Continuous Earth Monitoring System with Resistance Value Display

Now Certified for Gas Grouping IIC also

Model No.: CEMS-20-RM-0521
Use: To Monitor Earthing of 20 Equipment

Introduction

It is a well-known fact that friction created by any means will generate “Static Charges”. These charges if not dissipated to earth will result in Static Charges accumulation and subsequent Electro Static Discharge. The ESD may cause Fire and Explosions.

Pharma & Chemical Units

In Pharma & Chemical units, equipment such as Reactors, Centrifuges, Driers, Shifters, etc., are used continuously for 24 Hrs. in a day to manufacture different products. During the running of the above equipment, Static Charges are developed due to friction. All the equipment’s are to be earthed by means of earthing strips. Since equipment’s are running 24 hrs, the earth connections need to be healthy 24/7 to dissipate the Static Charges developed.

Read more

Constraints in Monitoring Earth Connections

The duty of checking earth continuity of the equipment is normally assigned to the electrical department. Due to limited manpower in the department, monitoring earth connections on daily basis is not practicable. The Earth connections are normally checked once in 3 months or 6 months. Any loose contacts are defects in earth connections goes unnoticed during these intervals.

Why less than 10.0 Ohms threshold? As per IS-7689/IEC-TS-60079-32-1, metallic items in good contact with earth should have a resistance to it of less than 10.0 Ohms. Although a value of up to 1.0 M Ohms is acceptable for static dissipation values above 10.0 Ohms may give an early indication of developing problems (e.g., corrosion or loose connection).

Need for designing Continuous Earth Monitoring System

Mr. P.V.Vidyadhara Rao (Proprietor) is an ESD Trainer and Certified ESD Auditor. During the ESD Audits, he noticed a safety gap in equipment earth connection monitoring and envisaged a need for a continuous earth monitoring system to fill this safety gap. Based on his findings and recommendations our Technical Team has designed and developed a continuous earth monitoring system CEMS-20-RM-0521 to fill the gap and reduce workload on electrical personnel, and continuity in the safety through the production schedule.

A key function of equipment Earthing is to provide a controlled method to prevent the buildup of static electricity, thus reducing the risk of electrical Discharge in Potentially hazardous environments. The Electrical resistance from the equipment to Earth should be 10.0 Ohms Maximum. This electrical resistance values are to be maintained continuously as per IS: 7689.

The system CEMS-20-RM-0521 monitors resistance value to Earth and any fault will be indicated by a RED LED and Audio Signal. The system monitors every equipment one after another with an interval of 5 seconds. The system draws the attention of the personnel to take remedial action should a fault arise in equipment earthing.

CEMS-20-RM-0521 has provision to monitor 20 Nos. of equipments, and comes in a flame-proof enclosure. Equipment to earth loop is measured by intrinsically safe voltage & current and this precision source has microcontroller-based switching.

CEMS-20-RM-0521 is a Ex-Certified System as per

IS/IEC 60079-0 : 2017, IS/IEC 60079-11:2011

It is a Ex Safety Certified Instrument Bearing Certification No. KLPL/Ex/16-014X, Issue No. 1,
Dated: 30/03/2023 for IIB.

It is a Ex Safety Certified Instrument Bearing Certification No. KLPL/Ex/16-014X, Issue No. 2,
Dated: 23/06/2024 for IIC.

INTERFACE UNIT AT SAFE AREA

Safe Area Unit: Located in safe area (Switch Gear Room)

I. ELECTRICAL SPECIFICATIONS:

1. Power Input:230V ~ (AC Mains)

2. Total Load: Approx. 6 Watts. Total System

3. Cable Entries: As given in System Block Diagram

4. Input Connection: 1). Mains 230 Volts input connection Cable Entry-1.

Type of Cable: 0.5 to 1.5 Sq.mm 3 Core PVC Cable.

Output Connection:  2). 12 V DC.

Type of Cable: 1.0 to 1.5 Sq.mm 2/4 Cores Flexible Armoured Cable.

  • Wire 1 Red + 12 Volts.
  • Wire 2 Black 0 Volts.
  • From 2-way terminal with marking of Polarity + and – near 2-way terminal block

In case of 4 cores cable wire 3 and 4 not used.

Read more

5. Enclosure: Non- FLP MS Box (Safe Area Unit)

6. Mounting: Wall Mounting by Four M8 x 25 Screws on extended fixtures.

2. MECHANICAL SPECIFICATIONS:

1) Dimensions: 165 x 240 x 90 mm

2) Material: M.S. Powder coated. 

3) Weight: 3.0 Kgs.

III. ENVIRONMENTAL:      Operating Temperature Range: – 100 to 500

TECHNICAL SPECIFICATIONS

FLP Unit at Hazardous Area

ELECTRICAL SPECIFICATIONS:

1. Power Input: 12 V DC through wires 1 & 2, 2/4 Core 1.5 Sq.mm flexible armored Cable As indicated in safe area unit.

2. Load: 6 Watts.

  •  Wire 1 Red + 12 V DC
  • Wire 2 Black – 0 V DC
  •  Wire 3 and 4 not used in case of 4 core cable.

3. Cable Entries: given in System Block Diagram.

4. Operational Switches:

  • Reset Switch
  • Hold Switch
  •  Release Switch

5. Operational Indications:

  • 1 to 20 Channels channel wise Nos. Indication by Two 7-digit LED DISPLALY, Yellow Colour.
  • Earth loop check (less than 9.5 Ohms) 10.0 mm Green LED. Fault greater than 9.5 Ohms 10.0 mm Red LED.         
  • Earth loop resistance value display. Channel Wise by 2 ½ Digit 7 Segment Digital Display Blue Colour. Reads 20.0 Ohms. 19.99 Ohms Max and 1-.- for greater than 20.0 Ohms. Display tolerance +/-5% system built-in Resistance 0.4 Ohms. +/- Digit.
  • Faulty channel Nos. registration by 5.0 mm Red LEDs 1 to 20.
  • Scanning time for each channel 5 Seconds (Adjustable 3 to 5 Seconds).
  • Faulty channel audio indication by Buzzer.

6. Intrinsically Safe Outputs: 1 – 20 – Lines to Equipment for Earth Loop Check and inputs 2 lines to Earth Pits.

7. Enclosure: FLP (Zone-1)

8. Mounting: Wall mounting by four M8 x 25 screw On extended fixtures.

MECHANICAL SPECIFICATIONS:

Main Console:  

  • FLP Enclosure 250 x 250 mm,
  •  Flame proof Window 96 x 96 mm glass window.
  • Flame proof and Weather proof as per IP 66.
  • Aluminium Alloy LM Casting – 8.00 Kgs.

Junction Box:

a) Material:S. Junction Box.

b) Dimensions:180 x 220 x 60 mm

c) Weight:0 Kgs.

FLP and SS Junction Box fitted on SS Sheet 320 x 620 x 2 mm thickness with mounting holes.

III. ENVIRONMENTAL:     

Operating Temperature Range: – 100 to 500

Material requirement for Installation of CEMS-20-RM-0521

(Under your Scope)

1.  0.5 to 1.5 Sq. mm Copper Multi-Strand 3 core P.V.C Cable. For connecting 230 volts main supply to safe area unit in switchgear room through M.C.B 2 Amp, Length as required. Typical – 10 to 15 meters.

2. 1.5 Sq. mm Copper 2/4 core flexible armored cable. For Connection 12 Volts D.C Supply from safe area unit to main FLP Unit in hazardous area (Process Plant), length as required.

3.  0.5 to 1.5 Sq. mm, multi-strand P.V.C Wire for Earth Loop check connections Length as required.

4. 2 Nos. 4.0 Sq. mm, Copper multi-strand P.V.C Wire for connecting corresponding earth pits to the junction box, length as required.

Read more

Your Scope of Work & Supply

1. The Earth Pit resistance pertaining to equipment grounding is to be checked and maintained as low as possible.

 2. The equipment earthing is to be thoroughly checked and a report on existing resistance values of equipment to Earth Pit for each equipment to be furnished to us prior to installation.

3. 1.5 Sq.mm copper flexible 3-core PVC Cable unarmored is to be provided in the switchgear room to the safe area unit.

4. 1.5 Sq.mm copper multi-strands flexible 2/4 Core armored cable from the safe area unit to the CEMS unit in the Hazardous area is to be provided.

 5.  1.5 Sq.mm Copper multi-strand PVC wires to be provided from main CEMS unit to every equipment body. 1 to 10 and 11 to 20 Nos. These wires are to be laid on cable trays.6. Two numbers of 4.0 Sq.mm copper multi-strand flexible P.V.C wires From Earth pits to the Junction Box are to be provided.

Caution Note:

Before carrying out any electrical welding works on connected Equipment structures and periferrals during maintenance activities.

Because CEMS – 0313 unit printed circuit remains connected to the earth pit, even if power is switch OFF to unit, branched out welding currents flows through E. loop sensing lead through narrow printed cirucit strips to earth pit, it damges the printed circuit board.

To prevent above damage, remove the two 4 Sq.mm cable coming from earth pit to terminal block in junction box. Remove the two wires, tape the open ends and lay it in free space in junction box. Other earth loop check wires (1.5 Sq.mm wires) are also to be remvoed from their terminals and pulled out of respective glands and hold out side the junction box. Before putting back in service CEMS-0313 restore all the 1.5 Sq.mm E. loop wires in their sequence and restore the earth pit wires.

Cable Connection Details

In reference to the system block diagram connection, details for cable connections are as under.

SAFE AREA UNIT: IN SAFE AREA

Cable Entry-1: 0.5 to 1.5 Sq.mm 3 core copper flexible PVC unarmored cable.

1st Connection: Control Panel End

  • Red wire: Live 230 Volts/AC through 2 Amp MCB
  • Black wire: Neutral – 0 Volts
  • Green wire: Ground connection inside the control panel

2nd Connection: Through cable entry 1 in safe area unit through

Non-FLP gland 

  • Red wire: L. Terminal on Top PCB
  • Black wire: N. Terminal on Top PCB
  • Green wire: Earth connection on the metal terminal mark ‘E’ on the left

Side of Top PCB on the chassis plate.

Cable Entry-2: 1.5 Sq.mm 2/4 core armored cable through cable entry 2.

  • Red wire No.1: 12 Volts D.C Terminal lower side PCB (+)
  • Black wire No. 2: 0 Volts terminal on lower side PCB (-) Two-way terminal block with 12 Volts polarity marked + Ve and – Ve.

Hazardous Area: FLP Unit

Cable Entry-3: 1.5 Sq.mm multi-strand copper 4-core armored cable.

Connections: 2/4 core armoured cable entry through cable entry 3 multi-strand 1.5 Sq.mm 2 wires removed From Outer Coaxial sheathing to 300 mm length.

In the case of 4 core wires – 3 and 4 not used.

  • Red wire No. 1: 2 pin Terminal block located on the bottom left side under 12V DC.
  • Black wire No.2: 0 Volts terminal on lower side PCB wires 3 & 4 not used in case of 4 core wire.                                                               Note: All intrinsically safe connections from the junction box to earth pits and equipment body to be carried out as per the Connections diagram given on page 12

Continuous Earth Monitoring System is designed to Monitor Earthing of Pharma product process equipment, one after the other for 5 seconds. Once installed the system starts scanning the earthing of 1 to 20 equipment all the 24 Hrs. There is no daily operation of the system.

In the event of equipment earthing fault (resistance more than 10 Ohms), the system detects it and indicates red color LED along with Audio Signal. At the same time, the faulty equipment number is registered in 1 to 20 Red LED array.

Whenever either Red LED indication or a registered faulty equipment number is noticed take the following actions.

Read more
  • Identify the faulty number.
  • Press the “HOLD” push button on the monitoring instrument at that defective equipment number while scanning. Now 5 seconds scanning stops and earthing defective equipment number is indicated in Red along with buzzer beeps continuously. If the production process is in progress and operation cannot be stopped, temporarily connect the body of defective equipment to the adjacent body of equipment by means of an earth clamp with a visual indication or by a wire shorting link between the two. At this stage, if the Green LED indication the buzzer stops, the earthing is temporarily safe and can continue till the process completes. Press the release button and resume scanning.
  • In case the above solution does not work, check the monitoring wire connection on the equipment body coming from the monitoring unit. Check for breakage of wire or connection. If the adjacent equipment shows green and has no earthing defect the temporary link provided can be continued till the end of the process. It is Safe.
  • After clearing the earth fault press the release button and observe for two cycles if there are no other earth faults, you can press the Re-set button to restart the system. This will clear all previously registered numbers.


This data is provided for general information and material comparison. The potential user should perform tests to determine the product’s performance and suitability in the intended application. Final determination of the fitness of the product for any particular application is the responsibility of the buyer.

 

Continuous Earth Monitoring System with Resistance Value Display

Model No.: CEMS-20-RM-0521
Use: To Monitor Earthing of 20 Equipment

Introduction

It is a well-known fact that friction created by any means will generate “Static Charges”. These charges if not dissipated to earth will result in Static Charges accumulation and subsequent Electro Static Discharge. The ESD may cause Fire and Explosions.

Pharma & Chemical Units

In Pharma & Chemical units, equipment such as Reactors, Centrifuges, Driers, Shifters, etc., are used continuously for 24 Hrs. in a day to manufacture different products. During the running of the above equipment, Static Charges are developed due to friction. All the equipment’s are to be earthed by means of earthing strips. Since equipment’s are running 24 hrs, the earth connections need to be healthy 24/7 to dissipate the Static Charges developed.

Read more

Constraints in Monitoring Earth Connections

The duty of checking earth continuity of the equipment is normally assigned to the electrical department. Due to limited manpower in the department, monitoring earth connections on daily basis is not practicable. The Earth connections are normally checked once in 3 months or 6 months. Any loose contacts are defects in earth connections goes unnoticed during these intervals.

Why less than 10.0 Ohms threshold? As per IS-7689/IEC-TS-60079-32-1, metallic items in good contact with earth should have a resistance to it of less than 10.0 Ohms. Although a value of up to 1.0 M Ohms is acceptable for static dissipation values above 10.0 Ohms may give an early indication of developing problems (e.g., corrosion or loose connection).

Need for designing Continuous Earth Monitoring System

Mr. P.V.Vidyadhara Rao (Proprietor) is an ESD Trainer and Certified ESD Auditor. During the ESD Audits, he noticed a safety gap in equipment earth connection monitoring and envisaged a need for a continuous earth monitoring system to fill this safety gap. Based on his findings and recommendations our Technical Team has designed and developed a continuous earth monitoring system CEMS-20-RM-0521 to fill the gap and reduce workload on electrical personnel, and continuity in the safety through the production schedule.

A key function of equipment Earthing is to provide a controlled method to prevent the buildup of static electricity, thus reducing the risk of electrical Discharge in Potentially hazardous environments. The Electrical resistance from the equipment to Earth should be 10.0 Ohms Maximum. This electrical resistance values are to be maintained continuously as per IS: 7689.

The system CEMS-20-RM-0521 monitors resistance value to Earth and any fault will be indicated by a RED LED and Audio Signal. The system monitors every equipment one after another with an interval of 5 seconds. The system draws the attention of the personnel to take remedial action should a fault arise in equipment earthing.

CEMS-20-RM-0521 has provision to monitor 20 Nos. of equipments, and comes in a flame-proof enclosure. Equipment to earth loop is measured by intrinsically safe voltage & current and this precision source has microcontroller-based switching.

CEMS-20-RM-0521 is a Ex-Certified System as per

IS/IEC 60079-0 : 2017, IS/IEC 60079-11:2011

INTERFACE UNIT AT SAFE AREA

Safe Area Unit: Located in safe area (Switch Gear Room)

I. ELECTRICAL SPECIFICATIONS:

1. Power Input:230V ~ (AC Mains)

2. Total Load: Approx. 6 Watts. Total System

3. Cable Entries: As given in System Block Diagram

4. Input Connection: 1). Mains 230 Volts input connection Cable Entry-1.

Type of Cable: 0.5 to 1.5 Sq.mm 3 Core PVC Cable.

Output Connection:  2). 12 V DC.

Type of Cable: 1.0 to 1.5 Sq.mm 2/4 Cores Flexible Armoured Cable.

  • Wire 1 Red + 12 Volts.
  • Wire 2 Black 0 Volts.
  • From 2-way terminal with marking of Polarity + and – near 2-way terminal block

In case of 4 cores cable wire 3 and 4 not used.

Read more

5. Enclosure: Non- FLP MS Box (Safe Area Unit)

6. Mounting: Wall Mounting by Four M8 x 25 Screws on extended fixtures.

2. MECHANICAL SPECIFICATIONS:

1) Dimensions: 165 x 240 x 90 mm

2) Material: M.S. Powder coated. 

3) Weight: 3.0 Kgs.

III. ENVIRONMENTAL:      Operating Temperature Range: – 100 to 500

TECHNICAL SPECIFICATIONS

FLP Unit at Hazardous Area

ELECTRICAL SPECIFICATIONS:

1. Power Input: 12 V DC through wires 1 & 2, 2/4 Core 1.5 Sq.mm flexible armored Cable As indicated in safe area unit.

2. Load: 6 Watts.

  •  Wire 1 Red + 12 V DC
  • Wire 2 Black – 0 V DC
  •  Wire 3 and 4 not used in case of 4 core cable.

3. Cable Entries: given in System Block Diagram.

4. Operational Switches:

  • Reset Switch
  • Hold Switch
  •  Release Switch

5. Operational Indications:

  • 1 to 20 Channels channel wise Nos. Indication by Two 7-digit LED DISPLALY, Yellow Colour.
  • Earth loop check (less than 9.5 Ohms) 10.0 mm Green LED. Fault greater than 9.5 Ohms 10.0 mm Red LED.         
  • Earth loop resistance value display. Channel Wise by 2 ½ Digit 7 Segment Digital Display Blue Colour. Reads 20.0 Ohms. 19.99 Ohms Max and 1-.- for greater than 20.0 Ohms. Display tolerance +/-5% system built-in Resistance 0.4 Ohms. +/- Digit.
  • Faulty channel Nos. registration by 5.0 mm Red LEDs 1 to 20.
  • Scanning time for each channel 5 Seconds (Adjustable 3 to 5 Seconds).
  • Faulty channel audio indication by Buzzer.

6. Intrinsically Safe Outputs: 1 – 20 – Lines to Equipment for Earth Loop Check and inputs 2 lines to Earth Pits.

7. Enclosure: FLP (Zone-1)

8. Mounting: Wall mounting by four M8 x 25 screw On extended fixtures.

MECHANICAL SPECIFICATIONS:

Main Console:  

  • FLP Enclosure 250 x 250 mm,
  •  Flame proof Window 96 x 96 mm glass window.
  • Flame proof and Weather proof as per IP 66.
  • Aluminium Alloy LM Casting – 8.00 Kgs.

Junction Box:

a) Material:S. Junction Box.

b) Dimensions:180 x 220 x 60 mm

c) Weight:0 Kgs.

FLP and SS Junction Box fitted on SS Sheet 320 x 620 x 2 mm thickness with mounting holes.

III. ENVIRONMENTAL:     

Operating Temperature Range: – 100 to 500

Material requirement for Installation of CEMS-20-RM-0521

(Under your Scope)

1.  0.5 to 1.5 Sq. mm Copper Multi-Strand 3 core P.V.C Cable. For connecting 230 volts main supply to safe area unit in switchgear room through M.C.B 2 Amp, Length as required. Typical – 10 to 15 meters.

2. 1.5 Sq. mm Copper 2/4 core flexible armored cable. For Connection 12 Volts D.C Supply from safe area unit to main FLP Unit in hazardous area (Process Plant), length as required.

3.  0.5 to 1.5 Sq. mm, multi-strand P.V.C Wire for Earth Loop check connections Length as required.

4. 2 Nos. 4.0 Sq. mm, Copper multi-strand P.V.C Wire for connecting corresponding earth pits to the junction box, length as required.

Read more

Your Scope of Work & Supply

1. The Earth Pit resistance pertaining to equipment grounding is to be checked and maintained as low as possible.

 2. The equipment earthing is to be thoroughly checked and a report on existing resistance values of equipment to Earth Pit for each equipment to be furnished to us prior to installation.

3. 1.5 Sq.mm copper flexible 3-core PVC Cable unarmored is to be provided in the switchgear room to the safe area unit.

4. 1.5 Sq.mm copper multi-strands flexible 2/4 Core armored cable from the safe area unit to the CEMS unit in the Hazardous area is to be provided.

 5.  1.5 Sq.mm Copper multi-strand PVC wires to be provided from main CEMS unit to every equipment body. 1 to 10 and 11 to 20 Nos. These wires are to be laid on cable trays.6. Two numbers of 4.0 Sq.mm copper multi-strand flexible P.V.C wires From Earth pits to the Junction Box are to be provided.

Caution Note:

Before carrying out any electrical welding works on connected Equipment structures and periferrals during maintenance activities.

Because CEMS – 0313 unit printed circuit remains connected to the earth pit, even if power is switch OFF to unit, branched out welding currents flows through E. loop sensing lead through narrow printed cirucit strips to earth pit, it damges the printed circuit board.

To prevent above damage, remove the two 4 Sq.mm cable coming from earth pit to terminal block in junction box. Remove the two wires, tape the open ends and lay it in free space in junction box. Other earth loop check wires (1.5 Sq.mm wires) are also to be remvoed from their terminals and pulled out of respective glands and hold out side the junction box. Before putting back in service CEMS-0313 restore all the 1.5 Sq.mm E. loop wires in their sequence and restore the earth pit wires.

Cable Connection Details

In reference to the system block diagram connection, details for cable connections are as under.

SAFE AREA UNIT: IN SAFE AREA

Cable Entry-1: 0.5 to 1.5 Sq.mm 3 core copper flexible PVC unarmored cable.

1st Connection: Control Panel End

  • Red wire: Live 230 Volts/AC through 2 Amp MCB
  • Black wire: Neutral – 0 Volts
  • Green wire: Ground connection inside the control panel

2nd Connection: Through cable entry 1 in safe area unit through

Non-FLP gland 

  • Red wire: L. Terminal on Top PCB
  • Black wire: N. Terminal on Top PCB
  • Green wire: Earth connection on the metal terminal mark ‘E’ on the left

Side of Top PCB on the chassis plate.

Cable Entry-2: 1.5 Sq.mm 2/4 core armored cable through cable entry 2.

  • Red wire No.1: 12 Volts D.C Terminal lower side PCB (+)
  • Black wire No. 2: 0 Volts terminal on lower side PCB (-) Two-way terminal block with 12 Volts polarity marked + Ve and – Ve.

Hazardous Area: FLP Unit

Cable Entry-3: 1.5 Sq.mm multi-strand copper 4-core armored cable.

Connections: 2/4 core armoured cable entry through cable entry 3 multi-strand 1.5 Sq.mm 2 wires removed From Outer Coaxial sheathing to 300 mm length.

In the case of 4 core wires – 3 and 4 not used.

  • Red wire No. 1: 2 pin Terminal block located on the bottom left side under 12V DC.
  • Black wire No.2: 0 Volts terminal on lower side PCB wires 3 & 4 not used in case of 4 core wire.                                                               Note: All intrinsically safe connections from the junction box to earth pits and equipment body to be carried out as per the Connections diagram given on page 12

Continuous Earth Monitoring System is designed to Monitor Earthing of Pharma product process equipment, one after the other for 5 seconds. Once installed the system starts scanning the earthing of 1 to 20 equipment all the 24 Hrs. There is no daily operation of the system.

In the event of equipment earthing fault (resistance more than 10 Ohms), the system detects it and indicates red color LED along with Audio Signal. At the same time, the faulty equipment number is registered in 1 to 20 Red LED array.

Whenever either Red LED indication or a registered faulty equipment number is noticed take the following actions.

Read more
  • Identify the faulty number.
  • Press the “HOLD” push button on the monitoring instrument at that defective equipment number while scanning. Now 5 seconds scanning stops and earthing defective equipment number is indicated in Red along with buzzer beeps continuously. If the production process is in progress and operation cannot be stopped, temporarily connect the body of defective equipment to the adjacent body of equipment by means of an earth clamp with a visual indication or by a wire shorting link between the two. At this stage, if the Green LED indication the buzzer stops, the earthing is temporarily safe and can continue till the process completes. Press the release button and resume scanning.
  • In case the above solution does not work, check the monitoring wire connection on the equipment body coming from the monitoring unit. Check for breakage of wire or connection. If the adjacent equipment shows green and has no earthing defect the temporary link provided can be continued till the end of the process. It is Safe.
  • After clearing the earth fault press the release button and observe for two cycles if there are no other earth faults, you can press the Re-set button to restart the system. This will clear all previously registered numbers.

 

Continuous Earth Monitoring System with Resistance Value Display

Model No.: CEMS-20-RM-0521
Use: To Monitor Earthing of 20 Equipment

Description

Introduction

It is a well-known fact that friction created by any means will generate “Static Charges”. These charges if not dissipated to earth will result in Static Charges accumulation and subsequent Electro Static Discharge. The ESD may cause Fire and Explosions.

Pharma & Chemical Units

In Pharma & Chemical units, equipment such as Reactors, Centrifuges, Driers, Shifters, etc., are used continuously for 24 Hrs. in a day to manufacture different products. During the running of the above equipment, Static Charges are developed due to friction. All the equipment’s are to be earthed by means of earthing strips. Since equipment’s are running 24 hrs, the earth connections need to be healthy 24/7 to dissipate the Static Charges developed.

 

Read more

Constraints in Monitoring Earth Connections

The duty of checking earth continuity of the equipment is normally assigned to the electrical department. Due to limited manpower in the department, monitoring earth connections on daily basis is not practicable. The Earth connections are normally checked once in 3 months or 6 months. Any loose contacts are defects in earth connections goes unnoticed during these intervals.

Why less than 10.0 Ohms threshold? As per IS-7689/IEC-TS-60079-32-1, metallic items in good contact with earth should have a resistance to it of less than 10.0 Ohms. Although a value of up to 1.0 M Ohms is acceptable for static dissipation values above 10.0 Ohms may give an early indication of developing problems (e.g., corrosion or loose connection).

Need for designing Continuous Earth Monitoring System

Mr. P.V.Vidyadhara Rao (Proprietor) is an ESD Trainer and Certified ESD Auditor. During the ESD Audits, he noticed a safety gap in equipment earth connection monitoring and envisaged a need for a continuous earth monitoring system to fill this safety gap. Based on his findings and recommendations our Technical Team has designed and developed a continuous earth monitoring system CEMS-20-RM-0521 to fill the gap and reduce workload on electrical personnel, and continuity in the safety through the production schedule.

A key function of equipment Earthing is to provide a controlled method to prevent the buildup of static electricity, thus reducing the risk of electrical Discharge in Potentially hazardous environments. The Electrical resistance from the equipment to Earth should be 10.0 Ohms Maximum. This electrical resistance values are to be maintained continuously as per IS: 7689.

The system CEMS-20-RM-0521 monitors resistance value to Earth and any fault will be indicated by a RED LED and Audio Signal. The system monitors every equipment one after another with an interval of 5 seconds. The system draws the attention of the personnel to take remedial action should a fault arise in equipment earthing.

CEMS-20-RM-0521 has provision to monitor 20 Nos. of equipments, and comes in a flame-proof enclosure. Equipment to earth loop is measured by intrinsically safe voltage & current and this precision source has microcontroller-based switching.

CEMS-20-RM-0521 is a Ex-Certified System as per

IS/IEC 60079-0 : 2017, IS/IEC 60079-11:2011

Specifications

INTERFACE UNIT AT SAFE AREA

Safe Area Unit: Located in safe area (Switch Gear Room)

I. ELECTRICAL SPECIFICATIONS:

1. Power Input:230V ~ (AC Mains)

2. Total Load: Approx 6 Watts. Total System

3. Cable Entries: As given in System Block Diagr

4. Input Connection: 1). Mains 230 Volts input connection Cable Entry-1.

Type of Cable: 0.5 to 1.5 Sq.mm 3 Core PVC Cable.

Output Connection:  2). 12 V DC.  

Type of Cable: 1.0 to 1.5 Sq.mm 2/4 Cores Flexible Armoured Cable.

  • Wire 1 Red + 12 Volts.
  • Wire 2 Black 0 Volts.
  • From 2-way terminal with marking of Polarity + and – near 2-way terminal block
  •  In case of 4 cores cable wire 3 and 4 not used.                                 

 

Read more

5. Enclosure: Non- FLP MS Box (Safe Area Unit)

6. Mounting: Wall Mounting by Four M8 x 25 Screws on extended fixtures.

2. MECHANICAL SPECIFICATIONS:

1) Dimensions: 165 x 240 x 90 mm

2) Material: M.S. Powder coated. 

3) Weight: 3.0 Kgs.

III. ENVIRONMENTAL:      Operating Temperature Range: – 100 to 500

TECHNICAL SPECIFICATIONS

FLP Unit at Hazardous Area

ELECTRICAL SPECIFICATIONS:

1. Power Input: 12 V DC through wires 1 & 2, 2/4 Core 1.5 Sq.mm flexible armored Cable As indicated in safe area unit.

2. Load: 6 Watts.

  •  Wire 1 Red + 12 V DC
  • Wire 2 Black – 0 V DC
  •  Wire 3 and 4 not used in case of 4 core cable.

3. Cable Entries: given in System Block Diagram.

4. Operational Switches:

  • Reset Switch
  • Hold Switch
  •  Release Switch

5. Operational Indications:

  • 1 to 20 Channels channel wise Nos. Indication by Two 7-digit LED DISPLALY, Yellow Colour.
  • Earth loop check (less than 9.5 Ohms) 10.0 mm Green LED. Fault greater than 9.5 Ohms 10.0 mm Red LED.         
  • Earth loop resistance value display. Channel Wise by 2 ½ Digit 7 Segment Digital Display Blue Colour. Reads 20.0 Ohms. 19.99 Ohms Max and 1-.- for greater than 20.0 Ohms. Display tolerance +/-5% system built-in Resistance 0.4 Ohms. +/- Digit.
  • Faulty channel Nos. registration by 5.0 mm Red LEDs 1 to 20.
  • Scanning time for each channel 5 Seconds (Adjustable 3 to 5 Seconds).
  • Faulty channel audio indication by Buzzer.

6. Intrinsically Safe Outputs: 1 – 20 – Lines to Equipment for Earth Loop Check and inputs 2 lines to Earth Pits.

7. Enclosure: FLP (Zone-1)

8. Mounting: Wall mounting by four M8 x 25 screw On extended fixtures.

MECHANICAL SPECIFICATIONS:

Main Console:  

  • FLP Enclosure 250 x 250 mm,
  •  Flame proof Window 96 x 96 mm glass window.
  • Flame proof and Weather proof as per IP 66.
  • Aluminium Alloy LM Casting – 8.00 Kgs.

Junction Box:

a) Material:S. Junction Box.

b) Dimensions:180 x 220 x 60 mm

c) Weight:0 Kgs.

FLP and SS Junction Box fitted on SS Sheet 320 x 620 x 2 mm thickness with mounting holes.

III. ENVIRONMENTAL:     

Operating Temperature Range: – 100 to 500

Material Requirements

Material requirement for Installation of CEMS-20-RM-0521

(Under your Scope)

1.  0.5 to 1.5 Sq. mm Copper Multi-Strand 3 core P.V.C Cable. For connecting 230 volts main supply to safe area unit in switchgear room through M.C.B 2 Amp, Length as required. Typical – 10 to 15 meters.

2. 1.5 Sq. mm Copper 2/4 core flexible armored cable. For Connection 12 Volts D.C Supply from safe area unit to main FLP Unit in hazardous area (Process Plant), length as required.

3.  0.5 to 1.5 Sq. mm, multi-strand P.V.C Wire for Earth Loop check connections Length as required.

4. 2 Nos. 4.0 Sq. mm, Copper multi-strand P.V.C Wire for connecting corresponding earth pits to the junction box, length as required.

 

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Your Scope of Work & Supply

1. The Earth Pit resistance pertaining to equipment grounding is to be checked and maintained as low as possible.

 2. The equipment earthing is to be thoroughly checked and a report on existing resistance values of equipment to Earth Pit for each equipment to be furnished to us prior to installation.

3. 1.5 Sq.mm copper flexible 3-core PVC Cable unarmored is to be provided in the switchgear room to the safe area unit.

4. 1.5 Sq.mm copper multi-strands flexible 2/4 Core armored cable from the safe area unit to the CEMS unit in the Hazardous area is to be provided.

 5.  1.5 Sq.mm Copper multi-strand PVC wires to be provided from main CEMS unit to every equipment body. 1 to 10 and 11 to 20 Nos. These wires are to be laid on cable trays.6. Two numbers of 4.0 Sq.mm copper multi-strand flexible P.V.C wires From Earth pits to the Junction Box are to be provided.

Caution Note:

Before carrying out any electrical welding works on connected Equipment structures and periferrals during maintenance activities.

Because CEMS – 0313 unit printed circuit remains connected to the earth pit, even if power is switch OFF to unit, branched out welding currents flows through E. loop sensing lead through narrow printed cirucit strips to earth pit, it damges the printed circuit board.

To prevent above damage, remove the two 4 Sq.mm cable coming from earth pit to terminal block in junction box. Remove the two wires, tape the open ends and lay it in free space in junction box. Other earth loop check wires (1.5 Sq.mm wires) are also to be remvoed from their terminals and pulled out of respective glands and hold out side the junction box. Before putting back in service CEMS-0313 restore all the 1.5 Sq.mm E. loop wires in their sequence and restore the earth pit wires.

Cable Connection Details

In reference to the system block diagram connection, details for cable connections are as under.

SAFE AREA UNIT: IN SAFE AREA

Cable Entry-1: 0.5 to 1.5 Sq.mm 3 core copper flexible PVC unarmored cable.

1st Connection: Control Panel End

  • Red wire: Live 230 Volts/AC through 2 Amp MCB
  • Black wire: Neutral – 0 Volts
  • Green wire: Ground connection inside the control panel

2nd Connection: Through cable entry 1 in safe area unit through

Non-FLP gland 

  • Red wire: L. Terminal on Top PCB
  • Black wire: N. Terminal on Top PCB
  • Green wire: Earth connection on the metal terminal mark ‘E’ on the left

Side of Top PCB on the chassis plate.

Cable Entry-2: 1.5 Sq.mm 2/4 core armored cable through cable entry 2.

  • Red wire No.1: 12 Volts D.C Terminal lower side PCB (+)
  • Black wire No. 2: 0 Volts terminal on lower side PCB (-) Two-way terminal block with 12 Volts polarity marked + Ve and – Ve.

Hazardous Area: FLP Unit

Cable Entry-3: 1.5 Sq.mm multi-strand copper 4-core armored cable.

Connections: 2/4 core armoured cable entry through cable entry 3 multi-strand 1.5 Sq.mm 2 wires removed From Outer Coaxial sheathing to 300 mm length.

In the case of 4 core wires – 3 and 4 not used.

  • Red wire No. 1: 2 pin Terminal block located on the bottom left side under 12V DC.
  • Black wire No.2: 0 Volts terminal on lower side PCB wires 3 & 4 not used in case of 4 core wire.                                                               Note: All intrinsically safe connections from the junction box to earth pits and equipment body to be carried out as per the Connections diagram given on page 12

Operating Instructions

Continuous Earth Monitoring System is designed to Monitor Earthing of Pharma product process equipment, one after the other for 5 seconds. Once installed the system starts scanning the earthing of 1 to 20 equipment all the 24 Hrs. There is no daily operation of the system.

In the event of equipment earthing fault (resistance more than 10 Ohms), the system detects it and indicates red color LED along with Audio Signal. At the same time, the faulty equipment number is registered in 1 to 20 Red LED array.

Whenever either Red LED indication or a registered faulty equipment number is noticed take the following actions.

 

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  • Identify the faulty number.
  • Press the “HOLD” push button on the monitoring instrument at that defective equipment number while scanning. Now 5 seconds scanning stops and earthing defective equipment number is indicated in Red along with buzzer beeps continuously. If the production process is in progress and operation cannot be stopped, temporarily connect the body of defective equipment to the adjacent body of equipment by means of an earth clamp with a visual indication or by a wire shorting link between the two. At this stage, if the Green LED indication the buzzer stops, the earthing is temporarily safe and can continue till the process completes. Press the release button and resume scanning.
  • In case the above solution does not work, check the monitoring wire connection on the equipment body coming from the monitoring unit. Check for breakage of wire or connection. If the adjacent equipment shows green and has no earthing defect the temporary link provided can be continued till the end of the process. It is Safe.
  • After clearing the earth fault press the release button and observe for two cycles if there are no other earth faults, you can press the Re-set button to restart the system. This will clear all previously registered numbers.