4.

2 Operation of diesel engines in hazardous zones

The contents of this chapter is based on an OCMA specification No. MEC-1 published on
behalf of the Institute of Petroleum [6].

There are considerable problems in providing assured protection to diesel engines for use in
zone 0, 1 and to a certain extent in zone 2 (BS 5345 PART 1). The use of permanently
installed diesel engines in zone 0 is unacceptable, and the use in zones 1 and 2 should be
avoided wherever possible. If the diesel engine is adequate and efficiently protected to all
electric, hot surfaces, exhaust systems, etc. they may be located in zone 1 and 2. Normally
these protection include the provision of an air source from an non-hazardous zone. However
if this is impracticable, the engine shall be fitted with an automatically operated combustion
air cut-out to prevent engine runaways in the event of flammable vapour ingestion.

Mobile diesel-engined equipment should preferably not be used in a hazardous zone, but if
this is unavoidable it should be fully protected as for fixed diesel installations or have a
minimum of protection and operate under a permit-to-work system. The minimum protection
should be spark arrestors, hot surface cooling and, in addition for zone 1, an automatic air cut
-off.

The following recommendations (table 9) are made for protection of diesel engines on drilling
rigs which are permanently installed in hazardous zones 1 and 2.

Nature of hazard Zones 1 and 2

Discharge of sparks from
electrical equipment
Discharge of sparks from
mechanical causes
Generation and discharge of
static electricity from belt
drives
Discharge of sparks or
flames from the exhaust
system
Flashback through induction
system
Excessive temperature of
exhaust gases and excessive
surface temperature of engine
and exhaust system
Starter:pneumatic, hydraulic, spring recoil, inertia or hand start.
Any other electrical equipment associated with the engine shall
be flameproof (BS 4683) or intrinsically safe (BS 1259).
Electrical equipment shall be effectively earthed and bonded to
the main engine frame.
Cooling fan blades shall be made from non-metallic materials.
All belts shall be of anti-static fire-resistant type.
A gas conditioner box and a flame trap shall be installed.
Alternatively, the exhaust should be designed to discharge to a
location within a safe zone.
Wherever possible, air intakes for engines shall be located in a
safe zone. Alternatively, a flame trap should be provided (Barber
valve).
The surface temperature of the engine and exhaust system
shall not exceed 250°C when tested under full load
conditions. Exceptions are when free movement of air is
restricted by thermal or acoustic shielding and/or when the
Nature of hazard
Overspeeding of the engine
due to induction of flammable
gas or vapour
Overheating due to failure
of cooling water system or loss
of lube oil pressure
Excessive engine vibration
Explosions in engine crankcase; A crankcase volume over 0.5 m3 shall be provided with relief
discharge from crankcase and
cylinder head relief valves
and breather
Explosions in intake or exhaust Intake and exhaust systems shall be designed in accordance
systems
Flame transmission to
atmosphere by opening by
opening of decompression
ports
Flame transmission to
atmosphere by opening by
opening of decompression
ports
Reverse running of engine
Zones 1 and 2
auto-ignition temperature of the flammable, determined by
ASTM test D2155-66 is below 200°C. (mobile combustional
fluid: methane gas than the engine surface temperature is
higher 500°C)
A means shall be provided to stop the engine when
overspeeding is caused by flammable gas or vapour.
Alarms or automatic shutdown devices shall be provided,
actioned by excessive water temperature and low
lube oil pressure.
An alarm or trip device to protect the engine from excessive
vibrations should be considered.
devices. Relief valves, preferably of BICERI
design, or breathers on engines shall be fitted with
flame traps or alternatively discharge into the
induction system downstream
of the flametrap, if fitted, and upstream of the shut-off valve, if
fitted. Dipsticks and /or filler caps should be
screwed or effectively secured by other means.
with Appendix 3.3 of the OCMA MEC-1 document.
Decompression systems should not normally be provided.
However, if they are essential, then the
decompression ports should be provided with
flame traps and ducted away to a safe zone.
Decompression systems should not normally be provided.
However, if they are essential, then the decompression ports
should be provided with flame traps and ducted away to a safe
zone.
The fuel injection pump and governor where fitted should be
so designed that reverse running of the engine is not possible.

Table 9. Recommendations for protection of diesel engines in hazardous zones (OCMA

MEC-1).

Rigs which have been designed and equipped with diesel engine power supply to the
drawworks, rotary table and mud pumps according to API RP 500B do not always comply
with hazardous zone restrictions as defined under the IP Code.