Unit 12:

Sources of ignition

Objectives:

On completion of this unit, ‘Sources of ignition’, you should know:

a) typical everyday sources of ignition in the workplace;

b) lesser known sources of ignition;

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Sources of ignition

Electrical sparks
Electrical sparks are caused primarily by the opening and closing of contacts, for example, electrical switches,
contactors and relays. To ignite a flammable mixture consisting of hydrogen and air requires only 20 J, the
energy produced as a result of a break of 0.1 mS duration in a circuit carrying 20 mA at 10 V. From this
perspective, it is clear that for devices such as these to operate safely in an hazardous area requires them to
be installed in, for example, a flameproof enclosure.

The voltage level has an influence on how incendive a spark will be. Flammable gases and vapours are more
readily ignited at high voltages than low voltages, and is basically why IS circuits are seldom designed for use
above 30 V.

The use of electrical test instruments, typically voltmeters and insulation resistance testers etc., are a potential
source of electrical sparks. These instruments should only be used under controlled circumstances, i.e. under
the control of a work permit and tests to ensure gas free conditions.

Hot surfaces
The flow of current through, for example, the windings of an electric motor invariably produces heat which will
raise the surface temperature of the motor. If the motor is excessively overloaded and the thermal overload
device in the starter is incorrectly set, the surface temperature of the motor may well exceed it’s T-rating.
Overheating can also be caused by blockage of the cooling fan intake, damaged cooling fan, or collapse of a
bearing due to lack of lubrication. The latter can dramatically raise the surface temperature locally to a ‘blue
heat’ state which equates to a temperature around
430 °C which is more than capable of igniting a flammable gas or vapour.

Other sources of heat are process pipes and machinery, combustion engine manifolds and exhaust pipes,
and light bulbs.

Batteries
Batteries whatever their size are a potential source of ignition as they will produce incendive sparks if their
terminals are short-circuited. Current of the order 1000 A can be generated if the terminals of automotive
batteries are short-circuited. There is also the added complication that during charging of lead-acid batteries,
hydrogen and oxygen are released. This requires well ventilated battery rooms.

The certification of portable instruments may only allow their use in hazardous areas if powered by low-power
batteries. High-power batteries must not be used unless permitted by the manufacturer. Replacement of
batteries must only be carried out in a non-hazardous area.

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Friction
The abrasive wheels of portable grinding machines are more than capable of producing incendive sparks, and
hot surfaces locally at the point of contact by the abrasive wheel. Drilling using portable tools can also
generate heat between the drill bit and the workpiece. Power tools, of course, must not be used in hazardous
areas, unless used under strictly controlled conditions, because they are themselves sources of ignition.

Static electricity
Static electricity is normally caused by two insulating materials rubbing together. The loosely held electrons in
the atoms of one material are detached and transferred to the other material, so that the material which loses
electrons becomes positively charged, and the other material which gains electrons becomes negatively
charged. This condition may remain for some time because the materials are insulators and do not offer a
conductive return path for the electrons.

Nylon clothing removed from the body can generate enough static electricity to ignite a flammable gas or
vapour, and there are instances on record of this occurring.

Plastic explosion protected enclosures normally carry the warning that they should be cleaned using a damp
cloth to avoid generation of static electricity.

The movement of fluids can also generate electrostatic charges, and up to 5000 V can be generated at the
nozzle of an aerosol canister. Similarly, 10000 V or more can be generated at the nozzle of high-pressure
steam cleaning equipment. Bonding and earthing of aircraft during refuelling prevents the build up of
electrostatic charges which might otherwise cause the aviation fuel vapour to ignite.

Lightning
Lightning is a type of static electricity caused by the movement of clouds. Air between clouds, or between
clouds and earth, acts as an insulator allowing the charges to build up, and the result is that very high
voltages are generated. Once the voltage reaches a critical point, breakdown of the air occurs and the energy
is released suddenly in the form of a lighting strike.

Lightning strikes will be readily discharged to earth by the normal metal construction of an installation, but
flammable gases or vapours can be ignited by lightning.

Impact
The combination of rusty iron or steel, aluminium and impact between the two is a likely source of ignition,
known as thermite action, which can produce sparks capable of igniting a flammable gas or vapour. The use
of aluminium ladders in hazardous areas should therefore be avoided.

The use of aluminium paint in hazardous areas also requires caution.

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Pyrophoric reaction
Hydrogen sulphide (H2S), or other sulphide compounds passing through iron pipes, reacts with the iron of the
pipe to produce iron sulphide. Iron sulphide when exposed to air very quickly oxidises and will reach
temperatures capable of igniting a flammable gas or vapour. This phenomenon is known as pyrophoric
reaction and can be prevented by soaking the iron sulphide with water or prevent its contact with air.

Radio frequency
The increase in the use of mobile telephones, which operate at high frequencies, has caused some concern.
Such concern was expressed by a major oil company in 1993 about the risk of using mobile telephones in
petrol stations. Petrol stations have Zone 1 areas around the pumps due to the presence of petrol vapour,
and the energy transmitted by a mobile phone, if used in these areas, could be picked up by metalwork in the
area which, acting as an aerial, could produce a spark of sufficient energy to ignite the petrol vapour.

Other sources of radio frequency are of course radio and television transmitters and radar installations.

With regard to radar installations, concern was expressed about the possible ignition of flammable gases at
the St. Fergus Gas Terminal in the North East of Scotland by radar transmissions from the nearby radar
installation at Crimond.

Vibration
Vibration is undesirable since it causes premature deterioration of equipment if allowed to persist. Typical
examples are increased wear in bearings, loosening of electrical connections, etc. Vibration has also been
known to cause metal fatigue of the copper sheath and conductors of MICC cable due to work hardening.

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