ALGO Proses Otomasyon

PROSES OTOMASYON

Logo_Mid_Blue_Retina

ex-proof solutions

In industrial facilities where flammable gases, explosive dust or hazardous chemicals are present, these areas are classified as Hazardous Areas. Automation applications in such environments are crucial for minimizing explosion risks and ensuring plant safety.

At ALGO Proses Otomasyon, we have extensive expertise in hazardous area automation solutions and have successfully implemented projects in full compliance with IEC 60079 ATEX and NEC 500 international standards.

Key Considerations for Hazardous Area Automation
1. Proper Zoning Classification

Hazardous areas are divided into different zones for flammable gases and flammable dust:

  • For gaseous environments
    • Zone 0. Areas where an explosive atmosphere is present continuously or for long periods.
    • Zone 1. Areas where an explosive atmosphere may occur under normal operating conditions.

    • Zone 2. Areas where an explosive atmosphere is likely to occur only in case of malfunction.

  • For dust environments

    • Zone 20. Areas where combustible dust is present continuously or for long periods.
    • Zone 21. Areas where combustible dust may occur under normal operating conditions.

    • Zone 22. Areas where combustible dust is likely to occur only in case of malfunction.

Automation equipment must be selected according to these zones with Ex-proof (Explosion-Proof) or Intrinsically Safe (IS) certifications.

2. Proper Selection of I/O and Control Equipment

Sensors, actuators and control systems used in hazardous areas must be designed to prevent explosion risks.

  • Siemens ET 200iSP Remote I/O

    • Suitable for Zone 1 and Zone 2 applications.
    • Ensures safe signal transmission in explosive environments.
    • Provides full integration with PCS7.
    • Modular design allows easy expansion of field devices.

    • One of the few I/O systems that can be installed directly in Ex areas.

  • IS (Intrinsically Safe) Barriers

    • Manufacturers such as Siemens, Pepperl+Fuchs provide IS barriers for signal isolation and energy limitation in Ex areas.
    • Prevents spark generation in hazardous environments, ensuring field devices operate safely.

    • Enables safe transmission of analog, digital and communication signals.

Incorrect I/O selection can lead to spark generation, electrical discharge or explosions in hazardous environments!

3. Proper Cabling and Grounding
  • Cables used in Ex areas must be shielded and have low capacitance.

  • Grounding systems must be designed to prevent static electricity buildup.

Incorrect cabling can lead to signal distortion, equipment failures or even explosions.

4. Use of Protective Enclosures

Automation equipment in hazardous areas should be placed in Ex d (Flameproof) or Ex e (Increased Safety) enclosures.

  • Ex d (Flameproof) enclosures: Contain and extinguish internal explosions without spreading outside.

  • Ex e (Increased Safety) enclosures: Designed to minimize spark risks through enhanced insulation and protection.

Incorrect enclosure selection can lead to non-compliance with ATEX and IECEx regulations!

5. Regular Maintenance and Inspections
  • Ex-proof equipment certifications must be checked periodically.
  • Grounding and connections must be measured and tested regularly.

  • Operators and maintenance personnel must receive appropriate training for working in Ex zones

Neglecting maintenance of Ex devices can lead to leaks, static electricity buildup and ultimately, explosions!

Potential Hazards If Proper Measures Are Not Taken
  • Explosions and Fires – Incorrect equipment or improper wiring can cause spark generation.
  • Production Losses – Failures and explosions can lead to prolonged production downtimes.
  • Environmental Disasters – Chemical leaks and explosions can cause severe environmental pollution.
  • Injuries and Fatalities – Explosions or electrical hazards can put workers’ lives at risk.
ALGO Proses Otomasyon’s Expertise
  • ALGO Proses Otomasyon has extensive expertise in hazardous area automation solutions for the chemical, oil-gas and energy industries.
  • We offer ET 200iSP Remote I/O solutions integrated with Siemens PCS7, ensuring safe and reliable control in explosive environments.
  • Our Functional Safety certified team delivers projects in compliance with IEC 61508 and IEC 60079 standards.
  • We provide ATEX and IECEx-compliant solutions with IS barriers, Ex-proof panels and safe field instrumentation.

 

For safe, efficient and sustainable hazardous area automation projects, contact us today!