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IECEx CoPC
Unit Ex 004, 007 and 008
Version 1.2015
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2
Trainor
4
 IECEx OD 504

• Gives competence reqirements for

each IECEx CoPC Unit
• http://www.iecex.com/docs/IECEx_OD504_Ed3.0.pdf

5
 Explosive atmospheres and
explosion- protection principles (OD 504 5.3
a)

• Properties of combustible substances and

their potential to create an explosive hazard
encompassing:
i. condition in the workplace that will lead to an explosion;
ii. the terms ‘combustion’, ‘ignition’ and ‘propagation’;
iii. explosive range of substances encountered in the
workplace i.e. LEL/UEL;
iv. explosive parameters of substances as given in tables of
substance characteristics, i.e., properties of combustible
materials – gases, Vapors (from liquids), such as flash
point; and Dusts;
v. the difference between gases and Vapors; and
vi. the toxic nature of gases and Vapors and potential harmful
consequences.

6
Condition in the workplace that could
lead to an explosion

7
Gas, vapor or mist

8
Areas containing dust/air mixtures

o
C

9
 Other areas.
Explosives (dynamite,
gunpowder etc.)
Areas containing explosives

Areas with gas or dust, where

the air contains more oxygen
than normal (21 %)

10
Condition in the workplace that could
lead to an explosion
• Generaly accepted as sources of ignition
• Hot surfaces
• Flames and hot gases
• Mechanically generated sparks
• Electrical apparatus
• Stray electric currents, cathodic corrosion protection
• Static electricity
• Lightning
• Radio frequency (RF) electromagnetic waves from 10⁴ - 3 x 10¹¹
Hz
• Electromagnetic waves from 3 x 10¹¹ - 3 x 10¹⁵ Hz (e.g. lazers)
• Ionizing radiation
• Ultrasonics
• Adiabatic compression and shock waves
• Exotermic reactions, including self-ignition of dust

11
 The terms “combustion”, “ignition”
and “propagation”
• “Combustion“:
The exothermic reaction between a substance and
an oxidising agent.
• “Ignition”:
The transfer of energy into a combustible
substance that causes it to burn.
• “Propagation”:
The process where a combustion reaction spreads
throughout the available explosive atmosphere.

12
 Explosive area LEL / UEL
Ignition energy
μJ

Max.
Below LEL = Too weak to burn
LEL = LFL (Lower flamable limit)

Above UEL = Too rich to burn

UEL = UFL (Upper flamable limit)

Min.

Mixture air/gas
% Gas

LEL Optimal UEL

mixture
13
 Explosion properties for gases,
vapors (and dust)
• Flash Point FP
Flashpoint is the lowest liquid temperature at which,
under certain standarized conditions, a liquid gives
off vapors in a quantity such as to be capable of
forming an ignitable vapor/air mixture.

14
 Auto Ignition Temperature

Auto Ignition Temperature AIT

The auto ignition temperature is the lowest
temperature at which a flamable mixture of
gas/vapor with air will ignite without an other
source of ignition than temperature alone.

15
 IEC 60079-20-1 AIT
Equip. Group Name Temp class Auto Rel. Density LEL UEL Flash point
Ignition Air = 1 % % o
C
temp
I Methane/Firedamp T1 595oC 0,55 4,4 17,0 Gas

Ethanal (acetaldehyde) T4 155oC 1,52 4,0 60,0 -38oC

Acetone T1 539oC 2,0 2,5 14,3 ≤-20oC

at 100oC
Gasoline T3 280oC 3,0 1,4 7,6 -46oC

Iso-Butane T1 460oC 2,0 1,3 9,8 Gas

IIA n-Butane T2 372oC 2,05 1,4 9,3 Gas

Methane T1 600oC 0,55 4,4 17,0 Gas

Propane T2 450oC 1,56 1,7 10,9 Gas

Kerosene T3 210oC - 0,7 5,0 +38 to 72oC

Ammonia NH3 T1 630oC 0,59 15,0 33,6 Gas

Diesel no2 T3 254oC- - 0,5 6,5 52 to 96oC

285oC

Ethylene T2 440oC 0,97 2,3 36 Gas

IIB Ethanol T2 400oC 1,59 3,1 19,0 at 60oC 12 oC

27,7 at 100oC

Hydrogensulfide H2S T3 260oC 1,19 4,0 45,5 Gas

Carbonmonoksyde CO T4 607oC 0,97 10,9 74,0 Gas

Acetylene T2 305oC 0,90 2,3 100,0 Gas

IIC
Hydrogen T1 560oC 0,07 4,0 77,0 Gas

Carbondisulfide CS2 T6 90oC 2,64 0,6 60,0 -30 oC

16
 Explosion properties for gases,
Vapors (and dust)

MIE stands for Minimum Ignition Energy

MIE is based on test of Minimum Ignition Current

MIC

17
 Explosion properties for gases,
Vapors (and dust)
MIC stands for Minimum Ignition
Current MIC test apparatus
• It is the minimum current which
will ignite a particular gas at a
given voltage under test
conditions.

A = positively charged wheel

B = rotating cadmium disc
C = test gas + air
D = explotion proof enclosure
W = tungsten wire

+ -
24 V (Standard Voltage)
18
 Explosion properties for gases,
Vapors (and dust)
MESG stands for Maximum Experimental Safe Gap
MESG – the largest gap which can safely contain a burning gas under test
conditions

21
 Explosion properties for gases,
Vapors (and dust)

Gases Vapors and dusts are divided into 3 groups with

subgroups based on MIC and/ or MESG for Group II

Equipment Sub-group Typical Explosive atmosphere

group
I N/A Coal dust + Methane (Firedamp)
IIA Propane
II IIB Ethanol
IIC Hydrogen
IIIA Combustible flyings
III IIIB Non-conductive dust
IIIC Conductive dust

22
 The difference between Gas and
Vapor

Gas is the term used for the

gaseous state of a material when it
is above it’s boiling point

Vapor is the term used for the

gaseous state of a material when it is
below it’s boiling point

24
 Gas Vapor

Gases mix readily with Liquid must first vaporise

air to form an explosive to allow molecules in the
mixture gas phase to mix with air
to form an explosive
atmosphere. (Flash Point)

25
 Relative density

Relative density affects dispersion, not ignition capability.

All Vapors (and some gases) are heavier than air,

at the same temperature and pressure as air.

26
 Relative density

IEC 60079-10-1, relative density:

• Density of a gas or a Vapor relative to the density of air at the same
pressure and the same temperature (Air is equal to 1)

• Relative density below 0,8 should be regarded being lighter than air,
above 1,2 heavier, between should be considered both.

27
 Toxic gases, Vapors and dusts

• There is no relationship between the toxicity of a substance and

it’s flammability
• Some toxic gases are not flammable, and some flammable
gases are not toxic
• Any gas or Vapor (except oxygen) will suffocate you if there is
enough in the air to reduce the oxygen content
• Minimum acceptable oxygen consentration in air is 18%
• Less than 10% oxygen is fatal
• Some dusts are toxic, but almost all are harmful when inhaled

28
 Explosive atmospheres and
explosion- protection principles (OD 504
5.3 b)

The nature of explosive atmospheres

encompassing:
i. the Standards definition of a ‘hazardous
area’;
ii. the recommended methods for classifying the
type and degree of explosion hazard in an
area;
iii. hazardous area classifications as defined by
Standards; and
iv. factors that are considered when a hazardous
area is classified.

29
 The Standards definition of a
‘hazardous area’ and ‘Explosive
atmosphere’;
(Do not mix theese!)

• Hazardous area; area in which an explosive

atmosphere is present, or may be expected to
be present, in quantities such as to require
special precautions for the construction,
installation and use of equipment (IEC 60079-
14/17)
• Explosive atmosphere; mixture with air, under
atmospheric conditions, of flammable
substances in the form of gas, Vapor, dust,
fibres, or flyings which, after ignition, permits
self-sustaining propagation (IEC 60079-0)

30
Hazzardous area

31
 The recommended methods for
classifying the type and degree of
explosion hazard in an area

• Classification by example
• Refer to examples (diagrams) in Codes of Practice
(e.g. IP 15)
• Classification by “Source of Hazard“
• IEC 60079-10-1 – Gas
• IEC 60079-10-2 – Dust
• Calculation
• Computional Fluid Dynamics (CFD) modelling

32
 What is a Hazardous area?

• Zone classification as defined in the

standards
• IEC 60079-10-1 – Gas
• «Frequency & Duration» (Definisions from IEC 60079-
14)
• Zone 0 – Continuous
– «… continuously or for long periods frequently»
• Zone 1 – Primary
– «… likely to occur in normal operation occasionally»

• Zone 2 – Secondary
• – «… not likely to occur in normal operation, if it does
occur, will persist for a short period only»

33
 What is a Hazardous area?
• Factors to consider when a Hazardous area is
classified
• (60079-10-1 Gas) – Updated/ "3D" document
• Define «Sources of release»/ «Grade of Release»
• Define Type of Zones (0, 1, 2)
• Define Limits of Zones
• Light/ heavy gas? (depressions/ roofing?)
• Physical obstacles? (Walls?)
• Calculate «Release rate», factors:
• % LEL (Lower LEL,)
• Calculate ventilation degreee
• Relative density,
• Other? Topography/ Climate

34
 What is a Hazardous area?
• Zone map, Gas (IEC 60079-10-1)

35
 What is a Hazardous area?
• Zone map, Gas (IEC 60079-10-1):
• Drawing in three dimensions showing type of zone/
extension
• Also Equipment/ gas group
• And AIT/ Temperature class

36
Zone map, gas
 What is a Hazardous area?

• Zone classification as defined in the

standards
• IEC 60079-10-2 – Dust
• «Frequency & Duration (Cloud in air)»
• Zone 20
– «… continuously or for long periods frequently»
• Zone 21
– «… likely to occur in normal operation occasionally»
• Zone 22
– «… not likely to occur in normal operation, if it does occur,
will persist for a short period only»

38
 What is a Hazardous area?

• Factors to consider when a Hazardous area is

classified
• (60079-10-2 Dust) – Updated/ "3D" document

• Is it flammable? Define dust group (IIIA, IIIB, IIIC)

• Find matherial chracteristics for the relevant process
(Data sheet?)
• Define «Source of release»/ «Nature of Release» Dust
layer?
• Define Type of Zones (20, 21, 22)
• Define Limits of Zones

39
 What is a Hazardous area?
• Zone map, Dust (IEC 60079-10-2)

40
 What is a Hazardous area?
• Zone map, Dust (IEC 60079-10-2):
• Drawing in three dimensions showing type of Zone/
extension
• Also Equipment/ Dust group,
• AIT (Auto ignition temperature) Dust cloud/ layer
• And Maximum dust layer depth

41
 Explosive atmospheres and
explosion- protection principles (OD 504
5.3 c)
The basics of how explosion-protection is achieved by the
methods of :
• Exclusion
• ; Ex m, Ex o, Ex p, Ex t, Ex nR
• Containment
• ; Ex d, Ex q, Ex nC
• Energy limitation
• ; Ex i, Ex nL
• Dilution
• ; Ventilation, some Ex p
• Avoidance of ignition sources
• ; Ex e, Ex nA

42
 Explosive atmospheres and
explosion- protection principles (OD 504
5.3 d)

Occupational Health and Safety responsibilities related

to explosive atmospheres encompassing:
i. the main features and purpose of a ‘clearance to work’ system
(includes hot work permit system);
ii. typical safety procedures that should be followed before entering a
hazardous area;
iii. the purpose of gas detectors and their limitations;
iv. effects of temperature on gas and Vapor detection;
v. frequency of monitoring for presence of gas or Vapors, i.e. effects of
temperature rise;
vi. factors affecting the accuracy of gas detectors, for example,
contamination, condensation, temperature;
vii. safety in use of gas detectors, for example, ‘read and run concept’;
and
viii. the safety precautions to be taken when working in a hazardous area.
ix. Housekeeping requirements to minimise the effect of dust layers
43
The main features and purpose of a
‘clearance to work’ system

Ensure safe work by having a

documented evaluation of:
• Hazards at the work place
• Human factors
• Work permit system
• Types of work permitted at the location
• Need for gas measurement
• Need for Personal Protective Equipment
(PPE)

44
Typical safety procedures that should
be followed before entering a
hazardous area

• Get Work Permit

• Check need for PPE
• Check if you have prohibited ignition
sources on you
• Check for location of escape routes

See also Annex B in 60079-14

45
 The purpose of gas detectors and
their limitations
Detector types
• Fixed systems (should not be used for ensuring area is gas
free during hot work)
• Portable detectors (for continous monitoring during hot
work)

Will give an alarm if gas

concentration is higher than a set
level, or lack of oxygen.

Within the range of the detector!

46
 Purpose of gas detectors and their
limitations

Factors to be considered:
• Are detector locations appropriate? (density)
• How many are required to cover the area?
• Is the alarm audible from the work location?
• Does the detector detect all the gases in the area
or just one?
• Is the alarm set point too high? % LEL
• Are the detectors calibrated often enough?
• Fixed detectors: does the alarm initiate action in
the control room?
• Portable detectors: battery capacity?
47
 Factors affecting the accuracy of gas
detectors, for example,
contamination, condensation,
Temperature:
temperature;
Low temperature can give longer response time.
Gas detectors need to comply with performance
standards, so deviance of performance by low
temperature should be insignificant.

Catalytic sensors could be affected by:

Contamination: commonly by silicon containing componds, such
as: machinery oils and lubricants with silicon
additives, sulphur compounds, chlorineheavy
metals – sensor does not recover.

Excessive gas concentration or heat - can permanently alter the detector

performance.

Inhibitors (e.g. halogen compounds in fire extinguishers, «Freon» refrigerant,

sensor recovers after 24-48 hours
48
 Safety in use of gas detectors, for
example, ‘read and run concept’;

All gas detectors have their limitations.

Always know your escape routes, and
retreat to safe area immediately at alarm.

If suspicion of false alarm, you shall still

retreat to safe area until the cause of the
false alarm has been identified.

49
The safety precautions to be taken
when working in a hazardous area.

50
The use of tools in Hazardous areas

EN 1127-1 Annex A
• Type a) - Single spark (Screwdriver, spanner, hammer)
• Type b) – Shower of sparks (Sawing, grinding)

51
 The use of tools in Hazardous areas

• Zone 0/ 20
• No tools which can generate sparks

• Zone 1/ 2, 20/ 22
• Steel tools of Type a) allowed, Type b) only when no
explosive atmosphere present.

52
 Housekeeping requirements to
minimise the effect of dust layers

Why?
• Dust prevents the identification of
damaged equipment.
• Dust insulates, and can thereby cause
an increase of temperature of
equipment.
• Dust layer has lower AIT than a dust
cloud and many gases/ Vapors

53
 Explosive atmospheres and
explosion- protection principles (OD 504
5.3 e)

The roles of the parties involved in the

safety of explosive atmospheres
encompassing:
i. Regulations related to the safety of explosive
atmospheres and the Authorities responsible
for their implementation;
ii. where assistance and further information can
be obtained to assist persons with hazardous
area responsibilities, for example, Standard
bodies, experienced consultants;
iii. the hazardous area responsibilities of various
parties.
54
 The hazardous area responsibilities
of various parties.
• the owner of premises in which a hazardous area exists;
• the occupier of premises in which a hazardous area exists;
• enterprises and personnel engaged in installation and/or
maintenance of explosion-protection systems;
• enterprises and personnel engaged in the classification of
explosive atmospheres and/or design of explosion-protection
systems;
• enterprises and personnel engaged in the overhaul,
modification and/or assessment of explosion-protected
equipment;
• enterprises and personnel engaged in the inspection of
explosion-protection installations;
• manufacturers of explosion-protected equipment;
• designated authorities;
• insurers.

56
 Protective measures (Owner/
occupiers responsibility)

In order of priority:
1. Substitute with non flammable material.
2. Avoid release
3. Control release at source
4. Prevent formation of Explosive atmosphere
5. Collect and render safe
6. Avoid ignition source
7. Mitigate the effect of a fire or explosion

57
 Explosion-protected equipment – Ex
certification schemes (OD 504 5.4)

a. Purpose and scope of certification schemes.

b. Other certification schemes.
c. Processes for having equipment certified under the
acceptable Ex schemes encompassing:
i. scheme procedures;
ii. quality management requirements;
iii. conformance testing and assessment; and
iv. requirements for ongoing certification.

58
 Purpose and scope of certification
schemes.

The purpose of Ex certification systems, is

to supply a standardised and repeatable
method for testing and assessment.

The scope is limited by the standards

applicable area and framework.

59
 Purpose and scope of certification
schemes.

IECEx System objective

The objective of the IECEx System is to facilitate
international trade in equipment and services for use in
explosive atmospheres, while maintaining the required
level of safety:
• Reduced testing and certification costs to manufacturer
• Reduced time to market
• International confidence in the product assessment
process
• One international database listing
• Maintaining international confidence in equipment and
services covered by IECEx Certification
IECEx 01 © IEC:2013
60
 Other certification schemes.

There are mainly 3 differnt certification scemes covering Ex:

• North American certification
• NEC 500 – Old certification
• NEC 505 – New certification adapted to IECEx
• European certification (ATEX)
• Rules (regulations/ laws) for a minimum safetylevel- Standards
administered by CENELEC, but adapted to IECEx
• Only require certification of Zone 0/20 and Zone 1/21
equipment
• Certificate validated for prototype – Declaration of Conformity
on end products
• International certification (IECEx)
• Certification of Ex equipment
• Require certificate on ALL Ex equipment
• Certificate of Conformity valid for end products
• Certification of Service facility
• Certification of Personnel Competence
61
Processes for having equipment
certified

62
 Explosion-protected equipment –
Principles (OD 504 5.5)

a) The principles of each explosion-

protection technique.
b) How explosion-protected equipment is
marked, including marking of old
equipment.
c) Visible conditions or actions that
would void the explosion-protection.

63
 Principles of explosion-protection
technique
Basic methodology on how explosion
protection is achieved by
Exclusion:
• Explosive atmosphere is kept out of the
equipment by
• Maintaining pressure of the internal atmosphere
above surrounding atmosphere
• Filling the equipment with liquid (Typically oil)
• Encapsulation in solid material
• Sealing the enclosure

64
Principles of explosion-protection
technique

65
 Principles of explosion-protection
technique
Basic methodology on how explosion
protection is achieved by
• Containment:
• The results of igniting an explosive
atmosphere inside the equipment are
contained within the equipment by:
• Enclosure withstands explosion pressure
• Narrow joints quench flames
• Ex d Flame proof

66
Ex d Flameproof

67
 Principles of explosion-protection
technique
Basic methodology on how explosion
protection is achieved by
• Energy limitation:
• The energy avalable for a spark and the
power available to generate heat are limited
sufficiently to prevent ignition of an explosive
atmosphere by:
• Limiting the energy and power in the circuit so the
sparks do not have enough energy to cause ignition
• Strictly controlling surface temperature rise

68
Intrinsicaly safe

69
 Principles of explosion-protection
technique
Basic methodology on how explosion
protection is achieved by
• Dilution:
• Dilute the explosive atmosphere below LEL, so
the gas is unignitable bymeasures such as:
• Extract ventilation

70
 Principles of explosion-protection
technique
Basic methodology on how explosion
protection is achieved by
• Avoidance of ignition sources:
• The design and construction of the equipment
eliminates arcs, sparcs and hot surfaces by:
• Avoiding sources of ignition
• Controlling surface temperature
• Excluding dust and water

71
How explosion-protected equipment
is marked, including marking of old
equipment
• Equipment group I : Equipment for use
in Coal mines.

• Equipment group II : Equipment for use

in areas with explosive gas/ Vapor or
mist atmosphere
• Equipment group III : Equipment for use
in areas with explosive Dust
atmosphere

72
How explosion-protected equipment
is marked, including marking of old
equipment
EPL (Equipment Protetion Level)

G = gas
D = dust

EPL G/Da = «Very high» level of protection – not a source

of ignition even concidering rare malfunctions

EPL G/Db = «High» level of protection – not a source

of ignition even concidering expected malfunctions

EPL G/Dc = «Enhanced» level of protection – not a source

of ignition in normal operation
73
How explosion-protected equipment
is marked, including marking of old
equipment

Ex d IIB T3 Gb Alternatively Ex db IIB T3

EPL (Gas/ zone 1 equipment)

Temperature class
Equipment group II sub-group IIB
Method(s) of protection
Denotes equipment for
explosive atmospheres

74
 IEC dust marking 2004-2007

Ex tD A21 IP65 T120ºC

Maximum surface temperature

IP (Ingress Protection) degree
Zone 21, A= standard dustlayer test
Protection method(s)
Denotes equipment for
explosive atmospheres
A21 = Standard test procedure (Temperature when loading with dust)
B21 = Bespoke test procedure (Temperature when immersed in dust)

75
 IEC dust marking 2007-

Ex tb IIIC T120ºC Db Alternatively Ex tb IIIC T120

EPL (Dust/ zone 21 equipment)

Maximum surface temperature
Equipment group III sub-group IIIC
Protection method(s)
Denotes equipment for
explosive atmospheres

76
Certifikate reference – IECEx

Suffix – U= Component

Certificate number

Year of certification

Three first letters in

name of certifying body

According to IECEx
scheme

Suffix: U = Component
X = Special conditions for safe use
R = Resertified
 ATEX Marking

Gas (Could also be D = dust)

ATEX Category 2

ATEX Equipment group

ATEX symbol

ATEX Category 1 = for use in zone 0

ATEX Category 2 = for use in zone 1
ATEX Category 3 = for use in zone 2
ATEX Equipment group I = for use only in coal mines
ATEX Equipment group II = for use everywhere else
Marking non-electrical equipment,
ATEX only

Temperature class

Equipment group, equipment sub-group

Protection method(s)

Gas

ATEX Category 2, for use in zone 1

ATEX Equipment group II, everywhere but coal mines

ATEX Symbol
 Marking Ex p Equipment

Protection For zone Internal ”zone” Atex cathegory

method/ EPL

Exp x 1 Non Ex G2

Exp y 1 Zone 2 G2

Exp z 2 G3
Non Ex

80
 Comparisontable IEC/CENELEC and
some older national standards
COUNTRY SYM- Protection Methods EQUIPMENT GROUP/ SUB-GROUP TEMP.
BOL CLASS
IEC Ex d e i o q p s I II
CENELEC EEx d e i o q p s A B C T1 - T6
TYSKLAND Ex d e i o (s) f/p s 1 2 3n G1 - G5
FRANKRIKE (ADF) ADF SA SI RD SP ATEX AI AII AIII AIV (200°C
max.)
ITALIA AD PE FE I s S SI S IIA IIB IIC T1 - T6
Ex d e i o q p
BELGIA Ex ADF E (I) (SI) I IIa IIb IIc G1 - G5
(SA)
HOLLAND Ex F E I O Q P H IIA IIB IIC T1 - T6
FLP e IS p Gr Gr Gr Gr (200°C
ENGLAND I II III IV max.)

CL2 CL1
U.S.A. Explosion IS T1 - T6
(NEC 500) proof P Gr Gr Gr Gr
F,E D C AB
USA I II
(NEC 505) AEx d e i o q p s A B C T1 - T6
CL2 CL1
CANADA Explosion IS T1 - T6
proof Gr Gr Gr Gr
F D C AB

81
Explosion-protection visual checks (OD
504 5.4)

a) HSE requirements
i. Entering explosive atmospheres, See 5.3 d
ii. Conducting close inspection, See 60079-17 pt.
4.8
b) Visible defects– see each method
c) Conditions that affect protection method
d) Reporting defects on Ex equipment
i. The purpose of a verification dossier; and
ii. Various ways for reporting defects
e) Procedures to be followed in the event of a
change in explosion hazard
82
 Change in explosion hazard

Changes to the plant must be fully

assessed and the verification dossier
updated, e.g.:

• The replacement of one flammable substance

by another
• Change in process conditions
• Re-routed or additional pipework

83
Reporting defects on Ex equipment

The purpose of the Verification Dossier:

Definision in 60079-14 pt 3.1.2/ Specification pt. 4.2

Collection of all neccesary information to evaluate the

safety of the plant:
• Area classification documents
• Gas, Vapor, or dust classification
• Documents describing Ex equipment
• Documents describing installation
..and all other neccesary documentation

84
Reporting defects on Ex equipment

There are no formal guidelines for the reporting

of data, but it should:

•Be consise – a «one-sheet per item» may

be effectively replaced by check-list
•Be easily referenced to the equipment,
- Tag system
•Highlight required actions – should be
prioritised
•Be easily retrieved at a future date

85
Procedures to be followed in the event
of a change in explosion hazard
When changing the plant effecting zone classification,
gas group or temperature class, the process of
classification must be repeated and updated in the
Verification Dossier.

IEC 60079-10-1, 5.1: … «Reviews should be

carried out during the life of the plant»

Owner/ occupier of the plant is responsible for this to be

carriied out, and therefore it is important that they
recieve information about changes to the plant/
process.

86
 Ex Equipment (OD 504 5.9 to 5.20)

a. The purpose and characteristics of the design

features of the protection methods.
b. Typical use of protection methods
c. Actions or conditions which would void the Ex
protection method.
d. The use of Standards in determining the
requirements to which the design of the
protection methods shall comply. See posters to
decide which standards should be used for each protection
method. ATT! Always two standards.

87
 Ex d - Flameproof

Purpose &
characteristics:
• Containment (and
Flamepath quench flame)

• Withstand explosion
pressure
Ex d gland
• Flamepaths (narrow
joints)
• Exterior temperature
class, also in the event of
interior explosion
• Ex d glands
88
• «no» IP requirements
Ex e – Increased safety

Purpose & characteristics:

• Avoid ignition source

• No ignition sources
• Certified terminations
• Creepage distances
• Internal and external
temperature class
• Excludes Dust and Water,
minimum IP 54

89
 Ex n – «zone 2 protection»

Several protection methods, Purpose & characteristics:

described by letter number • Depends on method, but
2: most are a simplified
• Ex nA non sparking (Ex e) version of the othe
• methods. See list on the
Ex nC enclosed (Ex d,q)
left.
• Ex nR restricted breathing
• Ex nR – Restricted breating
• Ex nL limiting energy (Ex i) stops an explosive
• Ex nP simple overpressure atmosphere from entering
(Ex p) internal ignition sources the
short time an explosive
atmosphere is present
• tight joints and seals

90
Ex m og Ex mD - Encapsulation

Purpose &
characteristics:
• Encapsules ignition
sources, so explosive
atmospheres do not come
in contact with ignition
sources

• Thickness of solid
compound
• Poperties of solid
compound
• free of voids
91
• External temperature class
Ex o – Oil immersion

Purpose &
characteristics:
Ignition sources immersed in
such a depth of oil that
explosive atmospheres do not
come in contact with ignition
sources

• Non-conductive liquid
• Ignition sources solidly fastned
• Oil-level indicator
• Immersion depth
• External temperature class
92
Ex q – Powder filled

Purpose &
characteristics :
• Excludes larger amounts
of gas inside enclosure,
and the powder, such as
granulated quarz,
quenches any flames.

• Properties of powder filling

• Distances/ amount of
powder
• External temperature
class
93
 Ex i og Ex iD – Intrinsic safety

Purpose & characteristics :

• Limit the energy of any sparks in
the circuit to values below the
MIE (Minimum Ignition Energy)
value of the gas present.

• Voltage limiting components

• Current limiting components
• Limiting stored Capasitive and
Inductive energy
• Internal and external
Note! IP requirements suitable temperature class on field
for area when Ex i junction box equipment
with more than one Ex i circuit!! • Min IP 20 on Ex i field equipment
(but often higher IP requirement94
on Ex iD field equipment)
Ex p og Ex pD - Pressurization

Purpose & characteristics

:
• Uses higher pressure inside
enclosure than surrounding
atmosphere to prevent
explosive atmospheres to
come in contact with internal
ignition sources.
Remember: Exp x/y/z.

• Solid enclosure
• Overpressure monitoring
• Alarm/ disconnection by
pressure below limit
• Purging 95
Ex t (prev. Ex tD) – Dust protection by
enclosure

Purpose & characteristics

Gasket
:
• Solid and tight enclosure
prevents dust from entering
ignition sources within the
enclosure.

• Solid enclosure
• tight seals
• Or semented joints
• External Temperature
klasse
• Min IP 5X or 6X 96
Common characteristics of explosion-
protection techniques (OD 504 5.21)

a) The purposes of ‘temperature classification’ and ‘gas

grouping/apparatus grouping’.
b) Equipment markings (nameplate). see 5.5 b
c) Limitations of non-metallic or specific alloy enclosures. see
60079-0 pt. 7
d) The purpose and use of conformity and
certification/approval for equipment used in explosive
atmospheres.
e) Environmental conditions that may impact on explosion-
protection techniques. see 60079-17 pt. 4.7
f) The principles and applications of other and mixed
explosion-protection techniques.

97
 The purposes of ‘temperature
classification’ and ‘gas
grouping/apparatus grouping’.
• Temperature classification describe the
maximum surface temperature of the
equipment due to AIT values of gases/ Vapors/
dusts present.
• Note! For Ex e, Ex i og Ex nA this also applies
to internal surfaces!

• Equipment Temperature class; combined with:

• Gas grouping/apparatus grouping’, limits
which gases the equipment can be used in.

98
 The purpose and use of conformity
and certification/approval for
equipment used in explosive
atmospheres.
• Test of conformity by the use of recognized
standards on internationally (IEC) or european
(CENELEC) level, ensures clear and repeatable
level of safety for the equipment, which is
recognized as acceptable within the standards’
scope.
• Certification (by a third party) ensures an objective
assessment of conformity.
• The certifying body is called CB in the IECEx
system and NB (Notified Body) in the ATEX
systemet.
• IECEx require certification in all zones – ATEX only
in zone 0 and 1.
99
 IECEx
certificate
Certificate available on web site.

All electrical equipment has a

certificate.

Mechanical equipment will come,

eventually…

100
 The principles and applications of
other and mixed explosion-protection
techniques.
• For electrical equipment for use in hazardous
areas not covered by existing standards, the
standard for Ex s is applied.
• This standard describe basic tests and
requirements to fulfill in order to reach
adeqate level of safety, without specifying
technical solutions.
• To achieve a higher EPL level, two or more
protection methods can be combined to
elevate the safety of the equipment to satisfy
the requirements for wanted EPL level.

101
Phone ExResistTel

Ex em[ib] IIC T5 Gb
102
 Certification of Personel competancy

Assessment procedures IECEx OD 503

• Structured assessment methods such as written, practical and oral exams

• Based on knowlege stated in OD 504
• Exam papers derived from the IECEx question bank
• Paper A, B and C
• Paper A Is a set number of absolute questions (100% correctly)
• Paper B Is a set number of multiple choice questions (75% correctly)
• Paper B Is a set number of written answers (75% correctly)
• Multiple choice 2 minutes per item
• Short written answer 3 min per item
• Extended written answer 5 minutes per item
• Reading time 10 minutes

103
 Certification of Personel competancy

Assessment procedures IECEx OD 503

• All written material is allowed during the exam at your responsibility

• Electronic equipment like Mobile phones and PDA is not allowed.
• Exam is supervised by an invigilator under the EXCBs responsibility.
• Result of the assessment will be sendt by Email end Postal service

104
 End result of the exam?

All certificats available on IECEx homepage

Same as for Equipment and Service facilities

Globaly Accepted by all IEC member states

Easy to access and difficult to manipulate

105
COMPETENCE
REQIREMENTS FOR UNIT
EX 004, 007 OG 008

(THAT IS NOT COVERED IN UNIT 001)

OD504 pkt 4.6.5, 4.9.5 og 4.10.5

106
Installations in Hazardous area (OD 504 5.22
a)

a) Preparation to install and maintain explosion-

protected equipment in explosive
atmospheres encompassing:
i. OH&S procedures to be followed when working in a
hazardous area
ii. the significance of information provided on the cert
ification documentation and schedules for a given item
of explosion-protected equipment
iii. the typical contents of a verification dossier and its
purpose; and (covered in Unit 001)
iv. limitations in the use of tools and testing devices in
explosive atmospheres (coverd in Unit 001)

107
 HMS prosedyrer for OH&S
procedures to be followed when
working in a hazardous area

• Identify area classification

• Identify from P&ID the correct equipment
• Permit To Work procerdure
• SFT procedure (Gas free test)
• Lock out procedure
• Proper PPE
• Return of equipment to service
• Report and return of permit procedures
108
 Important information derived from
the certification documents.

• How to attain certificates

• HTTP://www.iecex.com
• What to find in the certificat?
• Limitations in the use of the equipment (X in the
certification reference)?
• Equipment or component? (U in the certification
reference)?
• Is the certification valid?
• What standards are used for The certification
assessment?
• Are ther variations of the equipment coverd by the
same certificate?
109
Important information derived from
the certification documents.

110
 Limitations to the use of tools and
measure equipment in Hazzardous
area
Multimeter and electrical measuring devices are
sources of ignition!
To be able to use ordernary (not Ex i) measuring
equipment there has to be a «hot work permit».

Intrinsicaly safe instruments could be used under

certain specific conditions.

111
 Explosive atmospheres installation
requirements
(OD 504 5.22 b)

i. The relationship between explosion-protected

equipment, their certification documents and required
locations given in specifications and layout drawings
and/or written instructions encompassing:
i. the purpose of markings on the equipment and on the certification documents
for a given item of explosion-protected equipment;
ii. matching explosion-protected equipment with certification documents and
the equipment specified for an installation; and
iii. the location of the items of explosion-protected equipment for an installation
from specifications and layout drawings and/or instructions.

112
 The purpose of markings on the
equipment

• All Ex Equipment should be marked as

described in IEC 60079-0
• This is to:
• Be able to reccognise the protection methodes used
• To make sure the equipment is suitable for the gas and dust
group and temperature class of the area
• To be able to determine that the equipment has the requiered
EPL according to the zone classification or risc assessment
• Be able to retrieve the certificat and other documentation by
using the certificate reference.
• Any information regarding safe use of the equipment.

113
The purpose of markings on the
equipment

114
Election of Ex equipment according to
certification and equipment specs

• Equipment selection has to take into

consideration the equipment certification and
the plant spesific demands.

Ex d IIB T4 Suitable for Hydrogen?

Ex de IIC T6 Suitable for Hydrogen?

Ex de IIC T6 Suitable for zone 22?

Ex nA IIIC T4 Suitable for zone 1?

115
 Equipment location on the basis of
plant documentation

• Zoning
documentation
• Risk assessment
documents.
• EPL
• Drawings
• Ex dossiere

116
 Protection from dangerous
(incendive) sparking

• If a type of system earthing TN 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

117
 Non Ex electrical equipment
above hazardous areas

• Such equipment shall be either totally

enclosed or provided with suitable guards or
screens, to prevent it or hot particles from
falling into the hazardous area.
• Non Ex equipment in or above Hazaedous area
should be subject to a risk assessment.

118
 Regulations and standards for
installation of Ex Equipment.

• IEC 60079-14 covers the design, selection and

installation in hazardous area.

• The standards are the basis of a common

terminology.

• Use the content list

• Standards does not cover «everything»

119
 9.6.4 Openings in walls

• IEC 60079-14. clause 9.6.4 og 9.6.5

• Openings in walls for cables and conduits
between different hazardous areas and
between hazardous and non-hazardous areas
shall be adequately sealed, for example by
means of sand seals or mortar sealing to
maintain the area classification where
relevant.

120
 4.2 Documentation

• It is necessary to ensure that any installation

complies with the relevant equipment
certificate (see also Clause 5) as well as with
this standard and any other requirements
specific to the plant on which the installation
takes place.

121
 Explosive atmospheres cable
termination techniques (OD 504 5.23)

a) Selecting compliant cable termination

devices.
b) lnstalling conduit systems, where applicable,
including seals
c) Terminating a cable with a barrier gland.
Gases only.
d) d) Terminating a multi-pair, SWA, overall
screened, individual screened cable
e) Testing termination/connections of installed
cables/circuits.

122
 Terminations

• Connections shall be made in a manner

consistent with the type of terminal, type of
protection and the manufacturer’s instructions
and not introduce undue stress on the
connections.

• If multi-stranded and, in particular, fine-

stranded conductors are employed, the ends
shall be protected against separation of the
strands, for example by means of cable lugs or
core end sleeves, or by the type of terminal,
but not by soldering alone. 123
 Terminations

• The creepage distances and clearances, in

accordance with the type of protection of the
equipment, shall not be reduced by the
method in which the conductors are connected
to the terminals.

124
 9.6.2 Terminations

• If multi-stranded and, in particular, fine-

stranded conductors are employed, the ends
shall be protected against separation of the
strands, for example by means of cable lugs or
core end sleeves, or by the type of terminal,
but not by soldering alone.

125
 9.6.2 Terminations

• The creepage distances and clearances, in

accordance with the type of protection of the
equipment, shall not be reduced by the
method in which the conductors are connected
to the terminals.

126
 9.4 Conduit systems

• The conduit shall be provided with a conduit

sealing device where it enters or leaves a
hazardous area, to prevent the transmission of
gases or liquids from the hazardous areas to
non-hazardous areas.
• There shall be no union, coupling or other
fittings between the sealing device and the
hazardous area’s boundary.

127
 Connections of cables to equipment

• Cable glands shall be installed in a manner

that after installation they are only capable
of being released or dismantled by means of a
tool.

• If additional clamping is required to prevent

pulling and twisting of the cable transmitting
the forces to the conductor terminations inside
the enclosure, a clamp shall be provided, as
close as practicable to the gland along the
cable.
128
 Test of termination and connections
in Hazardous area

• Check terminations according to drawing.

• Check all terminations are properly fastend.
• Check isolation and that there is no bare metal

• Initial inspection:
• - Point to point test
• - Insulation test
• - Functional test

129
 Hazardous area maintenance work
performance (OD 504 5.25)

Evidence shall show an understanding in assessing

competent hazardous area maintenance work
performance.

a) Application of relevant statutory requirements.

b) Establishing or understanding procedures for engaging
competent persons.
c) Establishing or understanding and maintaining
procedures for identifying potentially explosive
hazards
d) Establishing procedures for implementing and
maintaining explosion-protection strategies

130
 5.26 Hazardous area operations
reporting work performance (OD 504 5.26)

Man skal kunne vise praktiske ferdigheter i:

a) Permits and clearance .
b) Hazard monitoring and evacuation procedures.
c) Operation of plant and machinery .
d) Plant and electrical isolation .
e) ldentifying visual damage and corrosion of
equipment and wiring systems.
f) Reporting defects .

131
 Initial recuierments before starting
work

• Permit To Work (PTW) og Gas free!

• Gas detection and «Read an run concept»
• Safe work prosedures
• Insulation procedure - Lockout og Tagg
• Inspection – Grades V, C & D
• Results Sheet og Check List

132
Explosive atmospheres maintenance
requirements(OD 504 5.27)

a) The purpose of a maintenance schedule .

b) The purpose and extent of 'visual', 'close', 'sample' and
'periodic' inspections.
c) The features of each explosion-protection technique that
should be included in a maintenance schedule.
d) The impact of environmental conditions on explosion-
protected equipment, including corrosion and frequency
of maintenance .
e) The documentation requirements for recording the
maintenance process and results.

133
 Explosive atmospheres management
(OD 504 5.28 a)

a) The responsibilities of a person managing

activities or a site related to a hazardous area,
encompassing

i. H&S procedures that are to be established

i. Responsibilities for ensuring that a hazardous area has
been made safe prior to commencement of work ; and
ii. Responsibilities and processes for establishing and
maintaining a verification dossier.

134
Explosive atmospheres management
(OD 504 5.28 b)

b) Explosion-protection strategies in relation to a

hazardous area, encompassing
i) the process of classifying a hazardous area;
ii) various ways in which electrical systems
/apparatus can be treated to prevent them from
becoming an ignition source; and
iii) the cost of the different ways of treating electrical
systems/apparatus associated with explosive
atmospheres .

135
Explosive atmospheres management
(OD 504 5.28 c)

c) Requirements for the maintenance of

electrical systems associated with
explosive atmospheres
i) the type and grades of inspection of
explosive atmospheres ;
ii) maintenance programs for electrical
explosion- protected systems/apparatus; and
iii) documentation requirements associated
with maintenance procedures

136
 5.29 Hazardous area maintenance
work performance (OD 504 5.29)
Show practical skill related to:
a) Establishing maintenance policies and procedures
that encompass OH&S responsibilities.
b) Establishing maintenance management systems
that address the special requirements for explosion-
protected equipment and installations.
c) Ensuring a hazardous area is appropriately
classified and explosion-protection strategies are
adequate.
d) Developing and implementing maintenance
programs and schedules in relation to explosion-
protected equipment and installations.
e) Evaluating maintenance programs in relation to
explosion-protected equipment and installations.
137
 Hazardous area maintenance work
performance (OD 504 5.29)
Show practical skill related to:

f) Working safely in a potentially hazardous area in

relation to work permits and clearances, hazard
monitoring and evacuation procedures, and plant and
electrical isolation.
g) ldentifying defects and faults .
h) lnterpreting certification documentat ion in relation
to maintenance, repair and replacement.
i) Following established maintenance procedures .
j) Documenting maintenance details .

138
 Explosive atmospheres visual and
close inspection requirements (OD 504 5.36)

Evidence shall show an understanding of the purpose and

process of visual and close inspections to an extent
indicated by:
i) occupational , health and safety procedures to be
followed befare entering explosive atmospheres; and
ii) occupational, health and safety procedures to be
followed while conducting close inspection.
b) Requirements for a verification dossier and
relationship to as-built electrical installation.
c) Purpose, scope and limitations of close inspections.
d) Documentation requirements resulting from a visual
or close inspection.

139
 Hazardous area visual and close
inspection work performance(OD 504 5.37)
In assessing competent hazardous area visual and close
inspection work performance the following aspects of
competence shall be considered:

a) Working safely in a potentially hazardous area in

relation to work permits and clearances , hazard
monitoring and evacuation procedures, and plant and
electrical isolation.
b) lnspecting equipment and wiring in a manner that
does not adversely affect the type of protection
afforded by the equipment design.
c) Conducting visual inspections.
d) Documenting inspection outcomes.

140
 Explosive atmospheres detailed
inspection techniques (OD 504 5.38)
a) The relationship between the documentation held in a
verification dossier and the installed equipment:
i. consistency between the location and type of equipment
with the area classification details in the verification
dossier; and
ii. equipment certification and any attached conditions that
relate to the equipment as it is installed.
b) b) lnspecting a hazardous area installation:
i. typical processes for undertaking the inspection of a
hazardous area installation;
ii. requirements applicable to a given installation; and
iii. reporting of an inspection of a hazardous area installation.

141
Hazardous area detail inspection work
performance (OD 504 5.39)
In assessing competent hazardous area detail inspection
work performance evidence regarding the following
aspects of competence:

a) Working safely in a potentially hazardous area in

relation to work permits and clearances , hazard
monitoring arid evacuation procedures, and plant and
electrical isolation.
b) Handling and installing equipment and wiring in a
manner that does not adverse ly affect the type of
protection afforded by the equipment design.
c) Conducting inspections.
d) Documenting inspection outcomes.

142
Questions?

143
Good Luck with
your Exam

144