SECTION 4.

ELECTRICAL
HAZARDOUS
AREA
EQUIPMENT
(EEHA)
Emergency Procedures

If alarm sounds :
1. Listen to the alarm, do not panic
2. Calmly evacuate through nearest exit route
3. Follow the exit signs
4. Go to designated Muster Point

2
Section 4

You will study the detailed requirements for the Electrical Apparatus for
Explosive Gas Atmospheres by Flameproof Enclosures (Ex d) and
Increased Safety (Ex e) protection methods

3
Ex d

Flameproof

IEC 60079 – 1

4
(Ex d) Definition:

▰ A type of protection in which the parts that can ignite an explosive gas
atmosphere are placed in an enclosure which can withstand the pressure
developed during an internal explosion, and which prevents the
transmission of the explosion to the surrounding atmosphere

5
(Ex d) Definition:

1. Enclosure will withstand the pressure of an internal explosion.

2. Hot gases generated by the explosion
▰ will cool through the flamepath,
▰ sufficiently so as not to ignite an external flammable atmosphere.

6
Ex d

Advantages:
Explosion Containment
Low Maintenance
No Moving Parts

Disadvantages
No warning mechanism for containment
failure
Possibility of Installation/Maintenance Errors
Cost of Protection Increases With Enclosure
Size
Condensation buildup is common
7
Ex d

8
Flameproof vs Explosion Proof

Flameproof
▰ Flameproof enclosures are used as protection on projects with IEC standards.
▰ Each of them, one by one, is factory tested to one and a half times the maximum pressures that
are released in an explosion.
▰ Flameproof enclosures cannot be drilled out in the field and must be drilled by the manufacturer
Explosion Proof
▰ Explosion proof enclosures are used as a means of protection more so in the United States and
Canada.
▰ Explosion proof enclosures are individually factory tested to four times the maximum pressures
that are released in an explosion.
▰ As a result, explosion proof enclosures are more heavily constructed than flameproof enclosures
are.
▰ It is also acceptable to drill an explosion proof enclosure in the field.

9
Flameproof vs Explosion Proof

FLAMEPROOF EXPLOSION PROOF

10
Flameproof vs Explosion Proof

Non-metallic enclosures
These are permitted if their free space
volume does not exceed 10 cms cubed

11
Ignition Capable Apparatus

Flameproof enclosures are intended for equipment that can produce sparks,
arcs or hot surfaces which may be incendive in normal operation.

12
Ignition Capable Apparatus

The surrounding explosive

atmosphere can enter the enclosure
and internal explosions are expected
during the life of the equipment.

13
 DESIGN FEATURES
▰ Mechanically strong construction
▰ Which can withstand the force of an
internal explosion in accordance with
the requirements of EN (IEC) 60079-1.

14
Design Features

Flamepath length, gap and form having

regard to the appropriate gas grouping.

Cable entry threads are of sufficient

length and construction to prevent
internal ignition.

Surface temperature control

15
Design Features

Temperature classification which does

not exceed the T classification of
components installed within the
enclosure

All internal components fitted at least

12mm from the enclosure wall

Special lid fixing arrangements

16
Design Features

Flameproof enclosures are

normally supplied complete by
the manufacturer with all
internal components included.
This complete assembly is
certified by a recognised Test
Authority.

17
Design Features

Any modification made to the Certified Unit (Including its internal

components) will invalidate the certification.

18
19
Ex d

Flameproof

IEC 60079 – 1

20
 PRESSURE PILING
▰ Pressure Piling and can occur as a result of sub-dividing the interior
of a flameproof
▰ enclosure thus preventing the normal development of an explosion.

21
Pressure Pilling

Compressing a flammable mixture in a confined space prior to ignition will

increase the explosion pressure to a value which may be much greater than if
the same mixture was ignited at normal atmospheric pressure.

22
Pressure Pilling

An explosion on one side of subdivision compresses the flammable mixture

on the other side resulting in a secondary explosion which may be up to three
times that of the first.

23
Pressure Pilling

▰ A potential result of this is that the enclosure may rupture.

▰ For this reason,
▰ the cross sectional area of free air within a flameproof enclosure must
be at least
▰ 25% of the total cross section.

24
Pressure Pilling

To prevent Pressure Piling between 2

enclosures, a suitable sealing device must be
fitted if conduit is installed and at a distance
no more than the size of the conduit or
maximum 50mm, whichever is the lesser.

25
 FLAMEPATHS
The design of Flameproof enclosures
must take account of gaps in the
enclosure which will undoubtedly
exist due to either its construction or
operation.

26
Flamepath

In the event of an internal explosion, the hot gases must be allowed to cool
down through the flamepaths so as not to ignite an explosive atmosphere
that may surround the enclosure.

27
Flamepath

There shall be no intentional gap at the joints of flameproof equipment, but

gaps will normally exist due to manufacturing methods, tolerances and
economics, but must not exceed the dimensions specified.

W – width of flamepath (Gap) L

– length of flamepath

28
Flamepath

The permissible flamepath dimensions depend on a number of factors

including

The internal volume of the enclosure

The type of joint

The gas group

29
Flamepath

Normally the flange gap should

not exceed 0.1mm for group
IIC areas and 0.15mm for
group IIA & IIB areas.

M.E.S.G
30
M.E.S.G. Gases

Acetylene IIC M.E.S.G 0.37mm

Butane IIA M.E.S.G 0.98mm

Diethyl Ether IIB M.E.S.G 0.87mm

Hydrogen IIC M.E.S.G 0.28mm

H2S IIB M.E.S.G 0.89mm

31
Table Maximum Gap Requirement

Maximum gap mm
volume volume volume volume
cm3 cm3 cm3 cm3
Minimum V ≤ 100 100 < V ≤ 500 500 < V ≤ 2 000 V > 2 000
Type of width of
joint joint L
mm

IIA IIB IIA IIB IIA IIB IIA IIB

6 0.3 0.2 - - - - - -

9.5 0.3 0.2 0.3 0.2 - - - -

Flanged
Cylindrical
or spigot
12.5 0.3 0.2 0.3 0.2 0.3 0.2 0.2 0.2
joints
25 0.4 0.2 0.4 0.2 0.4 0.2 0.4 0.15 32
Table Maximum Gap Requirement

Maximum gap mm
volume volume
volume volume
cm3 cm3
cm3 cm3
100 < V ≤ 500 < V ≤ 2
Minimu V ≤ 100 V > 2 000
500 000
m
Type of
width of
joint
joint L
mm
IIC IIC IIC IIC

6 0.1 - - -

9.5 0.1 0.1 - -

Flanged
joints 15.8 0.1 0.1 0.04 -
33
FLAMEPROOF JOINTS
All joints in the lids of enclosures between compartments
must be made by one of
the following methods

Flanged Joint

Spigot Joint Or a combination

of all three.

Screwed Joint
34
Flameproof Joints

Flanged joints are NOT

permitted with Group IIC
enclosures for use
in atmospheres containing
Acetylene.

These may be used in flammable atmospheres

containing other Group IIC gases where the internal
volume of the enclosure is not greater than 500cm2.

35
Flameproof Joints

Screwed joints are normally

used for enclosures in
atmospheres
having Group IIC gases.

The minimum number of threads to be fully

engaged in a flameproof screwed joint is 5

36
Flameproof Joints

Flanged and Spigot joints are

permitted for enclosures in
atmospheres having Gas
Groups IIA and IIB

37
Flameproof Joints

Push button spindle

Cable gland entry

Other Examples

38
Flameproof Joints

Other Examples

39
Flameproof Joints

Where Flameproof Enclosures are installed with the possibility of the

ingress of water or other liquid, it will be necessary to use enclosures
with a sealing arrangement such as a gasket ‘O’ Ring.

40
Flameproof Joints

The ‘O’ ring seal in the joints of is not part of the

flameproof arrangement but is fitted as a supplementary
component for
weather-proofing only.

41
Flameproof Joints

▰ The sealing component must be

factory fitted and included in the
certification
▰ Documentation for the enclosure so
that the flameproof joint is maintained
at the
▰ Required gap length and width.

42
Flameproof Joints

Under NO circumstances should an

unauthorised seal be fitted by the user
and, if a replacement gasket is required,
it MUST comply with the
manufacturer’s original
specification.

43
Flameproof Joints

Weatherproofing

Non Hardening Tape (Denso)

Permitted on IIA IIB & IIC apparatus used in IIA areas.
Permitted on IIB & IIC apparatus used in IIB areas.
One layer only with a short overlap.

Not allowed on IIC apparatus used in

IIC areas.

44
Denso Tape

45
Flameproof Joints

When positioning Flameproof (Ex

d) apparatus having flanged joints,
care must be
taken to ensure that the efficiency of
the flamepath is not inhibited by the
close
Such as walls, pipes, steelwork or proximity of other surfaces:
other equipment and the hot gases
must be allowed to pass freely
into the atmosphere.

46
Flameproof Joints

Minimum distance of
obstruction from the flameproof
flange joints
related to the gas group of the
hazardous area.

Gas Group Minimum

Distance
IIA 10mm
IIB 30mm
IIC 40mm
47
Flameproof Joints

Flange faces cannot be painted

Only non-metal scrapers and non-corrosive cleaning fluids must be

used to clean flamepaths.

48
 CABLE ENTRY
TECHNIQUES
▰ The design of cable entries into flameproof enclosures must be such
that hot gases
▰ Are not able to ignite the surrounding atmosphere following an
internal explosion
▰ Either through the gland or the cable.

49
Cable Entry Techniques

▰ Cable glands must comply with the requirements for screwed joints i.e.
a minimum of 5 fully engaged threads.

50
Cable Entry Techniques

Thread Engagement:
Depth:

Volume of enclosure
= to or < 100 cm3 > 100 cm3
Thread Thread
engagement Axial length engagement Axial length

= to or > 5 full = to or > 5 full

threads = to or > 5mm threads > 8mm

51
Non Parallel Threads

▰ NPT
 Under no circumstances shall a NPT gland be used into a metric
thread.
 Visa versa, a metric gland shall not be used into a NPT thread.
 NPT glands, adaptors & reducers shall be wrench tight, not all
threads need to be engaged.

52
Direct & Indirect Entry

53
Direct Entry

Cables may be brought into the enclosure directly by means of a cable

gland (Direct Entry). All cable entry holes must be threaded.

54
Indirect Entry

Alternatively, the cables may be brought into the enclosure by means of a

terminating chamber

55
Cable Entry Techniques

The components in the flameproof enclosure being connected to those in

the terminating chamber through flameproof bushings (Indirect Entry).
The terminating chamber of an indirect entry enclosure would normally
be designed as an ‘increased safety’ Ex e enclosure.

56
Flameproof Bushing

57
COLD FLOW

Coldflow in cables is described as the movement of the

sheath under the compressive forces applied by the
gland seal.

Coldflow does not compromise the integrity of Ex e

equipment.

58
COLD FLOW

Smoke and/or fire resistant cables usually show coldflow characteristics.

For this type of cable a diaphragm

seal should be used.
(Universal Gland)

59
COLD FLOW

60
Unauthorised Modifications

▰ Use of wrong type of gland.

▰ Attaching cable brackets.
▰ Drilling holes into enclosure.
▰ Use of hardening or sealant tape.
▰ Changing the layout of internal components.

Ex d apparatus cannot be modified.

61
Adaptors/Reducers have to be certified Ex d for use in Ex d equipment.

Only one adaptor or one reducer is allowed for each gland.

62
Ex d equipment.

Plugs have to be certified Ex d for

use in Ex d equipment.

63
Test Yourself

64
Test Yourself

Define Ex protection by Flameproof Enclosure (Ex d)

It can withstand the pressure of an internal

explosion.

And prevent the transmission of the explosion to

the surrounding atmosphere.

65
Test Yourself

Explain what is meant by ‘Pressure Piling’ in a flameproof enclosure

The compression of a flammable mixture in a

confined space prior to ignition which increases
the explosion.

66
Test Yourself

(a) What effect should the flamepath of a gap in a flameproof enclosure

have on hot gases which escape through it?

Must cool any flaming gases so that they will

not ignite the surrounding explosive atmosphere.

67
Test Yourself

(b) Flameproof Enclosures having ‘flanged’ joints are permitted for use
with which gas groups?

‘Flanged’ joints are permitted with Gas Groups

IIA and IIB.

68
Test Yourself

Why would a flameproof spigot joint have a gasket ‘O’ ring seal fitted?

for weather proofing purposes.

69
Test Yourself

Why must there be a minimum distance between flanged joints and

obstructions?

To allow hot gases to pass freely into the

atmosphere.

70
Test Yourself

Explain the difference between a Direct Entry and an Indirect Entry

enclosure?

Direct: Into the enclosure directly by means of

a cable gland.

Indirect: Entry via a terminal chamber with

flameproof bushings

71
Activity Ex d

▰ What are the essential features of the design:

72
Mechanical Strength

The materials used and the construction design must be able to withstand
the force of an internal explosion.

73
Gap Dimensions

The dimensions of gaps in the

flameproof enclosure must ensure that
the flamepath length, width and shape
must be suitable for the appropriate gas
grouping and be able to cool any hot gas
which passes through.

74
Cable Entries

Cable gland threads must be of sufficient length and construction.

75
Surface temperature

The temperature of enclosure surfaces must be kept below their

temperature classification.

76
Internal Components

Components are supplied by the manufacturer for flameproof enclosures

and are certified by a recognised testing authority and no modification is
allowed.

77
Component Temperature

To minimise heat exchange from the enclosure to internal components there

wil be a gap of 12mm to the enclosure wall.

78
Lid fixing arrangement

Enclosure lids shall be properly secured with the appropriate types of

screw, bolt, etc., and that all fixing holes contain the correct fixing device.

79
Lid fixing arrangement

Sealing gaskets may be used to provide the required degree of Ingress

protection and only manufacturers type shall be used.

80
Ex e

Incresed Safety

IEC 60079-7

81
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 arcs or sparks in normal service or under specified
abnormal conditions.

82
(Ex e) Definition:

▰ Additional measures are applied so as to give increased security.

▰ Against the possibility of excessive temperatures.
▰ and of the occurrence of arcs or sparks
▰ in normal service or under specified abnormal conditions..

83
This protection method relies on the design and construction of the
apparatus
▰ No arcing or sparking devices
▰ or hot surfaces

84
85
Stainless Steel Polycarbonate

86
The maximum voltage for this type of protection is 11kV (d.c.
or a.c. rms)

Increased Safety (Ex e) gives a high level of protection in accordance with

ATEX 95.

87
 Increased Safety is achieved by

reducing current ratings

and clearance distances above those required in

normal service.

Surface temperatures are limited

88
DESIGN FEATURES

Protection against
the ingress of solids and liquids to at least
IP54 if bare live parts are present and IP44
if these are insulated

89
Terminals and conductors selected to
Manufacturer’s Specification

Terminal design to Manufacturer’s

approved type

90
Temperature limitation of surfaces to
specification.

Protection of the enclosure against

mechanical impact to 4 or 7 joules

91
Appropriate creepage between two bare conducting
parts

Clearance distances between live parts must not be

less than the values stated for the appropriate voltage.

Electrical insulating materials must have thermal

stability at temperatures exceeding the maximum
service temperature.

92
Increased Safety protection offers reduction in weight,
a wide range of auxiliary parts, ease of installation and
maintenance.

Applications include
• Joint Boxes
• Luminaires
• Motors.

93
ADVANTAGES
Reduction in weight (Lighter construction)
Can use a wide range of auxiliary parts

Ease of installation and maintenance 94

 TERMINALS AND
TERMINATIONS
The passage of leakage current across insulation between live terminals or
between live terminals and earth due to the surface of the insulation
becoming contaminated or otherwise ineffective.

95
Terminal Insulation:

▰ Good thermal stability and a high resistance to tracking.

▰ Typical materials include thermoset plastics such as Melamine,
Polyamide and, for special conditions Ceramic.

96
To establish the quality and suitability of insulating materials
a test known as the comparative Tracking Index test (CTI) is
carried out.

This test provides the insulating material with a numerical

value

value indicating the maximum voltage which the material

can withstand without tracking

97
CTI (Test)

A number of drops (usually 50) of electrolyte (Usually ammonia chloride

solution in distilled water) are dropped across the terminals.
IEC 60664-1 Insulation coordination for equipment within low-voltage systems - Part 1:
Principles, requirements and tests
IEC 60112 Method for the determination of the proof and the comparative tracking indices
of solid insulation materials
98
 Once the CTI for the insulating material has been
established, then the minimum Creepage and Clearance
distances can be specified for a given operating voltage.

99
Creepage is the distance across the insulating material
between two conductive parts.

Clearance is the distance in air

between two conductive parts.

100
101
 102
102
TERMINAL DESIGN

The main function of a

terminal is to provide an
effective electrical and
mechanical
connection of a conductor to
a live part.

103
Terminal Design

Contact pressure must be

maintained and the
conductor must be locked so
that it does not come loose
due to vibration.

104
Terminal Design

The clamping yoke terminal

system where the conductor is
held firmly in place within the
tinned copper, hardened steel
yoke by the clamping unit.
Yoke

105
Terminal Design

High contact force independent

of conductor size

Integrated lock to prevent

accidental loosening

Large clamping area

Yoke

Gas tight contact points

Maintenance free 106

Ex e Terminal Types

Screw Type

Post Type

Cage Type

107
Terminal Lock

When the clamping screw is

tightened, the upper thread
tongue opens slightly and a
locking force is exerted.

Yoke

The contact pressure virtually constant over its lifetime and

little or no maintenance is required. 108
Terminal Design

109
Current de-rating

All conductors and terminals are de-rated i.e

Larger conductors and terminals than normal are used to

ensure that these are within their current rating and
therefore do not give off heat to the same extent.

110
Terminal Design

Any terminals inside Ex e

enclosures must also be
certified Ex e and / or Ex ia

111
Terminal Design

Ex e enclosures can be modified to accept more

cables but certification MUST be checked to
determine maximum capacity.

112
How many terminals can we put in a enclosure ?

Sample calculation using ‘load limit`

Type TB 11 Ser. No: Ex2135D
EEx e II T6
BASEEFA CERT No: Ex 95B3299X
Load Limit 600A

Enclosure Load Limit = 600A SAK

2.5mm EEx e terminal rating = 15A
Allowed number of SAK terminals = Load Limit =
600
SAK terminal rating = 15
= 40 SAK 2.5mm terminals
113
Terminal Design

114
HYBRIDS
(EX E COMBINED)

Electrical equipmant
can be designed with
more than one method.

115
Hybrids (Ex-e Combined)

The best features are

combined into one
enclosure.

116
Ex de
Suitable for Zones 1 & 2

117
Ex em
Suitable for Zones 1 & 2

118
Hybrids (Ex-e Combined)

Hybrid protection enclosures normally

cannot be modified and before any
modifications are carried out consult the
manufacturers documentation.

119
Cable Glands

The gland must be suitable for the cable and maintain

the protection concept and IP rating of the enclosure.

New standards coming into effect stipulate the use of

a certified gland.

120
IP Washers

Glands entering unthreaded holes, with less than 6mm thread length will
require an IP washer and a lock nut on the inside.

A star washer may be specified on the inside to maintain earth continuity.

121
Adaptors/Reducers have to be certified for use in Ex e equipment.

Only one adaptor or one reducer is

allowed for each gland.

122
Ex-e Equipment

Plastic plugs and glands must be

certified for use in Ex e
enclosures.

Plugs have to be certified for

use in Ex e equipment unless
manufacturers type.

123
The fitting of certified breather drains is permitted

124
Test Yourself

125
Test Yourelf

▰ How is protection achieved within an Increased Safety Ex e Enclosure?

Increased safety measures to prevent the

possibility of excessive heat, arcs or
sparks occurring on internal or external
parts of the apparatus.

126
Test Yourelf

▰ In relation to the terminals within an Ex e enclosure, what is meant by

the terms:

Tracking,
Clearance distance,
Creepage distance

127
Test Yourelf

▰ Tracking

The passage of leakage current across

insulation between live terminals or
between live terminals and earth

128
Test Yourelf

▰ Clearance

Shortest distance between two live parts

measured through air.

129
Test Yourelf

▰ Creepage

The shortest distance between two bare

conducting parts measured along the
surface of the insulation.

130
Test Yourelf

▰ What are the features of an Ex e certified terminal?

 High contact force

 Integrated lock to prevent loosening
 Large clamping area
 Gas tight contact points
 Maintenance free

131
Activity Ex e

What are the essential features of the design:

132
Ingress protection

Protection against the ingress of solids and liquids to at least IP54 if bare
live parts are present

133
Impact protection

Protection of the enclosure against a mechanical impact of 4 or 7 Joules.

134
Terminal Design

To allow conductors to be easily

inserted and clamped so that contact
pressure is maintained without
reducing the cross-sectional area of
the conductor and to incorporate a
locking device to prevent conductors
working loose by vibration.

135
Surface Temperature

▰ The temperature of enclosure surfaces must be kept below their

temperature classification by the design of circuit loading conditions.

136
Current de-rating

All conductors and terminals are de-

rated i.e. larger conductors and
terminals than normal are used to
ensure that these are within their
current rating and therefore do not give
off excess heat.

137
Internal Components

These are designed to be non-sparking.

138
Electrical Insulation

These should have mechanical stability at temperatures exceeding the

temperature classification.

139
Training Targer

▰ Describe the systems of Ex protection by enclosure type.

▰ Ex d & Ex e

Number 11

140
141
142
Thank You