Captive Component Glands

Captive Component Glands

CCG Started operations in 1972 100% privately owned The largest cable Gland Manufacturer in the Southern Hemisphere One of the Largest in the world

CCG Uses the Latest in CNC Manufacturing Technology. Employs over 200 people Operates out of a 55000 sq ft Factory

Uses over 200 Metric Tons of Brass a Month

CCG is The Largest Supplier of IEC Type Cable Glands to the Metals, Mining and Minerals Industry in the world.

One of the Fastest Growing Suppliers of Ex Certified Cable Glands to the Petrochemical Industry

ISO 9001 Listed Company with Underwriters Laboratory USA Products Tested and Certified to IEC, Chinese, South African, ATEX and Australian Standards

Worldwide Offices, Warehousing and Distribution

DEFINITIONS OF A CABLE GLAND

EN50262 European cable gland standard defines a cable gland as A device designed to permit the entry of a cable, flexible cable or insulated conductor into an enclosure and which provides sealing and retention. It may also provide other functions such as earth bonding, insulation, cable guarding, strain relief or a combination of these.

DEFINITIONS OF A CABLE GLAND IEC 60079-0 International standard for Electrical Apparatus for explosive gas atmospheres defines a cable gland as a device permitting the introduction of one or more cables into an electrical apparatus so as to maintain the relevant type of protection

In hazardous areas all Ex equipment needs to be installed and operate correctly according to the certification of the equipment.

We Are All in the Business of Preventing This!

The Problem of Loose Components

Almost all Ex glands have loose components such as seals, cones and cone rings, all of which must be correctly installed on site. Losing one of these components invalidates the Ex certification of the gland and the equipment its connected to.
Glands with loose components

Two Part Captive Component Gland

The Problem at installation

If cable gland components are left out during installation, the Ex certification of the apparatus to which they are attached will be compromised. This cannot happen with 2 part Captive Component Glands
Exd Glands on an Exd enclosure

2 part Captive Component Gland

Gland with loose components

Gland assembled on Exd enclosure with components missing

TYPICAL EX CERTIFIED CABLE GLAND CONSTRUCTION Armoured Cable Gland

TYPICAL EX CERTIFIED CABLE GLAND CONSTRUCTION Unarmoured Cable Gland

SELECTION and INSTALLATION: Equipment

A cable gland must always match or better the IP and explosion proof rating of the equipment it is being attached to. Exe: Increased safety the gland must be IP54 minimum but practically should be IP66. IP66

ExnR: Non-sparking and restricted breathing the Gland must be IP68 Exd: Flameproof. Flameproof Gland seals must withstand internal explosions of 30 Bar Pressure and fulfill all flame-path requirements.

Exde: Equipment has both Exe and Exd protection concepts of which the Exd enclosures are normally smaller than 2-litres volume.

PROTECTION CONCEPT: Exd for use in zones 1 and 2 IEC 60079-1 Flameproof
Defined As the type of protection in which the parts which can ignite an explosive atmosphere are placed in an enclosure which can withstand the pressure developed during an internal explosion of an explosive structure and which prevents the transmission of the explosion to the explosive atmosphere surrounding the enclosure.

PROTECTION CONCEPT: Exe for use in Zones 1 and 2 IEC 60079-7 Increased safety
Defined as the type of protection applied to electrical apparatus in which additional measures are applied so as to give increased security against the possibility of excessive temperatures and of the occurrence of arcs and sparks in normal service or under specific abnormal conditions.

PROTECTION CONCEPT:

ExnA non sparking ExnR restricted breathing IEC 60079-15

Similar concept to Exe however with lower requirements and only allowed to be used in Zone-2

PROTECTION CONCEPT:

Exi for use in zones 0, 1 and 2 IEC 60079-11 Intrinsic safety This concept removes the ignition source from a potential explosion through the prevention of high fault currents and voltages

PROTECTION CONCEPT: ExtD (old DIP) IEC 61241-1-1 Electrical apparatus for use in the presence of combustible dust. This protection concept is designed around high IP ratings

SELECTION and INSTALLATION

Cable: Type of cable, cable armoured or unarmoured? Sizing over the inner sheath and outer sheath. sheath Shape and construction of the cable. Is the cable round, filled and non hygroscopic?

UNARMOURED CABLE

Used in Europe and some parts of the Middle East, Australasia and Africa. Pros Fast, easy installation. Lower costs. Cons No protection against mechanical damage.

ARMOURED CABLE

Used in the UK, Commonwealth Countries, Middle East, Australasia and Africa. Pros Gives good earth continuity. Mechanical Protection. Cons Special care must be taken when preparing the cable.

CABLE QUALITY ??
VOIDS

SQUARE NOT ROUND

UNFILLED CABLE

SELECTION and INSTALLATION

Entry threads. When selecting cable glands one must make sure that the entry thread always matches the entry thread of the Apparatus. Threads could be NPT, BSP or Metric .

SELECTION and INSTALLATION

Entry threads:
Equipment can originate from many parts of the world. IEC and EN based equipment is normally ISO metric. However other threads such as NPT, PG and BSP are also available and care must be taken to correctly identify these threads and a certified thread adaptor used. It is very easy to mistake them as such. An interface between NPT and metric will not form a flameproof path. 1/2 NPT

20 mm METRIC

RISK ASSESSMENT

IIA

IIC

RISK ASSESSMENT

Exe

EXd

RISK ASSESSMENT

SELECTION and INSTALLATION

ENVIRONMENTAL:

Corrosion is the single biggest cause of equipment failure. failure Great care must be taken when selecting glands for highly corrosives locations.

SELECTION and INSTALLATION

ENVIRONMENTAL: One must also be aware of Electrolytic Action between 2 dissimilar metals such as brass and aluminium. Naked brass glands are not recommended and should be plated. plated The use of proper IP rated and corrosion proof glands must be considered.

SELECTION and INSTALLATION

ENVIRONMENTAL:

Chemicals such as hydrochloric acid nitric acid, ammonia, hydrogen sulphide, caustic soda aggressively attack brass cable glands.

RISK ASSESSMENT

RISK ASSESSMENT

RISK ASSESSMENT

RISK ASSESSMENT

With Unfilled, Un-round Cable Gas can Migrate from a Hazardous Area to a Safe Area

Hazardous Area Explosive Gas

Safe Area

Exd Enclosure

Non Ex Enclosure

An explosion in the Exd enclosure can propagate down the interstices of the cable causing damage to the cable as well as forcing pressure into a non certified enclosure.

Hazardous Area

Safe Area

Exd enclosure

Non Ex Enclosure

Exd BARRIER CABLE GLAND CONSTRUCTION BarrierTex-A Cable Gland ~ Armoured Cable

Exd CERTIFIED BARRIER CABLE GLAND CONSTRUCTION BarrierTex-F Cable Gland ~ Unarmoured Cable

INSTALLATION
Other Factors to consider for the safe installation of Ex Cable Glands

Training and competency of persons involved. Codes of practice as per the IEC standards and manufacturers instructions and certifications. Any modification to Ex Cable Glands is not allowed. 5 full threads must be engaged on entry threads. IP rating of minimum IP54 but practically IP66. Different threads may necessitate thread converters. Cable support may be needed depending on the cable type. The correct tools must be used.

INSPECTION and MAINTENANCE

(a) Initial Inspections:These inspections are directly related to required inspections before equipment will be commissioned for the first time e.g. on cable glands checking that the marking and certification is correct, correct checking tightness and that all components have been correctly fitted and not left out. (b) Periodic Inspections:It stipulates that the interval between periodic inspections shall not exceed two years, and shall be shorter if the deterioration of the apparatus could influence explosion protection sooner. (c) Sample inspections:Sample inspections are inspections of a portion of the installed apparatus. This can be visual, close or detailed. The size and composition of all samples should be determined taking into account the purpose of the inspection. The result of all sample inspections should be recorded.

GRADES OF INSPECTION
VISUAL INSPECTION: Visual inspections take note of all defects which can be determined by a visual approach either from the ground or from permanent access platforms, without the use of hand tools, without switching off and without climbing or using ladders. Binoculars and remote heat detecting equipment may be useful in some situations. In the case of a cable entry device no dismantling is required.

GRADES OF INSPECTION

CLOSE INSPECTION: Close inspections determine where any defects, including those detectable visually, may be detected without removing power. This may involve the use of some tools, ladders and other access mediums. In the case of a cable entry device a general check on tightness is required.

GRADES OF INSPECTION
DETAILED INSPECTION: Detailed inspections are also carried out at major shut down periods, normally on a sample basis. They include the disconnection of power and include opening up equipment. Access equipment, tools and test equipment may be used. In case of a cable entry devices: check tightness of cable glands (using a tool). If the corrosion is a possibility, partially dismantle the gland to check the earthing of cable armour onto the gland.

Bad Installations!!
The Wrong Size Cable Gland

Bad Installations!!
Problem Solution

Tight bending Radius and Corrosion

CCG Corrosion Guard

Bad Installations!!
Problem Solution

Severe corrosion to Cable Glands

CCG Corrosion Guard

Bad Installations!!
Problem Solution

Severe corrosion, Glands not Terminated, unused entries arent plugged

Corrosion proof enclosures all glands terminated all unused entries plugged

Bad Installations!!
Problem Solution

Severe Corrosion to Metallic Equipment

Corrosion Proof Glands and Equipment

Bad Installations!!
Problem Solution

Corroded Glands

CCG Corrosion Guard Gland

Bad Installations!!
Problem Solution

Loose Fitting Shrouds

CCG Screw On Corrosion Guard

Bad Installations!!
Problem Solution

Taping a Gland

CCG Corrosion Guard Gland

Loose Components in Glands Can be left out

The Problem of Loose Components

Almost all Ex glands have loose components such as seals, cones and cone rings, all of which must be correctly installed on site. Losing one of these components invalidates the Ex certification of the gland and the equipment its connected to.
Glands with loose components

Two Part Captive Component Gland

The Problem at installation

If cable gland components are left out during installation, the Ex certification of the apparatus to which they are attached will be compromised. This cannot happen with 2 part Captive Component Glands
Exd Glands on an Exd enclosure

2 part Captive Component Gland

Gland with loose components

Gland assembled on Exd enclosure with components missing

Captive Component Glands