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STANDARDIZATION OF THE EXPLOSION-PROOFTitle: PROTECTION FOR LOW VOLTAGE ELECTRICAL

MOTORS

Objec To assure the optimal explosion-proof protection type for lowtive: voltage electrical motors, depending on the operational area

Elaborated by: P-EP-DA DM-SS Cristian Preda

Checked by: P-EP-PE FE Nicolae Jugravu

-EP-DA-DM-SS Atif Sheikh b A

rApproved by: P-EP-PE-FE loan Manea

ss.~ile~jrP-EP-DA-DM Ion Anyhel

P-EP-DA Gabriel Selischi/ 91. ,&&~

Organizatia Nume -

In the interest of simplicity and readability, the language of this document isas far as possible gender neutral. Where applicable, the masculineincorporates the feminine.

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STANDARDIZATION OF THE EXPLOSION-PROOF PROTECTION FOR LOW VOLTAGEELECTRICAL MOTORS

Notes for users:A controlled copy of this version is on Intranet Petrom EP. Prior to make reference tothis document, the user must ensure that any other copy is the last reviewed one. Forfurther information, contact the issuer of the document.This document belongs to EP Petrom department. It cannot be disclosed to otherpersons, either partially or integrally, cannot be multiplied, stored or sent by anymethod (electronically, mechanically), cannot be recorded, graphically or in other wayreproduced, without the owners agreement.The users are encouraged to participate in a continuous enrichment of this documentby sending a constructive feedback to the author of document.

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1. ScopeThis standard is applicable for the low voltage electrical motors designed for potentiallyexplosive areas. It determines the type of explosion-proof protection for motors thatmust be used in hazardous environment.

2. IntroductionExplosion prevention and protection are of a crucial importance as explosionsendanger peoples life and health as a result of the uncontrollable effects of flame andblast (hot radiations, flames, pressure waves, projected particles, propelled debris), ofthe chemical toxic reactive substances and of oxygen depletion from air. Furthermore,damages caused by an explosion might be particularly significant in terms ofequipment and plant damage and can affect long term production loss and businessreputation.Oil&Gas Industry operates at high level of risk in regard with the potential explosiveareas.Relative to the electrical motor applications, more than 40% from operations take placein classified areas. Formerly, the explosion-proof motors were prominent because theyseemed robust, could be used in Area 1 and had the best rated turnover in the market.Another reason for the prevailing utilization of explosion-proof motors was also thelimits imposed by that time regulations. As the result of the standard modifications inthe nineties, non-incendiary protection type has been built, especially for Area 2, andthe Exe-increased safety type, has been accepted for Area 1. Based on somecommercial and financial reasons, Exe-increased (non-incendiary) motors should bepurchased against explosion-proof motors, which are much more expensive Its a pitythat some users, for some reasons (including the ignorance), keep on orderingexplosion-proof motors which are much more expensive than the Exe-increased safety(non-incendiary) motors.Furthermore, although the explosion-proof motors seem to be safe, most of themactually lose their ex-proof characteristics after the first intervention.As a consequence of the above mentioned, standardization of the protection types forlow voltage electrical motors designed for potential explosive areas has been decidedas being necessary.

3. Definitions

Zones : Hazardous areas are classified per zones, depending on the frequence andduration of a gaseous explosive atmosphere, as follows:

- Zone 0: An aria where a gaseous explosive atmosphere persists or lasts for along period of time.

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STANDARDIZATION OF THE EXPLOSION-PROOF PROTECTION FOR LOW VOLTAGEELECTRICAL MOTORS

- Zone 1: An aria where a gaseous explosive atmosphere is probable under normaloperational conditions.

- Zone 2: An aria where a gaseous explosive atmosphere is not probable undernormal operational conditions; even if it occurs, it will be seldom and for a shortperiod of time.

Protection types used in this standard:

Increased safety e : protection type comprising some additional characteristics foran increased safety in case of an overheating, flame arc and sparks, under theconditions of a normal operation or under specified abnormal conditions.Relative to this protection type, there are also defined the following:Non-incendiary ,,n: protection type applied to the electrical apparatus to preventignition of a surrounding explosive atmosphere under normal work conditions or undersome specified abnormal conditions.Explosion-proof encapsulation d: protection type where the potential flammableparts of apparatus are placed into an encapsulation reliable for the pressure developedby an internal explosion and able to prevent the explosion propagation to the externalexplosive atmosphere.

Explosion prevention and protection is based on two principles considering thesimultaneous conditions of an explosive atmosphere and an efficent ignition sourceand considering, at the same time, the foreseen effects of an explosion. These twopriciples are:

a) Prevention: To avoid an explosive atmospheres. This objective is mainly achievable by

modification of either the flammable substance concentration to a valueout of the ignition range or the oxygen concentration to a value under thelimit of oxygen concentration (LOG);

To avoid all the actual/potential ignition sources;b) Protection:

To limit the effects of an explosion to an acceptable limit throughconstructive protection actions. Unlike the actions described above, theprobability of an explosion has been considered here.

Risk elimination or mitigation can be achieved either by applying one of the aforesaidprevention/protection principle or by a combination of these priciples.

Protection types can be classified by three categories, depending on the lightingsource and the potential explosive atmosphere, as follows:1. Protection type allowing a direct contact between the ignition source and hazardous

atmosphere (explosion-proof encapsulation ,,d, intrinsic safety ,,i, non-incendiarynC).

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2. Protection type disallowing a direct contact between the ignition source andhazardous atmosphere (oil immersion ,,o, pressurized encapsulation p. sandembedment ,,q).3. Protection type tending (by its own construction) to eliminate the ignition sourceunder specified conditions (increased safety ,,e, non-incendiary ,,nA).

Equipment Protection LevelEPL (Equipment Protection Level), in accordance with the series of standards IEC /EN 60079-xx.Definition:Protection level assigned to equipment, based on the risk of becoming an ignitionsource, categorized per gaseous explosive atmospheres, dust explosiveenvironments and potential explosive environments in coal mines.Ratio between zones, Atex categories and EPL:

For some cases, it was established that the protection type can be divided indifferent protection levels matching to each zone. A better risk assesment shallconsider all factors. Use of the risk assessment instead of an inflexible approach, likeformerly, correlation to the zones with equipment under potential risk of ignition isobviously more profitable, irrespective of the protection type. Since 2007, IECtechnical standards from series IEC 60079 and, especially IEC 60079 part 14, havedetermined that, for some special situations, protection against ignition sourcesmust be increased over the normal levels. This concept can take into considerationthe risk (i.e., explosion consequences), unlike the simple probability of a flammableatmosphere a conventional selection criterium between the protection types andzone of use.

Petrom EP Standard RO-EP-DMSS-STD-046-O1-E

Risk

II

Zone classification Equipment category/levelExplosive Explosion ATEX IEC - EPLconcentration group categoryOften/long High, safe with 2periods defectsOccasional High, safe with 1

defectSeldom/almostnever

1G

II

Ga

Normal II

2G(1G) Gb(Ga)

3G(1G/2G) Gc(GalGb)

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Selection depending on the gas and vapour flash pointElectrical motor type must be selected so that the maximum surface temperatureshall not achieve the flash point of all potential gases or vapours in operatingenvironment. Temperature class shall be marked on the electrical equipmentaccording to the below table.

Ratio between the temperature class, surface temperature and flash point

STANDARDIZATION OF THE EXPLOSION-PROOF PROTECTION FOR LOW VOLTAGEELECTRICAL MOTORS

Under normal circumstances, EPLs effect will be a normal maintenance of the ratiozone/protection equipment. When, despite of all these, risk is deemed morecritical, the required EPL for zone can be increased. Similarly, when the risk isdeemed particularly low or neglectable, EPL can be decreased.Table below shows EPL for each protection type.

Codification DescriptionIntrinsic safety iaIntrinsic safety ibIntrinsic safety ic

Ex-proof encapsulationPressurized

Ex iaEx ibEx icEx dEx p

Ex pxEx pyEx pzEx e

EPLGaGbGcGbGbGbGbGcGbGbGaGbGbGbGc

Ex mEx maEx mbEx oEx qEx n

Increased safetyEncapsulationEncapsulationEncapsulationOil immersion

Sand embedmentNon-incendiary

Temperature class Maximum surface Gas or vapour flash pointtemperature

Ti 450C >450CT2 300C >300C

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T3 200C >200CT4 135C >135CT5 100C >100CT6 85C >85C

4. Standardization of the explosion-proof protection for low voltage motorsIt must be specified that an important percentage of electrical motors, more than 95%from the motors working in classified zones, are placed in Zone 2. Nevertheless, mostof the existing motors are Exd type which is more than necessary. For differentreasons, not the subject of this standard, the Exd motors are requested and usedinclusively for unclassified zones, like PUs with polished rod. For Zone 1 and 2 relatedmotors, the following protection types shall be used under the current regulatoryconditions:

- Exe with EPL Gb for Zone 1; additional protections, required by SR EN 60079relative to use of protection e in Zone 1, shall be applied in parallel;

- Exn with EPLGcforZone2.Exd protected motors shall not be purchased.

In order to not impede the technological evolution, some new explosion-proofprotections that could be manufactured, (like s type, for an attractive price), will betimely considered.

5. Additional requirements for the variable frequency driven ex-proof low voltagemotors

Motors intended to be driven through the frequency converters shall be marked inaddition with the following information:

- For Converter Supply;- Speed range or frequency range over which the machine is intended to be

operated;- Minimum switching frequency;- Type of torque application, e.g., variable torque, constant torque, constant

power; or alternatively the operational torque limits;- If applicable Type identification of specific converter intended.

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STANDARDIZATION OF THE EXPLOSION-PROOF PROTECTION FOR LOW VOLTAGEELECTRICAL MOTORS

In addition, irrespective of the zone (1 or 2), the below mentioned requirements shallbe observed for the following motor types:- Exe with EPL Gb or EPL Gc,

observance of the heat protection conditions; motor and converter shall be compulsory tested together, as an assembly.

- Exd with EPL Gb or EPL Go, observance of the heat protection conditions; provided with temperature sensors included in windings, for a direct

control of temperature; motor and converter test as an assembly is not compulsory.

- Ex nA with EPL Gc, Type test of the motor together with the specified converter, in accordance

with CEI 60079-15:2010.Note: The aforesaid conditions for Exd motors have been presented as additional

information and they do not infrige on decision from section 4 above.

6. Standardization of the ex-proof low voltage motors depending on the temperatureclass

Pursuant to the analysis bulletins for gas and crude conveyed/processed in E&P, as wellas to the data sheets for substance safety (MSDS) related to Ex equipment falling intemperature classes, T3 class (200 DEG C, test gas-Hexane) is deemed satisfactory forE&P crude and gas installations.

7. Standardization principles for the ex-proof low voltage motors depending on theexplosion-proof type

- Economic;- Technical (for converter supply).

8. Advantages and risks- Advantages:

Purchasing prices significantly decreased; almost 20% decrease of capitalexpenses is expected;Cheaper prices related to maintenance;Purchasing prices reduced by attenuation of the types number and bydecrease of the equipment weight.

- Risks:No risk identified.

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9. Actions to be undertaken- Blocking in the system of SAP codes representing motors with Exd protection

type (77 codes);- Blocking in the system of SAP codes representing motors with ExnA protection

type and T4 temperature class (97 codes);- Creation in the system of SAP codes for all the motors with ExnA protection type

and T3 temperature class, in balance with the blocked ones but with T4 class (97new codes).

10.Applicable standards- SR EN 60079 series of Explosive atmospheresstandards- NP 099-04 Regulations for designing, manufacturing, verification

and operation of the electrical installations in areas withexplosion hazard.

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