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Page
1
of
15
OC.
NO. KOC-E-004
Pt. 3
REV, 1
I
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KUWAIT
OIL
COMPANY
(K.S.C,}
KOC REGOMMENDED
PRACTICE
FOR
SELECTIOTU,
INSTALLATION
AND
MAINTENANCE
OF
ELECTRICAL
EOUIPMENT
IN
HAZIARDOUS
AREAS
QNTn/NSrC
SAFETÍ
',í',)
DOC NO.
KOC-E-ü)4
Part
3
ISSUING
AUTHORITY:
@
Ø
STANDARDS
DIVISION
7/25/2019 KOC-E-004 Part-3
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KOC
RECOMMENDED PRACTICE
FOR
SELECT¡ON,
INSTALLATION
AND
MAINTENANCE OF
ELECTRICAL
EOUIPMENT
IN HAZARDOUS
AREAS
INTRINSIC
SAFETY
'''
DOC NO.
KOC-E-004
Part
3
Formerly COP-E-OO'î
Part
4
rOC.
NO.
KOC-E-0O4 Pt.
3
REV.
1
age
2
of
15
{
Ø
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l:
TABLE
OF
CONTENTS
TITLE
1.
SCOPE
APPLICATION
TERMINOLOGY
REFERENCE CODES AND
STANDARDS
ENVIRONMENTAL
CONDITIONS
SERVICE CONDITIONS
SELECTION
OF SYSTEMIAPPARATUS
SYSTEM'S
INSTALLATION
REOUIREMENTS
EARTH¡NG
OF
INTRINSICALLY SAFE
SYSTEMS
1O.
INSPECTION,
TESTING
AND MAINTENANCE
1
1.
OUALITY
ASSURANCE
12.
MARKING
13.
DOCUMENTATION
14.
APPENDIX
A
-
INSPECTION SCHEDULË FOR
Ex'i'
PAGE
it
,l
'i
tr
4
{
t
i
1
4
5
6
7
7
8
9
10
10
12
12
13
14
2.
3.
4.
5.
6.
7.
8.
9.
t
T
'1
I
l
ì
t
Í
I
I
t
I
{
¡
I
t
i
(+
REV.
1
age
3
of
15
oc.
No.
Koc-E-oo4
Pt. 3
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1.1
1.2
2.O
APPLICATION
2.1
2.2
This part
of
the
Recommended
Practice
describes
the
specific
requirements
for selection,
installation
and
testing
of intrínsically safe
electrical
equipment and systems to
be used
in
hazardous zones.
It
also
gives
requirements
for
inspection, maíntenance
and
marking
of
electrical
equipment with the
type of
protection
'i'
llntrinsic
Safetyl.
This
RP
{Recommended
Practice) covers
those item
of
equipment
identified
as
Ex'i'with
both
categories
ia
and
ib
and
it
shall be
read-in conjunction
with
Part 1
of this
Standard.
All
equípment
and installations
with
the
type
of
protection
'i'
shall
conform
to
the
requirement
of
th¡s
document,
except
as
modified
or
supplemented
by the
project
specification
or
equipment
data
sheet.
2.3
This document
is issued
in
the following
six
parts:
Part
1
Recommended Practice
for
Selection, lnstallation and
Maintenance
of
Electrical
Equipment
in
Hazardous
Areas:
General
Requirements.
Part 2
Recommended
Practice
for
Selection,
lnstallat¡on
and
Maintenance
of
Electrical
Equipment
in Hazardous
Areas:
Flameproof
Enclosure
'd'.
Pa¡t
3
Becomnpnded
Pnctice
for
&þctÍon,
lnstallation
and lilaÍntenance
of Hectfræl
Eguípmcnt
Ín
Hanrdous
Aræs:
Inaínsic
Mety
'i'-
Part
4
Recommended
P¡actice
for
Selection,
lnstallation
and
Maintenance
of Electrical
EquiÈment
in
Hazardous
Areas:
lncreased
safety
'e'.
Part
5
Recommended
Practice
for Selection,
lnstallation
and
Maintenance
of
Electrical
Equipment
¡n
Hazardous
Areas:
Non-sparking
type
'n'
equipment.
Part
6
Recommended Practice
for
Selection, lnstallation and
Maintenance
of
Electrical
Equipment
in Hazardous
'ot
.
Page
4
of
15
oc.
No.
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REV.
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(,
3.O
TERMINOLOGY
3.1
lntrinsic
Sgfetv
A
protection
technique
based
upon the
restriction of electrical
energy
within the apparatus
and of
interconnecting
wiring, exposed to
a
potentially
explosive atmosphere, to
a level
below
which
can
cause
ignition
by either
sparking
or
heating
effects.
3.2
lntrinsicallv
Safe Circuits
3.3
The
circuits
in
an
electrical apparatus
are
termed
as
intrinsically safe
circuits
if
they
do not
produce
spark
or
thermal
effect
in
the
prescribed
test
conditions
(by
means
of
intrinsic
safe
devices).
lntrinsically
Safe
Syst-ç.m,
Assembly
of
¡nterconnected
items
of
apparatus,
which
may
comprise
intrinsically-safe
apparatus,
associated
apparatus
and
other
apparatus,
and
interconnectÍng
cables
in
which
the circuits
within
those
parts
of the
system
that
may
be
exposed
to
explosive
gas
atmospheres
are
intrinsically-safe
circuits.
3.4
9alegorv ia
Electrical
apparatus
and systems
containing
intrinsically-safe
circuits
that
are
incapable
of
causing
ignition,
with the
appropriate
safety
factors:
o
when
up to
two
countable
faults
are
applied
and,
in addition,
o
those
non-countable
faults
which
give
the
most
onerous
condition.
3.5
Category ib
Electrical
apparatus
and
systems
containing
intrinsically-safe
circuits
which
are incapable
of caus¡ng
ignition
with the
appropriate
safety
factors:
o
when up
to one
countable
faults
is a pplied
and,
in
addition
O
those
non-countable
faults
which
produce
the
most
onerous
condition.
3.6
lntrinsicallv-S.afg
Aoparatus
Electrical apparatus
in
which
all
the
circuits.
DOC.
NO. KOC-E-004
Pt.
3
REV. 1
age
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2
3.7
Associated
Apparatus
Electrical
apparatus in
which
there
are
both
intrinsically-safe circuits
and
non-intrinsically-safe
circuits.
3.8 Barrier
3.9
lsolators
4.2
4.3
4.4
CODES /
STANDARDS
o BS 5345
Part
4
Gode
of
practice
for
Selection,
installation
and
maintenance
of
electrical
apparatus
for use
in
potentially
explosive
atmospheres
(other
than
mining
applications
or
explosive
processing
and
manufacturel.
Electrical
apparatus
and
systems
with
the
type
of
protection
i
lntrinsically
Safe.
o
BS 5501
Part
7
EN
50020
Electrical
apparatus
for.
potent¡ally
lntrinsic
safety
i .
A
simple
passive
or
active
electronic
device
consisting of
diodes/resistors
to limit
energy
to
protect
electrical circuits
in
hazardous
areas.
This device requires
proper grounding.
A
complex electronic
device
to
limit
energy
to
protect
electrical
circqits
in hazardous
areas
without
the
requirement
of
earthing.
This
device
requires
power
supply.
4.O
REEFRENCE_CODES
AND
STANDARDç
4.1
ln
the event
of
conflict
between
this
Recommended
Practice and
the
Codes
referenced
herein, th e
most
stringent
requirement
shall apply
unless
otherwise
specified.
Any
exceptions
or
deviations
from this
document, along
wíth
their
merits
and
justifications,
shall be brought
to
the
attention
of KOC
Gontrolting
Department
for
their
review,
consÍderation
and
amendment
by
Standards
Division
(if
required).
A list
of Godes
and Standards
is
given
below
which
are associated
with
this
Recommended
Practice.
Hourever,
the
l¡st
does
not
prectude
the
use
of
other
technical
source
of information
provided
that
they do not
conflict
with.the
listed
Standards.
Page
6 of
15
OC. NO.
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o
KOC-G-002
KOC
Standard
for
Hazardous
Area
Classification'
.
KOC-|-O11
,* ** r lnstrument
Cables.
5.O
ElìlylRoNltlFNTAt
CONDITIONS
r
BS 55O1
Part
9
EN
50039
Electrical
apparatus
for
potentially explosíve
atmospheres
Specification
for
intrinsically safe
electrical
systems
'i'.
o
¡EC
79-11
Electrical
apparatus
for explosive
gas
atmospheres
lntrinsic
safety
'i'.
.
KOC-E.OO4
PART
1
KOC
Recommended
Practice
for
selection,
installation
and.
maintenance
of
electrical
equipment
in
Hazardous
Areas.
{General
Requirementsl.
The
environment
of
Kuwait,
is severe
on all
equipment
and
must
be
considered
carefulty
before
procurement
of
plant
and
equipment.
lt
must be
assumed
that,
unless
otherwise
specified,
equipment
may
be subjected
to
sand ànd
fine
particle
dust
storms,
salt
laden
winds'
thunderstorms,
heavy
rains,
chemical
contam¡nants
and
extreme
temperatures.
Humidity
can
pose
a serious
problem
with
long
periods
of
relative
humidity level
of
l$Oo/o
being
part
of the
normal weather pattern.
Alletectrical
components
shallbe
designed
for continuous
operation
under
ambient
temperature
of
-3oC
to
+ SOoC
in
the
sunshade.
5.1
5.2
5.3
6.0
SERVICE
COfUDmpNS
G.l
All materials
used
for
etectrical
installation
shall
be new
and
in
all
respects
suitabte
for continuous
operation
under
the
environmental
conditions.
6.2
Reliability
of
all
equipment
to
perform
condítions
specified
is
essential.
Such
reliability
shall
be
substantiated
by
a similar
elsewhere
for
a
minimum
period
of
3
years.
service
nts
use
DOC.
NO.
KOC-E-oo4
Pt.
3
REV.
1
ageT
of 15
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Page
I
of
15
OC.
NO.
KOC-E-004
ft. 3
REV. 1
All
construct¡onal
material
shall
be of hígh
quality
and
as
specified.
Prototype
or
unproven equipment not
having
well-established
record
of
satisfactory service shall
not
be
considered.
7.O
sErEçTroN
oF
sYsfErvl/APPARATlrS
7.1
All
energy
storing apparatus employed
in
a hazardous
area
must
be
selected
to
prevent
the
energy
escaping
and
be
certified as
intrinsically safe
to the relevant
zone,
gas
group
and
gas
ignition
temperature.
7.2
All
ol the
components within
lS circuit
must
be certified
for
use with
each
other
as
well as calculations
performed
regarding cable
capacitance, inductance,
etc.;
in order
to
guarantee the
safety
of
the
entire circuit.
Simple
certification
of
the
individual
components
shall
not be
sufficient.
7.3 Preference
shall be
given
to
use
lS
isolators
which
are not
dependent
on
the integrity of the
earthing
system.
7.4
The
system/apparatus
must
be used
within
the
ambient temperature
límits
for
which it is desÍgned
and certÍfied.
7.5 Simple
apparatus such as thermocouples,
resistive sensors,
LEDs
and
switches
may
be
employed in
a házardous area
without
certification
provided
that
it
does
not
generate
or
store
more than
1.2V,
O.1A
2OuJ
and
25mW.
7.6
Símple
apparatus having a
surface
area
between 2O
mm
square and
1O
cm sguare
will
be
classified
T4 when
the matched
output
power
of
the
interface
devíce does not
exceed:
o
1.3W
into 40oC ambient
a
1.2W into 60oC ambient
)
)
due
to
solar radiation
o
1.0W
into
80oC
ambient
)
7.7
Equipment
identified
Ex ia is suitable
for
all Zones
including
Zone
0
and
the
e{uipment
identified
Ex ib is
suitable
for Zone
I and 2.
6.3
7.4 The
documentation
for
the
system
or
self
contained
intrinsically
safe
apparatus
should
indicate the
category ia for
Zone
O
and
ia
or ib
for
other
Zones.
The
minimum
requirements
for conductor
sizes,
iunction
boxes
and
terminal
and
15.
7.9
units
shall
be in
accordance
with
4
Clause 14
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The
wiring
of
intrinsically safe electrical apparatus
shall
be
of
temperature
class Tl
to
T4
inclusive.
lt
shall be of
copper and
in
accordance
with
the
requirements
of
BS 5501 Part 7.
The
maximum
operating temperature
of
electrical apparatus shallnot
exceed
the
minimum
ignition
temperature
of any
gas,
vapour
or mist
at
intended location
For
guidance
on
the
Hazardous
Area
Classification',
reference shall
be
made to KOC-G-OO2
and
relevant'HAC
drawings
of the
facility.
8.O
SYSTEM'SINSTALLATIONREOUIREMENTS
8.1 For
general
instaHation requirements,
the
Part
I
of
this
document
shall
be referred.
It
is
necessary
to
ensure
that category
of
any
intrinsically
safe
system
or
apparatus
is suítable
for
hazardous
area.
lt is also
important
to
ensure
that
no
obvious damage
has
occurred during
installation.
4.2
8.3 The
installation
of
any intrinsically
safe
circuit
or system
shall
comply
with
the
requireinents
of
appropriate
certifícation
documents-
4.4
Multi-core
cables
of
lntri'nsically
Safe
circuits (lS)
shall
not
be
connected
to
non'lS' circuits.
The
Multi-core.cablesiunction
boxes
etc.,
must
be
dedicated
to
lntrinsícally
Safe
circuits
of
the
same
level
of safety.
8.5
The
cable
parameters
for'lS'círcuits
shall
meet the
requirements
of
KOC-I-ol
1.
8.6
The
method of
cable
entry
shall
preserve
the degree
of
protection
of
intended
location.
8.7
The
cabte
shall
be
supported
to
its
near
point
of
entry
to
the
equ¡pment
to
prevent
any
stress
on
conductor
termination.
7.10
7.11
7
-12
8.8
8.9
The
terminals
for intrinsically
safe
circuits
shall
be
segregated
and
identified
clearly
from
terminals
of
non-intrinsically
safe
circuits,
and
separation
shali meet
the
requirements
of IEC 79-11
The
terminals
for
externat
wiring
and
where
connections
to
plugs
and
sockets
are not
prefabricated
dur¡ng
manufacture'
then
it
shall
comply
w¡th
¡EC
79-11
subclause
6.3.1
and 6.3.2.
8.10
Where
intrinsically
safe system
or
associated
is
fitted with
more
than one
plug
and
socket
for
connections
it
shall
be
ensured
that
possible.
The
matÍng
plugs
& sockets
sha
or
colour
coding
preferably
blue.
internal
is
not
marking
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8.11
Cells,
batteries and accumulators whích
require current
limiting
devices
for safety
and intended to
be
used
in
hazardous zones
shall
be encapsulated or enclosed
with
the
current limiting
devices ín
such
a
way
that
any
conductor
or
terminal,
other
than
output
and
recharging
terminals
shall
not be accessible.
8.12
The
installation shall
be
inspected
for
complíance with
the
specifications and requirements
of
the relevant documentation
particularly
if the
special
installation conditions
are described.
9.O
EARTHTLG
OE
INTRIñISICALLY
SAFE_SJSTEMS
9,I
Where the earthing of enclosures, conductors,
metal
screens,
printed
wiring
board
conductors,
segregation contacts
of
plug-in
connectors
and
diode
safety
barriers
is
required
to
maintain
the type
of
protection,
the
cross-sectional
area
of any conductors,
connectors
andlerminals
shall
be capable of
carrying
rated
current.
9.2
The
minimum cross-sectional area
of conductor
used
for
earth¡ng
connections
should be equivalent to
a
copper
conductor
of
4
mm
square.
9.3
The
conductor
used
for
the
earth
connect¡on
should
be
insulated to
prevent
interference
of earth by fault current
which
might
flow in
metallic
parts.
9.4
The earthing
conductor
shall
be
given
extra
mechanical
protection
in
places
where
the
risk
of damage
is high.
9.5
The
impedance
between the barrier
earth
busbar
and the
point
of
connection
to
the
main
power
system
earth
shall
be
maintained
less
than
1 ohm even if a separate
earthing rod has
to
be
used
for
preserving
the integrity of intrinsically safe
system
(e.g.,
a diode
safety
barrier
earth,
a
transformer screen
earth,
a barrier
relay frame
earth
etc.).
9.6
The
integrity of
earthing
system
shall
not
be
affected
by
inadvertent
removal
of
a
plug
when
the
earthing
connection
is
made via
iunction
boxes,
plugs
and. sockets.
9.7
Where
diode safety
barriers
are
used,
care
shall be
taken to
ensure
that
barrier device
for intrinsically
safe
system
is
in accordance
with
BS
5345 Part
4
Clause 17
and system
documentation
A separate
lS
earthing
shall be needed
where barriers
are
in
use.
1o.O
lilsPECnON,
TESilNG
¡\ND
MAINT EIfANCE
1O.1
The
generalrecommendations for
inspection and given in
Part 1 of this
document that apply
equipment
or
installation
in hazardous
zo
inspection
and testing
requirements
for
protection i
ate
given
below:
t
nal
of
É,
REV.
1
age
1O
of
15
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NO.
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ñ
ú
2
,
:
I
10.2
10.3
14.4
10.5
10.6
10.7
Any change
in
area
classification
or
process
changes
on a
plant
should
be
immediately
followed by an initial
inspection
of
allaffected
systems,
to
ensure
that
intrinsically
safe
systems
and
apparatus
remain
suitable
(Refer
to
lnspection
Schedule
Appendix
A).
After
any
repair
or modification to
a
piece
of
equipment,
it shall
be
inspected
to
ensure its compliance
with
the
system
documentation
before
it is
reinstalled.
Regular
inspections
shallbe
carried
out
by
properly
trained
personnel
to
rninimize
the
risk
of
an
intrinsically
safe
system
or
apparatus
acting
as
a
source of
ignition
due
to
accidental
damage
or
unauthor¡zed
interference.
Guídance
for initial
and
periodic
inspections
is
given
in Appendix
A.
Sucli
inspections
shalt
be carried
out at least
once
every two
years.
More
frequent
inspections
may be
justified
for installation
in
particularly
arduous environmental
conditions.
A
dossier
should
be
retained
with
all
design
certification
available
to
which
the
inspection
and
tests records
are added
to.
This shall'be
held
by the
maintenance
Department
responsible
for the
equipment.
lntrinsically
safe
equipment,
assoóiated
apparatus
or
installation
shall
be
subject
to
a
type
test by the
manufacturer
to
ensure
that
intrinsically
safe circuits
are
incapable
of causing
ignition under
the
condition
specified
for
the
appropriate
category
of
electrical
equipment
and the
appropriate
grouping.
The
exemptions
from
this
test
may
be made for
the
circuits
only
in accordance
with
BS
55Ol
PartT
Clause 9
=
(EN
50020).
t
f
t
3
10.8
tntrinsically
safe
system
or
self
contained
electrical
equipment
be certified
and installed
in
accordance
with
the
requirements
of
its-
certificate.
10.9 A
proper
record
shall be maintained
for
all
intrinsically
safe
systems
and
setf
contained
intrinsically
safe
electrical
equipment
showing
results
of inspections
and tests.
ln
addition,
all
act¡on
taken
to
correct
defects
during
inspections shall
be recorded.
10.10
Where
compliance
with
the
appropriaté
documentation
cannot
be
demonstrated
by
physical
inspections
after
installation,
electrical
testing
shalt
be
carried
out in
accordance
with
BS 5345
Part
4
Clause
21.
10.1
1
lf
any self
eontained intrinsically
safe
equipment
is
removed'for
maintenance,
all exposed
cohductors
shall
be
secured
and
electrically.
lt shall
be ensured
that
maintena
s
not
reduce
the
level
of
safety achieved
by
I
oc.
No. Koc-E-oo4
Pt.
3
REV.
1
age
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15
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I
10.12
Only
certified,
relevant
and specified
test
instruments
shall
be
used
for
maintenance
work
at
hazardous
locations.
Where
certified
instruments aie
not
available,
the
'Hot
Work Permit' system shall
be
implemented.
The
site
maintenance
work
shall be
restricted
to
the
following:
o
Disconnection, removal
or
replacement
of items
of
electrical
apparatus
and
cabling.
o
Adjustment
of
any controls
that
is
necessary
for the
calibration
of
the
electrical apparatus
or system.
a
Removal
and
replacement
of
any
plug-in
components
or
assemblies.
I
Any
other
maintenance
activity specifically
permitted
by the
rêlevant documentation.
11.O
OUAUTY
ASSUBAIì|CE
11.1
The
manufacturer
shall operate
a
quality
system
which
ensures
that
the
requirements
of this Standard
are
achieved.
The
quality
system
shall
preferably
be based
on
lS0
9000
series of
standards
and the
manufacturer
shall
demonstrate
compliance
by
providing
a copy
of
the
accredited
certificate
or
thè
manufacturer's
quality
manual.
Verification of the manufacturer's quality system
is
normally part
of
the
pre-qualification
procedure,
and
is
thereiore
not
detailed
in
the
core text
of this
Standard.
12.A
MARKING
12,1
tntrinsically
safe
electrical
apparatus
and
associated
components
shall
carry marking
on
the
main
part
at
a visible
place.
The
shall
include:
o
The
name of the manufacturer
or his
registeled
trade
mark.
I The manufacturer's
type
of
identification.
a
The
sígn for
type
of
protection
and
category
Ex'ia'
or
Ex
'ib'or
with
additional
letter
'E'.
o
The
group
of electrical
apparatus.
o
Maximum
surface temperature.
o
Serial
Number.
o
Certification
reference.
o
lnstallai¡on
drawing No.
.
The
mark X,
if
applicable.
2
*
'Í
ü
ÉR
REV.
1
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OC.
NO.
KOC-E-004
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Ø,
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9.
8.
7
6.
5
4.
Sealing
of
trunkíng,
ducts,
pípcs
and/or conduits is satisfactory.
Earth
continuity
¡s sat¡sfactory
le.g.
connections
are
tight
and
conductors
are
of
sufficient
crosstection
and
in
accordance
with
clause 8.O.
The intrinsically
safe
circuit
is isolated from earth or earthed
st
ono
po¡nt
only
(rofer
to
documentation).
Separation
b
ma¡nta¡nod
betweên lntrinslcally
safo
and
non-intrinsically
safe
z.
.ï
o
o
t
a
o
a
a
ô
o
All
point-topoint
connections
are correct and
t¡ght.
circuits.
of
the
type of
protection.
arth connections
maintain the
3
a
here is no
obvious damage
to
cables.
2.
O
o
Cable
screens
are
earthed
ln
acco¡dance w¡th
tho
documontat¡on.
B
1
a
a
INSTATLATION
Cables are
installed
ln
accordance
with
the documentatlon.
11
a
ype
of
lamp
and
rating
are appropriate as
specifiad in the documentation.
10
a
ype
of
fuse
and rating are appropriate.
o
9
a
rinted
circuit boards
are clean
and
undamaged.
I
o
lectrical
connections
are
tight,
7
o
Safety
barrie¡
units, other energy limiling
devices and
field devices
are
of
the
approved
Çpe,
lnstalled
in
accordance
with
the cort¡f¡cation
raquirements
and
securely earthed
where reguired.
b
o
here
are
no
unauthorized modifications
o¡ visible damage.
5
a
nstallation
is clearly
labelled.
4
t
urface tsmpsrature
class
is corrsct.
3
a
ircuit
and/or a¡iparðtus category
and
group
is
correct.
2
a
Apparatus
installed
is
that
specified
in
the documentation
-
Fixed apparatus
only
O
APPABATUS
Gircuit
and/or apparatus
documentation is
appropriate
to
area classification.
A.
tt
v
It
c
t
D
Grade
of
Chock that:
APPENDIX A
INSPECTION
SCHEDULE FOR
Ex i
Legend:
D
=
Detailed, C
=
Close,
V
=
Visual,
o
=
Applicable
Õ
=
lnitial
*
=
Periodic
REV. 1
age
14 of 15
DOC.
NO.
KOC-E-004 Pr. 3
ffi
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APPENDIX
A
Cont..
¡NSPECTION SCHEDULE FOR
Ex'i'
Legend:
D
=
Detaìled, C
=
Close,V
=
Visual,
r
=
Applicable
*
=
lnitial
*r
=
Periodic
\,ê
\
a
No
undue external
accumulation
of dust
and
dirt.
O
ENVIRONM.ENT'
Apparatus is
adequately
protected
aga¡nst corrosion,
weathet,
vibration
and
other
adverse factors
c.
1
apacial
conditions
ol
use
(if
applicable)
arc compliad
wlth.
1.
a
s
applic¿blo,
3hort-c¡tcu¡t
protection
of the
powor
supply
is
in accordanco
with the
documentation.
10.
¡a
V
aa
c
o
D
Check
that:
Grade
of
lnspection
,Í
u
Page 15
of
15OC. NO. KOC-E-004
Pt. 3
REV.
1