ATEC

COMPEX

Training and Certification for personnel who

work on electrical apparatus for use in
potentially explosive atmosphere
Contents
INTRODUCTION
UNIT 1 –General Explosion principles & properties of gases
UNIT 2- Area Clssification
UNIT 3 –Standards,Certification Marking
UNIT 4- Sources of ignition
UNIT 5- Flameproof Ex ‘d’ / Eex’ d’
UNIT 6-Increased safety Ex ‘e’ /EEx ’e’
UNIT 7-Reduced Risk or Non – Incendive Ex’n’ / EEx ’n’
UNIT 8-Pressurization Ex ‘p’ E Ex ‘p’
UNIT 9- Other methods of protection -Ex / EEX ‘o’,Ex ‘q’,Ex’ m’ ,& Hybrid
UNIT 10- Intrinsically Safety Ex’i’ E Ex’i’
UNIT 11- Installation –Wiring Systems & Erthing Requirements
UNIT 12 – Inspection and Maintenance of Hazardous Area Equipment
UNIT 13 – Permit to Work and Safe Isolation
UNIT 14-Competency Vlidation Test (CVT)
UNIT 1
GENERAL EXPLOSION
PRINCIPLES & PROPERTIES OF
GAS
 1.1 Fire triangel consist of three element which must be present before combustion can take place

Combustion will take will take place if 3 element are present AND
1.The gas/air mixture is within certain limits and
2.The source of ignition has sufficient energi
Removing any one of the 3 element (oxygen ,fuel & source ignition is sufficient to prevent
combustion .another methode to prevent combustion is to isolate or separete the source of ignition
from 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 ignition is
maintened below specific values ,or allows an explosion to take plce inside a robust enclosure
without igniting the surrounding atmosphere
1.4.2 Pressurized gas :As gas is presssurized ,the number of molecules per unit of volume increase .this causes
any heat release per unit volume to also inncrease-there for increasing the intensity of any fire or explosion .
Pressurising a gas greatly decreases the MIE neede to initiate an explosion in fact ,do the doubling the gas
pressure can decrease the amount of MIE by 75%

 1.4.3 Relative Density

 The relatative density of gas can help us to determine whether it will rise or
fail in the atmosphere
 Air considered to have a relative density of 1
 Substances with relative density less than 1 are lighter than air ,and will raise
 Substances with relative density greather than 1 are heavier than air ,and will
sink
 If the relative density is lighter than air ,in the substance will seek the highest
point and will gather there .if the density is heavier than air ,the substance will
seek the lowest point and concentrate in that point
 Therefore ,knowing the relative density of the substance you are dealing with
is important for several reson
 1.knowing where place gas detector
 2.Knowing how to place supply & exhaust duct to best “sweep”the space
 3.knowing where the gas will concentrate
1.2 PRINCIPLES OF IGNITION
1.2.1 .Definitions:

1.Flashpoint:the lowest temperature at which a flammable liguid give enough vapour to produce an
explosive mixture with air
TYPICAL FLASHPOINT TEMPERATURES

FLASHPOINT (°C)
Acetylene -82
Ethylene -120
Hydrogen -256
Methane -188
Propane -104
Xylene 25
Carbon disulphide -95

The flashpoint of a material gives an indiction of how stable-and easily ignitable –a material in normal
ambient temperatures.However materials with high flashpoints should not be overlooked as a
potential hazard –exposure to hot surfaces can allow a flammable mixture to form locally .In addition
,a flammable material release under pressure from a jet may have its flashpoint reduced
2.IGNITION TEMPERATURE:The Minimum temp at which a flammable mixture will ignite
Spontaneously .
Note:that this does not require any other ignition sosurce nd can be internal or external
equipment

 TYPICAL IGNITION TEMPERATURE

MATERIAL IGNITION TEMP °C
Hydrogen 560
Methane 595
Propane 450
Ethylene 440
Acetylene 305
Hydrogen sulphide 260
Carbon disulphide 90
1.3 Flammable limits
Combustion can occur only if the flammable mixture –fule & air –are within certain limits
These limits are defined ad:

Lower Flammable Limit(LFL)

And the
Upper Flammable Limit
Range between these limits is knowsn as the Flammable Range
100%
When the prentage of gas ,by volume is above the UFL ,
the micture is to rich to burn
Upper Flammable Limit
UFL
FLAMMABLE RANGE
MIXTURE WILL BURN IF IGNITED

Upper Flammable Limit

LFL When the prentage of gas ,by volume is below the LFL ,
the micture is to weak to burn
0%
Some typical LFL & UFL Values are listed below

MATERIAL LFL (% By UFL(% By

volume) volume)

Acetylene 2.3 100

Ethylene 2.3 36
Hydrogen sulphide 4 45.5
Hydrogen 4 77
Methane 4.4 17
Propane 1.7 10.9
Carbon Disulphide .6 60
Different gas vapours have different flammable limit and greater the difference
between the LFL and UFL –in other words ,the wider the flammable range the more
dangerous the substance is
Operating above the UFL is safe –but not very practical ,though there are some
operations where this methode is utilized .it is much more practical and safer of
personel-to operate below the LFL
1.4 Other properties to consider
it is important to consider all known parameter and all possible scenario’s when considering
hazardous areas and the risk associated with them
two important considererations which may have significant impact on the risk are as follow

1.4.1 OXYGEN ENRICHMENT:An area with enriched or increased oxygen content (above
21%)is much more dangerous than other hazadous areas .Oxygen is ,of course one of
element s of the triangle ,and is explosive itself.
The presence of increased level of oxygen cause the heat released during any fire or
explosion to be significantly higher ,thereby making the explosion of much greater
magnitude
In addition the presence of increases oxygen lowers the amount of energy necessary to
initiate the explosion (called MINIMUM IGNITION ENERGY,or MIE) by significcant
amounts –by as much as 90%
Oxygen enrichment further increases the dangers by decreasing the ignition temp of most
gases

Material Air Ignition temp (°C) Incresed oxygen

Ignition Temp(°C)
Hydrogen Sulphide 260 220
Acetylene 305 296
Ethane 512 506
An oxygen enriched atmosphere also WIDENS the flammable range of most
gases

Material Air Increased Oxygen

LFL(%) UFL(%) LFL(%) UFL(%)
Methane 4.4 17 5.2 79
Propane 1.7 10.9 5.2 55
Hydrogen 4 77 4.7 94

NOTE:No equipment is certified or tested to ATEX requirements under –oxygen

enrichment condition
Some typical relative density values are listed below

MATERILA RELATIVE DENSITY

Acetylene 0.90
Ethylene 0.97
Hydrogen 0.07
Methane 0.55
Propene 1.50
Propane 1.56
Carbon Disulphide 2.64
Hydrogen sulphide 1.19
1.5 Gas Group

 ATEX & IEC Classivi combustible gases into 2 group

the two group are :
Group I:Mining Industry
Group II :All other SURFACE industry Group II is sub-
divided into 3 sub-groups
 IIA-Less easily ignitable(representative gas-Propane)
 IIB-Easily ignitable (representative gas-Ethylene)
 IIC-Most easily ignitable(representative gas-Acetylene
& Hydrogen)
 1.5.2.1 Minimum Ignition energy (MIE:The lowest amount of
energy in spark necessry to ignite the most easily ignitable concentration
(MEIC) of combustible substance (gas)

MATERIL Minimum ignition Gas Group

Energy (µJ)
Methane 280 IIA(and gas group
I)
Propane 260 IIA
Ethylene 85 IIB
Acetylene/Hydrogen 19 IIC
1.5.2.2 Maximum Experimental Safe Gap (MESG):In this methode ,a flameproof
enclosure is tested to see how much gap can be left between the cover & body before
an internal explosion inside the enclosure
ignites the surrounding atmosphere

Material MESG(mm) Minimum Gas Group

ignition Energy
(µJ)

Methane 1.17 280 I

Propane 0.97 260 IIA
Ethylene 0.71 85 IIB
Acetylene 0.5 19 IIC
1.6 Temperature Clsasses
As noted above ,all explosive gas /air mixtures have an ignition temperature at which they will
spontaneusly ignite.therefore ,it is extremely important that the mixture not be allowed to reach
this temperature or touch any surface or equipment which is at or above that temp
For that reason ,equipment Temperature Classification where devised.every piece of
equipment or assembly which is suitable for use in a potentiallly explossive atmosphere
must be evaluated and have a temperature classification –T-RATING-assigned to it
For group II electrical equipment,it must be selected to ensure that the maximum
surface temperature produced by the equipment shall not exceed the
ignition temperature of flammable gas atmosphere which may be present
around the equipment
ATEX / IEC T-Rating
Temp class of equipment Maximum Surface
Temperture(oC)
T1 450
T2 300
T3 200
T4 135
T5 100
T6 85
Temperature cassification are based on Normal ambient temp of -20 °C +40 °C unless
otherwise marked on the equipment.The T-Rating temperatures are based on maximum
ambient for the equipment
For equipment used in countries with very hot or cold climate where ambient temperature
of equipment in service exceeded,the additional marking will be specified by the
manufacturer.The marking would be Ta or Tamb with the range ,for exmple ,T85°C,Ta-
40°C to +60°C, -60°C ≤Ta≤+70°C
Temperature ratings are the highest temperature that equipment should reach in normal
and specified fault conditions.Therefore a T1-Rated device could reach a normal
operating temperature of 450 °C,while T6-rated device would only reach 85°C
Devices rated at a higher NUMBER T-rating can be used in all areas requiring the lower
numbered T-rating .for example a T5-Rated device could be used in any areas
requiring T5,T4,T3,T2,T1-But could not be used in aT6 area
Combustible materials-Gas& Dust-are also given T-Ratings, to show what minimum T-
rating is equipment sfe to use in a environment containing Hazard
 Test your knowledge –unit 1 properties
1.The temperature t which gas /air mixture will ignite without an additional
ignition source is
A.The flast point B.The Flame point C.The ignition temperture D.The upper
ignition temperature
2.What is the maximum surface temperature allowed for temperature clss T3:
A. 85°C B. 100°C C. 200°C D. 450°C
3. What is the design temperature range of equipment for use in the UK:
A.-20 to +50°C B. -20°C C.-20 to +40 °C D. +40 °C
4.Which gas group does Ethylene belong
A. 2B B. IIA C. IIB D. IIC
5.How many temperature classes are there :
A.4 B.6 C.6 Unless supervisor state otherwise D. Depends on type of
equipment used
 UNIT 2
ARE CLASSIFICATION
Unit 2 :Area Classification

1) Definition of the following terms

a)Hazardous area
b)Non-Hazardous area
2) Hazardous area zones as defined by The ATEX directive
3) Hazardous area zones as defined by the IEC standard
4) Symbols used to define Hazardous area zones
5) Typical source of release
6) Basic area classification process
2.Area Classification –ATEX/IEC
Relevant standard :IEC 60079-10-1
2.1 Definitions:
Hazardous Area: An area in which an explosive gas atmosphere is present ,or may be
expected to be present,in quantities such as to require special precautions for the
construction Installation and use of apparatus
Non- Hazrdous area : An area in which an explosive gas atmosphere is not expected to be
present in quantities such as to require special precautions for the construction
installation and use of apparatus
2.2 Area Classification
A methode of analyzing an area and the potential for developing a hazardous atmosphere (gas
and/or dust).The analysis must consider every hazardous substance present in the area ,the
potential for those substances to be release into the atmosphere ,and the potential for
developing an explosive atmosphere in the event of a release .Many things must considered
during analysis,such the as the following :

1)Hazardous substances being used ,stored,or transported in the area

2)Processes being performed on those substances (pressure,heating.etc.)
3) All potential sources of release
4) Area Ventilation
5) How enclosed the area is
6) Relative density of the hazardous substances(s)
2.3 Source of release
all potential sources of release (SoR)must be evaluted as to grade.The grade of the release is
measure of possibility that a release may occur.There are 3 defined grades of release

2.3.1 Continues-continues or expected to occur for long periods example

-Surface of a flammable liquid
-Inside tanks or containers holding flammable liquid
2.3.2 Primary-Expected to occure periodically or occasionally during
normal operation Example
-Seals of compressors or pumps
-Sample point
-Relief valve ,vent,and other opening which are expected to release
flammable substances during normal operation
2.3.3 Secondary - Not expected to occur in normal operation and if it does occur is likely to
do so infrequently and for short periods Example
-Flanges & pipe fittings where relesed is not expected in normal operation
-Sample points which arelease during designed to prevent release use
-Relief valves ,vent,and other openings which are NOT expected to release flammable substances
during normal operation

There may be other considerations as well-area classification should be performed

by trained and competent personnel who are knowledge of each of the above
items
Area classification should be performed AFTER all possible steps have
been taken to eliminate ,reduce ,or mitigate the potential for explosive
atmosphere to develop
The primary purpose of analysing and classifying and area is to allow the selection
and installation of equipment to be used safely in that environment
2.4 Zone
ATEX & IEC define hazardous ares as ZONES .in addition ,in 2007 the IEC
Introduced Equipment protection levels-EPL’s-as an alternative
method for classifying hazardous areas.EPL’s are discussed in more
details in a later unit
Zoning is a means of representing the frequency of the occurence and
duration of an explossive gas atmosphere based on the identification
and consideration of each and every source of release in the given areas
of an installation.defining the zones of a facility therefore provides
critical information on areas which may have explosive atmospheres,
and allows for the selection of equipment and system which area
appropriate for use in those areas
For ATEX & IEC ,area classification of gases is carried out in accordance
with IEC 60079-10-1:Classification of areas-explosive gas atmospheres
 Under TEX & IEC Hazardous areas are defined as one of three zones
ZONE 0: Explosive gas atmosphere is Continuosly present,or present for long periodes
Zone 1 : Explosive gas atmosphere is Likely to occur in normal operation
Zone 2: Explosive gas atmosphere is Not Likely to occur in normal operation and if it
does occur,is likely to do so only infrequently and will exist for short periode only
2.5 Grade of release
Note that the grades of release defined above normally lead to a particular zone
classification as follows:
Grade of release Zone Classification
Continues 0
Primary 1
Secondary 2
In IEC 60079-10-1 the total duration of gas release on a yearly basis is not specified
.however 2 institution ,the energy institute EI(formerly institute of petroleum IP)
and american petroleum institute API have stated the duration of release for
guidence .as per EI 15(Formerly referred to as IP 15) and API RP 505,The gas release
on a yearly basic for the different zones are as follow
Zone 0 – in excess of 1,000 hours per year
Zone 1 – between 10 and 1000 hours per year
Zone 2- lesss than 10 hours per year
However ,this is not Always the case ,as some conditions may lead to an area being
zoned up or down based on other factors,such as ventilation or being isolated
/close-up
Area classification Documentation
ATEX,IEC,and NEC all require that ,once a facility has been properly
assesed and zoned for hazardous areas,proper documentation-usually
in the form of drawings,blueprints ,equipment listings,etc-must be
completed ,and this documentation must be available to
designers,inspectors,installer,operators,and maintenance personnel
Typically ,area drawings are created which show the hazardous
(classified) location their extent & boundaries,and the hazards
involved.standrd symbol are normally utilized.such as those
below,however these are not mandatory-the designer or facility owner
may utilize whatever mrkings they choose,so long as they are clearly
indicated.therefor it is necessary to always check the symbol ,legend
and note on the drawing for correct representation of the respective
zones
1.If an explosive gas/air mixture is likely to occur in normal operation the area
classification will be :
A. Zone 0 B. Zone 1 C.Zone 2 D. Zone 20
2. If an explosive gas/air mixture is graded as continues the area classification will
normally be :
A. Zone 0 B. Zone 1 C.Zone 2 D. Zone 20
3.A zone 3 hazardous area drawing must be indicated by using:
A . Left to right hatching B. Cross hatching C. Circular hatching D. Markings
as per drawing legend
4. A secondary release could be expected from
A. A Flanged joint B. Inside a tank of flammable liquid C. On the surface of a
flammable liquid D. A sample point
5. Area classification is carried out in accordance with:
A. IEC 60079-10 B. IEC 60079-14 C. IEC 60079-17 D. IEC 60079-19
UNIT 3
STANDARDS AND MARKING
Unit 3 Standard and Marking
On completion of this unit,you should now
1) Current standards for certifying equipment suitable for use in
hazardous areas
2) The certification process for explosion protected apparatus
3) The methode of marking explosion protected apparatus
4) ATEX equipment categories and definitions
5) IECEx Equipment protection level
6) Ingress protection
Discussion
Standard for hazardous area equipment have been arround for many years .many of them
were developed from research and scientific study,often as the result of a catastrophe or
accident .Incidents such as the senghennydd colliery disaster in 1913,in which 439 miners
lost their lives ,were heavily investigated and often found to have been caused by
electrical sparks in an explosive atmosphere.such disasters were the springboard for the
creation of not only standards or “rules” but different construction & assembly
techniques for equipment considered safe for in explosive atmospheres .the piper alpha
platform explosion & fire in 1988 ,which claimed 167 lives,brough about significant
changes in protection and procedure-standards-for use these dangerous areas.
Today ,there are many national &international standards in existence,both dealing with the
construction or manufacturer of equipment designed for use in hazardous areas AND the
correct selection,installation and maintenance of such equipment .it is widely recognized
that equipment meant for use in these areas must follow accepted,tested construction
and assembly techniques in order to provide the protection from catastropic explosions
and fires
However ,although equipment meant for use in hazardous areas may be constructed in
accordance with relevant standards,it can only provide the protection it is designed to
provide if it is selected ,installed and maintened in accordance with the Manufcture’s
recomendations and / or the appropriate standard
While almost every country has some version of hazardous area standard ,there is a
movement to “globalize”such standards in order to ensure that the best methods area
being utilized everywhere-as well as to open up economic markets .Many countries have
adopted these International standards,though usually within the framework of, or
adapted to include ,their relevant national codes or standards
in the european union ,2 ATEX Directives,have been put into place .ATEX is an
abbreviation from the french word “ATMOSPHERES EXPLOSIBLES”ATEX 95 is The
Equipment directive 94/9/EC and ATEX 137 ,the workplace directive
1999/92/EC.With effect from 20 APRIL2016,ATEX 95 is superseded by ATEX 114
,Equipment Directive 2014/34/EU
The ATEX 114 (95) Equipment directive is to facilitatate free movement of goods
throughout the EUROPEAN Union (EU) by harmonising technical nd legal standards
to be applied to the equipment (electrican and None-electrical).the equipment
directive deals with the design of product or equipment and intended to remove
barriers to trade by ensuring that the quality of the equipment ,whereever it is
manufactured in the EU ,meets rigorous essential sfety requirements
The ATEX 137 Directive is aimed at ensuring the Health and safety of worker whils in
their place of work and the duties are placed on the employer .the ATEX 137 Directive
covers the risk assesment ,zoning and safety of facilities nd categories the work place
into zone .Zone provide a measure of the probability of the presence of a dangerous
mixture with air of any flammable gas or combustible dust .the flammable gases are
classified as zone 0,1,and 2 and Combustible dust zones 20,21 nd 22
With regards to europe ,the organization which publishes harmonized standards for its
member nations is the EUROPEAN COMMITEE FOR ELECTROTECHNICAL
STANDARDIZATION(CENELEC) and / or EURPEAN COMMITTEE FOR
STANDARIZATION (CEN) these standards are often based on or identical to standard
published by the Interntional electrotechnical commision (IEC) .The IEC Develop nd
publishes standards aimed at establishing GLOBAL standarization ,as mentioned
above
3.2Product certification

Product certification standards are developed to ensure that

product –electrical in particular – manufactured to work in
areas with potentially explosive atmospheres are done so in
accordance with accepted standards.
1)To demonstrate product quality with regard to the ability of
the apparatus to function safely in a hazardous
environment
2)To enhance market acceptability by inspiring confidence in
those involved in the selection ,purchase ,installation
,operation and maintenance of approved/certified product
3) To improve quality and safety control producer in
manufcturing and construction
 3.2.1 Certfication body
There are multiple certification bodies –sometimes called NOTIFIED BODIES throughout
the word .almost every country has at least one ,which is certified by the national
goverment s a recognized testing & certification organization.
Such organization have demonstrated the ability and quality control to test ,inspect and
asses products in order to assure they are compliant with all relevant laws ,standards,&
safety procedures .As such they are “Notified” to the relevant governing body –such as
the european union “EU”-as proper certification agency
These bodies are responsible for ensuring that any product submitted to them for
certification meets all applicable standards for safety and quality .this done by
a) Reviewing documentation for the product – called a “Technical File”-which contains
drawings,parts listings ,individual part certification,etc
b) Receiving and testing a prototype or sample of the product ,to ensure it meets the
applicable standar
c) Reviewing the manufacture’s quality assurance program ,if applicable
d) Visiting and inspecting the manufacture’s facility if necessary
A details certification report is compiled and retained on file by the test authority and ,if all
requirenments are satisfied ,the equipment will be issued with a Certification of
conformity This certificate allows the manufacturer to place the product on the market
and MUST be supplied with every product sold or shipped .the relevant data –rating
,certificate number etc.along with the manufacture’s name and address-must also
marked on the equipment label .It is mandatory for manufacturers of Ex Equipment to
have an ATEX quality assurance notification (QAN) certificate as well as a product
certificate of conformity (COC)
Equipment certified for zone 2 applications can be self –certified (or declared)by the manufacturer
,avoiding the need for involvement by Notified body (NB) - But must still be subject to all required
testing and /or inspection and must still have a technical file created for it the manufacturer issues
a”Declaration of conformity” which states that the product meets all relevant standards
3.2.1.1 Standards in electrical working in hazardous areas
Interpretation of certificate Number
Example :BAS 01 ATEX 2107
BAS-Notification Body (Certification body )is Baseefa ,UK
0 1- Year of certifcation
ATEX –ATEX (European ) certificate scheme
2107- Certification serial number
There are 2 suffix letters which may be present on the ATEX EC (EU)type
examination certificate number
a) U This means the item is a component only and not a full certification it must
be installed as part of an assembly and completed assembly must be re-
certified again for full certification .Example of component certificate :Baseefa
08 ATEX 1076 U
b) X This means there are special considerations,special conditions of use apply or
specific condition of use for the installation which the manufacturer has set
forth in the certificate .in other words,READ THE CERTIFICATE to
understand these condition for implementation and compliance .
Example of X certificate :SIRA 99 ATEX 1234 X
ATEX Categories
ATEX defines 5 categories of equipment ,which are related to the likehood of the presence of an
explosive atmosphere.these categories are used to define the zones of use for equipment
3.2.3 ATEX 137 Directive
The european parliament and council agreed and passes ATEX 137 directive or directive
99/92/EC which sets out minimum requrements for the safety and health
protection of workers potentially at risk explosive atmospheres
For the purposes of this directive,’explosive atmospheres’means a mixture with air
,under atmospheric conditions,of flammable substances in the form of gases
,vapours,mists or dusts in which,after ignition has occured ,combustion spreads to
entire unburned mixture
In the UK the directive was put into effect by regulation 7 & 11 of the DSEAR
2002(Dangerous substances and Explosive atmospheres regulation )
Introduced 30th June 2003
It became mandatory and fully into force by 1st july 2006
The Directive set out specific obligations that the employer has to fulfil as follows:
.prevent and protect agains explosions
.Carry out an assesment of the explosion risk
.Ensure safe working conditions including the provision of instruction
,training,supervision and technucal measures
.Duty of coordination subcontractor or visitor
.Classify the areas where an explosive atmosphere may occur in to zones including
where appropriate the marking of entry points in to such areas
.Select appropriate equipment
.prepare an explosion protection document
3.2.4 IECEx
Equipment approved or certified under IECEx must display the following markings :
a) The manufacturer’s name (or trade mark) and type identification
b) The symbol IECEx
c) The certificate number
d) The type protection used (e.g.d.e.n.i.p.m.o.q)
e) The gas group (e.g IIA,IIB or IIC)
f) The T Rating (e.g. T1,T2,T3,T4,T5,T6)
g) The equipment protection level (EPL)
h) A serial number (except for cable gland & small component)
Example of IECEx Marking
1) Ex e IIC T6 Gb or Ex eb IIC T6
2) Ex d II (NHȝ) or Ex db II (NHȝ)
3) Ex d [ia Ga] IIC Gb or Ex db [ia] IIC
NOTES
(1) Prior to 2007 ,Exe for example ,could be designnated simply “II” to indicate it was suitable for all gas sub-
divisions.after changes in 2007 equipment for gas group II must have the appropriate sub-division
markings.IEC have discontinued the practice of mrking equipment as group II and instead require such
equipmet to be marked IIC
(2) Rather than specifing a gas group or sub-division ,some equipment may be certified for a particular gas –in
which case that gas (and the corresponding name or chemical formula ) will be marked on device .Eg for
ammonia gas ,NH3.
(3) Equipment marked for a particular gas need not have the temperature classification marked on it
(4) Cable glands,blanking elements (Hole plugs) and thread adapters need not have the temperature
classification marjed
3.2.4.1 Equipment protection levels
The selection or acceptance of equipment into each zone is historycally based on the
type of protection .it has no consideration of the potential consequences of an
explosion ,should it occur.The IEC has introduced as an alternative the Equipment
protection levels or EPL’s that uses a Risk assesment approach which takes into
consideration of CONSEQUENCES of n explosion
IEC EPL’s mirroe ATEX equipment categories but additionally the area classification
tem conduct risk assesments taking into account the potential consequences of an
explosion EPL’s may not always correspond directly to the equipment normal area
of use
Example 1
The installation of zone 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 Prolonged gas release.the risk has
identified a ‘Higher than normal” consequence of n ignition
Example 2
It is reasonable for the owner of a small ,well secured ,remote 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 an explosion
can be discounted .the risk assesment has identified a “Lower Than normal”
consequence of an ignition
In some cases ,hazardous area documentation only identifies the zones nd not gas
grouping or temperature classification –in these instances EPL’s should be
utilized
The relationship between Zone ,ATEX category and IEC Equipment protection
level EPL is tabulated below
Zone ATEX Category IEC EPL
0 1 (1G or 1 D) a (Ga or Da)
1 2 (2G or 2 D) b (Gb or Db)
2 3 (3G or 3 D) c (Gc or Dc)

ATEX Category 1 means a VERY HIGH LEVEL of protection ,Category 2 means

HIGH LEVEL PROTECTION and category 3 mens a NORMAL LEVEL of
protection against the ignition of an explosive atmosphere
IEC EPL a means a Very high level of protection ,EPL b means High level
protection nd EPL c means enhanced level protection against yhe ignition of n
explosive atmosphere
3.2.5 Ingress protection
Ingress protection IP (ingress protection rting or international protection
rating) provide a methode for easyly idetifying n enclosure’s degree of
protection agains the intrusion of Solid object nd ingress of water
,yhe IP code as per international standard IEC 60529
IP rating are given in a 2-digit format
The 1st digit ,from 0-6 ,provide a measure of the protection against the
ingress of SOLID particles
The 2nd digit ,from 0-8 ,provide a measure of the protection against the
ingress of water
Test your knowledge –Unit 3 Standards and Marking
1) Which of following shows the equipment has been certified with ATEX
equipment directive
A. The CE mark B. A hexagonal with IEC Inside C. A hexagonal with EX inside
D A blue crown
2) if a certified piece of apparatus is marked :SIRA123456X .what does the
“X”mean?
A. It must be installed without armour cables B. The apparatus cannot be used in
a zone 2 C. The apparatus is a component D. Special condition apply to the JB
–consult documentation
3) For equipment used above ground ,within a flammable gas and /or combustible
dust area ,which of the following equipment categories would be used?
A. Group I nd categories 1,2,&3 B. Group II nd categories 1,2,&3
C. Group I nd categories M1 & M2 C. Group II nd categories M1 & M2
4) Which are the two symbols authorized to use on ATEX certificate?
A. ‘U’ and ‘X’ B. ‘U’ and ‘8’ C. ‘Q’ and ‘S’ D. ‘X’ and ‘8’
5) Which of the following refers to protection against temporary water immersion
protection
A. IP 54 B. IP 55 C. IP 56 D. IP 67
Objectives:

On completion of this unit ,you should know

1)Typycal everyday source of ignition in the workplace
2)Lesser know source of ignition
4.1 Hot Surface
If an explosive atmosphere comes into contact with a heated surface which is at
the mixtures ignition temperature ,ignition can occur .the capability of a
heated surface to cause ignition depends on the type and concentration of the
particular substance in the mixture with air .this capability becomes greater
with increasing temperature and increasing surface area . In addition to
electrical equipment which may become hot due to current flow ,consideration
must be given to mechanical processes which can generate significant heat –
such as failed bearings ,friction,etc

4.2 Open Flame

Flames ,even very small ones,are among the most effective sources of ignition,No
naked flames are permitted zone 0 and gases from flames and other heted
gases are not permissible unless special preventive measures are taken . In
other zones,devices with falmes are only permissible if the flames are safely
enclosed and the temperatures generated are not ignition capable for the area
use
4.3 Grinding ,friction ,and impact
Processes such as grinding or abrasion can generate significant heat at the point of
contact ,as well as producing particles which are heated and can be thrown over
a wide area.Rubbing friction ,even between similiar ferrous metals and
between certain ceramics ,can generate hot sports and sparks similiar to
grinding sparks
Metalic impacts involving rust and light metals (e.g. Aluminium and
magnessium) and their alloys cn iniate a thermite reaction which cn generate
significant heat the light metals titanium and zirconium can also form
incentive sparks under impact or friction against any sufficiently hard material
,even in absence of rust
4.4 Stray current
Stray current cn flow in electrically conductive system or parts of system as return
current in power generating systems ,especially in the vicinity of electric
railways and large welding systens. Fault in electrical installations – a short
circuit or a short –circuit to earth –can produce significant current flow in
structures and metallic equipment . Magnetic induction – such as near
electrical installations with high current or radio frequencies – has also been
known to cause current flow in metallic structure
4.5 Static Electricity
Static electricity cn generate very high voltages nd subsequently ,significant
sparks.Voltage as high as 5000 V have been measured at nozzle of a spray can
,and as high as 10.000 V at the nozzle of a pressure washer
Many processes can generate static electricity such as the flow of material through
piping-especially no-metallic piping .the use of non-metallic –equipment and
structures ,such as cable trays ,in hazardous areas requires special precautions
to avoid static charges which could give rise to ignition – capable sparks. Statis
electricity is one of the main reasons grounding is extremely crucial in
hazardous area
4.6 Radio frequencies (RF)
There are 2 range of frequencies to consider
4.6.1 10⁴ 10¹² HZ – Fequencies in this range are used by all system which generate
or receive energy from radio waves –radio transmitter ,for example.Any
conductive parts within the transmission field will act as a receiving aerial ,and
if sufficient energy is absorbed significant heat or even sparks can be generated
.in consideration of this ,power levels for radio - transmitting devices used in
hazardous areas are limited to the following
(a) Group I -6 watts
(b) Group IIA -6 watts
(c) Group IIB -3.5 watts
(d) Group IIC -2 watts
4.6.2
3 x 10¹¹ Hz to 3 X 10¹⁵ Hz –Radiation in this spectral range can ,especially when
focused become a source of ignition through absorption by explosive
atmospheres or solid surface .sunlight for example,can trigger an ignition if
objects cause convergence of the radiation (e.g. Bottles acting as lenses
,concentrating reflectors) .Any equipment protective system and component
that generates radiation (e.g.fiber optic ,lamps,electric arcs ,laser ,etc) can it
self be a source of ignition in order to protect against this frequency range ,yhe
energy of a radiated or energy flux(power) of continuoes radiation is limited to
such a low value that in cannot ignite the explosive atmosphere or the radiation
is safely enclosed ensuring that any escape of radiation that could ignite an
explosive atmosphere
4.7 Ionizing Radiation
Electrical equipment which generates ionizing radiation is admisible provided
that the energy of a radiated pulse or energy Flux (power) of continuous
radiation is limited to such a low value that it cannot the explosive atmosphere
or if the radiation is safely enclosed
 4.8 Ultasonic sound waves
In the use of ultrasonic sound waves ,solid or liquid substances absorb a large proportion of
the energy emitted by they electro acoustic transducer .as a result the substance exposed
to ultrasonic warms up so that ,in extreame cases ,ignition may be induced .Ultrasonic
waves with a frequency of more than 10 MHz are not permitted .for ultrasonic waves
with a frequency up 10 MHz the power density of the generated acoustic field shall no
exceed 1 Mw per mm²,unless it is proved that ignition is not possible
4.9 Electricl spark
Electrical spark of generally the largest potential source in hazardous areas ,and area and
create a significant risk pf explosion .electrical equipment suitable for use in hazardous
areas must therefore be designed ,installed ,operated and maintened correctly in order
to eliminate or reduce this risk as far as practical
Voltage and current levels determine how incendive a spark will be .as discussed previously
,every explosive or flammable mixture has a minimum level of energy neede to ignite it
,called the MIE . For some mixtures ,this is quite small-for example ,a flammable
mixture consisting of hydrogen and air requires only 20 µJ of energy can be produced as
a result o a brek of 0.1 milisecond duration in a circuit carrying 20 mA at 10 V
Flammable gases and vapours are more readily ignite at high voltages than low voltages and
basically why I.S. Circuit are seldom designed for use above 30 V
The use of electrical test instruments,typically voltmeter and insulation resistance tester etc
.,are a potential source of electrical spark .these instruments should only be used under
controlled circumstances,i.e. Under the control a work permit and test to ensure gas free
conditions
4.10 Phyrophoric reaction

Hydrogen sulphide (H2S) ,or other sulphide compounds passing through

iron pipe ,reacts with iron of the pipe to produce iron sulphide .iron
sulphide when exposed to air very quickly oxidies and will reach
tempertures capable of ignitinga flammable gas or vapour this can be
prevented by soaking the iron sulphide with water or prevent its
contact with air
Test your knowledge –Unit 4 Sources of ignition

1. Power levels for radio transmitting devices used in a IIC Hazardous areas must be
limited to :
A. 6 watts B. 3 watts C. 2 watts D. 0.5 watts
2. What is minimum level of energy (MIE) needed to ignite a flammable mixture of
hydrogen and air :
A. 19 µJ B. 20 mA C. 10 V D. 24 v
3. Which of the following statement is false :
A. Hot surfaces are likely ignition source
B. Adiabatic compression nd sock waves are a likely ignition source
C. Lightning is a likely ignition source
D. Electrical shorts are likely ignition source
4. What is phyrophoric reaction :
A. When sulphide compounds reach with iron pipe to cause ignition capable
temperature
B. When MICC cable are cables are used in aluminium junction box
C. When equipment is cooled with sulphide solution
D. A source of energy limitation for hazardous areas cabling
UNIT 5
FLAME PROOF
Exd & Eex d
Objectives:
On completion of this unit ,you should know
1) Principle of operation
2) General constructional requirements including type of
joint
3) Installation requirements with regard to thread
engagement of cable entries and stopping
devices,obstruction of flame paths and additional
weatherproofing methods according to IEC /EN 60079-14
5.1 Discussion

Flameproof was the first type of hazardous are protection developed .the concept
cme from the mining industry ,which noticed that heavily constructed motors
that experienced internal explosions due to explosive gases would not ignite
the surrounding explosive atmosphere
Flame proof enclosure when installed properly ,enable the use of component
which arc ,spark ,or get hot –switches ,contactors,relay etc .it is the only type of
explosion protection in which an explosion is permitted .any such explosion
however ,must be contined by the enclosure and not ignite a surrounding
external explosive atmosphere
Stndard
IEC 60079-1
EN 60079-1
5.1.1 Definition

Type of protection d –flameproof enclosure is an enclosure in which the parts which

can ignite n explosive gas atmosphere are placed nd 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 mixture
surrounding the enclosure
Zone of use 1 & 2 EPL Gb & Gc
5.2 Principle of operation
Flameproof enclosures are not gas tight and a gas or vapour may enter the enclosure
through cover gaps or cable entries .ignition of the gas may then occur ,since these
enclosures usually contain ignition-capable components.resulting explosions can
generate pressures up to about 15 psi –therefore the enclosure must be built well
enough to contain the over –pressurization .enclosure certified as flameproof must
be capable of withstanding 1.5 times the maximum potential over –
pressurization caused by an explosion
However ,gases from the explosion will escape the enclosure through any opening exist
in the enclosure –cover gaps ,cable entries,etc.All such gaps ,however ,must be long
and narrow enough to allow these escaping gases to cool before reaching the
outside of the enclosure ,so that they do not cause ignition of the surrounding
atmosphere
5.3 Construction
5.3.1 Material
Typical mterials used for the construction of flameproof apparatus include cast iron ,aluminium
alloys ,nd 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
10cm³
5.4.2 unused Entries
Any unused cble or conduit entries must be closed utilizing plugs which are certified for use in
hazardous areas .hole plugs for flameproof enclosures must be metal –Plastic stoppers are
unacceptable –and must be engaged by 5 full threads .in addition ,the standard requires that they
be capable of being removable only by “special toll”-some example are below
5.4.3 Pressure Piling
If flammable mixture is compressed prior to being ignited,the resulting explosion will be
considerably higher than if the same mixture was ignited at normal atmospheric
pressure-by as much as triple
Pressure pilling can be caused by sub-division or blockage of the interior of flameproof
enclosure ,which prevent the natural development of an explosion
An explosion occuring on one side of an obstacle or blockage compresses the flammable
mixture at the other side ,which then ignites .the resulting explosion .being much greater
than normal ,may be more than the enclosure can witstand
Flameproof construction standards require that there is adequate free space –typically 20-
25% of the total cross - section –around any potential obstruction.in addition ,all
component mest be installed at least 12 mm from the inetrior wall .following this
requirement sholud ensure that pressure piling doesn’t happen
Another installation practice which can cause pressure piling involves joining 2 flameproof
enclosures by conduit ,with no seals between the enclosures .such an arrangement can by highly
dangerous since an explosion in one of the enclosures will pressurize the interior of the 2 ⁿᵈ
enclosure – with a resulting explosion which can rupture the enclosure ,causing not only debris and
shrapnel ,but will also ignite the surrounding atmosphere

5.4.4 Obstruction of flame paths

A solid obstruction in close proximity to the opening of a flame path cn reduce
the efficiency enough to cause the ignition of the surrounding atmosphere
.placing the enclosure too close to walls,steelwork ,conduit,bracket ,etc.needs
to avoided,and the following guidelline are given by the stndards
Flange joint

Gas Group Minimum

Distance
IIA 10 mm
IIB 20mm
IIC 40 mm
5.4.4 Weatherproofing
Preventing the ingress of water and / or dust into flameproof equipment ,especially
enclosures with flanged flame paths ,is crucial ,but sometimes difficult .All
equipment –hazardous area equipment in particular –must have a level of ingress
protection suitable for environment condition in which it is installed .most
hazardous area equipment required minimum ingress protection level (IP) 54
Where enclosures are not provided with gaskets,o-ring ,or other seling devices,it is not
permissible to add any .Enclosures with are certified by the manufacturer with
seling devices may have those devices replaced if they are damaged,But the
replacement must be identical or meet the manufacturer’s specification
In extreame enviromental conditions,additionl mesures for ingress protection may
need to be considered
The standard allow-even recomended –the use of an non-hardening grease or lubricant
on flame paths,both as means to help with ingress protection and to eliminate or at
least reduce corrosion of the flame path
In addtion ,the use of non-hardening tape (Such as DENSO Tape ) is permissible ,with
the following restriction:
a)It may be applied around the flame path of equipment in group IIA area utilizing one
wrap with a slight overlp
B) It may be applied to devices in group IIB areas,providing the flame paths gap does
not exceed 0,1 mm ,and may consist of one wrap a slight overlap
c) It may not be utilized in group IIC areas
Note:that the deciding factor is the gas group of the zone ,not the equipment
5.5 Modification of flameproof enclosures

Flameproof enclosures are normally supplied complete with all internal

components and certified as an assembly by either a Notified body or by the
manufcturer.the certification takes many things into account ,including
a) Free internl volume after all the component have been fitted
b) Temperature rise (determined by the maximum power dissipation )
c) Creepage and clearance distance
d) The rise in pressure as a result of an internal explosion using a gas /air mixture
in its most explosive proportions
Any aunauthorize modificatios –including adding penetrations –will
invalidate the certification
Flameproof enclosure supplied empty will be certified as a “component”
(certificat suffix of “U”) and will have to be tested and certified as an assembly
after being modified
5.6 Maintenance Requirements

Flanges should not be broken without justification .flange gaps should be

checked for conformity with manufacturer’s specifications or as per the chart
listed in IEC 60079-1 Where corrosion is suspected or if the enclosure is opened
,the flange surfaces should be inspected for corrosion .damage from erosion
,paint or water ingress
A layer of non –hardening grease should be applied to the surface of the flange
A wrap of non-hardening grease –bearing tape (Denso tape)may be applied to the
exterior of the flame ppath,except in areas which are zone for IIC gas
Hole plugs,cover ,bolts,etc.must be original equipment as supplied by the
manufacturer or meet equivalent specifications.
Broken damage glass on flameproof unit should be replaced immediatelly .with
an original replacement provided by manufacturer or an equivalent
specifications
Test your knowledge –Unit 5 Flameproof
1) Which briefly describes’pressure piling?
A) Where heavy equipment is mounted on top of pressurized piles
B) Where ignition in one part of an enclosure causes higher explosion
pressure in another
C) When there is a build-up of stress due to materil fatique
D) Where gs pressure causes a vent to open
2) What is the objective of maximum joint gaps and face widhts
A) To prevent an internal explosion being transmitted to an external
explosive atmosphere
B) To maintain a pressure inside and outside a light fitting
C) To provide space for gasket
D) To strengthen equipment mounting poin
3). On EX d ‘Flame proof equipment with bolts , wht the minimum requiremnet
to maintenace integrity
A) All bolts spanner tight
B) All bolts are to be tightened using a torque wrench
C) All bolts are in place ,with alternate ones tight
D) All bolts are hand tight
4) What the minimum distance allowed between flanged joints or openings in Ex
d IIC apparatus and solid obstruction
A) Not less than 10 mm
B) Not less than 20 mm
C) Not less than 30 mm
D) Not less than 40 mm
5) Cble glands used with direct entry Ex d equipment ,have a minimum
requirement regarding engagement,this must be
A) Three fully engaged threads
B) Five fully engaged threds
C) Eight fully engaged threds
D) Ten fully engaged threds
Unit 6
increased safety Ex e & Eex e
On completion of this unit ,you should know :
1) Principle of operation
2) Principle design features
3) Methods for estimating terminal content of enclosure
4) Installation requirements according to IEC/EN 60079-14
6.1 The Increased safety ,Ex e explosion protection concept originated in germany ,and
has been widely used because because it offers several advantages such as being
cheaper ,lighter and ease of mintenance .however ,unlike Ex d flameproof prtection
increased safety EX e enclosures cannot withstand an internal explosion

Standards
IEC 60079-7
EN 60079-7
6.2 Definition
Type of protection applied to electrical apparatus in which additional measures are applied so as to
give increased security against the possibility of excessive temperatures and of the occurence of
arcs and sparks in normal service or under specified abnormal conditions
Zone of use 1 & 2 EPL Gb & Gc

6.3 Principle of operation

The saf operation of increased safety apparatus is dependent on the prevention of
any source of ignition –excessive surface temperatures ,arcs or sparks –which
might otherwise be produced by internal or external parts of the apparatus
.Special design features are ,therefore ,incorporated in the apparatus by the
manufacturer and as follows
1) Mechnicl strong enclosure resistant to impact-tested to 4 or 7 joules impact
energy depending on application
2) Ingress protection against solid object and water –at least IP 54
3) Terminal manufactured from high quality insulation material
4) Specifiedcreepage and clearances incorporated in design of terminals
5) Terminal locking devices to ensure conductors remain secure in service
6) Certified de-rating of terminal
7) Terminal population of enclosure limited by circuit design
8) Close excess current circuit protection
6.4 Increased safety terminal
The terminals installed in an increased safety enclosure must be “Component certified”
terminals.they will be manufactured from good quality materials such s
melamine,polyamid and for special applications,ceramic.these materials ,which have
good thermal stability ,have been subjected to a’Comparative Tracking index (CTI) ‘test
to determine their resistance to trcking

6.4.1 The following definitions are relevant :

Clearance distance :The shortest distamce through ir between two
conductors
Creepage distance: The shorted distance between two conductors along the
surafce of an insulator
Tracking: The leakage current which passes across the
contaminated surface of an insulator between live terminals ,or live
terminals and earth
Comparative tracking index: The numerical value maximum voltage ,in
volts at which an insulation material witstands .e.g.,100 drops of
electrolyte (usually ammonium chloride solution in distilled water
)without tracking
 6.4.2 Creepage and Clearance distance

Clearance distance
Creepage distance

Clearance distance
Creepage distance

6.4.3 Terminal Ratings

The terminals are de-rated so that the allowable maximum current is nearly half
that of standard industrial applications,as illustrated in the following table
.this helps that internal and external surface yemperatures do not rise above
the enclosure T-Rating
 Terminl type Conductore size Increaed safety Industrial
mximum current maximum
(amps) current (amps)
SAK 2.5 2.5 15 27
SAK 4 4 21 36
SAK 6 6 26 47
SAK 10 10 37 65
SAK 16 16 47 87
SAK 35 35 75 145
SAK 70 10 114 220

Using the de-rated amperage ratings and the manufacturer’s maximum

dissipated power rating for the enclosure allow you obtain the maximum
number of terminals that may be installed in a particular enclosure
6.4.4 Terminal Locking device
Because it is crucial that wiring os firmly secured within EX e enclosures and cannot become loose
,possible causing arcs ,spark ,or hot spots,increased sfety terminals are constructed with a terminal
locking device ,which helps prevent the screw connection from loosening

6.5 Instlltion practices

In order to mintenance the levels of protection an increased safety enclosure has been
designed and manufactured to provide ,proper installation and maintenace in
accordance with the standards is critical.persons how are tasked with selecting
,installing or maintining these type of enclosures should always consult the
enclosure certificate ,as well as any relevant atandards . Several important
installation requirements are listed below
1) Only component specificlly approved should be fitted in the enclosure
2) All terminal screws ,including those not in use ,should be tightened
3) No more than 1 mm of bare conductore should be visible at each terminal
4) If trerminal jumper are used ,partitions must be intalled on either side of the
linked section
5) Some terminals( e.g slot type ) may permit the entry of more than one conductor
where more than one conductor is connected to the some terminal ,care shall be
taken to ensure that each conductor is adequatelly clamped.Unless permitted by the
manufcturer’s documentation ,two conductor of different cross sectional area shall
not be connected into one terminal unless they are first secured with a single
compression type ferrule or other methode specified by the manufacturer
6) Only the conductors from each cble entry shall be loomedor “banded” together
.Bunching of more than 6 conductors may also give rise to high temaperatures tht
may exceed T6 and /or damage to the insulation nd should be avoid
7) Cable glands installed in enclosures having internal ground continuity plates
must have locknuts installed in order to bond the gland to the ground plate
8) When using clearance holes for cable gland entries ,Serrated metl washer
must be used between locknuts and the gland plate
9) If intrisically safe circuits are occupying the same enclosure as other
circuits,there must be a minimum of 50 mm separation between than
10) The length of the conductors inside the enclosure should not exceed the
diagonal length of the enclosure as this is the basis of calculations and type
tests .additional length of the conductors inside the enclosure running at
maximum permitted current may give rise to increased internal temperature
that may exceed the temperature class
11) All unused cable entry should be closed using suitable plug
12) The schedulle of the appropriate certicate should be consulted before cable
entry holes are drilled
13) Cable glands or conduit entries must maintain the minimum ingress
protection of IP 54
14) ALL lid and gland plate bolts must be fully tightened after installation
6.6 Increased safety motor
Motor made to comply with requrements of increased safety are not designed to
withstand an internal explosion ,and are constructed with special design features to
prevent arcs,sparks and excessive surface temperatures occuring both internally and
externally .some relevant details are as follow:
1) Motors are normally de-rated and operate at a temperatur lower than normal
industrial motors having same type of insulation
2) Overload protection must be of a specified in the approval certificate .use of the
wrong type will invalidate the approve certificate
3) Maximum temperature of the windings ,including the rotor ,must not exceed the
temperature class assigned to the machine .in any case maximum permissible rotor
temperature is 300 °C ,Regardless of the temperature class
4) The motor will have a “tᴇ time” associated with it (and marked on the namplate)
,nd overload protection must de-energize the motor within this specified time , tᴇ
time is define is follow:the time it taken for the motor winding temperature to
rise designed maximum running temperture to the maximum temperature
allowable for the class of insulation used in its construction
Ex e motors are normally required to have tᴇ time of least 5 second
The ratio of stalled current to normal current (IA / IN) cannot be more than 10 ,and
will be marked on the nameplate
Temp erature Ɵ limiting temp Limiting temp
C
T temp rise during
e
m temmperature in rated service 2 locked rotortest
p
B maximum temp t
° 1
C Maximum ambient rated current
Temp rise at rated A maximum ambient
current 0
Hours Sec
temp
tᴇ time from max temp (B) at
Rotor locked rated current to limiting temp
(C)
Temperture limiting either by a selected T-rating or by the class of winding insulating
material
Test your knowledge –Unit 6 Increased safety
1) Where can increased safety (Ex e) equipment be used?
A. In EPL locations’Ga’,Gb’,or’Gc’ B. In EPL locations ’Gb’,or’Gc’
C. In EPL locations ’Ga’ only D. In EPL locations ’Gb’ only
2. What a minimum IP rating for Exe equipment:
A. IP 20 B. IP 44 C. IP 54 IP. 65
3. How many cores of different cross section can be connected to one terminal of an Exe terminal
Box?
A. One B. Two,provided that they both soldered together
C. One ,unless permitted by the certification document
D. Depends on size of terminal
4. When combining Exi &Exe circuit in one enclosure you must :
A. Use different colours of cable sheathing
B. Maintain a minimum pf 50mm separation between each circuit
C. Not fit these is same enclosure
D. Ensure all are of equal length
5. What is the tᴇ time of an Exe motor
A . The maximum run up time B . The time tht overload protection must wit before restarting is
allowed
C. The time to disconnection for a stalled motor re –started from hot
D. The minimum run-up time
UNIT 7
Type of protection “n” Reduced risk

Objective:
On completion of this unit ,you should know:
1) Principle of operation
2) Principle design feature
3) Protection methods applied to arcing /sparking component to enable
their use in enclosures.etc
4) Installation requirenments according to IEC /EN 60079-14
Given that the possibility of having an explosive atmosphere in zone 2 areas is
considered “unlikely”or rare ,electrical equipment for use in these reas kas less
stringent construction and protection requirement used in zone 1.
Type “n” equipment –”Reduced Risk”or “NON –Incendive”,is similiar to increased
safety type “e”appartus except that there is a relexation in the constructional
requirements
Standard
IEC 60079-15
EN 60079-15
Definition
Type of protection applied to electrical apparatus such that ,in normal operation
and in certain specified abnormal conditions,itis not capable of igniting a
surrounding explosive gas atmosphere
Note 1 additionally ,the requirements of this standard are intended to ensure that
a fault capable of causing ignition is not likely to occur
Note 2 An example of a specified abnormal condition is a luminaire with filed
lamp
Zone of use 2 only EPL Gc ONLY
7.1 Principle of operation
Inzone 2 hazardous location the presence of a flammable gas or vapour is not likely to be present
,or if it is present its duration will be for a short time only. This fact allows the use of less expensive
methodsof protection ,since the chances of having both an explosive atmosphere AND a fault
capable of causing ignition at the same time are minimal

Type “n” equipment incorportes design feature that ensure source of ignition –in
the form of excessive surface temperatures ,arcs or sparks –are prevented from
occuring either internally or externally during normal operation .Because the
design requirement are not as strict as those for increased safety equipment ,it
is possible for the manufacturer to install within type “n” apparatus
components which produce hoy surfaces ,arcs or sparks ,providing these
component incorporate additional methods of protection ,which are discussed
later
The main design features for type “n”apparatus areas follows:
1) Enclosure and motor fan guards ,where exposed to high risk of mechanical
damage,must witstand impact of 3.5J
2) Minimum ingress protection IP54 Where an enclosure hs exposed live parts
internally
3) Must use certified terminals,manufatured from quality insulation mterial (such
as Ex e terminal) ,which have specified creepage and clearance distances and
terminal locking devices incorporated into their construction
7.2 Additional protection measure
As stated above component with produce arcs,sparks,or have hot surfaces may be installed in type
“n” apparatus as long as additional protection measures are provided as described below

7.3 Energy limited apparatus and circuit (nL)

Energy limited equipment and circuits operate much the same as instrically –safe
equipment or system ,by ensuring voltages and currents are maintained at
levels whichs are incapable of causing ignition of a specified explosive mixture
.the standard defines it as
“A concept applicable to circuit in which no spark or any thermal effect produced
in the test conditions prescribed in IEC 60079-15 is capable of causing ignition
of a given flammable gas or vapour
Energy limited devices were so closed related to intrinsic safety that in 2007 a new
IS protection was developed called”ic” which is suitable for use in zone 2 only
,and the latest edition of 60079-15 (edition 4,january 2010)has withdrawn the
nL Protection designation
7.4 Enclosed break device (nC)
Enclosed break devices incorporate electrical contact within a small enclosure which is able to
withstand an internal explosion of a flammable atmosphere without transmitting that explosion to
the surrounding atmosphere (similiar to flameproof devices .they are limited to a rating of 660 volts
.15 amps and may not have a free internal volume volume large than 20 cm²
7.5 Hermatically Sealed devices(nC)
A hermatically sealed enclosure is one sealed from surrounding
atmosphere,therefore
Any explosive mixture cannot enter the enclosure .by ensuring there cannot be an
explosive atmosphere within the enclosure ,electrical contacts which create
arcs,or sprks can incorporated within the device .these devices are typically
small components

Glass envelope
Switching contact
7.6 Encapsuled Device (nC)
Similiar to hermatically sealed device ,an encapsulated device contains electrical
components which can arcs or sparks ,or create heat –but because the device is sealed
and cannot be opened in normal service ,an explosive atmosphere cannot reach the
components .it may be sealed by a poured encapsulating compound or by gaskets
encapsulted devices may not have an internal free volume of more than 100 cm²

7.7 Restricted Breathing (nR)

An enclosure designed to restrict the entry or exit of gases ,this protection

technique is used most often for luminaires .as the interior of the light fixture
heats up ,the internal air expands ,and must be vented ,As fixture cools,the
internal air contracts and external air is drawn in .Using special breathing
devices which restrict the intake and exhaust air and ensuring that all other
openings into the fixture are well sealed,the introduction of any explosive gases
into the fixture can controlled and limited
Ex nR Fixtures require the use of Ex nR certified cble glands ,as well as the use IP
Washers on all cable entries
7.8 Other types of protection under “n”
Devices with no components ,which are arc or spark,are designated Ex nA Simple Pressurization
devices were previously designated Ex nZ but this has been replaced by pressurization protection
type “Ex pZ”
Restriction on Ex e and Ex n luminaires
Luminaires with fluorencent lamps and electronic ballast shall not be use where
temperature class T5 or T6 required or where the ambient temperature exceeds
60 °C
Lamps using non –conducting end –caps or pins with conductive coating
prohibited unless they have been tested with the equipment
Test your knowledge – Unit 7 Reduce Risk
1) Where can Reduced risk (Ex n) equipment be used ?
A) In EPL Locations ‘Ga,’Gb,’ or ‘Gc’ C) In EPL Locations ‘Ga, only
B) In EPL Locations ‘Ga, or ‘Gc’ D) In EPL Locations ‘Gc’ only
2) Ex’n’ equipment is subdivided 4 types ,what are they:
A) ‘nA,’nB,’nC,’& ‘nD, C. ‘nA,’nC,’nL,’& ‘nR
B) ‘nA,’nC,’nL,’& ‘Nr’ D. ‘px,’py,& ‘pz’
3) How can Ex nL equipment be installed
A) It may be used in intrinsically safe ic circuit
B) It cannot be used in an intrinsically safe ic circuit
C) It must be replaced with Ex ic circuit
D) It can be used in any intrinsically safe circuits
4) Equipment protection by type of protection “n”is coverred
A) IEC 60079-11 B) IEC 60079-12 C) IEC 60079-15 D) IEC 60079-19
5) What is minimum IP rating for Ex n equipment where an enclosure has
exposed live parts internally
A) IP 20 B) IP 44 C) IP 54 D) IP 56
UNIT 8
PRESSURISATION
Ex p & Eex p
Objective
On completion of this unit ,you should know:
1) Principle of operation
2) Type of pressuration
3) Different between purging and pressurisation
4) Required action on loss of overpressure
5) Installation requirements according to IEC / EN 60079-14
8.1 Introduction
Pressurisation involves maintaining a slightly higher pressure inside the protected
enclosure than the surrounding atmosphere. Since gases will not flow a lower
pressure to higher pressure ,an explosive atmosphere around the enclosure is
prevented from entering the enclosure
Pressurization is often utilised in place of flameproof equipment ,especially in the
case of large enclosures or rotating equipment ,because it allows the use of
much lighter and more easily maintined equipment .Control panel are often
pressurised because they can the be place closer to equipment located in a
hazardous area
In some case ,enclosure or equipment may contain a flammable gas source of
release (SoR) internally –in this case pressurisation in the form of”Continuos
dilution “or flow can ensure that level of gas inside the enclosure remains
below LEL. Hazardous area
Safe area Safe area

Safe area

Zones of use:1 &2 EPL Gb & Gc

Standards
EN 60079-2
IEC 60079-2
8.2 Techniques of pressurising
Static pressurization
*Apparatus is purge and pressurised outside the hazardous area
*Allowed into the hazardous area without a continuous supply of a protective gas
*Applications:Cameras,Analysing equipment
Pressurisation with continuous dilution (flow)
Continuous dilution (flow) is defined as a continuous supply of a protective
gas,after purging ,at such a rate that the concentration of a flammable
substance inside the pressurised enclosure in maintained at a value outside the
flammable limits at any potential ignition source (That is ,outside the dilution
are)
*Requires the enclosure to maintain an internl overpressure with sufficient
continuous flow of protective gs tto maintain the internal atmosphere below
the LEL ,in a worst case leak scenario
*Source of ignition exist –thermal and electrical
*Require protective device(s) to
*Isolate the power on low flow –again dependant on zone ,etc
*Ensure no build –up of excess pressure in the enclosure
Safe area Hzardous area Safe area

Gas
analyze
Leakage compensation
*Enclosure is maintained at pressure slightly bove the outside ambient pressure
*Therefore any leakage will be of the protective gas outwards rather than the flammable
atmosphere inwards
*Where an enclosure cannot be totally sealed , continuous supply of protective gas is applied in
sufficient quantity to compensate for any leakages
*Minimum overpressure to be 50 PASCAL’s (0.5 millibar )

Safe area Hazardous area Safe area

8.3 Pressurisation is sub-divided into three protection types
*Ex px-converts the interior of the enclosure from zone 1 (EPL Gb) to non –hazardous area .Can be
installed in zone 1 areas,nd can have general purpose equipment installed inside
*Ex py- px-converts the interior of the enclosure from zone 1 (EPL Gb) to zone 2 (EPL Gc)
can be installed in zone 1 areas .equipment inside must be rated for zone 2
*Ex pz - px-converts the interior of the enclosure from zone 2 to non-hazardous .can
be installed in zone 2 areas ONLY .Equipment inside can be general purpose
Doors & covers
Type px:Doors and covers which do not require the use of a tool or key to open MUST be
interlocked so that the electrical supply to the enclosure is disconnected automatically when the
door is opened and cannot be re –energize until the door is closed

8.4 Purging
While purging and pressurisation re somewhat related and are often used
interchangeably they are slightly different techniques
Pressurisation refers to maintaining a slightly higher pressure in an enclosure
than the outside atmosphere
Purging refers to the prctice of providing a certain amount of volume air changes
of an enclosure prior to eniergising .This done to clear ,or “purge” any explosive
gases fro the enclosure which might have entered while the presurisation
system may have been offline or prior to start up of an enclosure which may
have been opened.in most cases ,purging is required to be an automatic cycle
or process which must occur before the equipment inside the enclosure can be
energised .Manufacturers of enclosures which must be purged provide the data
relevant to the necessary volume of air which must be cleared through the
enclosure prior to enrgizing –however ,care must be taken by installers to
increase the purging cycle to include the supply and exhaust ducting attached
to the enclosure
8.5 Source of pressurisation
Air drawn from non-hazardous area is the easiest and most preferable wy
provide a pressurising medium to enclosure or machine .some facilities
provide a separate pressurisation system ,limited to providing the air just for
pressurised enclosures or machines ,while others may choose to provide each
enclosure with is own system .Any supplied air should be free of oil or
contaminants ,and nay need to have any moisture removed prior to entering
the enclosure .
The supplied air should never drawn from a Zone 0 or Zone 1 area ,in some cases,
air drawn from zone 2 may be utilized ,provided that gas alarms are intalled
which will alarm and /or shut off the air supply if the detectors sense an
explosive gas ,and mest be set well below the gas LFL.
Air from pressurised cylinders may be utilized in some cases ,but this requires
particular care because a failure of the cylinder pressure regulator may cause
severe over –pressursation of the enclosure ,including pressures capable of
rupturing the enclosure .In this case,a relief valve set well below the maximum
pressure the enclosure is rated for must be provided.
Care must also be tken if using inert gas –such as nitrogen –as the pressurisation
medium,since anyone opening the enclosure could become asphyxiated from
the gas. In this case ,a warning on the front of the enclosure is required
8.6 General requirement
While specific requirements may apply to each type pressurisation installation ,the
following criteria are typicall
1) Pressure must be maintained a minimum of 50 pa or .5 mb (.00725 psi) above
atmospheric pressure Px and Py enclosures and a minimum of 25 pa or ,25 mb
(.00362 psi) for Pz enclosure
2) Pressurized parts must be able to withstand a test pressure at least 200 pa or mb
(.029 psi)
3) A pressure relief valve is required to guard against over pressurisation
4) Flow rate must be proven by a flow switch
5) A minimum number of air changes must be provided for both the enclosure and the
duct work prior to energising
6) If hot device or energy-storing component (such as capaitors) are installed inside
the enclosure ,either a warning or timed interlock must be provided to ensure
sufficient time is provided for devices to cool or discharge prior to the door being
opened
7) A low pressure alarm must be provided ,and a trip function installed if necessary
8) Live circuit must be de-energised prior opening the door
9) Exhaust ducts should be located in a non –hazardous area ;where this is not
possible a spark and particle arrestors may be required (refer to chrt below)
 Equipment
EPL/category May produce ignition- Does not produce
requirements for location capable sparks in normal ignition –capable sparks
of the exhaust duct outlet operation in normal operation
Gb/2 Required* Required*
Gc/3 Required Not required

* If the temperature of the enclosed equipment constitutes a hazard upon failure of pressurisation ,a
Suitable device should be installed to prevent the rapid entry of the surrounding atmosphere into the
Pressurised enclosure
8.7 Loss of pressurisation
Since the application of pressure is the mens of protection to prevent an explosion
Inside a pressurized enclosure ,and since the means of protection allows the use of
Non-certified or general purpose equipment ,care must be taken to prevent the
equipment
From becoming an ignition source if a loss of pressurization occurs

The following chart illustrates the action required for loss of pressurisation in enclosure
With no internal souurce of release

EPL /category Enclosure contiains Enclosure contains

requirenment equipment not meeting EPL equipment meeting
Gc Requirements (without EPL Gc requirements
pressuristion ) (without
pressuristion )
Gb / 2 Alarm nd switch off* Alarm **
Gc / 3 Alarm * No action
•If automtic switch off would introduce a more dangerous condition ,other precautionry
Measures should be taken –for example ,dupliction of the air supply
**If the alarm operates ,immediate action should be taken –for example ,to restore the
Supply air
For the rquirement concerning loss of pressurisation in n enclosure which DOES have an
Internal source of release ,refer to IEC-60079-2
Pressurised Rooms and Analyzer House
Requirement for electrical installation in pressurised rooms and /or gas analyser house
can be Found in the following stndards:
IEC 60079-13:Construction & use of rooms or buildings protected by pressristion
IEC 61285 ed.2.0:Industrial process control-sfety of analyser houses
EN 50381:2004:Transportable ventilated rooms or without an internal source of release
 Test your knowledge-unit 8 pressurisation
1. Which one of the following statement is correct for type p protection?
A. Equipment is pressurised to contain explosive gas
B. The system must be maintained above 0.5 Bar
C. Equipment has to be pressurised for at least 1 hour before safe
D. Pressurisation air should be drawn from defined no –hazardous area
2. What level of protection is permitted for zone 1 when the enclosure has no ignition capable
equipment?
A. Ex Px B. Ex Py C. Ex px or pz D. No protection needed
3. If a pressurised room ,not containing any gas release ,in n EPL “Gc”fails ,what should be done
if the equipment does not meet EPL “Gc” requirements with pressurisation :
A. No action B . Alarm operates,isolate all flameproof equipment
C. Alarm operates ,tke immediate action to restore the system
D. Alarm operates,all equipment is automatically switch off
4. Which one of the following statements is correct for type p protectection provided additional
measures are taken
A. Supply air may be drawn froma zone 0 area B . Supply air may be drawn froma zone 1 area
C. Supply air may be drawn froma zone 2 area D. None of the above
5. Equipment protection by type of protection “p”is covered by:
A. IEC 60079-11 B. IEC 60079-13 C.IEC 60079-15 D. IEC 60079-2
 UNIT 9
OTHER METHODS PF PROTECTION
Ex o
Ex q
Ex m
Hybrid

Objectives:
On completion of this unit ,you should know
1) Principle of operation of various other types of hazardous are equipmaent
2) Construction requirements for each type of protection
3) Typical aplications for each type of protection
4) Installation requrements for each type of protection
5) Advntages and types of hybrid prtection
Encapsulation Ex m or EEx m
Encapsultion is a method whereby component which are ignition –capable –arcing
,sparking
,or heat-producing –are enclosed in a compound,typecally epoxy ,so that the hazardous
Atmosphere cannot reach them and therefore cannot be ignited
It is primarily utilized for smaller component –such as a circuit boards –and is not
suitable for
Component which move.
Standards
IEC 60079-18
EN 60079-18
Zone of use :m: 1& 2 (EPL Gb & Gc)
ma: 0 (EPL Ga,Gb & Gc)
mb: 1 (EPL Gb & Gc)
mc: 2 (EPL Gc)

Levels of protection
Prior to 2007 there was only one level of encapsulation –Ex m.In 2007 ,three “sub-levels”
Of encapsulation were introduced –ma,mb and mc-much like the sub -levels of
instrisically
Safe protection
1.Equipment market Ex m-with no sub-level of protection-may be utilized in areas
requiring
9,2 Construction
Encpsulating compounds may be any thermosetting,thermoplastic,epoxy resin, or elastomeric
Material ,with or without fillers.in its soilid state
The encapsulant must be free of voids.allowable free space and the required thickness of
Compound around them area as per the following table

9.3 Required compound thickness

The minimum depth of encapsulant depends on several factors ,as illustrated by the drawing
t Free surface of the compund t

f a Key
a.Distance to free surface
Non
Noncurrent carryingpart
current carrying part b. Distance to metallic enclosure
c. Distance to plastic enclosure with wall
c e
thickness t ≥ 1mm
d.Distance to plastic enclosure with wall
thickness t < 1mm
e.Distance to non current carrying prt withi
d The compound
f.Distance from no current carrying part to
Free surafce

Solid insultion
b according 7.2.4.2 Plastic wall with
Plastic wall with
Thickness t≥ 1mm Thickness t˃ 1mm

Metallic wall
9.4 Oil-Immersion Ex o or EEx o
Type of protection in which the electrical equipment or component are immersed in a
Protective liquid in such a way that an explosive atmosphere cannot reach the equipment
And therefore cannot be ignited
It is typically utilized for heavier equipment ,such as transformer,but is not widely utilized due
To the size ,weight ,and potential for spillage
Standards
IEC 60079-6
Zones of use : 1 & 2
EPL Gb and Gc
Construction requirements
1) Enclosure must have a minimum IP 66 rating
2) Enclosure which are sealed must have a pressure –relief device ,set a minimum 1.1 times
the pressure at maximum possible liquid level
3) Enclosure which are not sealed must be equipped with a breathing device with a minimum
IP 23 rating.The breathing device should be equipped with a suitable drying agent
4) All fasteners ,including drains ,plugs,and level –indicating device must be fitted with a
means to prevent accidental loosening ,such as lock washers ,thread sealant ,or locking wire
5) The enclosure must have a level –indicating device so that liquid levels can be verified
during norml operaration .the indicating device must constructed so that any leakage or
Breakage will not cause draining of the liquid below the minimum coverage for the
Components Inside the enclosure (see below)
6) All parts capable of producing arcs and sparks must immersed in the oil at depth not less
Than 25 mm
7) Non- sealed enclosures must be equipped with a liquid expansion facility and device which
will de-enegize the electrical supply if a fault occurs within the enclosure which would cause
gas to be formed . The device which would interrupt the power supply must be capable of
being reset only by manual operation
8) External connection must be an integral part of the enclosure.

9.5 powder Filled Ex q EEx q

Type of protection in which ignition –capable component are completely surrounded by a
Filling mterial to prevent the ignition of an external explosive atmosphere
This type of protection is limited to small component ,the filling material may not prevent the
Hazardous atmosphere from reaching the ignition –capable component inside the enclosure
,but any resulting explosion will be minimal due to small internal free volume ,and the resulting
Flame will be quenched by the filling material before reaches the surrounding atmosphere
Standards
IEC 60079-5
EN 60079-5
Zone of use : 1& 2 EPL Gb & Gc
Filling material
Solid QUARTZ or Solid glass particles.the material must pass both dryness and dielectric testing
before it can be utilized
Construction requirement
Enclosures must pass specified pressure test to ensure they will witstand the over pressurezation
From any internal explosion
Enclosures must have a minimum IP 54 rating ,unless they are intended for use only in clean ,dry
Rooms-in which case they may have a reduced IP rating of 43 ,but must be so noted with an “X”
On the certificate .Enclosures with an IP rating of 55 or higher must be equipped with a breather
Device ,which must maintain an IP rating of at least 54.
Filling must not leave any voids within the enclosure
Minimum distances through the filling material beween electrically conducting parts and
the enclosure
If electrical equipment contains components which have an enclosed free space not filled
With the filling material (e.g.a relay) ,the following requirements apply:
*if the enclosed free space of the component is less than 3 cm³,the minimum distance
Through filling material between the component wall and the inner surface of the enclosure
Shall comply with table 1;
*if the enclosed free space of the component is between 3 cm³and 30 cm³,the minimum
distance Through filling material between the component wall and the inner surface of the
Enclosure Shall comply with table 1 but with a minimum of 15 mm
*The component shall be fixed ,so that movement nearer tp the wall of the enclosure is not
Possible
•Free volume of more than 30 cm³ are not permitted
External wiring connection
Terminations or cables used for the entry of electrical conductors into a powder –filled
Enclosure shall be n integral part of the enclosure and shall be protected and sealed as
Specified in IEC 60079-5 ,4.1.1 When a cable provides the entry of conductors into a powder –
filled equipment or Ex component ,the clamping means shall comply with the cable gland
Requirements of IEC 60079-0 and shall no be capable of being removed without obvious
Damage to the enclosure.
9.6 Special protection Ex s
Special protection Ex s is applicable for equipment not meeting a particular construction
Standard. Previously it has been certified under BASEEFA special protection Ex s.
The current IEC standard for Ex s is IEC 60079-33 ,Explosive atmospheres –part-33:equipment
Protection by special protection Ex “s”
9.7 Combined (hybrid) methods of protection

Electrical equipment may be manufactured with more than one methode of explosion
Protection ,taking advantage of various concepts in order in order to reduce size ,weight ,and
cost.such equipment is generally known as having Hybrid protection .
Any number of different concepts can combined in orde to achieve adequate protection
against ignition of an explosive atmosphere.each concept utilized must meet the requirements
Of its particular standard
A Common Example is utilizing an Ex e enclosure to house a small Ex d swirch .since the swicth
Has arcing contact which are ignition –capable components ,it must be flameproof.
The switch can be constructed of fairly light materials ,including plastic ,because the internal
Volume is extremely small (Ex d enclosure mde of plastic may not have an internal volume
Greater than 10 cm³ )due to small internal volume ,any explosion occuring within the switch
Will be minimal .by utilizing the flameproof switch and installing it within an Ex e
Enclosure ,significant advantage is gained in weight ,maintenance requirements ,nd cost
glanding requirements are also greatly simplified.
Another common example illustrated below is the light fitting being manufactured for use in
Hazardous areas .the protection concepts is Ex d e q
In this light fitting ,the circuit include powder filling Ex q capacitor ,flmeproof Ex d
Switch and increased safety e terminals
9.8 Markings
Hybrid equipment will be marked with each of the protection concepts incorporated
Within the equipment .after 2007 ,the protection concepts will be listed in alphabetical
order
 Test tour knowledge –Unit 9 Ex o ,q m & hybrid protection
1. Which of the following is suitable for use in EPL location “Gc”only
A. Ex m B. Ex ma C. Ex mb D. Ex mc

2. Where can Oil immerson (Ex o) equipment be use

A. In EPL Locations ‘Ga’ Gb’ or ‘Gc’ B. In EPL Locations ’ Gb’ or ‘Gc’
C. In EPL Locations ‘Ga’ Only D. In EPL Locations ‘Gc’ Only

3. Where cn powder filled (Ex q) equipmwnt be use

A. In EPL Locations ‘Ga’ Gb’ or ‘Gc’ B. In EPL Locations ’ Gb’ or ‘Gc’
C. In EPL Locations ‘Ga’ Only D. In EPL Locations ‘Gc’ Only

4. What is the minimum IP rating for Ex ‘o’ enclosure

A. IP 66 B. IP 44 C . IP54 D. IP56

5. Which of the following is not an advantage of a hybrid Ex de lighting fitting.

A . Weight and/or size reduction B. Cost saving C . Maintenance reduction
D. Increase lux levels
 UNIT 10
INTRINSIC SAFETY
Ex i & EEx i

Objectives:
On completion of this unit your should know
1) Principle operation
2) Categories of intrinsically safe –ia,ib, and ic
3) The difference between zener and galvanic interfaces
4) Definitions and types of apparatus for intrinsically safe system
5) Installation requirements according to IEC /EN 60079-14
10.1 Intrinsic safety

Intrinsic safety is a type of protection bsed on the restriction of electrical energy,within

Equipment and the interconnecting wiring installed in a potentially explosive atmosphere
,to a level below that which is capable of causing ignition of a given explosive atmosphere
either by sparks or heating effecs
In other words,the energy of a given circuit and equipment for an IS circuit is prevented from
Rising to the MIE of a given explosive gas
Intrinsic safety is a “System concept”yype protection –it is not single piece of equipment or
Component .Every component ,enclosure ,cable ,etc.must be evaluated and approved for use
On an IS system ,and,specific calculations.must be made to ensure that the system is incapable
Of reaching the MIE of the given explosive substance under any condition
Standards
IEC 60079-11(EN 60079-11) –Equipment protection by intrinsic safety ’i’
IEC 60079-25(EN-60079-25)-Intrinsic safety system
Zone of use
Areas requirinG EPL Ga,Gb,or Gc
Areas requiring equipment categories 1,2,3
Zones 0,1,2
Note:that the approved area of use is dependent on the level of intrinsic safety
ia-highest integrity ,suitable for all 3 areas
ib-high integrity ,suitable for Gb and Gc
ic-good integrity ,suitable for Gc areas only
 Hazardous area Safety area

Intrinsic sfety
Field device Instrument
barrier

Three types of equipment or components can be utilized for intrinsically safe systems
Intrinsically safe apparatus is electrical apparatus in which all the circuits are intinsically safe
Circuits
Associated apparatus:is electrical apparatus which contains both intrinsically safe circuits and
Non-intrinsically safe circuits ,constructed so that the non-intrinsically associated apparatus
May be either:
*Electrical apparatus which has another type of protection (as listed in IEC 60079-0) for use
In the explosiveatmosphere
*electrical apparatus which is not so protected and therefore should be installed in the
non-hazardous area
Associated apparatus not suitable for installation in the hazardous area with out another
form protection will be identified by the use of square brackets around its protection
Concept-for exampe [Ex ia]
Simple apparatus is an electrical component or combintion of component of simple
construction with well-defined electrical parameters which is compatible with the intrinsic
Safety of the intrinsic circuit in which it is used.
Simple apparatus cab be the following :
*Passive component –switch ,junction boxes,resistors and simple semi-conductor devices
*Sources of stored energy with well –defined parameters –capacitors or inductors-whose
Values are considered when determining the overall safety of the system
*Sources of generated energy-thermocouples and photocells-which do not generate more
than 1.5 V,100 mA ,and 25 mV. Any inductance or capacitance for these ust be in detrmining
The overall safety of the system
Simple apparatus may not be include in an intrinsically safe system without careful
consideration of its electrical prameters and the effect it will have on the safety of the system
For this reason ,the addition of simple apparatus requires that the circuit designer provide
Detailed information regarding the parameters of the apparatus ,including manufacturer’s
Specifiction sheets,etc
Simple apparatus meeting the requirements listed above need not be certified or marked
It is extremely vital to the safety of intrinsically safe system that only equipment or
Components specified specified in the system documentation be attached to the circuit
or system
10.3 Intrinsically safe barrier
Intrinsically safe barriers function to the limit the energy vilable in the hazardous area part of
The circuit to sve levels –below the MIE of the explosive substance –in both normal and specific
Internal faults
Threre are two types of intrinsically safe barriers
1) ZENER BARRIER-also known as a basic shunt diode barrier ,zener barriers are compose of
three separate components
A. FUSE-Serves to protectthe zener diode from overvoltage
B. Resistor-functions to limit the current available in the hazardous part of the circuit
C. Zener diode-”turn on”and conducts circuit current in the reverse direction effectivelly
Shunting it to ground ,if the circuit voltage rises above its trigger voltage .
All three of these components must be extremely high quality nd considered “Infallible” in
Order to provide the best protection for the circuit .these components are also de-rated –in
Other words they operate well below theirnormal values.
Zener diodes are considered to be the most likely component to fail ,and therefore barriers are
Constructed with 2 or more diodes operating in parallel in order to provide the infallible quaility
.Generally
*ia barriers will have minimum of 3 diodes ,therefore will withstand two internal fault
*ib barriers will have minimum of 2 diodes ,therefore will withstand one internal fault
*ic barriers will normally have a single diode ,since they are rated for zone 2 only and are
Only required to prevent an ignition source in normal operation
 hazrdous area
Safe area

Fault path
Field
decice

Zener barriers rely on the ability to shunt excess voltage /current to ground in order to work
Properly and provide the necessary protection .for this reason the ground (or earthing) of a
Zener barrier is extremely crucial to its operation
Zener barriers therefore require a dedicated is ground connection nd network .the maximum
Impedance between the IS earth nd the main power system ground must not exceed 1 Ω .
the power system or bus bar earth should not be used an IS grounding point
Grounding conductors should be insulated wiring so as to prevent the induction of stray currents
From metalic structures or other wiring ,and must be a minimum 4 mm² in cross section –
Alternally 2X1.5 mm² is acceptable
Galvanically Isolated barriers- allow the transfer of energy from one side of the device or circuit
To the either without a direct wired connection between the power side and the hazardous area
Terminals .
While there are several specific types of galvanic barriers ,they must all accomplish the same
Basic function :
*Prevent high voltage breakkhtrough to the hazardous area
*Limit the voltage to the hazardous area
*Limit the current to the hazardous area
Galavanic barriers may use transformers,relays ,or opto-couplers to provide this protection ,but
Would also ,in most cases,utilize zener diodes to limit excess voltages

Isolation

Hazardous
area
devices
Swicth or
Hazardous logic signal
area Safe
area

Supply

Galvanic isolators have one major advantage over zener barriers-they do not require the hogh-
Quality,dedicated ground circuit that zener barriers do ,for this reason they are used often in
Retrofitting facilities which do not have such a network in addition to new installations
10.4 Enclosure
The minimum ingress protection for enclosures of IS circuits is IP 20 ,but environmental conditions
May require a higher rating .for all equipment located in the hazardous area after the safety
Barrier,general purpose enclosures may be utilized

10.5 Inductance and capacitance

Because the energy level available in intrinsically safe circuit is fundamental to its protection
Against ignition of a hazardous atmosphere ,every potential parameter which can affect these
Levels is critical and must be carefully evaluted.
Inductance and capacitance both store energy .if these parameters are not closely controlled
In intrinsically safe circuits ,they can cause the energy levels to rise above the critical MIE of an
Explosive mixture and could inadvertenly cause an ignition
Therefore the designer of an intrinsically safe system must take in acoount all of the inductance
And capacitance of every component in the system –including the cabling .
Electrical cabling can have significant impact on both of these parameters ,since it has its own
Inherent inductance and cpacitance.
Capacitance ,for example ,is greatest in small diameter cables .
Inductance is greatest when there is greater separation of the conductors ,and therefore
intrinsically safe system should never be wired using single conductor wiring ,since the
inductance cannot be defined.
IEC 60079-11 provide charts which relate maximum acceptable inductance and capacitnce levels
In relation to circuit voltage
10.6 System voltage
System input voltage should not exceed 250 Vac
Hazardous area voltage will normally be between 10-50 Vac ,but voltges higher than 50 vac
may be acceptable-the limiting factor is the current avilable in the hazardous area .the
following
chart ,from IEC 60079-1 ,illustrates the maximum acceptble current for various system
voltages
For simple resistive circuit,based on the gas group of the potential explosive mixture:
10.7 Other general requirements
1) If intrinsically safe circuits occupy the same enclosure with non-intrinsically safe circuits .
There must a minimum 50 mm separation between the two
2) Any bare conducting parts of separate intrinsically safe circuits must be separated by a
minimum of 6 mm,up to 90 V.Higher voltages will require more separation –see IEC 60079-11
For more dtail.
3) Any bare coducting parts of intrinsically safe circuits must be separated from any earthed
metal (such as the enclosure) by a minimum of3 mm
4) All parts of an intrinsically safe circuit or system –including cabling ,junction boxes plugs,
Sockets,etc.-should be clearly marked as being part of an intrinsically safe system ot circuit.
Junction boxes should be labelled to indicate that intrinsically safe circuits are present inside
5) Cabling ,terminals ,etc may be light blue in colour for easy identification of intrinsically safe
Circuits,but this not required
6) Cabling for intrinsically safe system must be capable of witstanding a 500 V ac or 750 V dc
Insulation resistant test(care must be taken to disconnect any instruments on the circuit prior
To performing this test
7) Screen for intrinsically safe cables should be terminated on one end only,usually on the
barrier barrier earth bar ,they must ,hewever be carried throughout the circuit-i.e joined across
Cables in a junction box –in order to maintenance continuity.
8) Intrinsically safe cabling should be separated from other cabling-power carrying cables in
Particular –by a minimum 50 mm.this requirement can be voided ,however ,if shielded or
Armoured cabling is utilized for least one of the types of cables(provided that the shielding or
armouring is properly grounded)
9) Unused conductors should be terminated via unused terminals and insulated from ground.
However ,if using multi –cored cable with other circuits which have an earth connection ,they
Should be connected to earth at the same point used to earth those circuits-but isolated from
Earth at the other end.
10) Intrinsically safe circuits and non-intrinsically safe circuits may not be run together the same
Multi –conductor cable
11) Intrinsiclly safe circuits in multi-conductor cables should utilize adjatent conductors
12) While intrinsically safe circuits do not specifically require certified enclosures or cable
glands ,intrinsically safe circuits entering certified enclosures must utilize cable gland consistent
With enclosure protection –i.e.an intrinsically safe cable entering a flameproof enclosure must
utilize certified flameproof gland,including a barrier gland if such is required by installation

10.8 Additional maintenance and inspection requirements

1) Electricl testing of intrinsically safe circuits should be carried out using test instruments appropriate for
The installation-i.e.IS rated test instruments.
2) Extreame care must be exercised when utilizing high-voltage insulation testers s these could generate
Sufficient energy in connected cables,due to capacitance ,to provide an ignition –capable spark
3) Circuit loop testing may be performed at the end –of-line point ,or by utilizing a temporary links at the
End-of-line .ensure temporary links are removed.loop testing my require that the circuit be disconnected
From the hazardous area terminals of the interface (barrier)
4) Do not measure across the hazardous and non-hazardous terminals of an interface .instead ,voltage
Readings should be taken from each set terminals to the IS earth.
5) Insulation resistance between conductors ,between the conductors and screen ,and between screen
must be greater than 10 MΩ perkilometre (3280 ft) of cable
 Test your knowledge –Unit 10 intrinsic safety:

1. What is the minimum clearance between bare conducting parts of external conductors and
earthed metal? A. 1 mm B. 3 mm C. 6 mm D. 50 mm
2. Where can intrinsically safe Ex i equipment be used?
A. In EPL Locations “Ga’,’Gb’, or ‘Gc’ B. In EPL Locations ’Gb’, or ‘Gc’
C. In EPL Locations “Ga’ Only D. Depends on the equipment specification
3. If an item is marked [Ex ic] IIB .What does this means?
A. That is intrinsically safe and can only be used with IIB gases
B. That the equipment is associated with intrinsiclly safe circuits
C. That it is suitable for installing in a IIB area
D. That it cannot be installed in a hazardous area
4. Which one of the following is an example of simple apparatus ?
A. A 110 v light B. A 1 kW motor C. An L.E.D D. A 12V Battery
5. The function of a zener barrier is to:
A. Limit the maximum energy ,transferred from the power supply to the hazardous area
B. Allow all types pf Ex apparatus to be used
C. Allow any simple apparatus to be used
D. Limit the capcitance from the power supply to the hazardous area
 UNIT 11
WIRING SYSTEM
&
CABLE GLANDS

Objectives:
On completion of this unit ,you should know:
1) Appropriate cable types for use with explosion protected equipment nd cable construction
2) How to select cable glands based on type of enclosure ,zone of installation ,gas group,and
Cable type
3) Installation procedures for single and multiple pair cable
4) Installation requiremnets and procedures for cble glands
5) Earthing (grounding) requirements in hazardous areas
6) General Installation requirements according IEC / EN 60079-14
11.1 Wiring System
Particular care must be taken in the selection ,instllation,and maintenance of cabling
Utilized in hazardouse areas to ensure that the risk of cable failure or damage which could
Pose an ignition hazard is reduced to negligible levela.

11.2 Cable types

RFOU Flame retardandt IEC 60332
Cable that inhibits,suppress, or delays the production of flames to prevent the spread of
fire
*R-Insulation-Ethylene propylene rubber
*F-Inner covering –flame retardant and halogen free thermoset compound
*O-Armour/screen –Tinned annealed copper wire braid
*U-Outer sheath-Flame retardant halogen free and mud resistant thermoset compound
BFOU Fire Resistant IEC 60331
Cable which can witstand fire for a periode of time usually 3 hrs ( cores contain mica)
*B-Insulation –Mica tape and Ethylene propylene
*F-Inner covering –Flame retardant and halogen free thermoset compound
*O-Armour /screen –Tinned annealed copper wire brand
*U-Outer sheath –Flame retardant halogen free and mud resistant thermoset compound
In addition ,the type of cable used should be low smoke zero halogen (LSZH).the LSZH
cable
Jacketing is composed of thermoplastic or thermoset compounds the emit limited smoke
And no halogen when exposed to high heat sources. Therefore the LSZH cable reduces the
amount of toxic and corrosive gas emitted during combustion
11.2 Cable constructions
Conductor material: Cables with copper conductors are preferable .if aluminium conductors
Are utilized ,they must have a minimum cross –section of 16 mm²

Cable outer sheaths:

1)Cables used for fixed wiring in hazardous areas shall be appropriate for the ambient
conditions in service .acceptable outer sheathing may be thermoplastic ,thermosetting ,or
Elastomeric material –examples are given in the chart below:

Chlorosulphonated Chlorosulphonated polyethylene

polyethylene
Cross –linked plyethylene Cross –linked plyethylene
Ethylene propylene rubber Ethylene propylene rubber
Elastomeric Ethylene vinyl acetate Ethylene vinyl acetate
Natural rubber Natural rubber
polychloroprene polychloroprene
Silicone rubber Silicone rubber
Poplyethylene Poplyethylene
Thermoplastic
polypropylene polypropylene
Polyvinil chloride Polyvinil chloride
2) Cables for portable equipment must have tough outer sheaths to prevent damage.
These cables should be sheathed in:
a) Heavy polychloroprene
b) Other heavy elastomeric material
c) Heavy rubber
The minimum conductor cross -section for portable cables is 1 mm²
Cable inner construction : because of the potential for cables to transmit hazardous
Gases or liquids ,the inner construction of cable must be:
a) Circular ,compact,and extruded bedding and fillers ,if any ,shall be non –hygroscopic or
b) Mineral insulated metal sheathed,or
c) Special ,e.g. Flat cables with appropriate cable glands
In some case ,the precaution of sealing cable utilizing a barrier-type gland may be necessary
To guard against the transmission of explosive gases or flammable liquids ,through the cable

Armoured cable
A primary concern for cabling in hazardous areas is physical protection against damage.
Fpr this reason ,cables which have an armoured sheath are generally preferred ,but are not
Required if the cable has adequate protection from damage by other means.
A secondary reason for utilizing armoured cable is to provide protection against
electromagnetic interference ,by suitble grounding the armouring of the cable ,it is effectivelly
“shielded’both against interfering with other cables or having interference induced into it by
other cables
Armoured cables will usually have an outer sheath over armour,primarily for protection against
Corrosion of the armour,especially in mrine or wet locations
Armour made be lead sheathing steel wire ,steel tape ,aluminium or bronze brid .aluminium is
Usually avided in hazardous areas both due to possibility of galvanic action and to the fact that
It corrodes more easily
Cables used for intrinsically sfe circuits are not required to be armoured,bu should be otherwise
protected from physical damage where necessary.however ,it may be preferable to use
armoured cable in many circumstances,especially to prevent electromagnetic interference
Which IS circuits are particularly susceptible to

11.4 Conduit
While the use of conduit provides excellent protection aginst damage for cabling in hazardous
Areas ,it poses some unique risk – and therefore special precautions must be taken.
In marine environments,conduit is usually avoided both because of weight considerations and
Because of its susceptibility to corrosion
A major consideration when utilizing conduit in hazardous areas is the potential for transmitting
Explosive gase or flammable liquids through the conduit .to avoid this conduit must be installed
With seals ,at various point:
1) Conduit entering or leaving a hazardous area from a non-hazardous area must have a seal
Installed at the point it enters or exits.there can be no other device between the seal and the
Boundary ,additional points
a) the sealing device should form a seal around the outer sheath of the the cable if the cable
Is effectively filled ,or around the individual conductors of the cable if is not
b) The sealing device should not be a type that shrinks when setting
c) The sealing device must be impervious to any chemicals found in the hazardous area
2) If required to maintain the IP rating of an enclosure ,the conduit should be sealed adjancent
To the enclosure
3) Conduit installed into flameproof enclosures MUST have a sealing device either integral to the
Enclosure or installed as close as practical to the entry.In addition ,conduit utilized with
flameproof enclosures:
a) Must engage the enclosure by 5 full threads
b) May be installed using a sealing washer (IP Washer)n provided that the proper thread
engagement can still be achieved
c) May be installed using a suitable ,non-hardening grease
d) Conduit utilizing tapered threads must be installed wrench tight ,but must also engage by 5
Full threads
Further considerations for conduit installation in hazardous areas
1) If conduit is utilized as the grounding conductor ,all threaded junctions must be capable of
Carrying the fault current (where the circuit is appropriately protected by fuses or circuit brakers
2) If installed in a corrosive area ,the conduit should be corrosion –resistant or otherwise
Pretected
3) Care should be taken to avoid galvanic corrosion between dissimilar metals
4) Non-Sheathed,insulated conductors or multi –conductor cables maybe used in conduit-however
If the conduit contains three or more cables,the total cross-sectional area of the cables
(including insulation) should not be more than 40 % of the cross –sectional area of the conduit
5) Long runs of conduit should be provided with suitable draining devices to ensure adequate
Draining of conduit .additionally ,cables should be suitably water-resistant.
6) Open conduit system ,sometimes used simply for mechanical protection ,do not have to meet
The above listed conditions-but must be sealed when entering or leaving a hazardous area in order
To prevent the transmission of explosive gases
11.5 Light metal as construction Materials
For the protection from dangerous incendive sparking ,the material composition of metallic
Installation materials (e.g. Cable trays,mounting plates ,weather protection and enclosures)
Shall comply with the following requirements .materials used in group II installations for the
identified equipment protection levels shall not contain ,by mass more than
a) EPL”Ga”
10% in total of aluminium ,magnesium,titanium and zirconium and 7,5% in total of
magnesium ,titanium,and circonium
b) EPL “Gb”
7,5 % total magnesium,titanium and zironium
c) No requirenments

11.5.1 Statis electricity

The use of non-metallic materials (e.g.plastic covered cable tray ,plastic mounting plates,plastic
Wether protection and enclosures) for construction or protecting purposes that are not part of
Certified equipment can create static electricity sufficient to generate an incendive spark to ignite
flammable gase or vapours
Therefore measures must be implemeted to control and reduce the effects of static electricity
To an acceptable or safe level for working in hazardous areas.
Construction and protecting parts shall be so designed that under normal conditionsof use
Maintenance or cleaning ,danger of ignition due to electrostatic charges is avoided .this
Requirement can be achieved by:
1) Suitable selection of the material to ensure that maximum surface resistance in accordance
With IEC 60079-0 does not exceed 10⁹ or 1GΩ or
2) Limitation of the surface area of non –metallic parts as per below mentioned IEC 60079-14
Table 5-limitation of surfaces areas

Construction and protecting parts(mm2)

Equipment Group Group IIB Group IIC
protection level IIA
required
EPL Ga 5000 2500 400
EPL Gb 10000 10000 2000
EPL Gc 10000 10000 2000
11.6 Cable Glands

Until 2006,there where no construction standards for cable glands for hazardous areas .the 2 standards
IEC 60079-0 and EN 50262 now hve such requirements.
IEC 60079:2003 and earlier edtions gave the users the option of selft –assesing equipment for use in
zone 2,it Also permitted the use of uncertified glands into Ex e and Ex n equipment provided they
would witstand the Impact tests and meet the ingress protection (IP) requirements for the type of
protection of the enclosureThe revision of IEC 60079-14 (Published in 2007) required that all glands
with the possible exception of those
Used in intrinsically safe enclosure to be certified in accordance with IEC 60079-0
Therefore an installation prior to 2007 may include cable glands which are uncertified but
after 2007 ,type Ex e & Ex n cable glands must certified
11.8 Gland Construction

1) Cable sealing :Sealing between the body of the cable gland and the cable gland shall be one of
The following types
a) An elastomeric sealing ring
b) A metallic or composite sealing ring
c) A filling compound
2) Clamping :cable gland shall provide clamping of the cble in order to prevent pulling or
twisting applied to it from being transmitted to the connections .such clamping can be provided
By a clamping device ,sealing ring or filling compound.

Glands which cannot provide adequate clamping strenght as specified by IEC 60079-0, Annex A
,May steel be utilize but must be marked with an “X” on its certificate,(indicating special
Conditions of use .such conditions must require the user to utilize an additional clamping
method for the cable .Cable glands with an “X” may not be utilized for portable equipment

3) Cable lead-in :Glands may not have sharp edges which are capable of damaging the cable,
And must have a rounded edge at angle of t least 75°

4) Cable glands must require a tool for removal or disassembly

5) Cable glands must maintain the ingress protection of the enclosure they are installed in ,but
In no case should ever be less than IP 54 rated.

11.8.1 Gland Markings

Gland marking include
1) Name of manufacturer
2) Certified number
3) Certification body number
4) ATEX AND IEC marking such as groups(IIA,IIB OR IIC) or EPLs
5) Type of Ex protection such as Ex d,Ex e & Ex n
6) With a reference to standard ,the meaning of the alphabets:
*A Outer seal only
*B Armour lock only
*C Outer seal & Armour lock (A+B)
*D Inner seal & armour lock
*E Inner sel ,outer seal & armour lock
*BARR Inner barrier seal ,outer seal & rmour lock
*W Single wire armour
*X Braid armour
*Y Aluminium Strip armour
*Z Tape armour
Note additional details may be included in the packing
Example marking
EIFW-Flameproof gland for single wire armoured cable
EIFX-Flameproof gland for galvanised steel braided armoured cable
11.9 Gland selection

In general cable glands must be selected to match the enclosure certification –e.g.an Ex d flmeproof
Enclosure would require the the use of cable gland certified as Ex d.
In addition ,several other criteria must be considered when selecting cble glnds:
1) Cable size :manufacturers of cable glands provide a minimum and maximum size of cables that each
Gland will accept .this diameter is the outside dimension of the cable (overall size)
2) Cable construction :several factors may apply:
a) Armoured or non armoured.if armoured the type of armour must be known
b) Is the cable circular –filled with non hygroscopic fillers and extruded bedding ?
See barrier glands selection below)
c) Is cable gland flat or around ? Cable glands for round cable may not be used for flat cabel and vice versa
d) Is cable susceptible to cold flow :cold flow is a condition described as the movement of the cable sheath
under the compressive forces created by the displacement of seals in cable glands where the
compressive force applied by the seal is greater than the resistance of the cable sheath to deformation
.this could cause a reduction in the insulation resistance of the cable .low smoke and /or fire resistance
cables usually exhibit significant cold flow characteristic
3) Enclosure specifications,including
a. Enclosure type specific requirements for different types of enclosures are discussed below
b. Size and thread of entry holes (metric or NPT?)
c. Enclosure IP rating
d. Wall thickness of enclosure –i.e.necessary lenght of threads on gland.
e. Is the entry into the enclosure made by direct ,or indirect ,methods ?this only applies to flameproof
enclosures,and is illustrated here:
 Direct entry methode Indirect entry methode

Flame path Flame path

Eex’d’ Eex’d’
Enclosure Enclosure
Bushing

Eex’d’

Direct or indirect entry will significantly impact the next selection criteria
4)Barrier gland entry or non-barrier gland?
A barrier gland –also known as a sealing gland –is a type of cable gland in which the cable conductors are sealed
within the gland by the use of a sealing compound –commonly epoxy –in orderto preventthe transmission of
Hazardous gases through the cable and into the enclosure.A barrier gland function the same as stopper box or sealing
Fitting used on conduit
11.10 Barrier gland selection

Note :In all editions of IEC 60079-14,prior the 5ᵗᵸ edition (nov 2013) ,a flow chart was included as
An aid to barrier gland selection.
In the 5ᵗʱ edition of IEC 60079-14 ,the flow chart was omitted and methodology for gland selection
Completely changed.standard Ex d glands(i.e.non barrier) are now permitted under the following
Requirements:
*The gland hs been certified to IEC 60079-1
*The cable used sheathed with thermoplastic ,thermosetting or elastomeric material .they shall
Be circullar and compact.Any bedding or sheath shall be extruded.fillers,if any,shall be non-hygrocospi
and
*The connected cable is at least 3 m
EEMUA believes that IEC 60079-14:2013 method of determining whether a barrier gland is
Needed for an Ex d enclosure is deficient and potentially dangerous
Research carried out by intertek in 2015(on behalf of EEMUA) confirmed that damage to cable
Bedding external to the gland occurs when:
-The enclosure is subject to repeated ignitions ,and the enclosure internal volume EXCEEDS 2 LITRES
The research also indicated that cable lenght is not a relevant criteria.
EEMUA recommends that the original flow chart (IEC 60079:14 2007 Figure 16) be followed for
All installations.however ,it is the responsibility of the site responsible person to determine the
Policy for the site ,installers should therefore ask the relevant site authorities for instruction on
This matter.
For more information refer to relevant standards,7ᵗʱ edition of EEMUA 186-A practioner’s handbook or th
appropriate superior technical authority
Figure 16 START

NO CIRCULAR NO
YES MICC CABLE USE BRRIER
USE MICC FILLED
CABLE CABLE GLAND
GLAND

USE GLAND YES NO

SPECIFIED INDIRECT
IN ENTRY
CERTIFICAT
E

YES INTERNAL
NO
SOURCE
IGNITION USE ANY
SUITABLE
CERTIFIED
CABLE
YES NO
USE GLAND
BARRIER IIC HAZARD
GLAND

YES NO
ZONE 1
AREA

YES INTERNAL NO
VOLUME ˃2
LTR
11.11 Splicing cable

Cable runs in hazardous areas should ,as much as possible ,be unintereupted.where splicing
Cannot be avoided,however ,the splice must be made mechanically ,electrically and
Enviromentally suitable for the situation .it should be
*Made in an enclosure with a type of protection appropriate to the EPL requirements for the
Location ,or
*Providing the joint is not subject to mechanical stress ,be ‘epoxy’filled ,compound –filled or
Sleeved with heat –shrunk tubing or cold –shrunk tubing,in accordance with the manufacturer’s
Instruction
Conductor connection –with the exception of those in flameproof conduit systems and intrinsically
Safe circuits-shall be made only by means of compression connectors ,secured screw connectors,
Welding or brazing ,soldering is permissible if the conductors being connected an held together
By suitable mechanical means nd then soldered ,so there is mo stress on the connection .
11.12 other wiring installation considerations
1. Cables used in hazardous areas should be have flame propagation properties which withstand
the testing requirements of IEC 60332-1-2
2. Cable glands with tapered threads (NPT) shall not be used in enclosures having gland plates
With non-threaded entries
3. Cables traversing a hazardous area (but bot terminating in a hazrdous area ) must meet the EPL
Requirements of the area it is passing through.
4. 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
5 The hazardous area end of each unused core in multi –core cables shall either be
connected to earth or be adequately insulated by means of terminations suitable for
The type of protection .insulation by tape alone is not permitted
This requirement does not apply to instrinsically safe circuits
6. Except for trace-heating ,contact between the metallic armouring or sheathing of cables and
And piping or equipment containing flammable gases ,vapors or liquids shall be avoided .the
Insulation provided by a non-metallic outer sheath on a cable will usually be sufficient to avoid this
7. Openings in walls for cables nd conduits between different hazardous areas and between
hazardous areas shall be adequately sealed in order to maintain the area classification
8. If truncking ,ducts,pipes or trenches are used for cable routing precautions must be taken
To prevent the passage of flamable gases ,vapors or liquids from one area to another and to
Prevent the collection of flamable gases ,vapors or liquids in trenches.

11.13 Grounding /Earthing

Grounding /earthing and bonding are crucial in any installations ,but especially so in hazardous
area installations –not only for prevention of electrical shock to persons ,but also to negate or
Dissipate any stray sparks or arcs which could be a source of ignition.
Definitons
1.Grounding (Earthing) –establishment of an electrically continuous path from a conducting body
the conductive mass of earth
2.Bonding- establishment of an electrically continuous connection between exposed conductive
Parts and /or extraneous conductive parts ,so that all connected items are at substantially equal
potential
3. Exposed conductors parts-path of an electrical installation which are not normally
Energized But which my become energized in the event of an equipment or cabling fault (motor frames
,swicthboard enclosure ,etc)
4. Extraneous conductive parts- any conductive part with the potential to be touched by a
human While simultaneously touching an exposed conductive part
5. Earth continuity protective conductor (ECP) –the principle earth (ground) conductor
Connected From the point of use to the point of use to the electrical supply earth (ground)
6. Equipotential bonding conductor- conductor that maintain n extraneous metaal parts or
structures at substantially the same potential ,usually earth .they do not replace the need for
earth continuity
7. Suplemetary earth bonding –bonding accomplished by use of other earth parts other than by
Copper wiring –for example ,welding or bolting components or structures together or to earth .
Requires careful evaluation of the potential for corrosion to interfere with the bond ,which may
require a copper bonding conductor also
8.Fortuitous Bonding-bonding which occurs via the interconnections of piping, cable support
Structures,cable armouring ,etc.Fortuitous bonding should be ignored as a protection method
And an earth continuity system or conductor should be utilized.
Type of system earthing (grounding)

1. TN-C uses the same conductor throughout the system for both supply neutral and ground .may not be
Utilized in hzardous areas unless the hazardous area supply is equipped with an isolation transformer
2. TN-S uses separate earth and neutral conductors which are intended to be connected only at the supply
System source earth point
3. TN-CS –similiar to TN-C ,utilizing the same conductor for both earth and neutral ,but the earth /neutral
Conductor is earthed at several point along the system ,may not be utilized in hazardous areas unless the
hazardous area supply is equipped with an isolation transformer
4. TT-relies on earthing at each installation via buried electrodes.the supply system is earthed at the supply
System transformer only
5. IT-has no direct connection between the supply and earth. The supply point may be earthed through an
Earthing impedance ,and bonding is accomplished via local buried electrodes
Earth (ground )connector sizing
Earthing (grounding) or bonding is only effective in the part to earth has a low enough
Resistance to prevent any dangerous voltages from being developed in the event of an earth
Fault or a build –up of static electricity.the necessary value of the earth resistant varies
According to the application and /or the facility ,but should be as low as possible.
Sizing of the earth conductors and the necessary impedance of the earth loop is dependent
On the maximum potential fault current available. Consideration must also be given to the need
For preventing excess heat or voltage drop in the earthing conductor
The following Chart provides some guidance for sizing copper earth conductors ,but each
Installation should be considered separately based on the criteria specified above:
 Phase conductor size Earth conductor size
≤ 16 mm Same as phase conductor ,but not less than 2.5
mm² if protected ,4mm² if not
≥16 mm² ≤ 35 mm² 16 mm²
,35 mm² .5 x phase conductor size
If aluminium earthing conductors are used ,they must be a minimum 16 mm² in size and be insulated
The use of bar earthing conductors requires special consideration ,because of the potential for dangerous temperatures
To be developed under fault current. Normally ,if the conductor is in location where it cannot be contacted by persons, a
Maximum temperature of 500°C is acceptable -but this may not be acceptable in hazardous areas because it is above the
Ignition temperature of many gases
The following chart provides sizing for bare conductors (copper and steal) which ,under the specified fault currents and
fault durations,would produce 500°C

Material Fault durtion Earth fault current (Ka)

(in second) 7 14 35 44 70
0.1 10 25 50 70 95
0.2 16 35 70 95 100
Copper
1.0 35 70 150 185 300
2.0 50 120 250 300 500
0.1 30 60 150 200 300
Steel 0.2 50 85 240 300 420
1.0 90 180 450 600 900
If 500°C is above the ignition temperature of the hazard for the area ,calcultions must be performed to enlarge
The size of the conductor to ensure that the ignition temperature is not reached in fault condition

Special condition for sizing

1.When connecting (bonding) two separate exposed conductive parts,the conductor (if sheathed or protected)
Should have a conductance not less than that of the smaller earthing conductor for each of the parts.if the
bonding conductor if not mechanically protected,it must be a minimum 4 mm²
2.When connecting (bonding) an extraneous conductive part to an exposed conductive parts ,the conductor
(if sheathed or protected) should have a conductance not less than that of the earthing conductor of the
exposed conductive part .if the bonding conductor is not mecanically protected ,it must be a minimum
of 4 mm²
3.When connecting two extraneous conductive parts ,if one is connected to an exposed conductive part
Follow 2) above .otherwise use a minimum of 2.5 mm² if mechanically protector or sheathed ,4 mm² if not

11.14 Lightening protection

Lightening poses significant risk to hazardous areas ,as any lightining strike in an area with an explosive
Atmosphere WILL cause ignition .specific precautions ,therefore must be made to alleviate the risk of ignition:
1. When using down conductors on a building ,they should be 20 meters apart for any building ≤ 20 meters
In height,or 10 meters for any building taller than that
2.All terminations,suspended conductors ,external down conductors ,and external bonds should be a minimum
Of 50 mm²
3. Resistance to the main body of earth from any metal part of the structure should not exceed 10 Ω
11.15 Potential Equalization in hazardous areas
Potential equalization is required for installations in hazardous areas .for TN,TT and IT systems,
All exposed and extraneous conductive parts shall be connected to the equipotential bonding system
The bonding system may include protective conductors ,metal conduits ,metal cable sheaths,steel wire
Armouring and metallic parts of structures,but shall not include neutral conduct.ors.
Connections shall be secure against self-loosening and shall minimize the risk of corrosion which may reduce
The effectiveness of connection . If the armour or screens of cables are only earthed outside the hazardous
Area (e.g.in the control room ) then this point of earthing shall be include in the potential equalization system
Of the hazardous area
NOTE if the armour is erthed only outside of the hzardous area in TN system there is possibility,that dangerous Sparks may
be created at the ending of the armour in hazrdous area ,therefore this armour or screen should Be treated like unused cores

Exposed conductive parts nedd not be separately connected to the equipotential bonding system it they area
Firmly secured to and are in conductive cantact with structural parts equapotential bonding system

Extraneous conductive parts which are not part of the structure or of the electrical installation ,for example
door or window frames,need not be connected to the equipotential bonding system ,if there is no danger
Of voltage displacement

Cable glands which incorporate clamping devices which clamp the braiding or armour of the cable can be used
To provide equipotential bonding.
For additional see 411.3 of IEC 60364-4-4-41
Metallic enclosures of intrinsically safe or energy –limite apparatus need not be connected to the
equipotential bonding system ,unless required by the apparatus documentation or to prevent accumulation
Of static charge .
Instllations with cathodic protection shall not be connected to the equipotential bonding system unless the
System is specifically designed for this purpose
 Test your knowledge –unit 11 wiring & glands
1. Which one of the following is the minimum requirement for terminating an SWA cable with an EX “e” cable
Gland in to an Ex ‘e’ steel enclosure ,with a clearance hole
A. Fit gland ,earth tag ,star washer and internal lock B. Fit gland ,external IP washer and internal locknut
C. Fit gland ,internal IP washer ,star washer ,internal lock nut and shroud
D. Fit gland ,external IP seal washer ,internal star washer and lock nut
2. If a cable glands is marked a suffix “X” wht does this means
A. It can only be used with an enclosure that is also marked with the “X” suffix
B. It can only be used with portable equipment
C. It cannot be used with fixed equipment
D. It can only be used with fixed equipment .it may require additional clamping for the cable
3. If direct entry Ex d group IIC enclosure in a location requiring EPL ‘Gb’ and gas group IIB ,has a volume of
1.5 litres .what is the minimum type of cable gland permitted:
A. Uncertified E1W brass gland B. Certified brass E1WF Ex d IIC Gland
C . Certified brass E1W Ex e gland D. Certified brass E1W Ex d IIC
4. Multi-or- fine –stranded conductors are protected against separation of strnds by :
A. Twisting the strands B. Soldering the strands C. Fitting cable lugs or soldering D. Fitting cable and ferrules
5. When terminating non-intrinsically safe multi-core cables,which is an acceptable practice for unused core:
A. Cut back and tape over B. Insulate the ends with tape ,leaving sufficient length to reach the furthest
Terminal C. Terminate in unearthed terminal D. Connect them to the neutral conductor
6. What can be done to reduce the effects of static electricity on plastic covered cable ‘tray’
A. Use armoured cables B. Limit the surface area C. Limit the tray length D. Use for IS circuits only
 UNIT 12
INSPECTION AND MINTENANCE
OF
HAZARDOUS AREA EQUIPMENT

OBJECTIVES
1) Requirement and importance of a regular inspection and maintence program
2) Types of inspection and when to use each
3) Grade of inspection
4) Required documentation for hzrdous area installation management
5) Inspection requirements according to IEC 60079-17 and EN 60079-17
12.1 Introduction
Inspection nd maintenance of electrical equipment and systems in any instllation is important ,both from a
safety and an operational standpoint .In hazardous areas ,however ,it is especially critical because a failure
Which jeopardizes the ignition protection capbility can potentially have catastrophic result
In addition ,equipment will only maintain its certication status if it is maintained in accordance with the
Recomendations provided by mnufacturers and relevant standrds.
Standards
IEC 60079-17
EN 60079-17
12.2 Causes of equipment deterioration or failure
Several factors can cause ,or contribute to equipment deteriorating or failing altogether.Many of these factors
should be considered when the equipment is selected and installed ,and mitigated or eliminated if possible
-However ,this might not always have been done,especially in older installations .it is important ,therefore ,
that facilities monitor these condition- especially in hazardous areas-and adjust inspection nd maintennce
Schedulle and procedures aacordingly:
1. Susceptibilty to corrosion
2. Exposure to chemical or solvent
3. Accumulation of dust or dirt
4. Water ingress
5. Excessive ambient temperatures
6. Risk of mechanical damage
7. Exposure to undue vibration
8. Training and experience of personal
9. Unauthorized modifications or adjusment
12.3 Inspection and mintennce system requirements

1) Documentation –to be effective ,an inspection and maintenace program must have up-to-date
Documentation of the following items:

a) Zone classification of areas and ,if included ,the equipment protection level (EPL) required for each
location (see IEC 60079-10-1 and 10-2)
b) Gas areas: equipment group (IIA,IIB or IIC) and temperature class requirements
c) Dust areas: Equipment group (IIIA,IIIB or IIIC) and maximum surface temperature requirements
d) Equipment characteristics e.g. Temperature ratings ,type of protection ,IP Rating ,corrosion resistan
e) List and location of equipment ,spares,certificates,technical information
f ) Copies of previous inspection records
g) Records sufficient to enable the explosion protected equipment to be maintained in accordance with
Type of protection .IEC 60079-14 states the requiremnets as follows:

It is necessary to ensure that any installation complies with the appropriate certificates as
well as with this Standard and any other requirements specific to the plant on which the
installation takes place.To achieve this result ,a verification dossier shall be prepared for every
installation and shall be either kept On the premises or stored in another location.in the latter
case ,a document shall be left on the premises Indicating who the owner and owners are and
where that information is kept,so that when required ,copies May be obtained
In addition to the requirements listed above ,IEC 60079-14 lists the following information which should be part
Of the facility hazardous area documentation file:
(a) Optional assesment of consequences of ignition (see EPL risk ssesment)
(b) Instructions for erection and connection
(c) Documents for electrical equipment with conditions of use ,e.g . For equipment with certificate numbers
Which have the suffix ‘X’
(d) Descriptive system document for intrinsically safe system
(e) Mnufacturer’s /qualified person’s declaration (the manufacturer’s /qualified person’s declaration if
applicable to situations where uncertified equipment it used ,other than simple apparatus in intrinsically
Safe or energy –limited circuits)
(f) Necessary information to ensure correct installtion of the equipment provided in a form which is suitable
To the personnel responsible for this activity (see IEC 60079-0)
(g) Details of any relevant calcultion ,e.g.for purging rates for instruments or analyser houses
(h) External influences and ambient temperature

12.4 Qualifications of personnel (operativies /technicians)

Equipment design and manufactured for use in hazardous areas has undergone rigorous design .manufacture ,
And testing procedures to ensure it complies with relevant standards and will provide protection against
ignition of a hazardous atmosphere .However ,the way the equipment is subsequently handled,selected ,
Installed, and maintained will have an influence on wheather it will continue to provide the protection it was
Designed for ,as well as whether it will remain certified.
Failure, for example to follow the “special condition of use” listed inthe equipment’s certificate cn not only
invalidate the certification ,it can pose a serious risk of causing ignition.
Therefore it is critical that personnel involved in the selection ,installation ,inspection and maintenance of
Equipment in hazardous areas be properly trained and competent in application of the relevant standards
And practies .they should have ,at a minimum ,the following:
(a) Understanding of the principle of explosion protection
(b) Understanding of the general principles of type of protection and marking
(c) Understanding of those aspects of equipment design which affect the protection concept
(d) Understanding of certification and relevant parts of IEC 60079 -17
(e) Familiarity with the particular techniques to be employed in the inspection and mintenance of equipment
referred to in IEC 60079-17
(f) Comprehensive understanding of the selection and installation requirements of IEC 60079-14
(g) General understanding of the repair and reclamation requirements of IEC 60079-19
(h) General understanding of area classification

Personal tasked with mnagement / oversight of hazardous areas and maintenance personnel should receive
Proper training ,and be able to demonstrate competence ,in the relevant practices and standards . Given
that standards change periodically ,,such personnel should also be subjected to continuing education and
Training ,as well as assesment of competence should be part of the facility hazardous area documentation and
Be available for review
In addition to general training in the requirements listed above ,skilled personnel must be provided with
sufficient training to familiarise them with the installation they are tasked with maintaining .this training shall
Include any plant ,equipment,operational or enviromental conditions which relate to their understanding of
The needs of the explosion protection of equipment.where any alterations or changes to the process or
Installation are effected this information shall be provided to the skilled personnel in a manner which supports
Their function as part of the continuous supervision process .where necessary ,training in the concepts of
Continuous supervision shall be provided together with refresher or reinforcement seminars
12.5 Safe Electrical Isoltion

To allow electrical work to be crried out safely ,a means of isolation shall be provided to isolate all live
Conductors ,including the neutral
The preferred means of isolation is by a device that operates in all relevant conductors at the same time .
The means of isolation may include fuse and neutral links where relevant .isolation means the withdrawal
Of fuses and links or the locking off an isolator or switch .

12.6 Types of Inspection

There are four types of inspections specified in IEC 60079-17-utilizing the varioustypes as ppropriate ,a facility
Can easily develop a comprehensive inspection program which will ensure it maintains all hazardous area
Equipment appropriately :
These four types of inspection are:
1) INITIAL Inspection –is the inspection conducted prior to plcing a facility ,equipment ,or system into
operation for first time .it should be s detailed as possible ,in order to identify any potential fault prior to
Energizing the equipment
2) Periodic inspection –Inspections carried out on a routine ,schedulle basis .they can be visual close ,or
detailed (see grades of inspection below) as necessary ,depending on facility needs and operational
Requirements-However careful consideration must be given to the conditions equipment is subjected to ,as
This may influence the grade of inspection needed . The time between periodic inspection for fixed installation
Should not exceed 3 years
For movable electrical equipment (hand held ,portable and transportable ) ,all equipment shall be submitted
To close inspection at least every 12 Months
3) Sample Inspection –When large numbers of identical equipment are present –light fixtures,for
Example –facilities may choose to select and inspect a representative sampling of the equipment .the sample
should be subjected to similiar operating and enviromental conditions.the sample inspections should provide
Indication whether or not an inspection of 100% of the equipment if necessry
4) Continues supervision -Equipment which is subject to inspection on a regular basic by skilled ,
competent personnel (See above) .such inspection may be other routine maintenance or operation which
cause such personnel to observe and / or inspect the equipment during the course of their normal duties.
In this case,regular periodic inspections may be dispensed with.

12.7 Grades of Inspection

Three grades of inspection are specified

1) Visual –An inspection which identifies defects apparent to the eye,without the use of acces equipment or
tools –for example ,mising cover bolt
2) Close-An inspection which includes all those aspect covered by a visual inspection and also identifies
defects which will be apprent only by the use of acces equipment (such as step ladder) and /or tools-for
example ,loose cover bolts.close inspections do not normally require the enclosure to be opened ,or the
equipment to de-energized
3) Detailed- An inspection which encompassesthose aspect covered by a close inspection and addition ,
identifies those defects,e.g loose termination’s which will only be apparent by opening the enclosure ,
and /or using ,where necessary ,tools nd test equipment
12.8 Moveable /portble equipment
Certified hand –held Ex portable equipment needs to be used in hazardous areas.it would not be
acceptable To use equipment “approve” by the plant manager hnd- held portable equipment is prone to
damage or
misuse and therefore the intervals between detailed inspections may need to be reduce
Generally 1 year 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
 Test your knowledge –unit 12 Inspection

1.Which of the following is a recognised grade of inspection

A. Close B. Periodic C. Frequent D. Sample

2. Where visual inspection is carried out which one of the following is requirement:
A. Lamp rating ,type and position are correct B. Apparatus circuit identification is availabl
C. Flange faces are clean and undamaged D. Type of cable is appropriate

3. At which grade of inspection would yo dismantle an Ex d cable gland:

A. Visual B. Close C. Detailed D. Initial

4. Which of the following statements is false:

A. Insulation resistance tests are required for all close inspection
B. No unauthorised modification can be made to Ex d equipment
C. Apparatus in hazardous areas must have circuit identification
D. Motor fans must have sufficient clearance to ensures/covers

5. Which of the following is required before undertaking a visual inspection:

A. Details of all lamp wattage
B. An area classification drawing
C. Tools and equipment
D. Access equipment
 UNIT 13
PERMIT TO WORK
AND
SAFE ISOLATION

Objectives:
On completion of this unit ,you should known
1) The importance of permit to work and sfe isolation
2) The safety procedures for isolation of electrical equipment and circuits before
working on competence validation testing CVT EX01, EX02, EX03 & EX04
3) The procedures to be carried out during the assesment of CVT EX01, EX02,
EX03 & EX04
13.1 Permit to work and safe isolation

After completion of the theory lessons ,the candidat are required to perform 4 practical CVT assesments for
EX01, EX 02, EX03 & EX04 in simulted in hazardous areas .the candidates are required to demonstrate their
Ability to work safely by following all necessary safety procedures and precautions to prevent any accidental
Ignition of flammable material /gas which is assumsed to be present

13.2 Permit to work system

For safe operation ,candidate need to operate within the control of a PTW system .they must request the work
Permit and gas free certified and these 2 document must be endorsed by the assessor or authorised persons
As required during the assesments .this necessary as there produce a source of ignition .In any realistic job
situation ,working without these document in hzrdous areas can be disastrous.

13.3 Safe Isolation

If we need to open any piece of electrical power equipment to perform inspection ,maintenance or any other
Work ,the equipment must firstly be safely isolated fromall electrical power sources.
The recommendation for hazardous areas is to isolate all incoming supplies including the neutral connection
It must also be locked out and tagged out (LOTO)
After sfe isolation ,the next step is to carry out a zero voltage check to prove that the circuit to work on is dead
.the recommendation is to perform the 3 step (test,prove,test ) using the voltage tester.
Step 1 is to test the voltage tester on a known source to validate that it is in working condition
Step 2 is to confirm on site that the reading of the voltage tester at the incoming power supply terminal is zero
Volt
Step 3 is to retest the voltage tester to validate that it is in working condition

The step 3 tken are to ensure that the circuit to work on is dead nd it is safe to carry out the work required
 Unit 14
Practical assesments-
Competency Validation
Testing (CVT)

Objectives:
1. The procedures and competency requirement for EX01:Preparation & installation
Of Ex d,Ex e and Ex n equipment
2. The procedures and competency requirement for EX02:Inspection of Ex d,Ex e
and Ex n equipment
3. The procedures and competency requirement for EX03:Preparation & installation
Of Ex i equipment
4. The procedures and competency requirement for EX04:Inspection of Ex i
equipment
14.1 Competency validation test (CVT) EX01,EX022,EX03 & EX04
Off-site work preparation :with reference to assesment workpacks ,review scope of work to ensure that
Complience of the selection of materials ,equipment & tools area in accordance to safe work practices ,
Procedures and standards. The use of personal protective equipment (PPE)inthe designted areas is
mandatory
Permit work (PTW) Test certificate (GTC) & safe electrical isolation : prior to electrical isolation ,candidates
To complete relevant parts of PTW & GTC and endorsed by Authorised person
ON-site work preparation : With reference to assesment workpacks ,all on-site conditions are checked and
Candidates to inform authorised person of any discrepances between specifications and site plans
14.2 EX01 Prepration & Installation of Ex d,Exe, and Ex n equipment
Time of assesment :3 hours and 45 minute (including 15 mins for safe isolation)
Section A
Preparation & safe isolation :Under the control pf PTW system ,correctly locate and safely isolate electrical
Installation follow by locked out and tagged out (LOTO)
Section B
Composite Installation of Ex d ,Ex e and Ex n Equipment :
1) Inspect suitability of pre-fixed equipment ,cables and glands
2) Select appropriate tools and components to complete the installation
3) Install appropriate cables and glands according to standards and without compromising integrity of pre-
Fixed equipment
4) Apply appropriate safeguards and conduct electrical and function test
14,3 EX02 Inspection of Ex d ,Ex e and Ex n equipment
Time of assesment :1 hour 30 minute (include 15 mins for safe isolation
Safe isolation of electrical
Circuits: Under the control of the PTW system ,correctly locate and safely isolate electrical installation follow
By locked out & tagged out (LOTO)
Section A,B,& C
Inspection of equipment and environment: With reference to IEC 60079-17 Table 1 ,perform inspection of a
Given installation :
1. Identify and record visual faults
2. Identify and record close faults
3. Identify and record detailed faults
NOTE:Candidates are to perform inspection only and no rectification work is required

14.4 EX03 Preparation and installation of Ex i equipment

Preparation and safe isolation :Under the control of the PTW system ,correctly locate and safely isolate the
installation
Composite installation :
1) Inspect suitability of pre-fixed equipment ,cables and glands
2) Select appropriate tools and components to complete the installation
3) Install appropriate cables and glands according to standards and without compromising integrity of
pre-fixed equipment
4) Apply appropriate safeguards and conduct electrical tests
14.5 EX04 Inspection of Ex i Equipment
Time of assesment 1 hour 15 mins
Safe isolation of electrical circuits: Under the control of the PTW ,Correctly locate nd safely
isolate the Installation
Section A,B,and C
Inspection of equipment and environment :with reference to IEC standards 60079-17 table 2 perform
Inspection of a given installation :
1) Identify and record Visual faults
2) Identify and record Close faults
3) Identify and record Detailed faults

Note : Candidates areto perform inspection only and no rectification work is required .