CompEx 01-04

Gas Vapour
Course Notes
 Cenelec Standards Inspections Ltd
Training Centre

National Training and Assessment for

Personnel Working in Potentially
Explosive Atmospheres
(Modules 1 to 4 Gas)

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 Introduction
This is a National Training and Assessment Scheme for electrical craft personnel
who work or intend to work in potentially explosive atmospheres.

On successful completion of practical and written assessments of each unit,

candidates will be awarded a Certificate of Core Competency which carries National
recognition among EEMUA members. JTL is the awarding body

CompEx is a competency validation initiative, jointly developed by the Engineering

Equipment  and  Materials  Users’  Association  (EEMUA)  and  JTL.  Based  upon  the  IEC  
International Standards, primarily BS EN 60079 - 10; 14 & 17, the scheme
certification body JTL, is now accredited by UKAS to ISO/IEC 17024: 2003 to
provide certification of persons. The IEC Standards are at the heart of all CompEx
delivery to ensure international conformity and harmonisation of safe working
practices.

Aims
The  aim  of  the  course  is  to  provide  delegates’  with  knowledge  and  understanding  on  
terminology and protection concepts for electrical/instrument equipment utilised in a
potentially flammable atmosphere.

Objectives
At the end of the course you will be able to:

 Recommend the remedial action required to maintain electrical/instrument

hazardous area equipment to meet the required standards.

 Select the protection concept, enclosure/equipment, glands and ancillary

components and install correctly in hazardous areas.

 Understand how to identify problems with electrical/instrument equipment

installed in hazardous areas with respect to the appropriate British, European
and IEC standards.

 Understand that electrical/instrument equipment can be a source of ignition

that could contribute to an Explosion.

 Understand the concept of area classification and the need to zone flammable
atmospheres accordingly.

 Understand the terminology and definitions associated with hazardous areas.

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  Understand the various protection concepts namely EExd, EExe, ExN, EExn,
EExia & EExib, EExp, EExo, EExq and EEXm.

 Understand how to identify problems with electrical/instrument equipment

installed in hazardous areas with respect to the appropriate British, European
and IEC standard.

Assessment
Combination of classroom delivery and practical/written assessment.

Each candidate is required to demonstrate competence through a series of practical

tests and written multi-choice question papers.

Certification
Successful course delegates will receive a UK JTL Certificate of Core Competence
valid for 5 years.

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History
Soon after the introduction of electric power into coal mines, it was discovered that
lethal explosions could be initiated by electrical equipment such as lighting, signals,
or motors. The hazard of fire damp or methane accumulation in mines was well
known by the time electricity was introduced, along with the danger of suspended
coal dust. At least two British mine explosions were attributed to an electric bell
signal system. In this system, two bare wires were run along the length of a drift, and
any miner desiring to signal the surface would momentarily touch the wires to each
other or bridge the wires with a metal tool. The inductance of the signal bell coils,
combined with breaking of contacts by exposed metal surfaces, resulted in sparks
which could ignite methane, causing an explosion.

Fire damp: consists of mostly methane, a highly flammable gas that explodes
between 5% and 15% - at 25% it causes asphyxiation

Senghenydd Colliery Disaster

The explosion was probably started by firedamp (methane) being ignited, possibly by
electric sparking from equipment such as electric bell signalling gear. The initial
explosion disturbed coal dust present on the floor, raising a cloud that then also
ignited. The shock wave ahead of the explosion raised yet more coal dust, so that
the explosion was effectively self-fuelling. Those miners not killed immediately by the
fire and explosion would have died quickly from afterdamp, the noxious gases
formed by combustion. These include lethal quantities of carbon monoxide, which
kills very quickly by combining preferentially with haemoglobin in the blood. The
victims are suffocated by lack of oxygen or anoxia.

In England, The Oaks explosion remains the worst mining accident, claiming 388
lives on 12 December 1866 near Barnsley in Yorkshire. The Hulton Colliery
explosion at Westhoughton, Lancashire, in 1910 claimed the lives of 344 miners.

An explosion in 1878, at the Wood Pit, Haydock, Lancashire, killed over 200
workers, although only 189 were included in the 'official list'. Another disaster that
killed many miners was the Hartley Colliery Disaster, which occurred in January
1862 when the beam of the main steam winding engine broke suddenly and fell into
the single shaft serving the pit. It blocked the shaft, and entombed hundreds of
miners. The final death toll was 204, most of whom were suffocated by the lack of
oxygen in the mine atmosphere.

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 Unit 1: Standards

International Standards - International Electro Technical Commission (IEC)

European Standards – Committee for Electro Technical Standardisation (CENELEC)

National Standards – British Standards

Standards moving towards harmonisation

IEC - Standards dealing with electrical apparatus for hazardous areas are numbered
in the series 79 - xx e.g. 79 – 14 this refers to electrical apparatus for explosive gas
atmospheres, Part 14: Electrical Installations in hazardous areas (other than mines)

Standards relating to this course are

60079-0 General Requirements

60079-10-1 Classification of areas (gas)

60079-14 Installation, design, selection & erection

60079-17 Inspection & maintenance

ATEX (ATmospheres EXplosive.)

Introduced into British Law March 1996 with transition periods.

All hazardous areas must now conform to ATEX 95 & ATEX 137 Applies to both
electrical & mechanical equipment.

The EC directive 94/9/EC applies to equipment, protective systems and components

intended for use in potentially explosive atmospheres. (ATEX Directive 95 )

The EC directive 99/92/CE concerns the minimum requirements for improving the
health and safety of workers in potentially explosive atmospheres.(Atex Directive
137( Was 118) – The UK regulations which puts into effect this directive is
DSEAR)

(Dangerous Substances and Explosive Atmosphere Regulations)

The main change in the EC directive 94/9/EC is that non-electrical hazards are now
brought within the scope of the directive.

Pump, mechanical seals, reducer, coupling, guard coupling and motor must be in
accordance.
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For new equipment, Compliance with the ATEX directive has been a legal
requirement in all European Union member states since 1st July 2003.

For equipment sold before 1st July 2003,

Equipment compliance with the ATEX directive is a legal requirement in all European
Union member states by 1st July 2006.

The end-user must complete with a notified organisation, an inflammation risk

assessment document relating to the use of each piece of equipment in potentially
explosive atmospheres.

The end-user must carry out the appropriate modifications.

ATEX – An Introduction
Two main Aims

• Achieve a high level of safety

(e.g. inclusion of dust and mechanical hazards)

• Harmonise regulations across Europe

Scope of ATEX

Mining AND Surface Industry

(Virtually) ANYWHERE there can be an explosive atmosphere present

Main exclusions are medical, military, PPE, Body repair shops, painting etc.

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Manufacturers’  Responsibilities
• Comply with Essential Health and Safety Requirements

• Either directly or by complying with STANDARDS

• Risk Assess products (Ignition Hazard Assessment)

• See 94/9/EC implemented in UK as SI 1996 /192

• Implemented by DTI

Users Responsibilities - Hierarchy

• Prevent formation of potential explosive atmosphere (eg. by substitution)

• Limit extent of hazard

• Reduce ignition risk by appropriate selection of Equipment eg. ATEX-certified

as IS, explosion proof, etc

• Main aim is protection of workers (and the public) from explosion hazards

• To classify the zone and the corresponding equipment group (dust or gas) in
accordance with the EC directive 94/9/EC

• To define the temperature classification in accordance with the EC directive

94/9/EC

• To determine the appropriate use of the equipment

• To indicate the zone 0, 1 & 2 areas

What Is an Explosive Atmosphere?

An explosive atmosphere is defined as a mixture of :

• An inflammable substance (dust or gas),

• The oxygen in the surrounding air  always present,

• Atmospheric conditions, in which, after ignition has occurred, combustion

spreads to the entire unburned mixture

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Equipment Groups and Categories

Equipment for surface installation, group II

Category 1

Category 2

Category 3

Atmosphere Type

Gas atmosphere, G

Dust atmosphere, D

Zones

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Equipment Groups and Categories

Explosion Group

For electrical equipment, the explosion group is subdivided into three apparatus
groups:

IIA – propane (petroleum industry)

IIB – ethylene (chemical industry)

IIC – hydrogen

The group is directly related to the minimum ignition energy required to initiate an
explosion in each group.

IIA – 180 Microjoules

IIB – 60 Microjoules

IIC – 20 Microjoules

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Zones and ATEX Categories

Zone 0 - Category 1

Zone 1 - Category 2

Zone 2 - Category 3

Intended to facilitate the free movement of goods within the EU

'New Approach' Directives (that is Community laws) set out essential requirements
(for safety, for example), written in general terms which must be met before products
may be sold in the United Kingdom or anywhere else in the Community. European
standards fill in the detail and are the main way for business to meet the essential
requirements. The Directives also say how manufacturers are to show that products
meet the essential requirements. Products meeting the requirements are to carry
CE marking, which should mean that they can be sold anywhere in the Community/
EEA(1). Directive 94/9/EC on equipment and protective systems intended for use
in potentially explosive atmospheres is one of these 'New Approach' Directives.

Known as the product/equipment directive; its purpose is to facilitate free movement

of  goods  throughout  the  EU  by  harmonising”  technical  and  legal  standards  to  be  
applied to the equipment (electrical and non electrical) which is to be installed in
hazardous areas and sets out the duties on manufacturers.

U.K. regulations which put into effect this directive are;

 Equipment and protective systems intended for use in potentially explosive

atmospheres FEBRUARY 2002

 ATEX Directive 137 (Was 118) The UK regulations which puts into effect
this directive is DSEAR

The ATEX 137 Directive is aimed at ensuring the health and safety of workers whilst
in their place of work. This directive categorises the workplace into zones. Zones
provide a measure of the probability of the presence of a dangerous mixture with air
of any flammable gas or combustible dust.

 Covers health and safety protection of workers

 Duties are placed on the employer

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This is intended to ensure that workers enjoy a minimum level of protection
throughout all member states.

 Special Requirements for Hazardous Areas in Accordance with ATEX 137

 ATEX 137 - Employers Obligations

 Prevent formation and ignition of flammable atmospheres

 Control effects of explosions

 Conduct Risk Assessments

 Classify work place into zones

 Maintain an explosion protection document

 Use ATEX 95 equipment

 Training of staff

 Identify areas with signage

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 The Risk Assessment
The employer is already required to carry out a risk assessment under the
requirements of the framework directive (89/391/EEC). The risk assessment is not
therefore an additional requirement.

Article 4 of directive 99/92/EC obliges the employer to carry out an assessment of

the risks arising specifically from explosive atmospheres. The risk assessment must
take account of the following:

The likelihood that an explosive atmosphere will occur

•  The  likelihood  that  potential  ignition sources will be present

•  The  intended  process,  installation, substances used and any possible interaction
between them

•  The  scale  of  the  anticipated effects.

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The Explosion Protection Document (EPD)

The EPD is based on the risk assessment. Once the risk assessment has been
carried out and identified a likelihood that workers may be exposed to an explosive
atmosphere, an EPD must be drawn up. This must be done before commencing
work and it must be revised in the event that the workplace, work equipment or
organisation of the work undergoes significant change. Existing documents or other
equivalent reports may be utilised to satisfy this requirement to avoid unnecessary
duplication. Any workplace which contains locations where an explosive atmosphere
may occur must be verified before it is put into operation for the first time.

This verification must be carried out by persons competent in the field of explosion
protection. This competence must be demonstrable in the form of experience and/or
professional training.

The EPD must demonstrate that all explosion risks have been determined and
assessed. Those locations or areas which have been identified as “hazardous  
locations”  shall  be identified in the EPD.

The Warning Sign

The requirement for a warning sign is in line with the EC Safety Signs Directive.
The purpose of this directive is to encourage the standardisation of safety signs
throughout the member states so that signs, wherever they are seen, have the
same meaning.

Directive 99/92/EC requires that, where necessary, locations where explosive

atmospheres may occur shall be marked with warning signs at their point of entry.
The warning sign must have certain distinctive features. It must be triangular in
shape, utilise black lettering on a yellow background with black edging.

The yellow background must constitute at

least 50% of the area of the sign. Other
explanatory data may be added to the sign.

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Summary of Main Duties on Employers:
•  Prepare  an  explosion  protection document (EPD)
•  Classify  the  workplace  into  Zones  where applicable
•  Select  ATEX  100a  products  according  to Zone
•  Identify,  using  warning  signs,  locations where explosive atmospheres may occur.

Conclusion
Directive 99/92/EC introduces specific legal requirements aimed at protecting
workers from the potential dangers of explosive atmospheres. Directive 94/9/EC and
directive 99/92/EC are complimentary. Although they both address the same risks
they are aimed at different sectors. Users and operators will therefore need to
ensure they are fully aware of the new requirements.

ATEX Markings

Complies with relevant EU directive

Meets ATEX Directive 95

(for use in explosive atmospheres)

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Nature of the Hazard

The Gas Group

Group I

Mining (Methane and Coal Dust)

Group II

Non Mining/Above ground

This course is intended for Group II gases and NOT for Group I Mining (M1 & M2).

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 Unit 2: Area classification

Hazardous Areas
A Hazardous Area is considered to be an area where an explosive atmosphere is or
maybe expected to be present which requires special precautions to be taken for the
construction, installation and use of electrical equipment. For the standard it is
considered to be a three dimensional space .

Causes of Explosions
Explosion

An explosion can occur if there is a combination of a flammable material, oxygen and

a source of ignition. If one component is missing no exothermal reaction will occur.

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Explosive Material

A flammable material which is present as a gas, vapour or dust is called an explosive

material. In the case of vapours or dusts, an explosive atmosphere is created if the
drop or particle size is smaller than 1 mm. Vapours, aerosols and dusts occurring in
practice have particle sizes between 0.001 and 0.1 mm. Dusts with larger particle
sizes are not flammable.

Combustion will take place if all three elements, in one form or another, are present,
the gas/air mixture is within certain limits and the source of ignition has sufficient
energy. The removal of one element is sufficient to prevent combustion as is the
isolation or separation of the source of ignition from the gas/air mixture. These are
two techniques used in explosion protected equipment. Other protection techniques
allow the three elements to co-exist and either ensure that the energy of the source
of ignition is maintained below specific values, or allow an explosion to take place
and contain it within a robust enclosure. These techniques are addressed in the
various sections of this manual.

Ignition Sources
 Welding

 Burning (naked flame)

 Radiation (sun on metal surfaces)

 Electro Statics:

 Lightning

 Nylon Clothes

 Water Jetting (Typically 10kV)

 Aerosols (Typically 5kV)

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Area Classification
The aim of Area Classification is:

 To reduce to an acceptable level the possibility of a flammable atmosphere

and an electrical source of ignition coinciding

 Undertaken by personnel from several disciplines including electrical,

mechanical, chemical and civil engineering

 DSEAR requires operators to undertake a full risk assessment of existing

workplaces

There are many codes of practice which specify methods of grading areas of
Hazard, a few typically are:

 ‘E.I’  Energy Institute.

(Formally the Institute of Petroleum 'I.P')

 A.P.I. (American Petroleum Institute) Recommended Practice for

Classification of area, etc.

 60079-10-1 Classification of Hazardous Areas

The nature of the hazard

 It's Gas Group

 It's Flash Point

 The Ignition Temperature

 LEL and UEL Values

 Potential source of release

 The extent of the release

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Group II Gases

Group II gases are divided into sub-divisions based on one or both of two test
methods:

MESG - Maximum Experimental Safe Gap

MESG (Maximum Experimental Safe Gap): The maximum clearance between two
parallel metal surfaces that has been found, under specified test conditions, to
prevent an explosion in a test chamber from being propagated to a secondary
chamber containing the same gas or vapour at the same concentration.

MIC - Minimum Ignition Current

MIC (Minimum Igniting Current) Ratio: The ratio of the minimum current required
from an inductive spark discharge to ignite the most easily ignitable mixture of a gas
or vapour, divided by the minimum current required from an inductive spark
discharge to ignite methane under the same test conditions.

Group IIA – Propane (least easily ignited)

Group IIB – Ethylene

Group IIC – Hydrogen (very easily ignited)

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The Flash Point
By definition flashpoint is:  ‘the  lowest  temperature  at  which  sufficient  vapour  is  
given off a liquid, to form a flammable mixture with air that can be ignited by an arc,
spark  or  naked  flame’.    

Typical values are given below;

Material Flashpoint

°C

Propane -104

Ethylene -120

Hydrogen -256

Acetylene -82

Diethyl Ether -45

Paraffin 38

Carbon Disulphide -95

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The Ignition Temperature
Ignition temperature is  defined  as:  ‘the  minimum  temperature  at  which  a  flammable
material  will  spontaneously  ignite’.

Ignition temperature, formerly known as auto-ignition temperature, is an important

parameter since many industrial processes generate heat. Careful selection of
electrical equipment will ensure that the surface temperatures produced by the
equipment, indicated by the T-rating, will not exceed the ignition temperature of the
flammable atmosphere which may be present around the equipment.

Typical values of ignition temperature are:

Ignition

Temperature
Material
o
C

Propane 470

Ethylene 425

Hydrogen 560

Acetylene 305

Diethyl Ether 170

Paraffin 210

Carbon Disulphide 102

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 UEL and LEL Values

UEL - Upper Explosive Limit

Is the concentration of flammable gas or vapour in the air above which the gas
atmosphere is not explosive.

LEL - Lower Explosive Limit

Is the concentration of flammable gas or vapour in the air below which the gas
atmosphere is not explosive.

Potential Sources of Release

Defines how likely it is that a hazardous Concentration will be present in any given

Geographical location commonly referred to as the 'Zone'

The extent of the zone is determined by;

Chemical and physical parameters in general the greater the release rate, the larger
the zone.

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Extent of Zone

Geometry of release – from open pool mechanical seal or flange

Release velocity – process pressure, liquid or gas

Concentration

Ventilation

Relative Density;

If a flammable material is released, it is important to know whether the material will

rise or fall in the atmosphere. The different flammable materials are compared with
air and allocated a number to denote their relative density with air. Since air is the
reference, its relative density is 1 so that for a material twice as heavy as air, its
relative density will be 2. Therefore, materials with a relative density less than unity
will rise in the atmosphere, and those greater than unity will fall in the atmosphere.

Materials which rise in the atmosphere can collect in roof spaces, and those which
fall, such as butane or propane, can drift along at ground level and possibly into a
non-hazardous location, or may collect in locations lower than ground level without
ever dispersing. Such locations should be well ventilated in order to avoid ignition
due to a stray spark or a discarded cigarette.

Knowledge of where a flammable material will collect ensures that gas detectors
when fitted will be located at the correct level
Relative vapour and ventilation is directed accordingly.
Material
density

Air 1

Propane 1.56

Ethylene 0.97

Hydrogen 0.07

Acetylene 0.9

Diethyl Ether 2.55

Paraffin 4.5

Carbon Disulphide 2.64

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 Area Classification
The result of an Area Classification Study is an 'Area Classification Diagram' which is
a graphical representation of the plant showing the hazardous areas (zones).

Non-hazardous, or Safe Area

DEFINITIONS

ZONE 0

A place in which an explosive atmosphere consisting of

a mixture with air of flammable substances in the form
of gas vapour or mist is present continuously or for
long periods or frequently.

ZONE 1

A place in which an explosive atmosphere

consisting of a mixture with air or flammable
substances in the form of gas vapour or mist is
likely to occur in normal operation occasionally

ZONE 2

A place in which an explosive atmosphere

consisting of a mixture with air of flammable
substances in the form of gas, vapour or mist is
not likely to occur in normal operation but, if it
does occur, will persist for a short period only

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Safe Area
An area associated with a plant which is designated free from flammable materials
and atmospheres, as designated on an area classification drawing.

Equipment Selection – Gas

Above a Hazardous Area IEC 60079-14 : 2007

Equipment that may produce HOT particles or surfaces Located less than 3.5m
above a hazardous area shall be; totally enclosed or provided with suitable guards or
screens to prevent any ignition sources falling into the hazardous area.

Such items may include:

 Fuses that may produce arcs, sparks or hot particles

 Switches that may produce arcs, sparks or hot particles

 Motors or generators that have sliding contacts or brushes

 Heaters, heating elements or other equipment that may produce arcs, sparks
or hot particles

 Auxiliary equipment such as ballasts, capacitors and starting switches for all
types of discharge luminaires, all lamps.

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Temperature Classification
Temperature classification is based on the maximum temperature which any relevant
part of the apparatus, (which maybe in contact with an explosive gas) will reach,
when operating within normal design ratings, (-20°c to + 40°c)

TEMPERATURE CLASS

Temperature class relates to the hot surface ignition temperature of a particular

explosive atmosphere. It must not be exceeded by the temperature classification of
the equipment intended to be used in that atmosphere.

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Relationship between types of protection  EPL’s  and  Categories

The ATEX Directives introduced Categories of equipment numbered 1, 2 & 3

followed by D (Dust)/or G (Gas).

In 2006 IEC 60079 introduced EPLs (Equipment Protection Levels) which mirror the
ATEX categories.

Duration of the occurrence of an explosive

Zone Equipment category
atmosphere
0 Continuously, for a long period, frequently 1
1 Occasionally 2
2 Rarely and for a short period 3

Where only the zones are identified in the area classification documentation, then
the relationship between categories/EPLs and zones should be followed.

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Equipment Protection Levels (EPLs)
EPL Ga (Equivalent to Atex Cat 1)

Equipment for explosive gas atmospheres, having a 'very high' level of protection,
which is not a source of ignition in normal operation, expected faults or when subject
to rare faults.

Type of
ATEX EPL Code According to
Protection

Intrinsically safe ‘la’ IEC 60079 – 11

Encapsulation ‘ma’ IEC 60079 – 18

Two independent types

CAT 1 of protection each IEC 60079 – 26
‘Ga’ meeting  EPL  ‘Gb’

Protection of equipment
and transmission
IEC 60079 – 28
systems using optical
radiation

EPL Gb (Equivalent to Atex Cat 2)

Equipment for explosive gas atmospheres, having a 'high' level of protection, which
is not a source of ignition in normal operation or when subject to faults that may be
expected, though not necessarily on a regular basis.

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EPL Gc (Equivalent to Atex Cat 3)

Equipment for explosive gas atmospheres, having a 'enhanced' level of protection,

which is not a source of ignition in normal operation and which may have some
additional protection to ensure that it remains inactive as an ignition source in the
case of regular  expected  occurrences……………

(for example failure of a lamp)

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IEC 60079-14:2007 (EPL APPROACH)
Traditional approach to selection of equipment

EPL Category Approach

However, where a risk assessment, taking into account the consequences of an

ignition, has been carried out and the resulting EPL requirements differ from the
norm, the required EPL/Categories are to be marked on the Area Classification
Drawing.

Why EPL (Atex categories)

Historically it has been acceptable to install equipment into specific zones based on
the type of protection.

In some cases it has been shown that the type of protection may be divided into
different levels of protection that can be correlated against each Zone. A better risk
assessment would consider all factors. When using a risk assessment approach
instead of the inflexible approach of the past linking equipment to Zones the inherent
ignition risk of the equipment is clearly indicated, no matter what type of protection is
used.
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An example using a risk assessment approach:

Plant operators often make intuitive decisions on extending (or restricting) their
Zones in order to compensate for this inflexibility.

A typical example is the installation of "Zones 1 Type" navigation equipment in Zone

2 areas of offshore oil production platforms, so that the navigation equipment can
remain functional even in the presence of a totally unexpected and prolonged gas
release.

On the other hand, it is reasonable for the owner of a remote, well secured, small
pumping station to drive the pump with a "Zone 2 Type" motor, even in Zone 1, if the
total amount of gas available to explode is small and the risk to life and property from
such as explosion can be discounted.

The situation became more complex with the publication of the first edition of IEC
60079-26 which introduced additional requirements to be applied for equipment
intended to be used in Zone 0. Prior to this, Ex ia was considered to be the only
technique acceptable in Zone 0.

It has been recognised that it is beneficial to identify and mark all products according
to their inherent ignition risk. This makes equipment selection easier and a risk
assessment approach, more appropriate.

Ingress Protection

The IP Code defined in international standard IEC 60529 classifies the degrees
of protection provided against the intrusion of solid objects (including body parts
like hands and fingers), dust, accidental contact, and water in electrical enclosures. It
consists of the letters IP (for "international protection rating" sometimes also
interpreted as "ingress protection rating") followed by two digits and an optional
letter. The standard aims to provide users more detailed information than vague
marketing terms such as "waterproof".

The digits ('characteristic numerals') indicate conformity with the conditions

summarised in the tables below. Where there is no protection rating with regard
to one of the criteria, the digit is replaced with the letter X.

For example, an electrical socket rated IP22 is protected against insertion of fingers
and will not be damaged or become unsafe during a specified test in which it is
exposed to vertically or nearly vertically dripping water. IP22 or IP2X are typical
minimum requirements for the design of electrical accessories for in-door use.

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 Unit 3: Certification
ATEX product certification (or EC Type Examination) is the check on the design
specification of a product in relation to a series of relevant standards laid out under
the directive.

It involves a detailed process of examination, testing and assessment of equipment

intended for use in potentially hazardous areas, with the end result being the issue of
an ATEX certificate and report, confirming and demonstrating that the product is safe
to use (within certain parameters) within potentially explosive atmospheres.

The certification process must be undertaken by a Notified Body who issue ATEX
certificates and conduct periodic surveillance of quality management systems.
Certification is the process of assessing a design to a specification set down in a
Standard.

 Apparatus certified to CENELEC Standards will bear the code Eex

 Older apparatus certified to a National Standard will bear the code Ex

 Component Certificate

 Certificate of Assurance

 Certificate of Conformity

 Certificates where special conditions of use apply

Component Certificate

Not a full certification and apparatus to which this certificate appears will need
additional protection before use in a hazardous area

‘Components’:  means  any  item  essential  to  the safe functioning of equipment and
protective systems  but  with  no  autonomous  function.”

Certificate  number  will  end  in  the  letter  “U”;;  components  do  not  require  the  CE  mark
A Component Certificate needs always additional certification before bringing into
service. You could recognise a component certificate through its name and through a
‘U’  behind  its  certificate  number.  ‘U’  is  German ‘Unvollständig’  and  means  
incomplete certification. Only the component is certified, but not - without further
action - suitable for installation in hazardous areas. Not completed component
certification has a way of protection- and a group marking. No temperature class is
mentioned on this type of certificate. Examples of component certified products are
terminals, switchgear, remote I/O. Often additional enclosures are required, however
empty enclosures belong also to the examples of component certified products.

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Certificate of Assurance

Apparatus certified to National Standard or CENELEC Standard by a Notified body

outside the EEC.

If you manufacture products intended for use in potentially explosive atmospheres,

you must provide assurance that your equipment will not cause an explosion during
routine operation. Demonstrating compliance with the ATEX Directive 94/9/EC will
provide that assurance. It is mandatory for these products to bear both the
Distinctive Community Mark (the Ex Mark in hexagon) and CE marking before being
sold in the EU

Certificate of Conformity

Apparatus certified by an EEC Notified Body to a CENELEC Standard recognised by

EEC Directives

The Declaration of conformity should include:

 Name & address of the manufacturer (or their authorised representative)

 A description of the equipment and its intended use

 All relevant provisions fulfilled by the directive (i.e. relevant product marking,
T-class and gas groups)

 Name & Address of the Notified Body who certified the equipment (if
applicable)

 Product Certificate Number (if applicable) i.e. SIRA06ATEX1234

 Reference to the harmonised standards used to certify the equipment

 Reference to other harmonised directives adhered to (if applicable)

 Signature  of  the  “responsible  person”

For components (i.e. unfinished parts) an attestation of conformity is required and

this must contain details of the characteristics of the component, how the component
is to be incorporated into the finished equipment such that it will meet the provisions
of the ATEX Directive.

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What is the difference between a Declaration of Conformity and a Certificate?

A Declaration of Conformity is the document that the manufacturer must enclose with
(or attach to) any equipment or protective system that is being sold in compliance
with the requirements of the ATEX Directive 94/9/EC.

The manufacturer has sole responsibility for creating this document and must do so
in accordance with the detailed list of contents given at Annex X in the directive. The
declaration complements the CE Marking which is applied to the product on the
manufacturer's responsibility.

A Certificate is normally the output of a process known as "Certification".

There are many types of certification schemes, but they all involve the use of a third
party certification body which is independent from the manufacturer and purchaser of
the product (or service) that is the subject of certification.

An ATEX product which has been subject to "certification" will normally have
two documents:

The "EC-Type Examination Certificate" is issued by an ATEX Notified Body (NB)

following test and examination of a prototype, in accordance with Annex III of the
directive. The name of the NB is incorporated in the certificate number marked on
the product.

A production document, usually a "Quality Assurance Notification" (QAN) is issued

following a review of production capability, in accordance with Annexes IV and/or VII
of the directive, and is subject to periodic review based on regular surveillance.
Alternatively, "Verification" may be followed for this production phase, where the
Notified Body examines each item of manufactured equipment. The NB number
(1180 for Baseefa) is included in the marking, adjacent to the CE marking.

Where the certification has been carried out on a voluntary basis (for example for
Category 3 equipment where certification is not mandated by the directive), the
document is simply known as a "Type Examination Certificate". Notified Bodies offer
this added service to assist manufacturers where a customer wants more assurance
than is given by the minimum legal requirements of the directive.

The existence of a certificate eases the manufacturer's task in writing his Declaration
of Conformity, but where the directive allows the use of "Internal Control of
Production" module (Annex VIII), the manufacturer is entitled to base his declaration
entirely on the technical file he has developed himself

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Where Special Conditions of Use Apply

Certificate will end with the letter 'X', in the past the letter 'B' was used and maybe
still encountered on some certificates

This  denotes  ‘special  certification  conditions’.  These  details  are  given  on  the  
certificate and on the installation leaflet. The conditions usually relate to cable entry,
operation, lamps and maintenance conditions and must be observed by the user.

Always inspect/ask to see certificate to ensure all special conditions have been met.

Certification General

All equipment certified to the harmonised European Standards must carry the
following information.

 Name of manufacturer
 Product reference and serial number
 Code and type of protection
 Gas group and temperature class
 Name of certifying authority and certificate number
 CENELEC symbol
 BASEEFA symbol
 Electrical rating

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 Unit 4: Labelling
All equipment certified for use in hazardous areas must be labelled to show the type
and level of protection applied.

ATEX equipment labelling follows a defined, systematic method in which the

assessment of the following categories can be interpreted by the letters and
numbers:

 Equipment group (use in mines with pit gas hazards: Group I versus all other
explosion hazards areas: Group II)
 Equipment category according to ATEX 95a (equipment safety for Group II)
 Type of atmosphere (for Group II)
 Ignition protection type
 Explosion group

Temperature class or maximum permissible surface temperature

In Europe the label must show the CE mark and the code number of the certifying
body. The CE marking is complemented with the Ex mark, followed by the indication
of the Group, Category and, if group II equipment, the indication relating to gases G
or dust D. For example: Ex II 1 G Explosion protected, Group 2, Category 1, Gas
Specific type or types of protection being used will be marked.

EEx ia IIC T4. Type ia, Group 2C gases, Temperature category 4.

EEx nA II T3 X Type n, non-sparking, Group 2 gases, Temperature category 3,

special conditions apply

Sierra Instruments Model 640S-EEX and 780S-EEX Flow Transmitters that have the
following label attached have been certified in compliance with the Directive 94/9/EC
of the European Parliament and the Council as published in the Official Journal of
the European Communities No. L 100/1 on 19 April 1994.

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KEMA ATEX official label from Sierra Instruments, Inc.

The following information is provided as part of the labelling of the transmitter:

• Name and address of the manufacturer: Sierra Instruments, Inc., 5 Harris

Court, Building L, Monterey, CA 93940, USA, Ph. 831-373-0200, Fax 831-
373-4402
• The serial number of the device
• Year of construction
• Model Number
• CE Mark
• Marking for explosion protection: ATEX II 2 GD EX d IIC T6-T2 T280°C
(Suitable for Use in Zone 1 Gas and Dust applications)
• KEMA ATEX certificate number: 06ATEX0105
• Cable  entry  treads  information  (3/4”  NPT)  and  housing  IP  rating

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New Marking – EPL's (Explosion Protection Levels)

The introduction of the EPL's and changes in the EN 60079 and EN 61241 series
standards has introduced new marking requirements.

Gas (Surface)

The gas group that was previously (II) for increased safety in surface applications is
now IIA, IIB or IIC, depending upon the certification

Dust

Grouping has also been applied to dusts where the marking is differentiated from
gases by the addition of another I i.e. IIIA, IIIB or IIIC.

Explosion Protection Levels

The explosion protection
levels are identified by their
lettering

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 Unit 5: Flameproof EEx d
Definition; (IEC 60079-1)
An enclosure in which the parts which can ignite an explosive gas atmosphere are
placed and which can withstand the pressure developed during an internal explosion
of an explosive mixture, and which prevents the transmission of the explosion to the
explosive gas atmosphere surrounding the enclosure.

Flameproof is one of the original methods of explosion protection developed for use
in the mining industry. It has a wide range of applications, typically junction boxes,
lighting fittings, electric motors etc.

The letter ‘d’,  which  symbolises  this  type  of  protection,  is  from  the  German  word  
‘druckfeste’  (kapselung),  which  roughly  translated  means  ‘pressure  tight’  (enclosure).

Flameproof apparatus, when properly installed in the intended location, enables

components such as switches, contactors and relays etc. to be safely used in
hazardous areas. Flameproof is the only one of the nine different methods of
explosion protection in which an explosion is permitted. This explosion, however,
must be contained by the robustly constructed flameproof enclosure.

EExd equipment is substantial in construction capable of withstanding and internal

explosion pressure, the design does not prevent gas/atmosphere entering. It
however ensures that if an ignition occurs within the enclosure, the hot gases do not
exit to a possible flammable atmosphere.

Covers are required to be tool removable, and secured with all the specified
fasteners in place.

The enclosure is certified along with the arrangement and its contents, no
modifications are permitted.

Principle of operation

Flameproof enclosures are not gas tight and a gas or vapour will enter the enclosure
where, for example, joints or cable entries exist. Since these enclosures are
designed to contain components which are an ignition source, ignition of the gas or
vapour may occur, and the resulting explosion pressure can reach a peak value of
around 150 p.s.i.

The enclosure must, therefore, be strong enough to contain this explosion pressure,
and the gaps at the joints and threads of cable entries must be long and narrow to
cool the flames/hot gases before they reach, and cause ignition of a flammable
atmosphere which may exist outside the enclosure.
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Typical materials used for the construction of flameproof apparatus include cast iron,
aluminium alloys, and where corrosion resistance is required, gun metal bronze,
phosphor bronze and stainless steel may be used. Plastic materials are also used
but the free internal volume must not exceed 10 cm3. Both standards specify that
‘THERE  SHALL  BE  NO  INTENTIONAL  GAP  AT  THE  COVER  JOINTS’ and that the
average roughness Ra of the flamepath surfaces must not exceed 6.3 m.

EEx d: Flamepath/joint.

A place where the corresponding surfaces of two parts of an enclosure, or the

conjunction of enclosures, come together and which prevents the transmission of an
internal explosion to the explosive gas atmosphere surrounding the enclosure.

When reassembling flameproof equipment, care should be taken to avoid getting

dirt, paint etc into the joints. This will prevent the joints (flamepath) being closed
correctly.

Spigot joints

Standard specifies the approved methods of making and determining the length of
flamepath, spigot joints are more effective than flanged joints with the following
noted;

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 Minimum width of joint and maximum gap for enclosures
of groups I, IIA and IIB

Minimum width of joint and maximum gap for group IIC

enclosures

Gaps to be measured with a feeler gauge

Maximum gap for IIC (Hydrogen) areas 0.1mm, < 0.5Lt

IIA & IIB 0.15mm

Flanged joints are allowed in a IIC area if gap is reduced 0.04mm

Spigot joints are preferred for IIC gasses with volumes greater than 500mm3

No intentional gaps are required in flamepaths for flameproofing, however, it is

required to have a gap for example on motor shafts

Flamepath joints types (rotating machines)

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Cylindrical (shaft gland) joint

Labyrinth joint for shafts

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Enclosure
Suitable for use in areas requiring EPL Gb and Gc or Category 2 and 3 only.

Prior to 2007, it was permitted to use in Gas zones 1 and 2 only.

The equipment grouping and temperature classification defined in IEC 60079-0 for
the use of electrical equipment in explosive gas atmospheres apply to flameproof
enclosures. The subdivisions A, B and C for electrical equipment of Group II also
apply.

Live maintenance not permitted

No unauthorised modifications to a certified enclosure are permitted;

Certified equipment may not be modified in any way, other than as indicated on the
certificate. Modification may invalidate the certificate.

Unauthorised modifications or changes include;

 Use of wrong size or type of hole sealing plug

 Use of wrong type of cable entry gland

 Use of any constructional screw for any purpose other than that originally
intended

 Attaching cable brackets using cover fixing bolts

 Drilling additional holes in any part of certified EExd equipment

 Drilling holes to attach cable brackets

 Use of any gasket other than specified

 Use of hardening sealants or tape

 Changing the layout of components in enclosure or adding additional items

not included in the EExd certificate.

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Pressure piling
Components not to be removed from flameproof equipment - pressure piling.

Results of an ignition, in a compartment or subdivision of an enclosure, of a gas

mixture precompressed;

For example, due to a primary ignition in another compartment or subdivision.

Minimum  distance  of  obstructions  from  flameproof  “d”  flange  openings.

Weatherproofing (Sealing tape)

One layer of tape allowed on IIA

One layer of tape allowed on IIB

Tape NOT allowed on IIC

If a gasket of compressible or elastic material is used, for example, to protect against

the ingress of moisture or dust or against leakage of a liquid, it shall be applied as a
supplement, that is to say neither be taken into account in the determination of the
width of the flameproof joint nor interrupt

The gasket shall then be mounted so that;

– The permissible gap and width of

flanged joints or the plane part of a
spigot joint are maintained.

– The minimum width of joint of a cylindrical joint or the

cylindrical part of a spigot joint are maintained before and
after compression.

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Eex d Motors
Motors must be specially designed to meet the stringent constructional and test
requirements for flameproof devices. A motor complying with the requirements
stated  above  will  require  a  thermal  test  at  manufacturer’s  rated  full  load  to  determine  
normal running temperatures.

Motors to be used with an inverter (variable speed drive) require special

consideration.

Glanding
New revision of IEC 60079 - 14 (2007) requires 'newly installed' glands to meet IEC
60079 - 0

Glands certified with an 'x' can only be used for fixed installations

Selected to reduce cable cold flow characteristics

Many  of  cables  exhibit  ‘cold  flow’  of  the  inner  sheath  bedding.  That  is,  the  material  
will flow away from pressure applied to it, such as that of a Cable Gland inner seal of
the compression or displacement type, hence creating an inefficient seal

Must be certified

The threaded part should be at least 8mm in length and comprise at least six full
threads

Engaged thread length five full threads minimum

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Barrier Gland
The minimum length of the compound shall be 20 mm when installed. The
manufacturer shall specify:

– the maximum diameter over cores of the cable that the gland is intended to accept;

– the maximum numbers of cores that can pass through the compound.

These specified values shall ensure that, throughout the required 20 mm compound
length, at least 20 % of that cross-sectional area is filled with compound.

The cable gland shall be capable of being fitted and removed from electrical
equipment without disturbing the compound seal after the specified curing period of
the compound.

The filling compound and appropriate installation instructions shall be provided with
the cable gland.

Where there is an internal ignition source

Zones 1 & 2 and IIC gas present

Zone 1 and IIA or IIB gas present and volume of apparatus greater than 2L

Barrier
Gland

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Blanks
Examples of blanking elements for unused apertures

Blanks (Plugs) must be

certified for the apparatus.

'Ex d' Plugs go in 'Ex d'

Equipment.

A blanking element shall

not be used with an
adapter.

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 Unit 6: Increased safety EEx e
Definition; (IEC 60079-7)

A type of protection in which additional measures are applied so as to give increased

security against the possibility of excessive temperatures and of the occurrence of
arks and sparks in normal service or under specified abnormal conditions.

The explosion protection concept Increased Safety was invented in Germany where
it has been widely used for many years. It is has become popular in the UK mainly
because it has a number of advantages for certain applications over the traditional
flameproof method of explosion protection. America has traditionally relied on the
use of explosion-proof enclosures in hazardous locations, and the prospect of using
an Increased Safety enclosure, which is not designed to withstand an internal
explosion, as an alternative, has probably been viewed with a little trepidation.

This method of protection has a good safety record and comparable with the other
methods  of  protection.    The  letter  ‘e’  which  symbolises  this  method  of  protection  is  
taken from the German phrase Erhohte Sicherheit, which roughly translated means
‘increased  security’.  Typical  applications  are  induction  motors,  lighting  fittings  and  
junction boxes.

This type of protection can only be applied to electrical equipment, or components of

electrical equipment, which do not produce arcing or sparks in normal operation.

The equipment is also designed so that it does not exceed specific temperatures
during normal operation (and in specified abnormal operation.

The equipment is robust in construction and tested to ensure that it meets the
requirements of impact testing in the standard (BS EN 60079-7).

Suitable for use in areas requiring EPL Gb and Gc or Category 2 and 3 only.

Prior to 2007, it was permitted to use in Gas zones 1 and 2 only.

The equipment grouping and temperature classification defined in IEC 60079-0 for
the use of electrical equipment in explosive gas atmospheres apply to increased
safety enclosures.

The subdivisions A, B and C for electrical equipment of Group II also apply. Live
maintenance not permitted.

Equipment will have warning label affixed, DO NOT OPEN WHEN ENERGISED.

Minimum of IP 54 to be maintained (if cable entry less than 6mm thick). Refer to
glanding. No unauthorised modifications permitted.
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EEx e Terminations

Certified EExe terminal assemblies are to be used.

The use of high integrity insulation material

employed which has been tested for thermal
stability and a high resistance to tracking.

Cable insulation should be maintained right up to

the metal of the termination.

The temperature de-rating of terminals from

industrial standard in order to limit the
possibility of high temperatures developing

Enhanced creepage and clearance distances

Creepage Distance 6mm - The shortest distance along the surface of an insulating
material between two electrically conductive parts

Clearance Distance 3mm - The shortest distance in air between two electrically
conducting parts

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Conductors per terminal
Terminals, such as slot types, may receive
and clamp more than one conductor.
Unless permitted by the certification, two
wires of different cross sections should not
be connected into one terminal unless first
secured within a single compression type
ferrule.

Screw type saddle clamps

Single conductors in single screw type saddle clamps should have the end U-shaped
around the screw to permit correct clamping.

Note;

The  manufacturer’s  details  of  terminal  types,  sizes,  number  of  terminals,  conductor  
size and maximum current ratings will be specified on the certificate and
manufacturers documentation and must be followed.

Spare terminals to be tightened down.

Eex e Motors
EEx e motors operate at a lower temperature rise than normal motors

O/L must be as laid down by certification,

The protection of an EExe machine is fundamental to its certification and therefore

should not be altered or adjusted without reference to the appropriate superior
technical authority.

Must be able to withstand stall rotor current for five seconds without damage to
insulation

Under stall (locked rotor) conditions, the rotor surface temperature will normally
increase faster than that of the stator windings, and hence, the T rating applies to
both internal and external surface temperatures.

Under fault conditions, the motor must trip within the tE time specified on the motor
data plate.

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Time 'tE' of Increased Safety Motors:-

Time 'tE' is the locked rotor withstand time. It is the time taken for heating up any
part of the motor from the steady state temperature up to the limiting temperature
under the locked rotor condition. This time is determined separately for stator and
rotor and the minimum one is taken as the tE.

Time tE is the time when, during the flow of the starting current, the motor
winding heats up to the limit temperature from the temperature of rated
conditions at maximum ambient temperature.

The current dependent protective devices must be so selected that the stalled motor
will be disconnected positively within the time tE, temperature class and starting
current are indicated on the name plate of ME motors.

The starting time normally permitted for these motors is up to 1.5 times the time tE
i.e. up to 1.5 x tE. If starting time is approximately of the order of tE, motor
protection becomes difficult, since over current protection may operate spuriously in
a repeated start. Hence, for heavy and frequent starting, an enquiry should be made
starting:

a) Duty Cycle
b) GD2 value of driven equipment referred to motor, and
c) Speed-Torque characteristic of the driven equipment

Increased Safety motors have time tE of minimum 5 seconds.

Motor current will cause a rise in winding temperature, which in turn will cause a rise
in casing temperature, as the motor load increases the winding current will rise
causing an increase in winding and casing temperatures

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In the graph;

OA represents the maximum ambient temperature, OB is the temperature reached in

normal working.

If a fault should occur and the rotor becomes locked, then the conditions shown in
part 2 of the graph apply.

The motor temperature will increase rapidly towards C which is just less than the T
rating of the motor.

The motor will reach point BC in time tE, control gear must be provided to disconnect
the motor from the supply within this time.

These motors are intended for S1 duty (continuous running and are unsuitable for
frequent start/stop duty or long run-up times.

These motors are not designed to withstand an internal explosion.

Hence, they have special design features to prevent arcs, sparks and excessive
surface temperatures occurring both internally and externally.

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The principal design features are.....

Special attention to air-gap between stator and rotor

Clearance of all rotating parts

Impact testing of motor frame

T2 or T3 surface temperature limitation

Temperature rise 10oC lower than normal

Compliance with winding temperature rise limit, called tE

Special terminal block with good creepage/clearance distances and locking devices
on terminals

Minimum ingress protection to IP54;

Increased safety motors are intended for continuous duty only, i.e. they are
unsuitable for applications which require frequent stopping and starting and/or long
run-up times.

IN = rated current of motor;

IA = locked rotor current of

motor.

Example 1: IA/IN = 5 and tE time = 10 secs

The above characteristic would trip the motor after 8 secs, which
is within the tE time and therefore acceptable.

Example2: IA/IN = 4.5 and tE time = 8 secs

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For these values the tripping time is 10 secs, which is outside the tE time assigned to
the motor, therefore an overload device with this characteristic would not be suitable
for the values specified.

Glanding
Prior to December 2007 EEx'e' only required glands to meet type of protection
requirements 'Ingress Protection and Mechanical Impact Strength'

New revision of IEC 60079 - 14 (2007) requires 'newly installed' glands to meet IEC
60079 - 0

Glands certified with an 'x' can only be used for fixed installations

Selected to reduce cable cold flow characteristics

Newly installed glands must meet the requirements of IEC 60079 – 0.

An IP sealing washer and a locknut

are required when less than five
threads are engaged (6mm thread
length).

A serrated washer maybe required to maintain

earth integrity.

When glanding into non metallic apparatus a banjo is

often required to maintain earth continuity

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Blanks
Blanks (Plugs) must be certified for the apparatus. EEx e or EExd plugs go in EEx e
Equipment.

Installation, inspection and maintenance

It is essential that Increased Safety enclosures are installed and maintained in

accordance with the relevant Standards and Codes of Practice in order to comply
with the Certification.

The following list specifies the main points.

1. Enclosure content should not be modified without consulting the manufacturer.

2. Only components specifically approved should be fitted in the enclosure.

3. All terminal screws, used and unused, should be tightened down.

4. Conductor insulation should extend to within 1 mm from the metal throat of the
terminal.

5. Partitions should be fitted at either side of terminal linking assemblies.

6. Only one conductor should be fitted to each terminal side.

7. An additional single conductor, min 1.0 mm2, may be connected within the same
terminal way when an insulated comb is used.

8. Only the conductors from each cable entry shall be loomed together.

9. The insulation of cables shall be suitable for use at least 80°C for a T5 temperature
class.

10. The individual earth continuity plates within plastic enclosures must be bonded
together and locknuts used to secure glands to the continuity plates.

a. For clearance holes, serrated metal washers must be used between locknuts
and the glandplate.

11. When Intrinsic and Increased Safety circuits occupy the same enclosure the two
types of circuit must have at least 50 mm clearance between them.

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12. There must be adequate clearance between adjacent enclosures to allow proper
installation of cables and glands.

13. All unused cable entries should be closed using suitable plugs.

14. The schedule of the appropriate certificate should be consulted before cable entry
holes are drilled.

15. Cable glands or conduit entries must maintain the minimum ingress protection of IP
54.

16. All lid and gland plate bolts must be fully tightened after installation.

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 Unit 7: Reduced Risk Eex n
Definition; (IEC 60079-15)
A type of protection applied to electrical equipment such that, in normal operation
and in certain specified abnormal conditions, it is not capable of igniting a
surrounding explosive atmosphere.

Since the presence of a flammable gas or vapour is less likely in Zone 2, the
constructional requirements for electrical equipment used in these hazardous
locations are not as strict as those for equipment used in Zone 1. A method of
protection which falls into this category  is  type  ‘n’  apparatus,  which  is  basically  
similar  to  increased  safety  type  “e”  apparatus  except  that  there  is  a  relaxation  in  the  
constructional requirements.

Additional, the requirements of IEC 60079-15 are intended to ensure that a fault
capable of causing an ignition is not likely to occur.

An example of a specified abnormal condition is a luminaire with a failed lamp.

Suitable for use in areas requiring Gc or Category 3 only.

Prior to 2007, it was restricted to use in Gas zones 2 only.

The equipment grouping and temperature classification defined in IEC 60079-0 for
the use of electrical equipment in explosive gas atmospheres apply to increased
safety enclosures. The subdivisions A, B and C for electrical equipment of Group II
also apply.

Live maintenance not permitted.

Principle

In Zone 2 hazardous locations, the presence of a flammable gas or vapour is not

likely  to  be  present,  or  if  it  is  present  it’s  duration  will  be  for  a  short  time  only.  This  
fact allows the use of less expensive methods of protection, i.e. non-incendive or
type  ‘n’  protection.  As  previously  stated,  type  ‘n’  protection  is  similar  in  concept  to  
increased  safety  type  ‘e’  protection.  The  design  features  for  this  type  of  protection  
ensure that, in normal operation, sources of ignition in the form of excessive surface
temperatures, arcs or sparks are prevented from occurring either internally or
externally.

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Since  the  design  requirements  are  not  as  strict  as  those  for  increased  safety  type  ‘e’  
protection, it is possible for the manufacturer  to  install  within  type  ‘n’  apparatus,  
components which produce hot surfaces, arcs or sparks, providing these
components have incorporated in them additional methods of protection. These
additional methods are described later in this unit. The principal design features for
type  ‘n’  apparatus  are  as  follows.

1. Enclosures and motor fan guards, where exposed to high risk of mechanical
damage, to have resistance to impact of 3.5J;

2. Minimum ingress protection IP54 where an enclosure has exposed live parts
internally;

3. Use of certified terminals;

4. Terminals manufactured form high quality insulation material;

5. Specified creepage and clearance distances incorporated into the design of

the terminals;

6. Terminal locking devices to ensure conductors remain secure in service.

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Sub Divisions of Type EEx n Apparatus
EEx nA Non-sparking Apparatus

Designed to prevent any means of ignition arising

Electric Motors/Cage Motors

Terminal Boxes

Light Fittings

Transformers

If sparking occurs it; will occur in a hermetically sealed device & will occur in an
enclosed break device.

BOTH MARKED EEx nC

Non-incentive component
Marking Ex nC Gc II 3 G in accordance with IEC 60079-0.

Principle

Variant of the Ex n type of protection with contacts which close and open a circuit
potentially able to trigger an explosion, where the contact mechanism or the
enclosure into which the contacts are enclosed is designed in such a way that the
ignition of a mixture of subgroup IIA, IIB or IIC in the surrounding environment is
prevented as long as defined operating conditions apply.

Type EEx nC

ENCLOSED BREAK DEVICE

A type n enclosed break device incorporates electrical contacts. It is able to safely

withstand an internal explosion of any flammable gas that may have entered inside.

This  technique  is  used  in,  for  example,  the  lamp  holders  of  type  ‘n’  apparatus.    The  
example below shows a typical lamp holder in which there are two sets of contacts.
One set of contacts is enclosed in what is effectively a flameproof enclosure in which
the free internal volume must not exceed 20 cm3. This enclosure is designed to
withstand an internal explosion and the voltage and current limitations are 600 V and
15 A respectively.

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HERMETICALLY SEALED DEVICE

Sparking contacts may be safely enclosed within a hermetically sealed enclosure.

The seal may be by soldering, brazing or the fusion of glass to metal.

A device which prevents an external gas or vapour gaining access to the interior by
sealing of joints by fusion, e.g. welding, soldering, brazing, or the fusion of glass to
metal. The example of hermetic sealing shown below is a reed switch which
comprises a set of contacts hermetically sealed within a glass envelope.

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ENCAPSULATED DEVICE

An encapsulated device has similarities to hermetically sealed device. External

connections are normally by flying leads or terminals.

ENERGY LIMITED EQUIPMENT Eex nL

Where circuit components restrict the maximum available energy in a circuit to a
level incapable of causing gas ignition.

Now being replaced by EEx ic

EEx nR Restricted Breathing Enclosures

Technique relies upon the ignition capable part within an enclosure which, although
not fully sealed, being constructed in such a way it would take a long time for a
flammable gas/vapour to penetrate.

Designed to restrict the entry of gases, this technique is often applied to luminaires
where, because of the high temperatures developed, the air within the enclosure
expands and will develop an increase in pressure (thus excluding any entry of a
potential explosive atmosphere), when the luminaire is switched off and cools down,
the enclosure regulates the slow ingress of air across the gaskets. It is important
therefore to maintain I.P. ratings, minimum of I.P 54.

Cable entries for EEx nR

An IP washer is always required immaterial of thread length.

Terminals
Certified terminal assemblies are required to be used.

Lighting – General
Luminaires with fluorescent tubes and electronic ballasts not to be used in T5 or T6
Areas or where ambient temperature exceeds 60°C.

Lamps/tubes with conductive coated connections shall NOT to be used unless tested
with equipment.

Low Pressure Sodium lamps shall not be installed above a hazardous area.

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Glanding
Prior to December 2007 Ex'n' only required glands to meet type of protection
requirements 'Ingress Protection and Mechanical Impact Strength'

New revision of IEC 60079 - 14 (2007) requires 'newly installed' glands to meet IEC
60079 - 0

Glands certified with an 'x' can only be used for fixed installations

Selected to reduce cable cold flow characteristics.

Because I.P 54 must be maintained then I.P washers and locknuts are required
when;

Glands entering unthreaded holes, threaded holes with less than 6mm thread length,
require an I.P washer on the outside and a locknut on the inside. A star washer may
be specified to ensure earth continuity.

Where an earth tag is required, this shall be placed between the gland body and the
seal washer, it should not be placed between enclosure and I.P washer.

Blanks

Blanks (Plugs) must be certified for the apparatus,Ex n equipment to maintain IP54
minimum.

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 Unit 8: Oil-Immersion EEx o
Definition IEC 60079-6
Protection is provided by immersing the equipment in oil to a sufficient depth, such
that any ignition capable products do not reach the surface where they could ignite
any potentially explosive atmosphere.

However precautions are required to ensure an adequate oil level is maintained.

Technique commonly applied to heavy current switchgear and transformers

Use of mineral insulating oil to provide protection, with the fluid actually quenching
the electrical arc or spark.

Principle

The oil level is used to completely cover the components within the apparatus which
arc/spark or produce hot surfaces during normal operation, thereby effectively
establishing a barrier between the components below the oil and any flammable
gases which may be present above the oil or outside the enclosure. A particular
advantage of this method of protection is that circulation of the oil, by convection,
enables hot-spots to be dispersed.

One function of the oil is to quench arcs occurring at the contacts and, where mineral
oil is used, a by-product of this process is the production of hydrogen and acetylene.
This condition was considered to be undesirable for apparatus intended for use in
hazardous locations, which may explain why, until recently, its use was limited to
Zone 2 in the UK. The revised standards, however, have stricter specifications and
this type of protection is now permitted in Zone 1.

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Circulation of oil around apparatus allows for any hot spots to be dispersed allowing
for improved apparatus reliability

Suitable for use in areas requiring EPL Gb and Gc or Category 2 and 3 only.

Prior to 2007, it was permitted to use in Gas zones 1 and 2 only.

The equipment grouping and temperature classification defined in IEC 60079-0 for
the use of electrical equipment in explosive gas atmospheres apply to oil immersion
enclosures.

The subdivisions A, B and C for electrical equipment of Group II also apply.

No live maintenance permitted

Sealed enclosure IP 66

Potential Health Hazard with old oil & PCB's (polychlorinated biphenyl).

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 Unit 9: Sand/powder filling EEx q

Definition IEC 60079-5;

Protection is provided by covering the parts that may cause ignition to a critical depth
in a fine powder such as quartz. This quenches any arc before the combustion
products can ignite a surrounding gas. An additional form of external protection is
required to limit the maximum current that may be safely used.

Principle

The filling, which may be quartz, or another material which complies with the
requirements of relevant standards, achieves safety by what is known as
“suppression  of  flame  propagation”.    It  is  inevitable  that  a  flammable gas or vapour
may permeate the granules and reach the parts producing arcs/sparks or hot
surfaces. The quantity of gas or vapour, however, will be too small to support an
explosion within the inert powder. The depth of granules is influenced by the level
and duration of the of the arc current produced by the components within the filling
material, and tests specified in the construction standard enable a safe correlation
between these two parameters to be established. This method of protection is
suitable for use in all group II gases or vapours.

Code 'q' stands for quartz - medium used in the form of small glass or silica beads

Suitable for use in areas requiring EPL Gb and Gc or Category 2 and 3 only.

Prior to 2007, it was permitted to use in Gas zones 1 and 2 only.

The equipment grouping and temperature classification defined in IEC 60079-0 for
the use of electrical equipment in explosive gas atmospheres apply to powder filling
enclosures.

The subdivisions A, B and C for electrical equipment of Group II also apply.

No live maintenance permitted

Minimum IP 54 Required

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 Unit 10: Encapsulation EEx m
Protection is obtained by encapsulating/encasing hot or sparking components with a
material (organic resin) that prevents ingress of any explosive gas, cools heat
producing components and can withstand maximum temperature during normal and
under fault conditions

The method of protection, encapsulation, is used mainly for smaller items of

equipment such as solenoid coils and electronic components.

Apparatus is not readily repairable and mostly used for low cost throw away items.

Principle

With this type of protection, the encapsulant, typically a thermo-setting compound,

establishes a complete barrier between any surrounding flammable gas or vapour
and the source of ignition within the compound.

No live maintenance permitted.

Suitable for use in areas requiring EPL Ga,Gb and Gc or Category 1, 2 and 3.

Prior to 2007, it was permitted to use in Gas zones 0, 1 and 2.

The equipment grouping and temperature classification defined in IEC 60079-0 for
the use of electrical equipment in explosive gas atmospheres apply to powder filling
enclosures.

The subdivisions A, B and C for electrical equipment of Group II also apply.

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 Unit 11: Cables for fixed wiring.

Electrical equipment in hazardous areas may be wired using cable having metallic or
non-metallic sheath, or conduit. The use of cable is generally predominant and one
reason is its ease of installation compared to conduit.

With regard to conduit, one of its disadvantages, particularly on offshore installations,

is  it’s  susceptibility  to  corrosion  as  a  result  of  exposure  to  sea  spray.    Deterioration  
due to corrosion can occur relatively quickly and, as a consequence, can reduce the
strength of the conduit. This is undesirable particularly where conduit is the method
of entry to a flameproof enclosure because of the possible inability of the conduit to
contain an internal explosion in the run of conduit between the enclosure and the
sealing device. Furthermore, corroded conduit may not meet the impact resistance
requirements essential for use with Increased Safety apparatus.

Earthing and bonding

The principal reasons for earthing and bonding in electrical installations are:

1. To eliminate the possibility of electric shock to personnel;

2. To enable protection devices to operate correctly so that the duration of

fault currents are kept to a minimum;

3. To equalise the voltage potential of normally non-current carrying

metalwork;

4. To prevent electrostatic charge of process plant due to fluid movement.

In hazardous areas, the elimination of sources of ignition is very important and

effective earthing and bonding will play an important role here. Electrical faults, if
allowed to persist, can develop to a point where excessive surface temperatures
and/or arcs/sparks are produced.

BS EN60079-17  clause  4.7  states:  ‘Care  shall  be  taken  to  ensure  that  the  earthing  
and potential equalisation bonding provisions in hazardous areas are maintained in
good  condition’

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 Explanation of Terms

Electrical earthing or circuit protective conductors (CPC)

Conductors installed to provide a low impedance path for the current which flows
under fault conditions to the general mass of earth. Normally the CPC is connected
directly to any associated metal work of the equipment.

Electrical bonding

Conductors installed to establish continuity between adjoining metal work and the
armouring of separate cables to ensure that, under fault conditions, all metal work
and cable armouring are maintained at the same potential.

Exposed conductive parts

Exposed conductive parts include the metal work of switchboards, enclosures, motor
frames and transformer tanks.

Extraneous conductive parts

My metal work associated with the plant, for example pipe work which can be
touched at the same time as a metal switch board cover or motor frame, will be
deemed extraneous conductive parts.

Letter classifications are used to denote the earth system used.

The first letter indicates the supply earth type.

T Terra

At least one point of the supply is directly earthed. (Terra is the Latin word for dry
earth)

I Impedance

There is a deliberately inserted impedance in the supply, or an infinitesimal earth

impedance (i.e. open circuit) designed to limit the fault current.

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The second letter indicates the installation earthing system.

T Terra

All exposed conductive metalwork is directly connected to earth.

N Neutral

All exposed conductive metalwork is directly connected to the Electricity Supply

Companies earth conductor.

The third and fourth letters indicate the arrangement of the earthed supply
conductors.

S Separate

Neutral and Earth are separate systems.

C Combined

Neutral and Earth are combined into one system.

This gives the following systems IT, TT TN-S, TN-C-S, TN-C.

Note: the TN-C system is no longer allowed as a new installation with the
introduction of ESQCR.

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TNC SYSTEMS

The regulations specifically prohibit the use of TNC systems within buildings that is
distribution systems with a combined neutral and earth as used in the PME supply
systems are not allowed within an electrical installation. This reflects concerns with
respect to the need for multiple earthing of TNC installations and the effects on EMC
and building life of load currents flowing through structural steelwork of buildings.

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BS EN60079-14 specifies the conditions for the following earthing systems in hazardous
areas.

Type TN systems

If a type TN earthing system is used, it shall be type TN-S (with separate neutral N and
protective conductor PE) in the hazardous area, i.e. the neutral and the protective conductor
shall not be connected together, or combined in a single conductor, in the hazardous area.
At any point of the transition from type TN-C to type TN-S, the protective conductor shall be
connected to the equipotential bonding system in the non-hazardous area.

The monitoring of leakage between the neutral and PE conductors in the hazardous area is
also recommended in the standard.

Type TT system

If a type  TT  earthing  system  (separate  earth’s  for  power  system  and  exposed  conductive  
parts) is used in zone 1, then it shall be protected by a residual current device.

This system may not be acceptable where the earth resistivity is high.

Type IT system

If a type IT earthing system (neutral isolated from earth or earthed through an impedance) is
used, an insulation monitoring device shall be provided to indicate the first earth fault.

With this system, there may be a requirement for local bonding which is also known as
supplementary equipotential bonding.

Potential equalisation

In order to prevent different voltage potentials occurring in the metal work of plant in
hazardous areas, potential equalisation will be necessary. This applies to TN, TT and IT
systems where all exposed and extraneous conductive parts are required to be connected to
the equipotential bonding system. The bonding system may comprise protective conductors,
metal conduits, metal cable sheaths, steel wire armouring and metallic parts of structures,
but not neutral conductors. The security of connections must be assured by non-loosening
devices.

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Fixed apparatus

Cables manufactured from thermoplastic, thermosetting, elastomeric or mineral

insulated insulating materials may be used in fixed wiring installations. Cables
commonly used in the industry are of the EPR/CSP type. Mineral insulated metal
sheathed (MIMS) cable is also suitable for use in hazardous areas, but its aluminium
variation requires careful consideration before use. Aluminium conductors must only
be connected to suitable terminals and have a cross-sectional area (c.s.a.) not less
than 16 mm2.

Cables may also be selected with consideration to their fire resistant and/or flame
retardant properties, and two standards are relevant in this respect.

IEC 331 (Fire resistant): A cable manufactured in compliance with this

standard will continue to operate in a fire without
disruption of essential circuits and emergency
circuits.

IEC 332 (Flame retardant): A cable manufactured in compliance with this

standard is self-extinguishing and will not
propagate the fire.

Glands for mineral insulated cables

Glands for use with MICC (Mineral Insulated Copper Cable) or MIMS (Mineral
Insulated Metal Sheath) cable for use in hazardous areas will be marked EEx d.
This gland, however, may be used as a means of entry to Increased Safety
apparatus providing an alternative EEx e seal is used. This seal is specially
constructed to comply with the requirements for Increased Safety apparatus as
illustrated by the diagrams.

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Seal Assemblies

EEx d type seal

EEx e type seal

The EEx e seal assembly must only be used with double bond non-metallic black
epoxy putty 1536. The  Component  Certificate  for  this  seal  will  contain  a  ‘schedule for
conditions  of  use’  which  must  be  observed.

Difficulty may be experienced in achieving the desired level of ingress protection with
MICC/MIMS cable glands due to the very small shoulder on the gland body, and may
be overcome by the use of hard plastic washers manufactured for this purpose.

Jointing of cables

In hazardous areas, cable runs should, ideally, be continuous and without

interruption where possible. Joints may only be made using appropriate methods,
for example, in an enclosure having a type of explosion protection suitable for the
Zone, or by epoxy or compound filled devices, or heat shrink sleeving in accordance
with  the  manufacturer’s  instructions.    Whichever  method  is  used,  the  joints  must  be  
mechanically, electrically and environmentally appropriate. Conductor connections
are required to be made by compression connectors, secured screw connectors,
welding or brazing. Soldering is permissible if the conductors being connected are
held together by suitable mechanical means and then soldered.

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Conduit

The use of conduit in hazardous areas requires particular care, especially when used
with flameproof enclosures. In addition to maintaining the ingress protection (IP)
rating of an enclosure - this applies to all types of protection - the integrity of the
enclosure must be maintained, i.e. the conduit in the run between the enclosure wall
and the conduit sealing device must also be able to withstand the force of an
explosion within the enclosure so that the flames/hot gases are prevented from
reaching the external atmosphere. Where two flameproof enclosures are connected
by means of conduit, seals must be fitted to avoid pressure piling occurring during an
internal explosion.

Sealing devices are also used to prevent the migration of gases from one hazardous
location to another. Although not entirely gas-tight, they will limit, to an acceptable
level, the quantity of gas which will pass at normal atmospheric pressure. Where
positive or negative pressures are likely, appropriate measures must be
implemented.

Appropriate installation practices must, therefore, be observed and this requires

observation  of  the  manufacturer’s  installation  specification  and  the  recommendations  
given in BS EN60079-14.

Selection of conduit

Conduit used with explosion protected apparatus will be that recommended by the
manufacturer and selected from either:

a) Screwed heavy duty steel, solid drawn or seam welded conduit

manufactured in accordance with IEC 614-2-1; or

b) flexible conduit of metal or composite material construction, for

example metal conduit with a plastic or elastomer jacket, of heavy or
very heavy mechanical strength classification manufactured in
accordance with IEC 614-2-5.

Conduit entering flameproof enclosures is required to be engaged by 5 full threads.

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Sealing of conduit

Conduit seals are required to be fitted:

(a) Where conduit leaves or enters a hazardous area;

(b) Within a distance of 450 mm from the wall of any enclosure which
contains a source of ignition in normal operation;

(c) At all enclosures entered by conduit of 50 mm diameter or greater,

which contain taps, splices, joints or terminals.

Instrument and Control Cables will be specified by the design engineer and indicated
on the system documentation (see I.S. Section later).

Cables - Transportable and Portable Equipment

Heavy duty sheath – Robust construction

1.0mm squ minimum size

Earth conductor – if necessary incorporated within sheath

Flexible armour not sole CPC

Portable equipment - 250v and not exceeding 6A

Ordinary polychloroprene, rubber or synthetic elastomeric cable

Not allowed where exposed to heavy mechanical stress, for example hand lamps,
barrel pumps, etc.

Cable Terminations
Normally one cable per terminal (Cable terminations as per the manufacturers
documentation)

Ex e terminations

Cable insulation to be maintained right up to the metal of the terminal.

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General

All cables, cores and terminals should be marked for identification purposes by
permanent indelible methods (cable markers). All cable wiring and identification
should be documented.

Crimped terminations are generally preferable to bare copper (there is a risk of stray
strands causing circuit faults), crimped connections are more readily inserted and
removed.

Crimping tools of the hand ratchet type are to be used, hydraulic in larger size cable.

Note; the simple plier type often results in slack joints.

The good general rule is only one wire per terminal, some terminals have special
conditions  applied  and  the  manufacturer’s  documentation  will  need  to  be  referred  to.

For the provision of re-terminating cables, enough length of conductor core should
be left to allow for at least one termination.

Unused cores
Are not to be left un-terminated

Static Requirements
The risk of incendive sparks from non metallic installation material (plastic coated
cable tray, plastic weather protection shall be controlled by the following.

Material  IR  not  to  exceed  1GΩ  or

Limitation of surface area of non-metallic parts.

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Light Metals/Cable tray
Installation materials

(Example - Cable trays, Mounting plates, weather protection must not contain more
than):

Location EPL Requirement

10% total aluminium, magnesium, titanium & zirconium

Ga
or 7.5% of magnesium, titanium & zirconium

Gb 7.5% of magnesium & titanium

Gc No requirements

User is responsible to verify

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 Unit 11: Knowledge and Skills

Knowledge and Skills - Designer

Detailed knowledge of general principles of explosion protection

Detailed knowledge of principles of types of protection and marking

Detailed knowledge of those aspects of equipment design which affect the protection
concept

Detailed knowledge of content of certificates and relevant parts of IEC 60079-14

Understanding of practical skills for the preparation and installation of relevant

concepts of protection

Detailed knowledge of additional importance of Permit to Work Systems and safe

isolation in relation to 'explosion protection'

Detailed knowledge of particular techniques to be employed in the selection and

erection of equipment referred to in this standard

General understanding of Inspection and Maintenance Requirements of IEC 60079-

17

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Knowledge and Skills - Responsible Persons
General understanding of relevant electrical engineering

Understanding and ability to read and assess engineering drawings

Practical understanding of 'explosion protection' principles and techniques

Working knowledge and understanding of relevant standards in explosion protection

Basic knowledge of quality assurance, including principles of auditing,

documentation, traceability of measurement and instrument calibration

Knowledge and Skills – Operatives

Understanding the general principles of explosion protection

Understanding the general principles of types of protection and marking

Understanding those aspects of equipment design which affect the protection

concept

Understanding content of certificates and relevant parts of this standard

General understanding Inspection and Maintenance Requirements of IEC 60079-17

Familiarity with the particular techniques to be employed in the selection and

erection of equipment referred to in IEC 600-14

Understanding the additional importance of Permit to Work Systems and safe

isolation in relation to Explosion Protection.

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 Unit 12: Pressurisation (EEx p)
Pressurisation is a simple technique for providing explosion protection. If the interior
of an enclosure is at a pressure above that externally, any flammable gases around
the enclosure will be prevented from entering the enclosure. Components which are
a source of ignition, i.e. they produce arcs/sparks or hot surfaces, are permitted
within the enclosure and, clearly, safety is dependent on the maintenance of the safe
gas.    The  safe  gas  is  the  medium  which  ‘segregates’  the  flammable  gas  from  the  
source of ignition, and its continued presence will be confirmed by an
approved/certified  ‘fail-safe’  control/monitoring  system.  A  slight  over-pressure is
usually adequate to maintain safe operation.

Definition

Pressurisation is defined as:

‘The  technique  of  guarding  against  the  ingress of the external

atmosphere, which may be explosive, into an enclosure by maintaining
a protective gas therein at a pressure above that of the external
atmosphere’

Applications

Pressurisation has a wide range of applications, i.e. it can provide explosion

protection for a diverse range of instrument or electrical apparatus, there being no
limit to size, within reason, which can be accommodated. Typical examples are
transformer/rectifier cabinets, oil drilling control consoles, visual display units
(VDU’s),  gas  analysis  equipment,  control  rooms,  switch  rooms  and  workshops.    With  
regard to flameproof apparatus, and in particular rotating machines, there is a
maximum practical limit above which handling becomes difficult and manufacturers
may overcome this difficulty by the use of a pressurised enclosure. A pressurised
machine would be significantly lighter than a flameproof machine of the same rating.
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Three types of enclosure px, py and pz

Suitable for use in areas requiring EPL Gb and Gc or

Category 2 and 3.

Prior to 2007, it was permitted to use in Gas zones 1

and 2.

The equipment grouping and temperature classification

defined in IEC 60079-0 for the use of electrical
equipment in explosive gas atmospheres apply to oil
immersion enclosures.

The subdivisions A, B and C for electrical equipment of

Group II also apply.

No live maintenance permitted

Non certified apparatus can be used

Marking of EEx p is complex and the Technical Authority should be consulted

Why to buy an EExp system from an ATEX certified manufacturer?

According to the ATEX 137, the end user is always responsible for the safety of the
installation. For an EExp installation,many standards can be applicable: EN 50014,
EN50016.”p”      EN  50018.”d“,  EN  50019.”e“  and  the  EN  50020. “i“.

An ATEX certified manufacturer is expected to have the necessary knowledge to

fulfil all the requirements to build an EExp installation according to the applicable
standards.

ATEX certified EExp explosion protected systems must comply with following
requirements:

All front mounted components to be certified according to EN 50014 (EN/IEC 60079-

0).

The mounting of internal components is restricted to the requirements as mentioned

in the EN 50014 (EN/IEC 60079-0), EN 50016 (EN/IEC 60079-2) and EN 50020
(EN/IEC 60079-11).

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The test procedure for EExp systems has to be done according to the EN 50016
(EN/IEC60079-2). For example: an overpressure test, leakage compensation test,
pressurisation test, verification minimum overpressure test, etc.

How to recognise an ATEX certified EExp system zone 1

A few points to recognize whether an EExp system has been built according to the
ATEX directive 94/9/EG (ATEX 95) or not:

1. A certificate number must be mentioned on the type label of a zone 1/zone 21

installation.
2. On the type label of the system an ATEX code should be marked: Ex II 2 G/D....
3. The type label of a zone 1/ zone 21 installation is marked with a CE mark followed
by 4 number digit. This number indicates the notified body (e.g. KEMA is 0344).

In case this number fails, it is not allowed to put the installation in operation in a zone
1 area. This number can be issued only by a notified body, like: PTB, DMT, KEMA,
etc.

Every system should be accompanied by an EC declaration of conformity and a well

written manual according to the ATEX directive.

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Three types of enclosure px, py and pz

It may not be feasible to duct issuing air from purged equipment into a safe area. A
spark flame arrestor is then required in the outlet air duct.

A flame arrestor is a mesh or perforated metal insert within a flammable storage

container (safety can, cabinet) which protects its contents from external flames or
ignition. It also dissipates heat. It allows gas to pass through it but stops a flame in
order to prevent a larger fire or explosion. There is an enormous variety of situations
in which flame arrestors are applied. Anyone involved in selecting flame arrestors
needs to understand how these products work and their performance limitations.
One example is Davy safety lamps used in mines.

Actions required on loss of protection

Gb/Cat 2 Px (alarm shut down) Py (alarm)

Gc/Cat 3 Px or Pz (alarm) Py (no action)

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Concept
Firstly - It maintains a pressure, known as an overpressure inside the enclosure
which prevents the ingress of any flammable atmosphere

Secondly - It can be used to dilute any potential flammable material released into
the enclosure to a level below the LEL

Thirdly - A combination of the two

Characteristics of the Protective Gases

The technique of pressurising and purging enclosures of electrical apparatus is to
prevent the ingress of a flammable atmosphere. Purging is a widely accepted
protection concept for explosion protection. It is accepted world-wide (using
European Standards, NFPA or IEC Standards) and is relatively straightforward to
comprehend. Explosion protection is achieved by keeping the potentially explosive
atmosphere away from any source of ignition (thermal or electrical). The potentially
ignition capable apparatus is mounted inside an enclosure, the enclosure is then
pressurised to a positive pressure relative to the atmospheric pressure (a positive
pressure of 0.5mbar is all that is required).

As long as this positive pressure is maintained, no gas (or even dust) will be able to
enter the enclosure; hence the internal equipment cannot be exposed to a potentially
explosive gas. There is however a chance that an explosive gas mixture may have
entered the enclosure prior to the positive pressure being achieved. To ensure that
the enclosure is pressurised with a non-explosive gas (i.e. Air or Nitrogen) the
enclosure is 'purged' to flush out the existing contents and ensure that all areas of
the enclosure contain only the purging gas (purging of internal dusts have not yet
been considered). It normally takes between 5 and 10 volume changes to ensure
that the enclosure is 'purged'. (In Europe the first edition purge standard defined five
air changes as a minimum, in North America the minimum is defined as 10 air
changes)

It is a condition of certification for Zone 1 equipment that power cannot be applied to

the equipment until the 'purging' (a specified flow of purging gas for a specified time)
has been completed. To ensure continuity in the effect of the purging, the maximum
leakage rate for the enclosure is also specified. When the purging has been
completed, power can still not be applied until the specified positive pressure (at
least 0.5 mbar) has been achieved.

In the event of a failure to complete the purging cycle (drop in flow or incomplete
duration) or if the enclosure pressure drops below the specified positive pressure,
power to the equipment shall be removed (for Zone 1) or an alarm indication shall be
given (Zone 2).

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In the event either of these conditions, the entire purging cycle starts again with the
full purge time duration. The control of the automatic purging and pressurization is
normally by a 'Purge Control Unit' (PCU). The PCU is required to measure flow and
pressure, and must fail-safe in all conditions.

The enclosure that houses the equipment to be purged must have sufficient physical
integrity to withstand impacts and overpressures. The enclosure should also be
designed to facilitate the free flow of air. As enclosure integrity is required to a level
of IP40 (no holes greater than 1mm), any non-metallic material must be tested for
durability and longevity (against effects of heat and light etc.). External
considerations, such as the surface temperature of the equipment or static from
plastic parts, must be considered. To ensure incandescent particles cannot be
vented from the equipment, a spark arrestor must be fitted (or the vented gas must
be ducted to a safe area). This technique is virtually unlimited particularly in physical
size or power rating of the apparatus being protected.

Application of the EEx p Technique

1. Static Pressurisation

2. Pressurisation with leakage compensation

3. Pressurisation with continuous flow

Static Pressurisation

Apparatus to be purged and pressurised outside the hazardous area

Allowed into the hazardous area without a continuous supply of a protective gas

Applications: Transportable data collection equipment

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Static Pressurisation
Static pressurisation relies on the enclosure being pressurised with an inert gas and
having a sealed enclosure to maintain the pressurisation.

 The protective gas shall be inert.

 Internal sources of release of flammable substances are not permitted.
 The pressurised enclosure shall be filled with inert gas in a non-hazardous
area using the procedure specified by the manufacturer
 Two automatic safety devices shall be provided to operate when the
overpressure falls below the minimum value specified by the manufacturer.
 The automatic safety devices shall only be capable of being reset by the use
of a tool or a key.
 The purpose for which the automatic safety devices are used (i.e. to
disconnect power or to sound an alarm or otherwise ensure safety of the
installation) is the responsibility of the user.

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Pressurisation with Leakage Compensation
One of two techniques most associated with EEx p

Where an enclosure cannot be totally sealed, a continuous supply of protective gas

is applied in sufficient quantity to compensate for any leakages

Generally used where a source of ignition exists but the flammable hazard is outside
the enclosure

Minimum overpressure to be 50 PASCAL's (0.5 millibar)

Pressurisation with Leakage Compensation

Enclosure is in a Zone 2

No flammable materials are piped into the enclosure

The enclosure contains 230 volt equipment fed via plug and socket

Contains electrical space heaters

Pressurisation with Leakage Compensation

Enclosure is maintained at a pressure slightly above the outside pressure

Therefore any leakage will be of the protective gas outwards rather than the
flammable atmosphere inwards

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Pressurisation with Continuous Flow
The second technique most associated with EEx p and the most complex method

Requires the enclosure to maintain an internal overpressure with sufficient

continuous flow of protective gas to maintain the internal atmosphere below the LEL,
in a worst case leak scenario

Typical applications are enclosures where:

Internal source of release and electrical equipment exist

Flammable materials are piped into the enclosure so the potential for release and the
formation of a flammable atmosphere exist

Example - Analyser Houses/Chromatograph

Equipment with an internal source of release

Manufacturer’s  instructions  followed

What’s  the  difference  between  Leakage  Compensation and Continuous Flow

Systems

a) The Continuous Flow system will continuously flow air through the control panel.
The flow rate depends on which orifice plate you choose. Applications: small
enclosures and analyzers.

b) The Leakage Compensation system purges the enclosure; and then shuts itself
down and just tops off for any leakages your enclosure may have. It will maintain a
minimum pressure in the enclosure.

EEx p Purging
Before pressurisation can take place, it is necessary to remove any existing
explosive atmospheres.

The enclosure volume should be changed by the protective gas at least five times
before energising.

However Zone 2 purging may be omitted if the interior of the enclosure and the
associated supply ducting is proved to be below LEL.

Purge control units must be able to measure and act on the following information:

 Pressure (pressurisation)
 Flow (purging)
 Time (purging)
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The operations performed by the PCU must be 'failsafe' by virtue of test and
assessment with one fault (i.e. a valve failing), this is even more prevalent with the
advent of the ATEX Directive. Failure modes of components must be considered;
even relays can fail open or short-circuit (normally open relays can 'arc-weld' in to a
closed position). Purging timers must always re-set to zero if they are interrupted
during the purging cycle or after a purge failure. There are two basic types of control:

Constant Flow (CF) - The air flow for the purging and pressurization stages are the
same. The flow is left as a constant after it is set, and power is applied after a set
period of time.

Leakage Compensation (LC) after purging, the air flow is reduced to a figure just
above the leakage level to maintain the pressurisation. The PCU is required to
switch from an initial high flow rate (often referred to as fast purge) to a much lower
flow rate on completion of the purge time. CF systems are simpler to design, but are
more expensive (in air or nitrogen) to run. There are other examples of hybrid
systems (CF/LC) but in reality they are just variations on the two basic types.

PCU's (Pressure Control Units) are normally either pneumatic or electrical. If the
PCU is mounted in the safe area only the operation will require verifying (unless it
contains intrinsically safe outputs). PCU's mounted in the potentially explosive
atmosphere will require certifying both as safety systems and as potential ignition
sources (although sources of ignition from pneumatic systems were not considered
until the ATEX Directive).

Practical implementation

Enclosures

A standard IP54 enclosure may not be suitable for use as a pressurised enclosure
because the sealing is in the wrong direction. The standard enclosure is designed to
prevent the external environment entering the enclosure which means that they are
generally unsuitable for retaining internal pressure.

For this reason enclosures from suppliers of pressurised systems are not generally
the same as general-purpose enclosures. Also, the enclosure must be able to
maintain the pressure, on large enclosures the unit can be seen to deform even with
relatively low pressures. Additional hinges and cover bolts may be required when the
pressure is acting on a large surface area. Plastic parts (e.g. switches) should not
penetrate the housing walls. Plastic parts may be used externally if, when the plastic
is removed, metal parts remain that provide an ingress protection rating of IP40 (no
objects greater than 1 mm can penetrate the enclosure). No live (or potentially live)
parts should be exposed outside of the purged area. As switches are normally
sealed devices that contain sparking contacts, it is preferable to either use certified
switches or mount the switches inside the purged enclosure. Plastic ducting should
not be used if the plastic part failing does not create a fail-safe condition, e.g. on the
secondary purge system.

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Enclosure covers/doors

Where the interior of a pressurised enclosure can be accessed via doors/covers

without the use of tools or keys, an interlock is required to automatically de-energise
the electrical supply when the door/cover is opened, and restore the electrical supply
only when the doors/covers are closed.

When a pressurised enclosure contains components which have hot surfaces, or are
capable of storing energy, e.g. capacitors, doors/covers should be fitted with a
warning notice which states the time delay after isolation of the electrical supply to
the components before opening the doors/covers.

Supply and Return of Purging Medium

Special precautions are needed where the pressurisation method uses a fan or
blower. It is generally undesirable to put the fan in a hazardous area because this
means that the ducting, which extends to a non-hazardous area, will be below
atmospheric pressure and, unless it is completely leak tight, may draw in flammable
gases. The other advantages of putting the fan in the non- hazardous area is that it
does not need to be suitable for use in hazardous area itself and the ducting is under
positive pressure which prevents ingress of flammable gas.

The use of compressed air is the normal method of supplying purge air, it must be
noted that several purged enclosure on one supply line may drop the operational
pressure to below working levels for the pneumatic logic, if such a system is used.

The exhausted air from a purged enclosure may contain small particles that have
been heated by the internal sources of the enclosure. To prevent these particles
being vented into the potentially explosive atmosphere the following methods are
used:

 Spark arrestors on the air outlet.

 Ducting (to a safe area) on the air outlet.

Pressurisation
The minimum pressure required is 0.5 mbar (50 Pa) and this should be achieved
with the lowest possible flow of pressurising gas. The pressure measurement has to
at least raise an alarm if the pressure falling below this level so that the working
pressure will be above this. The enclosure has be tested to prove it will withstand 1.5
times its normal working pressure (minimum 200 Pa) for 2 minutes without distortion,
a figure of 10 mbar is not uncommon as a working pressure.

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Purging
Effective purging of the enclosure and its contents has to be provided. As a
guideline, 5 volume changes are generally sufficient if the enclosure has been
designed to a few basic guidelines:

a) Avoid air traps (pockets)

b) Avoid 'channelling' of the purging air
c) Create turbulence
d) Avoid sealed volumes

Temperature Classification
Since the flammable gas is prevented from entering the enclosure the exterior of the
enclosure determines the temperature classification. It is to be noted, however, that
internal hot surfaces will remain hot even after the power has been removed. A full
assessment of the thermal properties of hot parts of a purged enclosure must be
conducted.

Pressurised and Purged Enclosure with People Working Inside (Purged

rooms)

Naturally inert gas cannot be used and compressed air is not generally
recommended. In addition, emergency facilities for the personnel are required.
Lighting and means of escape are of prime importance. The lighting is required
under all circumstances and hence must be protected by some other suitable means
such as flameproof. Kick-out panels or crash bars on doors usually provide for
escape.

Cable Glands – Must maintain the system integrity.

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 Unit 13: Intrinsic Safety EEx i

Definition of Intrinsic Safety: IEC 60079-11

Type  of  protection  “i”  is  a  protection  type  in  which  the  energy  available  in  the  
hazardous area is limited to a level below that which could ignite a flammable
atmosphere.

Basic principles of IS

Intrinsically Safe circuits achieve safety by maintaining very low energy levels such
that hot surfaces will not be produced, and electrical sparks, if they occur, will have
insufficient energy to ignite the most easily ignitable concentration of a flammable
mixture. This is achieved by limiting the voltage and current supplied to the
apparatus in the hazardous area. To maintain safety, it is of paramount importance
that these levels of voltage and current are not exceeded under normal, or even fault
conditions.

The circuit parameters, i.e. voltage, current, resistance, inductance and capacitance
are factors which have to be considered in the design of an IS circuit. Consultation
with the characteristic ignition curves given in the construction standard, and
reproduced in this section, and the application of appropriate safety factors, will
ensure that safe values are established for these parameters during the design
stage.

Typical uses:

Instrumentation, control circuits, low power apparatus

Three Categories:

Difference lies in components integrity of the equipment

Continued Intrinsic Safety under fault conditions

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Ex  “ia”
Suitable for use in areas requiring EPL Ga,Gb and Gc or Category 1, 2 and 3.

Prior to 2007, it was permitted to use in Gas zones 0,1 and 2.

Live maintenance permitted

Ex  “ib”
Suitable for use in areas requiring EPL Gb and Gc or Category 2 and 3.

Prior to 2007, it was permitted to use in Gas zones 1 and 2.

Live maintenance permitted

Ex  “ic”
Suitable for use in areas requiring EPL Gc or Category 3.

Prior to 2007, it was permitted to use in Gas zone 2.

Live maintenance permitted

Temperature classification and gas group

The equipment grouping and temperature classification defined in IEC 60079-0 for
the use of electrical equipment in explosive gas atmospheres apply to powder filling
enclosures.

The subdivisions A, B and C for electrical equipment of Group II also apply.

Ex 'ic' and Ex 'nL' are the same

The energy-limited apparatus 'nL' and the energy-limited parts of associated energy-
limited apparatus, shall comply with the Ex'n' standard.

Equipment for connection into energy-limited (nL) circuits should be installed in

accordance with the requirements of equipment to type of protection 'ic'

Equipment to type of protection 'nL' may be used in an intrinsically safe 'ic' circuit

Equipment which contains energy-limited circuits shall be terminated in accordance

with the requirements of the type of protection of the terminal enclosure (example
Ex'nA', Ex 'd', Ex'e')

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Intrinsic Safety - A System Concept
Other types of protection achieve their safety on an item-by-item basis, for example
flameproof equipment

Intrinsic Safety relies on the associated apparatus and the energy levels of the
equipment and cables connected to the hazardous area terminals

Intrinsically safe circuit (IEC 60079-11)

circuit in which any spark or any thermal effect produced in the conditions specified
in this standard, which include normal operation and specified fault conditions, is not
capable of causing ignition of a given explosive gas atmosphere

Electrical apparatus
Assembly of electrical components, electrical circuits or parts of electrical circuits
normally contained in a single enclosure.

NOTE 1 – The term "normally" has been introduced to indicate that an apparatus
may occasionally be in more than one enclosure, for example, a telephone or a radio
transceiver with a hand microphone.

NOTE 2 – This definition is more precise than that contained in IEC 60079-0.

Intrinsically safe apparatus;

Electrical apparatus in which all the circuits are intrinsically safe circuits

Associated Apparatus is defined as:

Electrical apparatus which contains both intrinsically safe circuits and non-
intrinsically safe circuits and is constructed so that the non-intrinsically safe circuits
cannot adversely affect the intrinsically safe circuit.

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Intrinsically Safe Equipment
Equipment that is energy storing or produces energy, and is intended for use in an
Intrinsically Safe Circuit needs to be certified intrinsically safe.

Simple Apparatus is defined as:

A device not capable of producing energy to a value greater than 1.5V, 0.1A, 25mW
or 20µJ

Switches, thermocouples, RTD's, terminals, junction boxes and LED's (Certification

not required)

The temperature classification awarded is generally T4, however JB's, switches and
terminals may be T6 because they do not contain heat dissipating components

Simple apparatus (IEC 60079-11)

Electrical component or combination of components of simple construction with well-

defined electrical parameters which is compatible with the intrinsic safety of the
circuit in which it is used.

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Certified Associated Apparatus
The certification may appear in square brackets [EEx ia], Provides a defined point at
which the intrinsically safe circuit start. Normally installed in the non-hazardous safe
area.

Typically they are Barriers

Shunt Diode Barrier

A current and voltage limiting device, that uses an infallible resistor to limit current
into the hazardous area and Zener diodes to limit the voltage.

(Commonly known as Zener Barriers), Application;

Zener barriers are used in control and instrumentation systems for the processing of
standardised signals, such as 20 mA and 10 V. Zener barriers contain intrinsically
safe circuits that are used to drive intrinsically safe field devices within hazardous
areas. The manufacturer’s data sheets must be consulted.

The relevant regulations and directives governing the intended application must be
observed.

Shunt Diode Barrier or Zener

Barrier Installations require a high integrity earth to function as designed Barriers
designed to remain safe with a maximum voltage (Um) 250v applied to the non-
hazardous area terminals

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The Zener barrier

The faults which can jeopardise the security of IS systems are either overvoltage or
overcurrent, and protection against these conditions is afforded by the use of an
interface, typically a Zener barrier, the construction of which will be considered in
terms of its individual components.

The interface, which is connected between the safe area and hazardous area
apparatus, is normally located in the safe area and situated as close as possible to
the boundary with the hazardous area, but may be located in the hazardous area if
installed in a flameproof enclosure.

A simple zener barrier has three principal components, (1) a resistor, (2) a zener
diode, and (3) a fuse, all of which must have infallible properties.

Infallibility, with regard to the current limiting resistor, means that in the event of it
failing, failure will be to a higher resistance value or open-circuit. Clearly, failure to a
lower resistance value or short-circuit would allow more current to flow in the IS
circuit, which is contrary to the concept of this type of protection. Infallibility will be
satisfied by the use of a quality wire-wound or metal film resistor, and its operating
power, as required in the standards, should not exceed 2/3 of its maximum quoted
rating for a specified ambient rating. The next component for consideration is the
zener diode, the purpose of which is to limit the voltage available to the apparatus in
the hazardous area. The zener diode, as a single item, is not considered to be an
infallible component, must also be operated at only 2/3 of its maximum stated rating.
For infallibility to be satisfied, the zener diode is required to fail to a short-circuit.
Failure to a higher resistance or open-circuit could allow voltage levels beyond safe
limits  to  “invade”  the  hazardous  area.

Note: Tests by manufacturers have shown that diodes virtually always fail to a short-
circuit state, but there can be no guarantee of this. Diodes can only be
considered infallible when two or more are connected in parallel as discussed
later.

The third component, a fuse, is located at the input (safe) end of the zener barrier, its
purpose being to protect the zener diodes, and not to protect against, for example, a
short-circuit in the field apparatus. Infallibility of the fuse is assured by the use of a
sand-filled ceramic type capable of operating properly even when exposed to a
prospective fault-current of up to 4000 A. A fuse of this type avoids the problem
which can occur with other types of fuses when they rupture, namely vapourisation
which can allow the fuse to continue to conduct.

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As required by the standards, the fuse is encapsulated along with the other
components of the barrier to deter replacement. The repair of Zener barriers is not
permissible, even by the manufacturer.

In the event of a short-circuit

developing in the apparatus in the
hazardous area, or across the IS
wiring, the series resistor in the zener
barrier will limit the short-circuit
current to a safe level so that the
integrity of the system is maintained.

If a voltage greater than the normal maximum voltage of the IS system invades the
circuit at the input terminals of
the zener barrier, this will
trigger the zener diode, and
the resulting fault current will
be shunted to earth. The
excessive voltage is,
therefore, prevented from
reaching the apparatus in the
hazardous area.

Servicing and maintenance

The transmission characteristics of the devices remain stable over long periods, so
that regular adjustments or other precautions are not required. This also means that
no maintenance work is required.
Fault elimination
No modifications may be made to devices that are operated in connection with
hazardous areas. Repairs must only be carried out by specially trained and
authorised personnel.

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Intrinsically Safe Earth
I.S. systems using Zener barriers require a high integrity earth and good earth
connections are required.

Minimum of one 4mm2 or two 1.5mm2 conductors required from the barrier earth bar
in an enclosure to the main I.S. earth bar. Good practice is two conductors in
parallel to allow for testing.

The size may need to be increased to satisfy low impedance value

The impedance from the barrier earth bar to the star point of the transformer should
be less than 1

EN 60079-14;

Tells us that the barrier earth terminals should be connected to a high integrity earth
point which will ensure a path of not more than 1 ohm to the main power system
earth point.

It  is  perhaps  unfortunate  that  for  many  years  the  expression  “main  power  system  
earth  point”  has  been  taken  to  mean  the  point  at  which  the  electricity  supply  
company makes the earth connection to its substation transformer neutral. Many
diagrams which show the barrier earth connected back to this point may have been
misleading-especially as not all power systems have an earthed neutral point.

The  “main  power  system  earth  point”  should  be  understood to mean the earth point
to which all the electrical (and often structural) earth connections are made (directly
or indirectly) from the hazardous area to be protected.

EN 60079-14 Clarifies that the use of the power supply earth point applies to TN-S
systems only (separate neutral and earth conductors in the hazardous area), i.e. not
TN-C systems in which both earthing and neutral power share the same conductor,
nor IT systems in which the supply neutral is not directly earthed.

The standard gives the useful alternative instruction that the barrier earth terminals
shall be connected to the equipotential bonding system by the shortest practicable
route. This alternative earthing method is not affected by the style of power supply
system, nor is the limiting maximum path resistance of 1 ohm stated. This means
that in almost all cases a suitable earthing point can be found without any difficulty.

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For the earth connection which is related to the main power system earth point both
the standards give the same advice, in suggesting a connection to the earth bar
which may be found in a local switch room or by the use of separate earth rods.
while the use of the switch room earth busbar is usually a good choice, in a practical
situation it is often very difficult to ensure that the path resistance of less than 1 ohm
can be relied upon by the use of separate earth rods and it is strongly recommended
that providing a barrier earth in this way is avoided.

The connection between the Zener barrier earth busbar and the chosen earthing
points needs to be made by at least one conductor having a cross section of not less
than 4mm squared copper. However, it is usual both for purposes of reliability and to
facilitate testing, that at least two separate conductors between the barrier earth
busbar and the chosen earthing point are provided.

In this case each shall have minimum cross section of 1.5mm squared copper, and it
is usual to run these conductors along different routes where possible.

Each conductor should have individual terminations at each end so that any one
path is completely independent of any defects which may occur in the continuity of
other paths in the earthing system.

To prevent the possibility of unrelated fault currents being passed down the barrier
earth conductor these conductors shall be installed for Zener barrier earthing
purposes alone, and shall not be used for earth connections of any other equipment

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Earthing and Bonding

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Galvanic Isolating Barriers
Although zener barriers have been, and continue to be, widely used in industry, they
have particular limitations which are:

a) A dedicated high-integrity earth is necessary to divert fault currents away from

the hazardous area;

b) A direct connection exists between the hazardous and safe area circuits and
earth, which tends to apply constraints on the rest of the system;

c) Hazardous area apparatus must withstand a 500 V insulation resistance test

to earth.

Devices which overcome these difficulties are isolation interfaces typically relays,
opto isolators and transformers.

This concept relies on transformer isolation between the hazardous area and safe
area circuits within the barrier.

Typical galvanic barriers will give in the region of 4000 volts isolation between these
circuits

Achieved using Transformer Isolation or Electronic Optical Isolation Techniques

In addition to limiting energy and providing isolation galvanic barriers usually perform
some additional function

Galvanic barriers do not require any I.S. earthing arrangements

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A galvanic isolator is any device that connects two circuits together without allowing
electricity to flow directly from one circuit to the other. Instead of transferring
electricity through direct contact, galvanic isolators use other means, such as
electromagnetism, mechanical devices, optical systems, or acoustic systems to
convert the electricity into another form of energy, transfer it to an output device, and
then convert it back into electricity. There are many different types of galvanic
isolators and they can be used in a wide variety of applications.

How Galvanic Isolators Work

A galvanic isolator separates two circuits by converting electricity from one circuit or
circuit component into another form of energy and then converting it back into
electricity once it has reached another circuit. Galvanic isolators prevent current that
could damage sensitive electronic circuits from traveling between one circuit section
and another. Galvanic isolators depend on light, electromagnetic waves, sound
waves, mechanical energy, inductance, capacitance, or other means to ensure that
the output current is the same or less than the input current.

Advantages

Galvanic isolators prevent electricity in one circuit or circuit component from

damaging other circuits or circuit components that may be more sensitive and/or
designed for a different function. Galvanic isolators also prevent interference or
“noise”  that  variations  of  electricity  in  multiple  circuits  generate  from  disrupting  the  
regular functionality of an electronic device. Galvanic isolators can be used in a wide
variety of systems and can be made of different components in order to provide
maximum efficiency for a number of situations.

Installation of Barriers

They are normally installed in a non-hazardous (safe) area.

Can be installed on open racks behind panels and in switch houses (old technique)

Normally installed in enclosures in a safe area.

Recommended as good practice not to mix Zener and Galvanic Barriers on the same
mounting rail.

Barriers should be mounted so that a minimum 50mm segregation is

maintained between all safe and hazardous area terminations

Provision should be made to terminate cable screens when utilised

To increase the integrity of the I.S. circuit, I.S. and non-I.S. cables should be kept
segregated in barrier enclosure by either:

Looming of the cables, running cables in trunking

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 Unit 14: Intrinsic Safety I.S Cables
Freedom to use ordinary instrument cabling in hazardous area, armouring not
required but cable must be insulated.

Capacitance, Induction & Resistance/Induction ratio must be taken into consideration

when cable run in hazardous area exceeds 1000 metres (1km)

Where an interconnecting cable is fitted with a screen, this should be earthed at one
point only. (Usually non-hazardous area)

Where interconnecting cables incorporate individually screened conductors, screens

should be insulated from each other in such a manner that the insulation resistance
is not less than 1M/kilometre

Core to core to withstand a test voltage of 500V ac – 750V dc

Diameter of individual wire strands should not be less than 0.1mm

Creepage and clearance dimensions to be observed (6mm between bare

conductors and 3mm to earth)

Cores of circuits should be identified and made off using crimped connectors

Under no account should I.S. and none I.S. circuits be mixed in the same multicore
cable

I.S. and non I.S to be 50mm apart

Facilities for connection of external circuits

Terminals

In addition to satisfying the requirements of table 4, terminals for intrinsically safe

circuits shall be separated from terminals for non-intrinsically safe circuits by one or
more of the methods given in a) or b).

These methods of separation shall also be applied where intrinsic safety can be
impaired by external wiring which, if disconnected from the terminal, can come into
contact with conductors or components.

NOTE – Terminals for connection of external circuits to intrinsically safe apparatus

and associated apparatus should be so arranged that components will not be
damaged when making the connections.

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a) When separation is accomplished by distance then the clearance between
terminals shall be at least 50 mm. Care shall be exercised in the layout of terminals
and in the wiring method used so that contact between circuits is unlikely if a wire
becomes dislodged.

b) When separation is accomplished by locating terminals for intrinsically safe and

non-intrinsically safe circuits in separate enclosures or by use of either an insulating
partition or an earthed metal partition between terminals with a common cover, the
following applies:

1) partitions used to separate terminals shall extend to within 1,5 mm of the

enclosure walls, or alternatively shall provide a minimum distance of 50 mm between
the terminals when measured in any direction around the partition;

2) Metal partitions shall be earthed and shall have sufficient strength and rigidity to
ensure that they are not likely to be damaged during field wiring. Such partitions shall
be at least 0,45 mm thick or shall conform to 10.10.2 if of lesser thickness. In
addition, metal partitions shall have sufficient current-carrying capacity to prevent
burn-through or loss of earth connection under fault conditions;

3) Non-metallic insulating partitions shall have sufficient thickness and shall be so

supported that they cannot readily be deformed in a manner that would defeat their
purpose. Such partitions shall be at least 0,9 mm thick, or shall conform to 10.10.2 if
of lesser thickness.

The clearances between bare

conducting parts of terminals of
separate intrinsically safe circuits
shall be equal to or exceed the
values given in table 4. In
addition, the clearances between
terminals shall be such that the
clearances between the bare
conducting parts of connected
external conductors are at least 6
mm when measured… In
accordance with the diagram
provided.

Any possible movement of

metallic parts which are not rigidly
fixed shall be taken into account.

The minimum clearance between the bare conducting parts of external conductors
connected to terminals and earthed metal or other conducting parts shall be 3 mm,
unless the possible interconnection has been taken into account in the safety
analysis.

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Plugs and sockets
Plugs and sockets used for connection of external intrinsically safe circuits shall be
separate from and non-interchangeable with those for non-intrinsically safe circuits.

Where intrinsically safe or associated apparatus is fitted with more than one plug and
socket for external connections and interchange could adversely affect the type of
protection, such plugs and sockets shall either be arranged, for example by keying,
so that interchange is not possible, or mating plugs and sockets shall be identified,
for example by marking or colour coding, to make interchanging obvious.

Where a plug or a socket is not prefabricated with its wires, the connecting facilities
shall require the use of a special tool, for example by crimping, such that there is no
possibility of a strand of wire becoming free, then the connection facilities need only
conform to table 4.

Earth conductors, connections and terminals

Where earthing, for example of enclosures, conductors, metal screens, printed wiring
board conductors, segregation contacts of plug-in connectors and diode safety
barriers, is required to maintain the type of protection, the cross-sectional area of any
conductors, connectors and terminals used for this purpose shall be such that they
are rated to carry the maximum possible current to which they could be continuously
subjected.

Terminals shall be fixed in their mountings without possibility of self-loosening and

shall be constructed so that the conductors cannot slip out from their intended
location. Proper contact shall be assured without deterioration of the conductors,
even if multi-stranded cores are used in terminals which are intended for direct
clamping of the cores. The contact made by a terminal shall not be appreciably
impaired by temperature changes in normal service.

Terminals which are intended for clamping stranded cores shall include resilient
intermediate part. Terminals for conductors of cross-sections up to 4 mm² shall also
be suitable for the effective connection of conductors having a smaller cross-section.
Terminals which comply with the requirements of IEC 60079-7 are considered to
conform to these requirements.

The following shall not be used:

a) Terminals with sharp edges which could damage the conductors;
b) Terminals which may turn be twisted or permanently deformed by normal
tightening;
c) Insulating materials which transmit contact pressure in terminals.

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Permanently connected cable

Apparatus constructed with a permanently connected cable.

Clearance and creepage distance requirements for terminals carrying separate

intrinsically safe circuits.

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Separation of Intrinsically Safe and Non-Intrinsically Safe Wiring

To reduce the possibility of their interconnection, additional requirements exist for the
separation of intrinsically safe and non-intrinsically safe circuits. IEC 60079-11
requires a minimum separation distance of 50 mm (2 in.) be provided between
intrinsically safe and non-intrinsically safe conductors.

This separation may also be accomplished by using a grounded metal or insulating

partition, or by locating either of the circuits in a grounded metal shield capable of
carrying the maximum prospective fault current should either circuit be connected to
earth.

Cores of circuits should be identified and made off using crimped connectors

Under no account should I.S. and none I.S. circuits be mixed in the same multicore
cable

I.S. and power cables can be run together on the same cable tray provided that on of
the cables is armoured, the armour earthed and the I.S cable screened

Single core high current carrying conductors should be avoided

Segregation by physical spacing is recommended

Where non-armoured cable is used a non-certified A2 cable gland is acceptable

Spare cores in multicore cables to be terminated to unearthed terminals

Spare cores installed in barrier boxes should be connected to the I.S. earth.
(Easily achieved using a dummy barrier)

All cable cores and screens should be connected as per the hook up or installation
diagrams

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Cable Screens

Provision should be made to terminate cable screens when utilised

Terminations should be provided in junction boxes to maintain segregation of circuits

including screens

The screen wire should be insulated adequately to prevent it touching earth or any
other circuit terminations

At the field device the screen wire is normally insulated, coiled and tied back

When I.S. circuit contains a Shunt Diode (Zener) Barrier, the screen is normally
connected to the I.S. earth at the barrier end of the cable

When I.S. circuit contains a Galvanic Barrier the screen is normally connected to the
dirty or equipment earth and NOT the I.S. Earth

All terminations should be wired as per the system documentation.

Instrumentation cables commonly incorporate earthed screens or shields to reduce

noise on long cable runs. Where these screens are covered by an insulating sheath,
as is the usual cable construction, then the screen is connected to the barrier earth
terminal or busbar in the safe area barrier enclosure.

These cable screens must be kept isolated from earth in the hazardous area to avoid
spurious earth currents been fed back into the barrier earthing system.

Identification of I.S. Circuits

Common practice for cables to have blue outer sheath

The colour light blue is used to indicate I.S. and greatly assists in the identification of
cables, I.S. apparatus and junction boxes

The use of light blue is a recommendation

Identification of Intrinsically Safe Field Wiring

Raceways, cable trays, and other wiring methods for intrinsically safe system wiring
shall  be  identified  with  permanently  affixed  labels  with  the  wording  “Intrinsically Safe
Wiring”  or  the  equivalent.  The  distance  between  labels  shall  not  be  more  than  7.5  m  
(25 ft.). Alternatively, colour coding may be used as a method of identification
provided that the colour light blue is used, and that no other conductors or wiring are
coloured light blue.

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 Unit 15: I.S Junction boxes
I.S Junction boxes are by definition simple apparatus and therefore DO NOT need to
be certified. The minimum required is IP54.

A label is required to indicate I.S. circuits or I.S. equipment are contained in the
enclosure

I.S. and non-I.S. circuits must be kept separate: (a minimum distance of 50mm
required)

Creepage and clearance distances to be observed (6mm between bare conductors

and 3mm to earth)

Cable entry must maintain IP54: if less than 6mm an IP washer is required

The choice of glands is determined by the cables used and the requirement to
maintain the integrity of the enclosure. In practice the use of a large number of
glands frequently lowers the enclosure integrity from IP 65 to IP54. The use of
anything other than round cables should be avoided

Light blue terminals preferred

Provision must be made for all cable cores including screens

Terminals
Terminals are by definition simple apparatus and therefore DO NOT need to be
certified. They should maintain creepage and clearance distances (6mm between
bare conductors and 3mm to earth)

Light blue terminals preferred

I.S. and non-I.S. circuits must be kept separate (a minimum distance of 50mm
required)

It is common practice to use terminals of the type  used  in  low  powered  ‘Exe’  circuits  
[sometimes blue] because these satisfy the requirements of segregation between
circuits and clearance to ground. Their construction ensures a degree of operational
reliability, which is desirable, and there is usually an adequate provision for marking.
Terminals carrying intrinsically safe levels of current are allocated a temperature
classification of T6 [85C from 40C ambient] and consequently the temperature
classification of intrinsically safe junction boxes is never a problem.

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 Unit 16: I.S Certification

Self-Contained Electrical Apparatus

This includes, for example, Test Equipment which should normally be certified I.S.
This should be approved for use by the Technical Authority and must be installed
and used in accordance with its certification when in the hazardous area.

Intrinsically Safe Systems

Should normally be certified via a System Certificate unless they can be shown to be
safe by being:

Simple Systems
Defined as a system in which all electrical is certified as I.S. or as associated
apparatus

Systems Including Simple Apparatus

Systems which contain simple apparatus do not require any additional certification

Complex Systems
If there is any doubt, between the compatibility of two components then the system
should be considered by a National Authority

Always remember Intrinsic Safety is a system concept.

Safety cannot be assumed by reference to one item of apparatus

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Unit 17: Combined methods (Hybrid).
Electrical equipment may be manufactured with more than one method of explosion
protection. Equipment of this type has combined methods of protection but may also
be known as a hybrid. Such an approach combines the best features of each type of
protection into one piece of equipment for both economic and practical purposes.

A traditional push-button station for use in an hazardous location comprises a

flameproof EEx d enclosure, in which a standard industrial switch is fitted. An
alternative to this arrangement is an Increased Safety EEx e enclosure with a small
flameproof EEx d component certified switch fitted inside. Because the switch
produces sparks in normal operation, clearly it has to be flameproof to comply with
the Increased Safety concept of protection. Such equipment will be marked EEx ed
or EEx de.

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The advantages of the hybrid arrangement discussed over the traditional flameproof
method are:

(a) Lower cost and weight;

(b) Glanding arrangements are simplified;

(c) Minimum ingress protection IP54 but may be as high as IP66.

Motors - EEx de

Motors - EEx de

Manufacturers also produce electric motors in which there are combined methods of
protection. The main body of the motor will be flameproof EEx d and the terminal
box increased safety EEx e. An alternative terminal plate is fitted to a motor of this
type to accommodate special terminals which are screwed into the terminal plate.
These are hybrid terminals, i.e. they employ both flameproof EEx d and increased
safety EEx e concepts in their construction.

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EEx de motor terminal box

To achieve the required level of ingress protection, gaskets are fitted between the
terminal  box  and  it’s  cover,  between  the  terminal  plate  and  box,  and  between  the  
gland plate and terminal box. On no account, however, should a gasket be fitted
between the terminal plate and the frame of the motor as this joint is a flamepath.

It must be emphasised that, on some motors, the increased safety terminal box looks
very much like a flameproof box in terms of its construction. This likeness means
that there is a possibility that the gaskets may be removed by personnel unaware of
this concept and, therefore, it is important that certification labels are studied before
any  work  is  carried  out.    Removal  of  the  gaskets  in  attempt  to  return  the  box  to  it’s  
assumed status, i.e. flameproof, would be an unauthorised modification which would
invalidate the certification.

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Lighting fittings - EEx edq

The lighting fitting illustrated below employs three protection concepts, i.e. increased
safety  type  ‘e’,  flameproof  type  ‘d’  and  powder  filling  type  ‘q’.    This  type  of  fitting  is  
widely used in the petro-chemical industry.

The constructional features are:

1) flameproof lampholders;

2) increased safety choke designed not to overheat if lamp fails;

3) temperature rating based on internal and external surface

temperatures;

4) enclosure sealing providing high ingress protection;

5) increased safety enclosure including glands designed to withstand

specified impact.

In this lighting fitting, the circuits include capacitors which are protected by a method
of  protection,  powder  filling  type  ‘q’.    Switches  will  be  of  flameproof  type  ‘d’  
construction  and  terminals  will  be  increased  safety  type  ‘e’.

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EEx e m ib

An enclosure may have an encapsulated component inside. A typical example is a

telephone for use in a hazardous location. The casing of the telephone would use
increased  safety  type  ‘e’  protection,  most  of  the  internal  circuits  would  be  intrinsically  
safe,  type  ‘i’,  but  part  of  the  circuitry  would  operate at a higher voltage and therefore
encapsulation  type  ‘m’  would  be  used  to  protect  that  part  of  the  circuit.    Terminals  
would  be  increased  safety  type  ‘e’.

Eex  ‘e’  Enclosure

EEx pde

Enclosures which employ the protection concept, pressurisation type  ‘p’,  may  have  
internal apparatus which have to remain energised in the absence of overpressure.
Such apparatus must be protected in accordance with the Zone in which the
enclosure is located. A typical example is an anti-condensation heater within a
pressurised machine which will be energised when the machine is idle.

Apparatus outside the machine, e.g. junction boxes, pressure sensors etc., will also
have to be protected in accordance with the Zone.

Note: Since anti-condensation  heaters  are  normally  ‘live’  when  a  machine  is  idle,  
notices warning of this danger should be displayed.

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EEx pi

The part(s) of an IS system which are marked to indicate that they should be
installed in a non-hazardous area may be used in a hazardous area if installed in, for
example, a pressurised enclosure as illustrated below.

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 Unit 18: Inspections
BS EN 60079-17:2007 Explosive atmospheres. Electrical installations inspection and
maintenance.

Electrical installations in hazardous areas possess features specially designed to

render them suitable for operations in such atmospheres. It is essential for reasons
of safety in those areas that, throughout the life of such installations, the integrity of
those special features is preserved.

The inspection and maintenance of installations should only be carried out by

experienced personnel whose training has included instruction on the various types
of protection and installation practices, the relevant rules and regulations, and on the
general principles of area classification. Appropriate continuing training should be
undertaken on a regular basis.

General

Before a plant is brought into service for the first time, it must be given an initial
inspection. This work can be done by the operator or an outside company (third
party). To ensure that the installation is maintained in a satisfactory condition, it is
necessary to carry out either:

•  Regular  periodic  inspections,  or

•  Continuous  supervision  by  skilled  personnel and, where necessary, maintenance
must be carried out.

Correct functional operation of hazardous area installations does not mean, and
should not be interpreted as meaning, that the integrity of the special features
referred to above is preserved.

Definition

An action comprising careful scrutiny of an item, carried out with either visual partial
dismantling or dismantling in order to arrive at a reliable conclusion as to the
condition of an item

Types of Inspection
Initial

Periodic

Sample

Continuous Supervision

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Initial Inspection
The purpose of an initial inspection is to ensure that the apparatus is suitable for the
hazardous area in which it has been installed

During the act of installation no item of equipment has invalidated its certification

Detailed inspection carried out.

The best time to carry out an Initial Inspection is:

Immediately after installation

Before plant is operational

Before location becomes hazardous

Periodic Inspections
Even if the apparatus is initially installed correctly there is no guarantee it will remain
in this condition, due to the effects of environmental corrosion, vibration, plant and
operational changes.

In addition to initial inspection some form of routine/periodic inspection is required

The frequency of a periodic inspection:

Determined by Responsible Engineer (not normally exceeding three years)

Operation conditions

Environment

Normally up to a close inspection

To set an appropriate inspection interval accurately is not easy, but it should be fixed
taking into account the expected deterioration of the equipment. Major factors
effecting the deterioration of apparatus include: susceptibility to corrosion, exposure
to chemicals or solvents, likelihood of accumulation of dust or dirt, likelihood of water
ingress, exposure to excessive ambient temperatures, risk of mechanical damage,
exposure to undue vibration, training and experience of personnel, likelihood of
unauthorised modifications or adjustments, likelihood of inappropriate maintenance,
e.g. not in accordance  with  manufacturer’s  recommendation.  Once  intervals have
been set, the installation can be subjected to interim sample inspections to support
or modify the proposed intervals or inspection grades. Where inspection grades and
intervals have been established for similar apparatus, plants and environments, this
experience can be used to determine the inspection strategy.

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Sample Inspection
 This is an inspection that reflects a proportion of the installed apparatus

 Size of sample determined by purpose of inspection

 Used to monitor effects of environmental conditions, vibration, possible design

weakness

 Can be visual, close or detailed

Continuous Supervision
 Frequent attendance by skilled personnel

 Experience in specific installation

 Does not remove requirement for initial and sample inspections

 Evidence of training for all inspectors

The objective of continuous supervision is to enable the early detection of arising

faults and their subsequent repair. It makes use of existing personnel who are in
attendance at the installation in the course of their normal work, e.g. erection work,
modifications, inspections, maintenance work, checking for faults, cleaning, control
operations, functional tests and measurements.

Therefore, it may be possible to dispense with the regular periodic inspection and
utilise the more frequent presence of the skilled personnel to ensure the ongoing
integrity of the apparatus.

A technical person with executive function will be responsible for each installation
and its skilled personnel. He will assess the viability of the concept and define the
scope of equipment to be considered under continuous supervision.

He will also determine the frequency and grade of inspection as well as the content
of reporting to enable meaningful analysis of apparatus performance.

Three Grades of Inspection

 Visual

 Close

 Detailed

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Visual Inspection
An inspection which identifies, without the use of access equipment or tools, those
defects which are apparent to the eye

For example - Missing bolts

Close Inspection
An inspection which encompasses those aspects covered by a visual inspection and
in addition those defects apparent by the use of access equipment and tools, i.e.
loose bolt

Close inspections do not normally require the equipment/enclosure to be opened or

de-energised

Detailed Inspection
An inspection that encompasses those aspects covered by a close inspection and in
addition identifies defects only apparent by opening the enclosure/ equipment, where
the necessary tools and test equipment are required, i.e. loose terminations.

Moveable/Portable Equipment
Hand-held portable equipment is particularly prone to damage or misuse and
therefore the intervals between detailed inspections may need to be reduced

Generally twelve monthly close inspection intervals should be used and recorded

Six monthly detailed for equipment with battery casing for example frequently
opened housings

In addition visual checks by the user prior to use

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Maintenance
Appropriate remedial measures might have to be taken following an inspection
report. Care must be taken, to maintain the integrity of the type of protection
provided for the apparatus; this may require consultation with the manufacturer.
When necessary, the area of work shall be confirmed gas-free prior to
commencement of work.

Maintenance requires more detailed knowledge than when the equipment is first
installed. Defective parts should only be replaced by manufacturers' authorised
replacement parts, and modifications that might invalidate the certificate or other
documents should not be made. For equipment that is manufactured and certified
according to ATEX 95, the maintenance requirements, including the need for special
tools, can be found in the operating instructions supplied with each piece of
equipment.

Some maintenance tasks are listed below:

Flameproof flanges should not be broken without justification. When reassembling

flameproof enclosures, all joints shall be thoroughly cleaned and lightly smeared with
a non-setting grease to prevent corrosion and to assist weatherproofing.
Only non-metallic scrapers and non-corrosive cleaning fluids should be used to clean
flanges.

A wrap of non-hardening tape may also be used in conjunction with gases allocated
to group IIA.

The gasket on increased safety enclosures should be checked for damages and
replaced if necessary. Terminals might have to be tightened. Any discoloration could
indicate a rise in temperature and the development of a potential hazard.

Cable glands and stopping plugs should be checked for tightness.

When replacing lamps in luminaries, the correct rating and type should be used,
otherwise excessive temperatures may result.

If it is necessary to withdraw the equipment for maintenance purposes, the exposed

conductors must be correctly terminated in an appropriate enclosure, e.g. EEx 'e', or
isolated from all sources of supply and either insulated or earthed.

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Repair
Ideally, repair work on explosion-proof electrical equipment should only be carried
out by the manufacturer. This rule can be waived in cases where the repairs are
carried out by instructed and specially trained, skilled personnel, and only genuine
spare parts are used. IEC 60079-19 gives guidance on the repair and overhaul of
certified equipment. It is not permissible for modifications and rework to be carried
out that could jeopardise the characteristics essential to explosion protection (type of
protection and temperature class). Rewiring of installations is permissible if carried
out by trained, skilled personnel. The rewiring work done must be properly logged.
It is forbidden to rework the gap lengths and gap widths of flameproof enclosures by
machining, or to apply paint or other coatings to the respective joints. Such
modifications could impair the integrity of the enclosure and cause an uncontrolled
explosion.

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 Unit 19: Isolation & Testing
For hazardous areas the neutral is considered to be a LIVE conductor, therefore
must be isolated.

Permit-to-work and safe isolation

Candidates attending the 5-day CompEx course are required to carry out four
practical assessments in the simulated hazardous areas. During these
assessments, candidates must demonstrate their ability to work safely by ensuring
that all precautions are taken to prevent ignition of a flammable gas which, for the
purpose of the assessments, it is assumed may be present at any time.

Work permit

In order to ensure that safety is maintained, candidates must operate within the
control of a work permit - which must be requested from the Assessor / Authorised
Person.

In association with the work permit, a gas-free certificate must be endorsed by the
Assessor/Authorised Person at all instances when, for example, a particular action is
likely to produce a source of ignition. Such situations occur when electrical test
instruments and/or portable electric tools are used.

Safe Isolation

The Electricity at Work Regulations 1989 require those in control of part or all of an
electrical system to ensure that it is safe to use and that it is maintained in a safe
condition.

Unsuitable test probes, leads, lamps, voltage indicators and multimeters have
caused arcs due to:

(a) Inadequately insulated test probes (typically having an excessive length of bare
metal at the contact end) accidentally bridging a live conductor and adjacent
earthed metalwork; or

(b) Excessive current drawn through test probes, leads and measuring instruments.

This happens when a multimeter is set to the wrong function, e.g. set on a current or
resistance range when measuring voltage.

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Other causes of accidents which could lead to electric shock are:

(a) Inadequate insulation of test leads and probes;

(b) Exposed live terminations at instruments and indicators;

(c) A lead falling off one of the terminals of a meter and either the meter terminal or
the lead terminal remaining live;

(d) Incorrect use of test equipment, e.g. a multimeter applied to conductors at a

voltage which exceeds the maximum working voltage of the instrument;

(e) Use of poorly constructed makeshift test equipment, eg a test lamp consisting of
a combination of a bayonet lamp holder, bulb and two single insulated conductors
with bared ends;

(f) The use of long intertwined leads which were not easily distinguished, resulting in
one lead being connected across the instrument and the other short circuiting the
live conductors under test.

Voltage detection instruments

Instruments used solely for detecting voltage fall into two categories.

These are:

Detectors which rely on an illuminated bulb (test lamp) or a meter scale (test Meter).
Test lamps fitted with glass bulbs should not give rise to danger if the bulb is broken,
It may be protected by a guard.

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These detectors require protection against excess current. This may be provided by
a suitable high breaking capacity (hbc or hrc) fuse or fuses, with a low current rating
(usually not exceeding 500 mA), or by means of a current-limiting resistor and a
fuse. These protective devices are housed in the probes themselves. The test lead
or leads are held captive and sealed into the body of the voltage detector.

Detectors which use two or more independent indicating systems (one of which may
be audible) and limit energy input to the detector by the circuitry used. An example is
a 2-pole voltage detector, ie a detector unit with an integral test probe, an
interconnecting lead and a second test probe.

These detectors are designed and constructed to limit the current and energy which
can flow into the detector. The limitation is usually provided by a combination of
circuit design, using the concept of protective impedance, and current limiting
resistors built into the test probes. These detectors are provided with in-built test
features to check the functioning of the detector before and after use. The
interconnecting lead and second test probe are not detachable components.

Test lamps and voltage indicators are recommended to be clearly marked with:

(a) The maximum voltage which may be tested by the device; and

(b) Any short time rating for the device if applicable. This rating is the recommended
maximum current which should pass through the device for a few seconds. These
devices are generally not designed to be connected for more than a few seconds.

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Precautions before testing

Before testing begins it is essential to establish that the test device including all
leads, probes and connectors is suitably rated for the voltages and currents which
may be present on the system under test.

Before any testing is carried out ensure that:

(a) The equipment which is to be worked on is safe for the intended tests; and

(b) The working environment does not present additional dangers. These dangers include:

●  Inadequate space to work safely ●  An insecure footing ● Insufficient  light  ●

Potentially flammable  gases  or  vapours  ● Explosive or conductive dusts.

Where a test is being made simply to establish the presence or absence of voltage,
the preferred method is to use a proprietary test lamp or 2-pole voltage detector
suitable for the working voltage of the system rather than a multimeter. Accident
history has shown that the use of incorrectly set multimeters or makeshift devices for
voltage detection has often caused accidents.

Note: Test lamps and some voltage indicators may fail to danger, eg a faulty lamp
not indicating a live circuit. These devices should be proved before and after use on
a known live source of similar voltage to the circuit under test, or alternatively on a
portable test source.

Testing
It is essential that instruments be regularly checked if correct test results are to be
achieved.

They should be systematically checked and recalibrated as necessary, using a

system which keeps a record of each instrument and any action taken regarding the
instrument e.g. calibration, repair, etc.

Check boxes or test resistors may be used as an interim check for instruments used
for insulation and continuity testing.

A socket of known impedance can be used as a simple routine check of Earth Fault
Loop Impedance (EFLI) testers.

Each instrument should have its own serial/identification number and this should be
recorded against test results when it has been used for that particular test, this will
also help to avoid unnecessary re-testing when one of a number of instruments is
found to be faulty. Test instruments and their leads should be kept in their cases to
protect them from mechanical damage.
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 Unit 20: Self Assessment.

1. The Areas A, B, C are zoned, Gas grouped and temperature classified as follows.

Area A B C D

Zone 1 Gc 2 Gb

Gas Group IIA IIB IIA 11C

Temp Class T6 T6 T5 T3

Indicate, if any, the areas in which the following items may be installed:

Item Equipment Marking Area

1 Gb IIA T6

2 EExn II T4

3 EExe II T5

4 Gc II T6

5 EExd II T4

6 EExn IIB T6

7 EExe IIA T5

8 Ga IIB T5

9 Cat 2 IIA T6

10 Cat 1 IIC T5

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2. If an item is marked EEXe IIA T5 where may it be used?

Area Yes/No

Zone 0 IIC T6

Zone 1 & 2 IIB T5

Zone 1 & 2 & 3

Zone 1 IIA T4

3. Where can a EPL Gb IIB T4 piece of equipment be used?

Area Yes/No

Zone 1 IIA T5

Zone 1 & 2 IIB T3

Zone 2 IIC T2

Zone 1 & 2 with any gas sub division

4. According to IEC 60079 – 14 what is the minimum distance from flamepaths when
installing IIB Equipment?

5mm

10mm

30mm

40mm

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5. BS EN60079-14 specifies conditions which require the use of a barrier gland.
Consider  the  statements  in  the  table  below  and  indicate  by  answering  ‘true’  or  ‘false’  
when a barrier gland is or is not required.

Situation True False

a) A barrier gland is always required

when an enclosure contains a
source of ignition.

b) A barrier gland is always required

when a IIC gas is the hazard.

c) A barrier gland is always required

when an enclosure has a volume
greater than 2 litres, contains a
source of ignition and is installed
in Zone 1.

d) A barrier gland is always required

when enclosures are installed in
Zone 1.

6. When carrying out a detailed inspection, what is the acceptable minimum

creepage distance?

3mm

4mm

8mm

6mm

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7. Which ATEX Directive covers the use of equipment in Potentially Hazardous
Areas?

ATEX 59

ATEX 97

ATEX 137

ATEX 95

8. What is the Maximum safe gap permitted with flameproof Equipment designated
IIC ?

1.0mm

0.15mm

0.1mm

1.15mm

9. Which of the following is not a Grade of Inspection?

Close

Sample

Detailed

Visual

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10. Which one of the following methods of explosion protection is suitable for use in
locations  requiring  EPL  “Ga”  (  Category  “1G”)  ?

EEx  “d”

EEx  “q”    

EEx  “mb”

EEx  “Ia”

11. What are the Voltage and Current restrictions when using portable equipment in
Hazardous area?

16 Amps,200V

250V, 1.6 Amps

220V, 6 Amps

250V, and not exceeding 6 Amps

12. Which of the following protection methods of explosion protection are suitable
For  use  in  locations  EPL  “Gb”  (  Category  “2G)?

EEx  “ic”  &  EEx  “d”

EEx  “ic”  &  EEx  “nl”

EEx  “q”  &  EEx  “e”

EEx  “e”  &  EEx  “nA”

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13. If an explosive gas/air mixture is present continuously or for long periods,

What would the Area classification be?

Zone 2

Zone 3

Zone 0

Zone 1

14. To identify Zones on a drawing, special markings are used. Which of the
Following applies to a Zone O?

Small circles

Cross Hatching

Small squares

Symbols as shown on the drawing key

15. What is the abbreviation uses internationally which corresponds to The ATEX
Categories?

E.I

AEI

IEC

EPL

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16. New equipment should be installed in accordance to which standard;

BS EN 60079-10.

BS EN 60079-14.

BS EN 60079-19.

BS EN 60079-20.

17. Hydrogen belongs to which sub division;

I.

IIA

IIB

IIC

18. Which aspect of flamable gas has to be considered when assessing the T rating
of equipment to be used?

The flashpoint.

The sub division.

The U.E.L.

The ignition temperature.

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19. An item marked EEx ib IIC T6 can be used where.

In an location, in gas sub divisions IIA &

IIB only.

EPL Gc (cat 3G) only in gas sub division

IIB.

EPL Gb & Gc (cat 2g & 3g), in gas sub

divisions IIA, IIB or IIC.

In any location and any group.

20. I.S Apparatus, which statement is true.

EEx ib is only suitable for locations

requiring EPL Gc (cat 3G).

EEx ia is suitable for locations requiring

EPL Ga,Gb or Gc (cat 1G,2G or 3G) with
specified sub groups.

EEx ib is suitable for all locations and

sub groups.

EEx ia is not suitable for locations

requiring EPL Ga (cat 1G) with gas sub
division IIC.

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21. Glands installed into Ex n junction boxes after December 2007 need to be.

Certified Ex d.

Certified Ex e.

Certified Ex d barrier glands.

Certified as meeting the requirements of

IEC 60079-0.

22. A EEx e motor rating plate shows Te 6.5 sec T3, what does it mean.

The motor shall not be restarted within 6.5 seconds, if

the T3 rating is to be maintained.

The motor control gear must disconnect the motor

within 6.5 seconds if the motor stalls after reaching its
normal operating temperature (to maintain T value).

The motor will take 6.5 seconds to run up to speed

from an ambient temperature equivalent to T3.

The insulation has been tested for 6.5 seconds at a

temperature equal to T3.

23. Zener barriers work by.

Limit the maximum energy which may be transferred

from the power supply to equipment in the hazardous
area.

Allow any type of certified equipment to be used.

Allow any type of certified equipment & simple

apparatus to be used.
equivalent to T3.

Limit the capacitance and inductance.

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