How to choose a sensor in a hazardous environment

The definition of a dangerous environment in Europe includes the oil, natural gas, chemical and process industries, which are operated according to the different regulations of each EU member, and are drafted in strict accordance with EU ATEX clauses. Each EU country translates these terms, and based on these ATEX regulations, it promulgates a set of rules that meet its own requirements.

This set of instructions includes two major parts.

Clause 100a, the product directive, specifies how the device will be used in a potentially explosive environment. This part of the directive contains the concept of explosion protection, but also defines the product, such as how process industry sensors should be set up. The EU Directive 137, published in 1999, is a completely different concept from this one.

As a user directive, Item 137 is quite well known and describes how to deal with worker safety issues in a hazardous environment. The terms describe who should be responsible for safety and describe the process of assuring safe operation. In the directive, three areas of hazardous environment are defined to classify explosion protection. The most dangerous area is defined as zero level. In Zore0, there is a potentially explosive mixture of gases, such as natural gas, steam, or dust, or inside a vessel or pipeline that carries process fluids. Zone1 refers to a potentially explosive mixture environment that is prone to occur during process operations. This grade generally refers to the edge of the storage container, the spill point, or the overflow of the container or the discharge of the stored material. Zone2, which is the lowest level of security, refers to the time when an explosive mixture appears, or only during a certain period of time.

A hazardous environment means that there is a flammable material. The omnipresent oxygen makes it possible to burn and explode. Once the three elements of combustion are in place, dangers can be triggered, such as sparks, flames, or excessive ambient temperatures that can excite danger at any time.

The equipment used in the zone Zone0 must be intrinsically safe so that it does not become a source of ignition. The application of the explosion protection concept is described by the product instructions and appears in the user instructions.

To ensure safety, sensors used in hazardous environments must be specially designed to suit their application environment. The sensor must be of the intrinsically safe (IS) type and it is not sufficient to accumulate enough energy to trigger unsafe factors in a particular environment. IS equipment is usually designed using safety barriers. When any fault occurs, the current flowing through the circuit can be limited to its flow, as well as energy. A passively protected safety barrier can establish a protection mechanism to prevent overvoltages and limit currents.

Another technique is to control the explosion in equipment. Place a non-flammable sensor in an explosion-proof enclosure so that in the event of an accident, the volumetric container can withstand the expected reaction force and prevent further propagation of the explosive force or fire.

The third method is a system method that mixes some inert gas and isolates sensors and other equipment from dangerous areas. There are several different variations of this method, but it is important that these systems introduce non-flammable gases, such as nitrogen, carbon dioxide, and eliminate the entry of combustible materials. In this way, a closed system makes combustible materials impossible to exist, thus enabling safe production.

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