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982 views293 pagesCompEx Course (ATEX Certification)
CompEx
Uploaded by
sithulibraCopyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
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/ 293
ot Assets Training & Technical Services Pte Ltd
ce Brie cere ONE ee
(ge, Jee eee:
Introduction
About the ‘Ex’ facility
_Extrainng courses have been run in Aberdeen Callege ince 1990 and have developed tothe level ot
Sopitoaton we have osay Ine present form the CompEx coutee has been In cpsraion since
‘August 1904 and’ haa been designed and consfuctod spectcaly for the National Training of
personnel who work wth slacieal talons and plat in hazardous andlor poteiialy explosive
Envsenmants, The fasy eludes doh classroom and simulated wark areas, hese beng designed
{o give as rele ste condtons as posse to achieve
“The praia! work you mil gud Wo att Owl ake place in these simulated reno nd tia lo
Intended to make you fel hat you are working under ste condos,
Approximately hal ot your time wil be spent inte classroom whore te job knowledge elements of
the course wil be Gaered by means of presentaons Inearporaing lectures, domponstations, and
Dhotographic see of od and bad pra on apparatus. The remaining ime wil be spent on
Bompetence Validation Testing n tho smsated hazardous arcas. Tho tests are nationally set for
Eerening
The outcome
“The abjctve of he hing is 0 inraduco you to operating procedures and techniques and to ge
yu and your employers coildeace tha you are. compete to work on eectical appara in
Fezardous or potentaly exiosve enorme. "The competunoo cereaes gained by you wil
prove evaance that you have achieved the standards of competence lid down nationally by
Idtry and trough he wll help maka your Inuty a eae one.
About the programme
“The nood for traning n this areas of work is se evident in thatthe safo operation of eecrcl
[2qulpmentn hazardous areas paramount. tis eremely important for a personne wh operate
inthove condone to be compatertn the cored techniques and operational procodures, This can
bst be achevod by means of trang by sled stain an environment as cose fo te real thing a
possible. In addon b ths, the Job Knowledge developed through he course most be put into
‘Operation in te actual woiéng shuston 80 that the levels of experise are Increased trough
experience,
‘The design of the programme
“The programs chided nto wo halves, namely:
(2) sod Knowedge:
©) Competence
ation Testing (VT)
“The job knowadge' component takes place during ho fst haf ofthe week snd provides the
Information and experience you need tackle the CVT. 4
airs Assets Training & Technical Services Pte Ltd
eit
i $F DOOO Bie ae aes BIO Gee
(ze) aos
International training and certification of personnel for work on electrical
apparatus for use in potentially hazardous atmospher
“This package nas beer compiled wth information gathered from curent standards end the authors
i not ba el esponbie for any inaccuracies fou tert
Acknowledgements:
“The precueton of the document would not have boon possible without the much appreciated
Aasitance from te folbwing utes and, eretre, the authors of the docuent wish to thank
land rately seknontedge al thoce who provides mater and advice forthe production of the
‘kage: partcuaty the foo!
Aberdeen Sle And Enerprie Tealnng Lined
‘The Stioh Standards irstute
(Cables Intemational Pe Ld, Sngapers
Weidmuller Kppon reduts Li
Hawke Intemational, Singapore
Cooper Crouse Hinds, Singapore
“The Design and Presentation Team of Aberdeen Callog, including al staf involved athe Ans
Conre
“The BASEEFA Grown mark shown inthis documents the property ofthe Heath and Safty
Exocutv and shouldnt be Interpreted fo convey oaticaion. The marks have been reproduced
‘win the kind prmisir of te E20 (HSE)
Copyright of document:
No part ofthis document may be reproduced, stored in retrieval system or transmitted in any
form by any means. 1a. electronic, electrostatic, magnetic media, mechanical, photocopying,
recording or otherwise without the absolute permission in’ writing of the appointed
‘representatives of Aberdeen College.
SF 3rd Edition, January 2000
ABERDEENCOLLESE Assets Training & Technical Services Pte Ltd
e200 O@ ESSE SE. |
Course outline
‘The training scheme
“The taning scheme f ansnged 1 prepare candidates for the assessment progamme which
Comprises four crest Competence Vabdation Tess (CV's) offored as compimentary pais. The
{our Vs areas flows:
x01 Preparation &Insaiaton of d, Bx, Exn and Ex p Systems
‘2xue inspection & Maintenance of eu, x xs ad Ex p Systems|
{2X69 Preparation & nstalation of Sxl Systems
{©X04 Inspection & Mairtonance of Ex Systems
Job knowledge
“The slassroom (ob knewladge) pat ofthe traning Scheme consists of 12 Unt which apply to the
{our GVTs 8 nsated below.
Uni General prindples | [Unit2 Standards, Wats Flamoproot Exe
Certification and
Marking
OTE OE x01 & Exo xorg EOE
EX0S & EXO4 EXOS & EXO4
Unita increased Say Take: Type 7 Unite Pressurisaion
Exe protection EExp
Exar E EXO EXOT REX Exo! EXO
‘Witten Assessmoni
Unt7: Intinsie Sefey Ex] [Unit Oihermethods of | [Units Combined (Hybrid)
i protection protection methods
EXOS B EXOA (Witen Assessment) Bor & EXO
at 16: Wing Syston Unit 17 Inspection & Unit 12 Sources ofigniion
Maintenance to
BS EN6OO7S-17
BROT EXO E01 8 E02 EXOT EXO
X03 & EXO4 EXO & EXO EXO 6 EXO
ait TS Ipduaton to Unit 1a: Pari to Wore
‘Competence and
Validation Tesing Sale isolation
EXO! & EXO2 EXO & EXO
EXOD & EXOd EXOS & EXO Assots Training & Technical Services Pte Ltd
‘ap, nejra eee, Pola gore 25130.
Farios (os) sues 26 ex (6) ass 338,
Be icoone senna. com "Co og. No = 2008119480
“The CVT's ar a serie of practical tests which you wil undertake win the simuiatad work areas
‘dung the second hak of the programme. On successful complaton of these tess you wil be
‘Svardod a Certtate of Core Competonce which wil Indicate the reas the awarding bed, Jot
‘Framing Lia. UTL), hasdosmes you ae compat
During ne ta! haley of he progtémme you ae roqued ost wren assessments nthe frm of
mut-ahiee papers whi are ated tothe practical CVT asseesmons
“The staff who ae inva in mentoring the various assossrants are preset ony s observers and
‘otto prompt or ofr technical assistance, Ther obeervatlons of your work i recorded on Nationally
(ertenchecldst whicnara processed cui the Cove and you results cannot be Getemined unt
{hus process complet
Self-assessment project
[Ae 18erof hie mania, you wil find aasesement materi which you should complete during the
Course, Ths exerae nil enable You to Getrmine Your prior Koowledge ofthe subject, especialy in
‘he area of interpretation of apparatus labeling. ASET Ex Manual
Unit
1
10
1"
1%
“
Tile
General Principles
Standerds, certification and marking
Flameproof Exd & EEX d
Increased Safety Exe & EEXe
Type napparatus
Pressurisation Exp & EEX p
Intrinsle Safety Ex & EEXi
Other methods of protection EEx 0, EEX q,
EEX m andExs
Combined (hybrid) methods of protection
Wiring Systems
Inspection and Maintenance of BS ENS0078-17
‘Sources of ignition
Induction to Competence Validation Testing
Permitto Work System and Safe Isolation
‘Appentiices
Data for flammable materials
Self assessment project
‘Supplement to gland selection procedures
Pages
1-20
118
1-8
1-19
1-27
1-10
1-8 ®2ece
Unit 1:
General principles
Objectives:
‘On completion ofthis unit, ‘general principles’, you should know:
the nature of flammable materials with regard to ‘explosive. limits?
CCELUEL), “fashpoint’, “ignition temperane’, the effect of ‘oxygen
cnrichment” und “relative density’;
»
1b) the basic principles of area classification;
the Grouping of gases according to ‘minimum ignition energy’ (MIE) and
‘maximum experimental safe gap" (MESG);
4) sporopriste T-ratings for apparatus relative to the ignition temperature of
siven flammable material;
°
©) the levels of ingress protection” General principles
‘Nature of flammable materials
Fire triangle
‘The fire triangle represents the thee elements which must be preseat before
‘combustion can take place. Each point ofthe triangle represents one of the essential
elements which re:
Poet: ‘This can be in the form of a gas, vapour, mist or
dust,
@ Onygen: Plentfal supply since there is approximately 21% by
volume in ai.
(@) Source ofignition: This can be an are, spark, naked flame or hot
surface.
Gas or vapour
Oxygen
21% in air) Source of ignition
Combustion will uke place if all three elements, in one form or another, are preseat,
‘he gavair mixtur is within certain limits and the source of ignition has sufficient
‘nergy. The removal of one elemeat is sufficient to prevent combustion, as is the
isolation or separation of the source of ignition from the gasfair mixture, ‘These are
‘wo techniques used in explosion protected equipment. Other protection techniques
allow the tree elements to co-exist and either ensures that the energy ofthe source of
ignition is maintained below specific values, or allows an explosion to take place and
‘contains it within 2 robust enclosure. ‘These techniques are addressed inthe various
secdons of this manual.
oqv Flammable (Explosive) Limits
‘Combustion wll only occur if he female mixture comprising fuel inthe form of
2 gus or vapoe, and air ae within cea limits These limits ae the ‘lower
explosive limit (LEE), andthe ‘upper explosive limi (UEL, and betweca these
limite is nownss the Gamumable range
‘An every day example of this is the carburetor of a petrol engine, which must be
‘tuned toa particular point bewoen thse limits in order that the engine may function
elfcieaty.
Lower Explosive Limit: When the percentage of gas, by volume, is below this
limit the mixture is too weak fo bum, ie. insufficient
fuel and/or too much at,
Upper Explosive Limit: When the percentage of gas, by volume, is above this
limit the mixture is too rich fo bur, ie. insufficient air
andjor oo much fuel.
‘The flammable limits of some materials are given below.
TEL
Sby Volume Flammable (Explosive) Limits (continued)
Different gases or vapours have different flammable limits, and the greater the
dlifference between the LEL and the UEL, known asthe flammable range, the ore
dangerous the material. An explosive (Gammmable) atmosphere, therefore, only exists
‘tween these lit,
Operational safety with flammable mixtures above the UEL is possible, but is not a
practical proposition. It is more practical to operate below the LEL.
Sources of ignition
Soures of ignition are many and varied and inciude:
(@) elec aressparts;
©) tons spas
(bot surtacess
(©) welding stvtes
© caarenes;
© sic discharges;
(@) bates,
(@) exhausts of combustion engines;
© termite action;
6) sodium exposed to water
(8) pyrophotie reaction;
© chemical reactions;
(@)Hghting strikes;
‘The source of ignition as far as this text is concemed is primarily electrical
‘equipment.
4h»
‘Unit 1 Revised 202007 Flashpoint
‘By definition Mlashpoint is: ‘the lowest temperature at which sufficient vapour is
siven off a liquid, o form a flammable mixture with sir that can be ignited by an arc,
spark or naked fame’. Typical values are given below.
‘The Mashpoint of a material gives an indication of how readily that material will
ignite in nomml ambient temperatures, Reference 10 the tables of flammable
‘materials from PD TECSQ079-20 (see Appendix 1) reveals that different matedals
Ihave different Zashpoiats, which vary from well below to well above 0°C.
[Materials with bigh Gashpoints should not be overlooked as a potentil hazard since
exposure 1 hot surfaces can allow a flammable mixture to form locally.
Furthermore, if Dammable material is discharged under pressure from a jet, is
‘lashpoint may be reduced,
Amount of vapour released dependent
‘on temperature
sQw Flashpoint (continued)
Kerosene: flashpoint 38°C
Ata7c:
Insufficient vapour
given off
At ONC: \ \ ‘\ \
Negligible vapour J} } )
siven off ceed
e& ‘Ignition temperature
Ignition temperature is defined as: “the minimum temperature at which alammable
‘terial wil spontaneously ignite’
Ignition temperature, formerly known 2s auto-igntion temperature, is an important
perameter since many indusirial processes generate beat. Cateful selection of
Clectical equipment will ensure that the sutface temperamres prodaced by the
‘equipment, indicated by the T-rating, will not exceed the ignition temperature ofthe
flammable amosphere which may be present sround tho equipment. Typicel values
of ignition temperature are:
Tama
Teiitiew
fe jouLe)
1g3
(Carbon Disuiphide
yaw ‘Oxygen earichment
‘The normal ozygen content in the atmosphere is sround 20.95% and if a given
location has a value which exceeds this itis deemed tobe oxygen enriched. ‘Typical
examples of where oxygen enrichment may occur aro ga8 manufacturing plants,
hospital operating theatres, and where oxy-acetylene equipment is used.
Oxygen enrichment has tree distinct disadvantages. First of al, it can lower the
Jgnition temperature of flammable materials as shown inthe table below,
Mata
Tipdiogen vlphe
‘Acetylene
thane
‘Allvaluo obtained from a source other than FD TECE0079.20,
‘Secondly, oxygen enrichment significantly raises the upper explosive limit (UEL) of
‘the majority of gases and vapours, thereby widening their flammable ange. This is
illustrated inthe ‘ollowing table
Al values obialned from source other than PD IBCG7920
‘Thirdly, oxygen enrichment of g flammable atmosphere can allow it tobe ignited
‘with much lower values of electrical energy.
Explosion protected equipment will have been tested in normal atmospheric
conditions and, terefore, the safety of such equipment in an oxygen enriched
‘atmosphere cannot be assured because of the modified nature of the flammable
mixture.
84
alt o1- Revised s0a007 Density
1a fammable material released, it is important to know whether the material will
se or fll i the atmosphere, The different lammable materials are compared with
‘ar and allocated a sumber to denote their relative density with sir- Since air is the
reference, its relative density is 1 so that for a material wvice as heavy as at, its
‘relative density willbe 2. Therefore, materials with a relative density less than unity
vill ris inthe atmosphere, and those greater than unity wil fall inthe atmosphere.
‘Materials whict rise in the atmosphere can collect in roof spaces, end those which
‘al, such as butane or propane, can drift along at ground level and possibly into a
oathazardous location, or may collect in locations lower than ground level without
ver dispersing, Sach locations should be well ventilated in order to avoid ignition
de to asiray spark or a discarded cgarete
Koowledge of where s Dammble material will collet enenres that one detectors
‘When fitted willbe located a the core level and ventilation is directed accordingly.
adr Area classification
‘An hazardous area ig defined as: ‘an area in which an explosive gas atmosphere is
present, or may be expected to be present, in quantities such as to require special
precautions fr the construction, installation nd use of apparatus.”
‘A non-hazardous area i defined as: ‘an area in which an explosive gas atmosphere
{is not expected tobe prestat in quantities such as to require special precautions for
the consructir, installation and use of apparatus.”
Zones
Zoning is a means of representing the frequency of the occurrence and duration of
‘an explosive gas atmosphere based on th identification and consideration of each
and every source of release inthe given areas of an installation. Zoning will have a
bearing on, and simplify the selection of, the type of explosion protected equipment
‘which may be vsed. Hazardous areas are, therefore, divided into three Zones which
represent his rik in eras ofthe probability, frequency and daration af a release
‘The three Zones, a5 defined in BS EN6OO79-10: Hlectical appara for explosive
gs atmospheres Par 10, Clasifiotion of hazardous seas, ae as follows:
Zone® = In this Zone, an explosive gas atmosphere is
‘continuously present, or present fr long periods;
Zone! -_In this Zone, an explosive gas atmosphere is Likely to
occur in norinal operation.
Zone2 =m this Zone, an explosive gas atmosphere is not
Ikely to occur in normal operation and, if it does
cccur, is likely to do so only infrequently and will
exist fora short period only.
Although not specified in the standard, itis generally accepted in the industry that
the duration of » gas release, or a number of gas releases, on an annual basis (one
‘year comprises cia 8760 hous), forthe different Zones is as follows.
Jone? - 0 -10hours
Zonet ~—10- 1000 hours
Zone over 1000 hours Area classification (continued)
Zone representation for ‘Area Classification Diagrams’ as recommended
BS EN60079-10
9]
9}
9
3|
|
9}
|
|
|
:
a
Zone 2
Zone 0 representation
%
3
2
3
E
3
6
Whe Area classification (continued)
Fixed roof storage tank
55
see
SS
“st
es
z
=
<
ee
355
S
oe
So
=
ae
me
SS
SS
wee
RE
a
SS
Me
mes
ae
oe
see
oe
SS
°
bx
on
&
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ae
Be
ae
BS
b&w ‘Area classification (continued)
Sources of release
= Non-hazardous
Flanged joint:
=Zone2
Pump gland:
=Zone
‘Space above liquid
in a closed tank:
=Zone0
Bae
Unit o1 -Revsod sun007 Platform hazardous areas
bye
: Ae
= i 3
23 bs:
Non-hazardous
Hae Gas / apparatus grouping
In the TEC system, the Group allocation for surface and underground (mining)
industries are separate. Group I is reserved for the mining industry, and Group IT
‘which is subdivided into IC, IIB and IIA for surface industies, The representative
ses forthe sub-groups are shown in the table below.
* Two methods have been used to ‘group" these flammable materials according tothe
egree of risk they represent when ignited. One method involved determining the
Suminimum igniton energy which would igaite the ropeseatative gases. The values
‘obtained are rlovant to ntrinslcaly Safe apparatus. In the table below it can be
seea that for Group 1, hydrogen and acetylene are the most easly ignited and
propane the last easly ignited,
‘The other meth nvolved tests using, for example special ameproofencosare in
the form ofan lie sphere which was situated inside a gas-tight calosure. Both
halves ofthe sper had 25 mm slanges anda mechanism enabled the gap dimension
Doreen the fanges oe varied. During test, the aeas inside and ouside the sphere
‘were oocupied with ages in its most explosive coaceatration in ir and, by mesns of
Sparcplug the sas aside th sphere was ignited. ‘The maximum dimension between
the flanges, which prevented ignition of the gasair mixture, is known as te
~Smaximum experimental sae gap" (MESG), and the values forthe representative
{gates are shown in he table below. The more dangerous aes, the ght the gep at
{he flanges has be. Tri import t note sat tae MES values are aot used for
the design of Pameproof apparatus, only the maximum working gps.
‘The table alo shows that chee flammable materials fll into the same order for bo
tests, i. in a relative context, hydrogen and acetylene present the most risk and
propane the leas risk in terms of “minimum ignition energy" and “MESG’,
‘Note: Apparatus other than Mameproof or intrinsic safety, which has 20 sub-
Aivision iter (A,B or C) after the group I mark, may be used in all hazards.
‘Apparatu marked IXXXXX: _XXXKX represents the chemical
‘fommula or name of @ flammable material, and apparatus marked inthis way
‘may onlybe used in that hazard.
wire Gas / apparatus grouping
‘The sub-group marking is one of the important considerations during the selection
process af explosion protected apparatus. For example, apparatus marked IIA can
‘only be used in TTA hazards such as propane, it cannot be used in IIB ot IC hazards,
Apparetas mated IIB can be used in IB and IA hazards but aot IIC hazards
‘Apparatus marked TIC canbe use inal hazards.
Apparatus for determination of MES.G.
1 @Smen) FLANGE WIDTH
kaw Gas / apparatus grouping
(Comparison of BS 229 and IEC
[BS 229 is an eld British Standard, which is obsolescent, but electrical apparatus,
although very fow, has still been manufactured to this standard. Apparatus
‘manufactured to BS 229 has sub-group markings which ae different to those of the
TEC system and the comparison is shown in the table below. The introduction of the
'ATEX Direcives after 30 Tune 2003, however, may well cause manufacturers 10
Giscontinue the production of apparatus to this standard, but apparatus already in wse
willbe unaffece.
tear ‘Temperature Classification
Approved electrical equipment must be selected with due regard 10 the ignition
temperature ofthe flammable gas or vapour which may be present ia the hazardous
location. Apparatus will usally be masked with one of the temperature codes shown,
inthe table belew.
Temperature codes
Inthe table below, it willbe observed that for each material, che T-rating temperature
Is below the ignition temperature of the Dammable material, Moreover, the T-ating
temperatures are based on a maximum ambient rating of 40°C as far a8 the UK is
‘concemed. For example, apparatus classified 7S, based on a 40°C ambient rating,
will have macimum permitted temperature rise of 60°C. In order 10 avoid
infringement of the apparatus certification, the ambient rating must be compatible
with environmesal ambient temperatures, and the temperature rise not exceeded.
‘This is demoastrted on page 19.
‘A further consideration is apparatus for use in hotter climates, typically found in
‘Middle and Far Easter counties, which will usually require ambient ratings greater
than 40°C.
Sthylene 425 12 600°C)
Cyelohexane 3 200°C)
Diethyl Etter TH (35°C)
775 (100°0)
Carbon Disulphide TESO,
whe
nit O1- Read syenr007 ‘Temperature Classification (continued)
(75)
too’
40°C
20°C
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P2emn* C10 Gane sumpace renrenatuee C200 °C
Ste me Youn ounrmen CTS We
08 Rain AT ASE kupicwy 8000007
A Reyveey we paw 0/60 AMBIUT OR 1.0W wl Ane AUBERT Ingress Protection
‘Enclosures of slectrical equipment ae classified according to their ability to resist the
Ingress of solid objects and water by means of a system of numbers known a8 the
International Protection (IP) Code’. This Code, which is aot always marked on
spparatus, consists ofthe leters IP followed by cwo numbers, eg. IPS6,
‘The fist numer, in the range 0 - 6, indicates the degree of protection against solid
Dodls, and the higher the number the smaller the sold object tht is prevented from
entering the enclosure, Zero (0) indicates no protection and 6 indicates the apparatus
is dustsight.
‘The second number, ranging from 0 - 8, identifies the level of protection against
water entering the enclosure, ie. 0 indicates that no protection is afforded, and & that
the apparatus con withstand continuous immersion in water at a specified pressure
‘An abridged version ofthe fal table is shown below.
Level of Protection “Level of Protection
[No protection No protection
Protection against bjs Proteetion against drops of
greaer than 50 mm wate falling vertical
Protection against objects Protection against drops of
greater than 12 mm water when ited up 1 15"
Protection agains objec Protection agninst sprayed
tr than 2.5 mim ‘water up to 60"
‘Protecdon against objects Protection against splashed
greater than 1.0 mm ‘water fom any direccion|
Protection against ets of wats
Dus from any direction
5 Proecton a
Dustighe Pets ast
Froecion gins mein
inward and for @®ece
Unit 2:
Standards, certification and marking
Objectives:
(On completion of this unit, ‘Standards, Certification and Marking’, you should know:
current British, European end Intemational Standards and also relevant older British
a
Standards and Codes of Practice;
) the certification process for explosion protected appareas;
©) the methods of marking explosion protected apparatus. Standards, certification and marking
Introduction
‘There are many industries involved in the process of hazardous materials, and these
include chemical plants, oil reiaeries, gas terminals and offshore installations. These
{ndustis rely heavily on electrical energy to power, for example, lighting, heating and
rotating electrical machines.
‘The safe use of electrical energy in the hazardous location ofthese industries can only
be achioved if tied and tested methods of explosion protection are implemented and to
this end, the authortes involved in the writing of standards, testing and certification of
‘equipment have a very important role to play.
Since the easly 1930's, many standards have evolved as a result of careful research,
‘often prompted by incidents such asthe Senghennydd colliery disaster in 1913 in which
4439 miners lost their lives. The cause at that time was not fully understood but afer
investigation, was thought to have been due to an electrical spark igniting methane
(Gredamp) present in the atmosphere. Other disasters include Abbeystead Water
Pumping Station in which 16 people lost their lives, once again due to the electrical
{ignition of methane gus, Flixborough where an explosion Killed 28 people due 10
{ignition of a massive release of cyclohexane, and moze recently Piper Alpha in the North
Sea in which 167 men lost hee lives.
‘Construction of apparatus to relevant standards coupled wih testing by an Independent
expert test authority wil ensure thatthe apparatus is suitable for is intended purpose.
[Explosion protected apparatus may be constructed in accordance with relevant
standards, but the inxegaity of such apparatus will nly be preserved if such apparatus is
selected, installed and maintsined in accordance with the manfscturers
fecommendatons. Guidance in tis respect has been provided for many years by the
UK Code of Practice BS 5345, but this document has been superseded by a new series
‘of five separate standards based on the TEC79 series of Intemational standards. These
five documents apply to explosion protected apparatus/systems in all counts in the EU
‘and cover (1) selecion and installation of apparatus, 2) classification of hazardous
areas, and (3) inspection and maintenance. Repair of explosion protected apparatus (4)
snd data for fammable gases (9) awe provided by two IEC documents. These new
Standards are a furtier stage in the process to harmonise standards within the EU.
“Although BS 5345 has been withdraw, it nevertheless remains a source of information
for older installations, but applies tothe UK only wit regard to the EU.
Jn the United Kinglom, manufacturing and testing standards are published by an
‘rganisetion Inown as the British Standards Institute (BSD. With regard to the
‘Buropean Community the organisation which publishes harmonised standards for i's
member nations is tie European Committee for Electrotechnical Standardisation
(CENELEO) and, with global harmonisation of standards the ultimate aim, the
International Electrotechnical Commission (IEC) publishes standards for this
Purpose,
Historically, equipment designs were evaluated and prototypes tested by independent
arganisations, one of which was formerly known as “British Approvals Service for
Electrical Equipment in Flammable Atmospheres (BASEEFA), but was later known,
ten neind menace ss ‘Electrical Equipment Certification Service (ECS). The scronym, BASEEFA,
‘which bas been closely associated with explosion protected apparatus for many years,
‘was retained by EECS for cerification marking purposes. EECS, which was pao the
‘iealth and Safety Executive (HSE), sso published standard for special applicaons.
TEBCS, however, closed for business in September 2002, but encouraged by several
‘major customers, former staff established an independent organisation known as Bseef
(2001) Lid. “Having traded since March 2002, Baseefa (2001) Lid. became in EU
‘Notified Body (NB) in June 2002 and wes allocated the NB Number 1180. With the
ATEX Directives becoming mandatory after 30 June 2008 the certification authors in
‘Burope are nove known as Notified bodies with thei own uaigue NB number, which
‘will be marked on the certification labels of ATEX approved apparatus. Other Notified
‘Bodies in the UK include SIRA Certification Service, NB Number 0518, and ITS
‘Testing and Certification Ltd., NB Number 0359.
Some of the other overseas organisations involved in the publication of manvfacuring
and testing standards, and also certification services are introduced later in this Unit.
Reasons for Product Certification
1) To demonstrate product quality with regard to the ability of the apparans to
function safely in an hazardous environment.
2) Toenbance market acceptability by inspiring confidence in those involved inthe
seletion, purchase, instalation, operation and maintenance of approvedicentfied
products
3) Toimprove quality and safety contol
contin onss APEX ~ EU Bt
‘The ATEX Directives, ATEX 95 (formetly ATEX 100s) and ATEX 137, became
‘mandatory after 30 June 2003. ATEX 95 is the product directive and ATEX 137 s the
user directive. ATEX 95 requires all new equipment, ie. equipment and protetive
systems for use in potentially explosive atmospheres, placed on the matket of the
Buropean Community for the frst time to be manufactured in compliance with the
irective. Apparatus from out withthe EU, whether new or second hand, imported into
the European Community and placed on the mazket forthe fist time must also be in
‘compliance with the directives.
etn
In onder to comply with ATEX 95, products must satisfy the Esseaial Safety
Requirements (ESR’s), specified in the annexes ofthe Dizectives, with regard the
inherent risks associated with the product forthe protection af the public. This agplies
to both electrical and non-letical (mechanical) equipment. Subject to a succes
‘Conformity Assessment, his wil enable the product o display the CE mark.
‘The Conformity Assessment involves a series of Basic Modules which ae listed in the
‘able below and their aplication in the subsequent simplified flow char.
net petit CE Conformity assessment modules
[RT ntemat conte of production ]
Gover tntemal dsign and production contol
Does not require the involvement of a notified
bos
TEC type-examination
‘Covers the design phase, the BC type-examination
being issued by a notified body. Has to be
followed by a module for assessment during the
production phase
[| Product quality assurance
© | Contorainy ope ‘Covers the production phase wer module B. This
‘module confirms conformity ofthe product with
that described in the EC examination certificate as
{issued during module B.
[D_ | Production qualiy asurance | Covers the production phase following module B.
Production quality assurance is based on the
standard EN ISO 9002 and the involvement of a
notified body who has responsibilty for the
approval and control of the quality system
ning production, ed product inspection and
the manufacture.
Gores te producer ne lowing alae B
Production quality assurance is based on the
standard EN TSO 9008 ind the involvement of =
notified body who has responsibilty for the
approval and contol of the quality. system
regarding end product inspection and testing
implemented by the manufacturer.
‘Product verification
‘Covers the production phase following module B.
‘The EC type examination carried out by the
notified body, to ensure conformity to type in
module B, is followed by the isue ofa certificate
‘of conformity.
alt verification
[Hr | Fall quality assirance
‘Covers the design and production phases. A
cetificate of conformity is issued after
examination of
Covers the design and production phases. Quality
assurance is based on the standard EN ISO
‘9003 and the involvement of 2 notified body who
has responsibility forthe approval and contol of
the quality system for design, manufacture, final
product inspection and testing implemented by the
‘manufacturer. CE Conformity assessment modules (continued)
‘The illustration below shows how the modules listed on the previous page may
implemented to obain the CE marking for epparats
ATEX 95
‘The ATEX Directive 94/9/EC (ATEX 95) was adopted by the EU to enable fre trae of
products between member states through alignment of technical and legal requirements.
‘The directive applies not only to electrical equipment but also to mechanical equipment
and protective systems used in the presence of potentially explosive atmospheres
‘containing gases/vapours or combustible dusts
[Equipment is defined as any item which is inherently ignition capable or is potentially
‘ignition capable and requiring the inclusion of special design and installation techn ques
to prevent ignition of any surrounding flammable atmosphere which may be prescat
‘The ‘equipment’ may also be interfaces located inthe non-hazardous area which ate pare
‘of an explosion protection oystom. Protecdve systems include qucuching systems, Hane
arestors, fastacting shut-off valves and pressure relief panels installed to limit the
‘damage or prevent the spread of explosions.
koa Reed reeset ATEX 137
‘The ATEX Directive 99/92/5C (ATEX 137), commonly known as the “us directive,
will ‘be implemented in the UK via the Dangerous Substances and Explosives
‘Atmospheres Regulitions 2002 (DSEARs). Employers are obliged to implement the
following minimum requirements in the workplace with regard to DSEARS.
8) carryout arse assessment where dangerous substance is or may be present;
eliminate or reduce risk as far as is reasonable practicable;
©) classy locations in the woskplace where explosive atmospheres may be preseat
into hazardous or non-hazardous aeas ;
4 have in place proceduresfacilities to deal with accidents, incidents and
emergencies volving dangerous substances inthe workplace.
©) [provide appropriate information and taining of employees for their safety
Tegarding precautions to be taken when dangerous substances are present in the
‘workplace, written instructions for tasks undertaken by employees and operation
of permit-osvork system;
1) clearly identify the contents of containers and pipes
{®) co-ordinate operations where two or more employees share a workplace in which
a dangerous substance may be present
1) posting of waring signs for locations where explosive atmospheres may occur,
4) selection of equipment in accordance with ATEX 95 and establishment of =
maintenance programme.
Marking of hazardous areas
All workplace hazardous areas must be indicated by a sign,
as illustrated opposit, at the entry points to the hazardous
seas. This applies fo all new installations brought into
service after 30 June 2003. Existing installaions have an
additional 3 years to meet this requirement. ‘The directive
specifies the exact requirements for te sign but generally it
{is required to be triangular with yellow background, black
border and marked ‘Er’, European test authorities
For the purpose ofthe ATEX Ditectves, the European test/cerification authorities are
‘now known as Notified Bodies, organisations which have been appointed by -heir
respective governments. Some examples are shown inthe map of Europe below along
with their Notified Body (NB) number.
Finhnds VIT nduail Svseam 557)
‘Sweden SP Swedish Natal Tein (402)
Norway: NENKO AS (270)
DNV AS (0575)
Deamarks UL in DEMKO A'S 0539)
"UK: Basees@00 LDA 18D)
SRA 0518)
nna (Germany: FB (1)
TTS Testing & Cu Lid 359) if
ya's Reg Ver Lid (008)
‘Neherlandss KEMA (368)
‘Belainm: [SSP (0539)
France LOE (08)
NERS (0080)
‘Spain: LOM (0163)
aie CES
oan Raine ett Evolution of BS - British Standards
2000 i
185 J BS - Euronorms (BS - EN) a rue
1990 |8| Sex pe °
1930 | BS 5501 1 (pc ronean pos
- E
oe fF 1970 |Z 5s UK
© b. 1960/3
= 4950 |2| ome,
| fF Rey
CP 1003 ,
1940 BS 1259 Use
1930 «BS 889
1920 BS 229 (Flameproof- FLP)
SMRE: —_Safetyin Mines Research Establishment
BASEEFA: Brtist Approvals Service for Electrical Equipment in Flammable
Atmospheres ‘Comparison of IEC, European (CENELEC) and British Standards
Pilot to the closer ties between the UK and Europe, electrical equipment, such as
flameproof or increased safety etc, was manufactured in accordance with the Batsh
Standard BS 4683, Equipment bull and certified to ths standard was ented to display
the mark Ex on its label, which indicated that the apparatas was explosion protected.
This term should not be confused with term explosion-proof as they are entirely
diferent. In addition to the “Ex” mark, the label was also marked with a ‘crown’
symbol, which isthe distinctive mark for the UK test house BASEEFA, later to become
known as EECS, Other examples of marks are shown on page 12 ofthis unit.
‘Because ofthe diferences in standards, equipment manufactured in the UK could not be
‘used inthe other European countries and vice-versa, and hence, equipment made to BS
4683 could only be used inthe UK, or in other countries outside Europe. Co-operation
between the standards writing bodies inthe UK and Europe resulted inthe development
‘of “Harmonised” standards, also known as “Euronorms’, for which the English version
‘was published a8 BS $501 and comprised nine separate parts as shown in the thed
column of the table on page 10. The Euronorm equivalents, written in French or
German, awe shown in the first columa. Column four shows the new numbers forthe
revised standards which will rplace BS $501.
However, with the trend towards global harmonisation of standards continuing to make
progress, «new series of standards has been gradually introduced having numbers based
‘on the Intemational Standard numbers as shown in column five of the following table.
[Note:The draft Buropean (CENELEC) standard, ENSO 021 for type of protection ‘a’,
‘which fd been under consideration for many years, was finally approved
‘on 1 August 998 and issued as BS ENSO 021 in April 1999. Asa consequence,
the UK standard BS 641 although curent a the time of writing, is proposed for
obsolesoence.
ea Revie Pesci Comparison of fC, European (CENELEC) and Bi
DARBY
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BS 4683:Pan 3 | Type ofprotetion 'N OpsoueTe (414)
'BS-4685:Part4 | Type of proteton
"BS 5000: Par 15 | Machines with ype of protection‘
BS 5000: Far 16 | Type °N’ elecire motors
je
a nd Pees ‘Standards for Selection, Installation and Maintenance
‘As previously stated, the UK Code of Practice BS 5345, which has for many years
provided recommesdations for te selection, installation and maintenance of explosion.
protected apparatus for use in potentially explosive atmospheres (other than ‘ining
spplications or explosives processing and manafacrre), listed inthe upper table below,
‘has been superseded by the standards isted inthe lower table, but may be referred to for
installations installed in accordance with its requirements. ‘The table below illustrates
its component pars of BS 5348.
UK Code of Practice “Type of Protection
BS 5345: Partt General Recommendations
BS S5:Pan 2 ‘Chesca of Haardow Anas
BS S33 9.5mm providing the free intemal volume dacs not
‘exceed 500 en.
8) Flanged joint
») Spigot joint
©) Screwed joint Flamepath joints types (rotating machines)
(@ cylindrical (shat gland) joint
(©) labyrinth joint for shats
pene ‘Flamepath joints (other examples)
‘lamepaths other than those at cover joints are also necessary where, for example, an
actuator spindle passes through the wall of an enclosure, of where a cable gland ot
‘conduit enters an enclosure. Examples are shown below.
‘Push-button spindle Entry by cable gland or conduit
‘The thread engagement requirements for cable and conduit entries are specified in
'BS EN60079-1 and apply to the three sub-groups ITA, IIB and TIC.
Only threaded entries are permitted for ll cable glands or conduit entering flameproof
enclosures - clearance entries are not permitted.
> 100 oat
Thread ‘Axial
engagement | _
> 5 fallhroads
As already stated the above requirements for thread engagement are specified in the
latest standard BS EN60079-1: 2004, but the previous standard BS ENSOOS: 2000
‘required at least 6 full tteads engagement in order to make sure that 5 ful threads
were actually engaged.
es rpsat Unused cable or conduit entries
Its important tha: unused cable/conduit entries in fameproof enclosures are closed
using appropriate stoppers as specified in the standards or supplied by the
‘manufacturer. These must be ‘component certified’ metal stoppers - plastic stoppers
are unacceptable - which are fully engaged by § full threads. The construction
‘Standard specifies suitable types, examples of which are ilustated below.
Split pin Screwativer slot
| < Special fastener
Interior Exterior
Hexagon head
‘Shearable neck
‘Stoppers of the typ ilustrated by example ‘C’ in the above diagram are available
‘with certifeation markings on ether the plain side or the same side as the hexagon
recess. ‘Ideally, stoners ofthis type should be fitted with the plain side facing the
‘exterior to make uauthorised removal more difficult, but may be fitted with the
Dbexagon recess facing the exterior. Whichever way round they are fitted the
certification markings must be visible for ease of identification during ‘Visual’
Inspection programmes and also the thread engagement requirements must be met.
‘Stoppers ofthis type are tightened using an Allen Key. ions - BS EN60079-1, Table 1
‘Flamepath gap ait
def inane oq Bosuaro.op vawn uByEH 64 PMOVS OVE OSI} Buoase popunan Fone TPUORIRARUOD ALON
wo elo wo] sro sf0 w'a]sro sro wfo|ove sco wo] or
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zo oco ovo] oco sro ova] oro sro oso a ov) stn
~ = =] = = = |sv0 ovo oso] sco sro oso] oe
- - -|- - -|- - = |oco ora ovo 9
sco 070 o0| oro of | arv oF ovo] oro ovo ovo] or i
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= oro ovo] oro oro ova| ero ove oro| aco seo oro] se *tammal gtore
- = =] = = = Jove ovo se0| oz cco seo} 6 span yee
= - - - = == | ovo oe'o oc’ 9 resupung |
wo ovo ool oro oro oso[azo oro oo] oro oro oso] se
sro ozo ora| oro oro oro|aro aco oro|azo oro oro) sz
- = =| = = = foro oo seofoco oro sco] se
- = -|- - -|- ~ ~ foro ovo aco] 9
ita lw [a [a [wpo vf
a
sungrtiey | cunforevos | oun esoy | _aumin'tsos_| sop
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08 winpeoyy
ap eeae Flamepath gap dimensions - BS EN60079-1, Table 2
“da ras a9 Suomaion eau ye a nee 1¢ 06m Bnae papana! Sita RUNTARIOD AULA
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sedate = Pressure piling
fs ammable mixture is compressed prior to ignition, the resulting explosion willbe
‘considerably higher then if the same mixture was ignited at normal stmospheric
pressure,
Pressure piling can materialise as a result of sub-division of the inteior of
‘lameproot enclosure, which prevents the natural development ofan explosion.
‘An explosion atone side of an obstacle pre-compresses the flammable mixture the
other side, resulting in a secondary explosion that can reach an explosion pressure
around three times that of the first or normal explosion pressure
“Manufacturers, guided by relevant construction standards, must ensure that, in any
‘cross-section within an enclosure, there is adequate fre space (typically 20 - 25% of
the tofal cross-section) around any potential obstruction, which may be a large
component or a number of components. ‘This will ensure that pressure pling is kept
‘under cont.
aes estas Pressure piling in flameproof motors
In rotating electrical machines, sections with appreciable fre volume normally exist
at each end within the main frame of the machine. ‘These sections are linked by the
airgap between te stator and rotor cores. In the illuswation ofa flameproof machine
in the diagram below, an explosion in section ‘I’ must be preveated from migrating
‘o, and causing ignition of the fammable mixture in section ‘2" which will have been
pressurised by te intial explosion. The airgap, therefor, also acts as @famepath. Obstruction of Flamepaths
‘The UK Code of Practice BS 5345 Part 3 recommended that obstruction of
‘lameproof enclosures, particularly those with flanged joins, should be avoided. ‘This
recommendation is also given in BS EN60079-ié: Flectieal insallatcns in
Inazardons areas (other than mines)
‘A solid obstruction such as 2 wall, stehwork, conduit, brackets, weatherguards or
“other electrical apparatus ec, in close proximity tothe opening at the joint can, in the
{event of an internal explosion, reduce the efficiency of the Darnepath tothe exteat that
‘ignition ofthe extemal gas or vapour could occur.
‘The minimum distances between the Damepath opening and an obstruction, as
specified in BS EN60079-14 and BS $345: Part 3 ae:
ves eur ‘Weatherproofing
lameproof equipment must have a level of ingress. protection to suit the
‘environmental conitions in which the equipment is installed. Equipment should
Ihave, as part of their approved design, seals or gaskets to prevent the ingress of water
and/or dust. Additional measures may be required, however, to comply with the
requirement in BS EN6QQ79-I4 that flameproof joints must be proteced aguint
corrosion andthe ingress of water.
‘Where eavironmental conditions are extreme, consideration of additonal measures
‘may be necessary If this is permissible after Consultation with relevant standards,
or the manufacturer or other authority. These measures ste specified in BS
TEN60079-14, the Standard which gives recommendations for the selection and
Installation of electrical equipment in hazardous areas. This standard specifies the
limitations of use for non-hardening grease bearing textile tape (typically Denso tape)
1s detailed below, and non-setting grease or compounds
‘The use of non-sating grease on the machined surfaces of flamepatis has two
sdvantages since, ic addition to providing an additional level af ingress protection, it
als inhibits the formation of rast on these surfaces.
Silicone based greases require careful consideration in order to avoid possible damage
to the elements of gas detectors.
For flameproof equipment, the limitations for the use of non-hardening tape as
specified in BS EN€0079-14 ae as follows.
—(@) _Non-hardenig tape may be applied around the famepaths of spparatus with
flanged joins allocated to group TIA applying one layer only with a short
‘overlap.
(©) Forgroup IB apparains, one layer witha sort overlap may be applied eround
{he Mamepats of apparatus with flanged joins, but only ifthe gup i less than
(O.1mm regariless of the joint width. (S,ISULT TANGA AUTHORITY
Note: The Code of Practice BS 5345: Part 3 (withdrawn but a relevant
source of infomation for older installations) recommended that expert advice
be sought when considering the use of non-hardening tape on group IIB or
THC equipmeat installed in locations containing group IIB gases or vapours.
(©) Non-hardening tape must not be used on equipment marked IIC (or IB + Hs)
installed in Iestions containing group TIC gases or vapour.
(© The machined surfaces of flanged joints must not be painted prior to assembly
Hlowever, an enclosure mey be painted after assembly
Age =
“(PBC rey peTyL- eer cuinys tL
PR) orl Come ponsross
pect. esisrOT,
was TEM, STB VE en
Mee Ingress protection methods
‘The diagrams below ilstate the location of gaskets or rubber ‘O" rings for ensuring
4 high level of ingress protection. ‘The gaskets etc. must be an integral part of the
original desiga, ie. they cannot be added ata later date to an enclosure manufactared
without gaskets. Typical examples for outdoor use ar illustrated below.
cee ete Direct / indirect entry
‘The selection of cable glands for fameproof apparatus is influenced by several
factors, one of which isthe method of entry into the apparatus. There are {0 entry
methods, namely direct and indirect, examples of which are shown below.
Direct entry comprises a single fameproof chamber within which components such
as switches, relays or contactors may be installed. Flameproof apparatus with
indirect entry has two separate chambers, one of which contains only terminals for
connection of the exaductrs of incoming cables or conduit. Connection to the acing
‘components inthe second compartment is made via these Bameproof terminals whieh
ass through the ameproof interface between the two compartments,
Peete Electrical protection
lameproof enclosures are tested for their ability to withstand intemal gas explosions
only; they are not capable of withstanding the energy which may bo released as a
result ofan intemal short-circuit. In order to avoid invalidation of the certificaton, it
is important that propesiy rated/alirated electical protection, e.g. fuses end/or
circuit breakers, are utilised.
vue pete ‘Modification of flameproof enclosures
Flameproof enclosures are normally supplied complete with all internal components
fitted and certified as e single entity by a recognised test aubority. The testing
procedure will take into consideration the free internal volume after all the
‘components have been fited, the temperature rise (determined by the maximum
power dissipation), ereepage and clearance distances, and the rise in pressure as 2
result of an intemal explosion using a gas/sir mixture in its most explosive
proportions.
‘The certification, therefore, “Seals” the design of the apparatus so. that any
‘unauthorised modifications will effectively invalidate the approval/certification
Modifications will modify the original test results recorded by the testertification
authority and, consequently, the following points should be observed,
(@) Replacement components should always be exactly the same as the original
specified components in order to avoid intingement of the certification. For
example, @ component larger or smaller then the original will affect the
internal geometry of the enclosure. Pressure piling isa possibility if a larger
componeat i fitted, and increased volume will result ifa smaller component is
‘ited,
Note: illustrations are for demonstration only and must not be carried
*
;
a (©) adding components is also forbidden because ofthe possiblity of increased
explosion pressure asa result of pressure piling.
fi
Addition of
‘component ‘C’
(© The removal of components should also be avoided since an increase inthe
{ee internal volume will result. The original test results, prior to certiestion,
‘would be compromised as a result ofa modification such a this,
Removal of
component ‘8°
lustrations are for demonstration only and must not be carried
out © Dailling and tapping of cable gland/conduit entries should only be carried
fut by the manufacturer of the enclosure, or his approved agent. The
threads ofthe entries are required to be compatible with those of cable glands
fr conduit in terms of type of thread, thread pitch and clearance tolerance
since flamepaths exist at these pints
Correct alignment of the threaded entry is also important since the
flamepath length at one side will be reduced ifthe cable gland or conduit is
‘ot fitted perpendicular tothe face ofthe enclosure.
‘The strength of a flameproof enclosure may be impaired ifthe number and
size of entries exceeds that permitted in the orginal design certified by the test
suthorty. Compliance with thé original design is paramount with regard to
number, size and location of entries to ensure the enclosure will contain an
internal explesion.
(©) Gaskets can only be replaced; they must not be added retrospectively if not
included as par of the original design.
‘The use of unmuthorised sealants should also be avoided when it is required to
maintain or improve the IP rating. BS EN 60079-17: Table 1: Inspection Schedule for Ex'd’, Ex'e’, and Ex‘n’
Installations (D = Detaled, C = Close, V = Visual)
0 Eee Ere [Ea
Die vor erv vic
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‘AL | Flange gap dimensions at wii sail permitd values
12 Lamp rng. spe and postion ae coer
13 | lest mses ae gh
14 | Conon of eoclosur stats ary
Tiny of cool system sd iterce with ed sem mao
i
“Eathng conection, nldg say spplemenay eng Yonding
soonectos are sista (9. canes ae ght nd condos te
suet cr soto,
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9 | Autti lacealpoestve devise SpEaie win poralod
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12 Giles ot ina re cael trated
13] Obsrctons adjacent o Hameo ange jaa ae Ta arodane wlk
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amo
“Rana db gaily rte agains Somaan, weal, ion
Later
‘No undo eccuusion of as and
Fle islaton i dea nd ry
eat Note 1
Note 2:
Apparat using a combination ofboth ‘d" and ‘e rypes of protection will
‘ei reference to both columns during inspection.
‘The use of elecerical test equipment, in accordance with items B7 and BS,
should only be undertaken after appropriate steps are taken to ensure the
surrouncing aeais fee ofa flammable gas or vapour. Qpoeoge
Unit 4:
Increased Safety Ex e & EExe
Objectives:
On completion of this unit, “Increased Safety Ex e & EEx e apparatus, you
should know:
8) the principe of operation;
») the principle design features;
©) the methods for estimating terminal content of enclosures;
the installation requirement according 1 BS EN 60079-4;
©) the inspection requirements according to BS EN 60079-17.
aot Reind rates Increased Safety Ex e or Exe
‘The explosion protection conoopt Increased Safety was lavented in Germany wher it
‘hasbeen widely used for many years. It is has become popular in the UK mainly
because it has a number of advantages for certs applications over the traditional
‘Mameproof method of explosion protection. America hes traditionally relied on the
tase of explosion-preof enclosures in hazardous locations, and the prospect of using an
Increased Safety enclosure, which is not designed to withstand an intemal explosion,
san alternative, hat probably beea viewed with a lite trepidation
‘This method of protection has a good safety record and comparable with the other
methods of protection. The leer ‘e” which symbolises this method of protection is
taken from the German phrase Ertohte Sicherheit, which roughly translated means
‘increased security’. Typical aplications are induction motors, lighting fitings and.
junction boxes.
THloovical apparats Tor explosive ges smosphores,
Increased Safety
BSENSO OID: 200 Increased Safety enclosure ©
BS ENGDOTOT TODS ‘Electrical apparatus for explosive gas aimospheres:
Par 17 Inspection and maintenance of electrical
installations in hazardous areas (othe than mines
BSS: Pan & 1978 Code of Practice forthe Selection, Installation and
ihren tenance of Increased Safe Definition
“A type of protection applied to electrical apparatus in which addtional measures are
applied so as 10 give increased security against the possibility of exossive
temperatures and of the occurrence of ares and sparks in normal service or ander
specified abnormal conditions.”
Zones ofuse: 1&2
Ambient temperatures
Increased Safety enclosures are normally designed for use ia ambient temperatures in
the range 20 °Cto +40 °C unless otherwise marked,
cownl ten oF USE
cate
NIT
ae open
ae Compe
fat CRT IF |
pre Principle
‘The safe operation of Increased Safety apparatus is dependent on the prevention of
any source of ignton, i excessive surface temperatures, ars or sparks, which
might otherwise be produced by intemal or exteral pats of the apparatus. ‘Special
design features are, therefore, incorporated inthe apparatus by the manufacturer and
areas follows.
1) Mechanically strong enclosure resistant to impact - tested to 4 or 7 jules
impact energy depending on application.
2) Tages protection guns solid objects and water a eas IP 4
3) Teminas manufactured rom high quality insulation mati
4) Specie cepage and earances incorporate the design of emia.
5) Terminal eng devices to casure conductors remain secur in sie
8) Ceriteddecang ofteminas
7) Terminal population of enclosure limited by creat design.
8) Close excess current cirenit protection. .
Joh coment
emp J" an
Increased Safety Terminals
‘The terminals installed in an Increased Safety enclosure must be ‘component
certified” terminals. They will be manufactured from good quality materials such as
‘Melamine, Polyamide and, for special applications, Ceramic. These materials, which
have good thermal stability, have been subjected to a ‘Comparative Tracking Index
(Cr test to detemine their resistance to tacking.
“The following definions are relevant
— Te stores dima shagh ir bass
seri Be .
— eee eee
THAEHLe pete ‘the surface of an insulator.
tog The iabag cat wtih pus acon te
contaminated surface of an insulator between live
‘terminals, or live terminals and earth
‘Comparative Tracking Index: The numerical value of maximum voltge, in volts
at which en insulation material withstands e.g, 100
drops of elecrolyte (usually ammonium chloride
solution a distilled water) without tracking. Increased safety terminals
Test criteria » Comparative Tracking Index (CTD
‘The Comparative Tracking Index (CT) tet criteria are given inthe table below. Four
grades of materials ‘s', ‘6’ ‘cand “a” are considered, the highest quality meteial
boeing ‘a’ which is subjected to the greatest number of drops of eleeolyte filling
between the test electrodes, and the highest voltage applied across the electrodes from
the variable voltage souree. Each material must withstand the specified numter of
«drops ofthe electrolyte atthe specified voltage frit to be acceptable.
‘Thus, the combination of high quality materials and good design, which incomperates
specified creepage and clearance distances, ensues that Increased Safety terminals
hhave a greater resistance to tracking to prevent arcing or sparking.
[Number of drops
TEC 60112 groups insulating materials according to their tacking resistance as
illustrated inthe following table.
‘Material group | Comparative wacking index (CTI)
1 00 < CTT
i 400 < CT < 60
Ta, 175 < CTT < 400,
Creepage and Clearance Distances
[Bena Disa
Greepage Distance.
ff JL
tote meses Increased safety terminals
(Creepage distances relative to voliage and grade of insulation
‘The following table from BS EN6O079-7 shows the creepage distances relative othe
sade of material and applied voltage.
Votge (ean 1) | ini csage dnsncs (ma) _] Wit Gemooe
U'rma seo de Mata em)
o. T |
0 (ase) igs [16 is,
aS. 16| 6] 16 16
16 16 | —46—[ “is 1a
20 1s | 16 [ts a6
25 ig [a7 47 aT
3 18 [1g] 18 is
‘2 19 | 2430 19
E zi [36 134 zi
a 31 [26134 2A
a0 323s 6 23.
10 2a] 30138 a
13 2s —[ 32 [40 25
160 sa [4-5 Fy
200 [30 | ~a5 aa)
230 a 30
320 63 en | 100. 0
<0 30 —| “109 [2 ‘60
00 102s} “60 a
‘30 120 |i [~an 7a
ca 160} a0] 250 120
000 au —|~389 | 0. 1407
0 ‘20 [350 —| se ie.
1a. 330[ 70 | 2a
2000 230—[ 260 | a0. 20
2300 s20_—| 360 | a0. a0
S200 ‘0 —|—as0 1500. 360
sc. 500 | ~s60 | 30. ‘ao.
$000 ‘sso [ 71.0] a S00.
300 ‘no —|~900 | “i000 CI
000 woos [i100 | “as. 0
7000 1250 | 1400} 1600 000
Note I> Voge how are deed om IEC 6666-1. The working vallage may enced the
‘voltages given inthe tbe by TS. Tiss based o he ratonaiation supply ages
vena ale 38 of TEC lest
‘Note 2: The repage dtc and learns values sbowa ar sed on a maximum apply walage
tolerance of 108,
[Nat 3: AITO andtelow, te valve of CTI is at levane nd metre aot mating ie
roquirenent or tial group Ila many be acepabe Increased Safety terminal types and ratings
‘The terminals are de-ated so that the maximum current for Increased Sefety
applications is nearly half that for standard industrial applications as illustrated inthe
following manufacturer's table for enclosures manufactured to BS ENSOOI9. This
