not exceed two years, and shall be shorter if the deterioration of the apparatus could influence explosion protection sooner. c) Sample inspections:- Sample inspections are inspections of a portion of the installed apparatus. This can be visual, close or detailed. The size and composition of all samples should be determined taking into account the purpose of the inspection. The result of all sample inspections should be recorded.
32 GRADES OF INSPECTION VISUAL INSPECTION: Visual inspections take note of all defects which can be determined by a visual approach either from the ground or from permanent access platforms, without the use of hand tools, without switching off and without climbing or using ladders. Binoculars and remote heat detecting equipment may be useful in some situations. In the case of a cable entry device no dismantling is required.
33 GRADES OF INSPECTION CLOSE INSPECTION: Close inspections determine where any defects, including those detectable visually, may be detected without removing power. This may involve the use of some tools, ladders and other access mediums. In the case of a cable entry device a general check on tightness is required.
34 GRADES OF INSPECTION DETAILED INSPECTION: Detailed inspections are also carried out at major shut down periods, normally on a sample basis. They include the disconnection of power and include opening up equipment. Access equipment, tools and test equipment may be used. In case of a cable entry devices: check tightness of cable glands (using a tool). If the gland corrosion is a possibility, partially dismantle the gland to check the earthing of cable armour onto the gland.
35 WE ARE ALL IN THE BUSINESS OF PREVENT
36 QUESTIONS
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