(00/00000/00 National Training and Assessment for Personnel Working in Potentially Explosive Atmospheres Foundation Module (EX F) Course Notes ‘The TTE Technical Training Group Edison House, Middlesbrough Road East, South Bank, Middlesbrough TS6 6TZ UK TE International Limited c/o Edison House, Middlesbrough Road East, South Bank, Middlesbrough TS6 6TZ UK ‘TTE Apprenticeships Limited c/o Edison House, Middlesbrough Road East, South Bank, Middlesbrough TS6 612 UKCompex Foundation TTE> 18 December 2014 - Version 1 CONTENTS UNIT UNIT : LEGISLATION/STANDARDS. REA CLASSIFICATION von UNIT 3: LP. CODE: UNIT 4: CERTIFICATION .snnsesnneses UNIT 5: EQUIPMENT SELECTION UNIT 6: LABELLING.. UNIT 7: FLAMEPROOF (EEX D). UNIT 8: INCREASED SAFETY (EEX E) UNIT 9: REDUCED RISK (EEX N).. UNIT 10: GLANDING. UNIT 11: INTRINSIC SAFETY. UNIT 12: PRESSURISATION .. UNIT 13: BEX 0, Q & Messnnnsnnne UNIT 14: CABLES.. UNIT 15: NON ELECTRICAL APPARATUS wssssnns UNIT 16: INSPECTION. UNIT 17: DUST. UNIT 18: EXTRA INFO. Course Notes Page 2 of 71Compex Foundation TTE> 18 December 2014 - Version 1 The ATEX Directive legislation underlines the need for practitioners in potentially explosive environments or hazardous areas to be competent. It is implemented through regulations 7 and 11 of DSEAR- Dangerous Substances and Explosive Regulations. This course has been developed to give an introduction into Hazardous areas for practitioners. AIMS The aim of the course is to provide delegates’ with knowledge and understanding of terminology and protection concepts utilised in a potentially flammable atmosphere. OBJECTIVES At the end of the course you will be able to: * Understand the concept of area classification and the need to zone flammable atmospheres accordingly. + Understand the terminology and definitions associated with hazardous areas. * Understand the various protection concepts. * Understand |.P codes in relation to ingress protection. * Understanding of current ATEX directives. + Awareness of DSEAR Regulation. + Understanding of equipment groups and temperature rating. CERTIFICATION Successful course delegates will receive a UK JTL Certificate, valid for 5 years. COURSE STATEMENT © This course covers the hazardous areas. imum Legal Requirements for installations wi + Individual companies may and do install higher specification equipment and accessories above the levels stated during this course. * This is to provide a higher level of protection for plant, equipment and personnel as they deem necessary. Abbreviations used on this course. DSEAR (The Dangerous Substances and Explosive Atmospheres Regulations). ATEX (ATmosphere Explosive). MHOR (Manual Handling Operations Regulations). ALARP (As Low as is Reasonably Practicable). Course Notes Page 3 of 71Compex Foundation TTE> 18 December 2014 - Version 1 INTRODUCTION Soon after the introduction of electric power into coal mines, it was discovered that lethal explosions could be initiated by electrical equipment such as lighting, signals, or motors. The hazard of fire damp or methane accumulation in mines was well known by the time electricity was introduced, along with the danger of suspended coal dust. At least two British mine explosions were attributed to an electric bell signal system. In this system, two bare wires were run along the length of a drift, and any miner desiring to signal the surface would momentarily touch the wires to each other or bridge the wires with a metal tool. The inductance of the signal bell coils, combined with breaking of contacts by exposed metal surfaces, resulted in sparks which could ignite methane, causing an explosion. Fire damp: consists of mostly methane, a highly flammable gas that explodes between 5% and 15% - at 25% it causes asphyxiation. SENGHENYDD COLLIERY DISASTER The explosion was probably started by firedamp (methane) being ignited, possibly by electric sparking from equipment such as electric bell signalling gear. The initial explosion disturbed coal dust present on the floor, raising a cloud that then also ignited. The shock wave ahead of the explosion raised yet more coal dust, so that the explosion was effectively self-fuelling. Those miners not killed immediately by the fire and explosion would have died quickly from afterdamp, the noxious gases formed by combustion. These include lethal quantities of carbon monoxide, which kills very quickly by combining preferentially with haemoglobin in the blood. The vi suffocated by lack of oxygen or anoxia. In England, The Oaks explosion remains the worst mining accident, claiming 388 lives ‘on 12 December 1866 near Barnsley in Yorkshire. The Hulton Colliery explosion at Westhoughton, Lancashire, in 1910 claimed the lives of 344 miners. An explosion in 1878, at the Wood Pit, Haydock, Lancashire, killed over 200 workers, although only 189 were included in the ‘official list’. Another disaster that killed many miners was the Hartley Colliery Disaster, which occurred in January 1862 when the beam of the main steam winding engine broke suddenly and fell into the single shaft serving the pit. It blocked the shaft, and entombed hundreds of miners. The final death toll was 204, most of whom were suffocated by the lack of oxygen in the mine atmosphere. Course Notes Page 4 of 71Compex Foundation TTE> 18 December 2014 - Version 1 UNIT 1: LEGISLATION/STANDARDS, HASAWA MHSWA Electricity ETC. Regs at work Regs HASAWA ‘The Health and Safety at Work Act 1974 is an Act of the Parliament of the United Kingdom that as of 2011 defines the fundamental structure and authority for the encouragement, regulation and enforcement of workplace health, safety and welfare within the United Kingdom. The Act defines general duties on employers, employees, contractors, suppliers of goods and substances for use at work, persons in control of work premises, and those who manage and maintain them, and persons in general. The Act enables a broad regime of regulation by government ministers through Statutory Instrument which has, in the years since 1974, generated an extensive system of specific provisions for various industries, disciplines and risks. It established a system of public supervision through aids the creation of the Health and Safety Commission and Health and Safety Executive, since merged, and bestows extensive enforcement powers, ultimately backed by criminal sanctions extending to unlimited fines and imprisonment for up to two years. Further, the Act provides a critical interface with the law of the European Union on workplace health and safety. COSHH COSHH is the law that requires employers to control substances that are hazardous to health. You can prevent or reduce workers exposure to hazardous substances by: ‘+ Finding out what the health hazards are: ‘* Deciding how to prevent harm to health (risk assessment); * Providing control measures to reduce harm to health; ‘+ Making sure they are used ; + Keeping all control measures in good working order; ‘* Providing information, instruction and training for employees and others; + Providing monitoring and health surveillance in appropriate cases; + Planning for emergencies Most businesses use substances, or products that are mixtures of substances. Some processes create substances. These could cause harm to employees, contractors and other people. Course Notes Page 5 of 71Compex Foundation TTE> 18 December 2014 - Version 1 Sometimes substances are easily recognised as harmful. Common substances such as paint, bleach or dust from natural materials may also be harmful. COSHH covers COSHH covers substances that are hazardous to health. Substances can take many forms and include: © Chemicals * Products containing chemicals © Fumes: © Dusts + Vapours © Mists * Nanotechnology * Gases and asphyxiating gases and biological agents (germs). If the packaging has any of the hazard symbols then it is classed as a hazardous substance ‘+ germs that cause diseases such as leptospirosis or legionnaires disease and germs used in laboratories COSHH does not cover + Lead, + Asbestos or + Radioactive substances because these have their own specific regulations PUWER PUWER replaces the Provision and Use of Work Equipment Regulations 1992 and carries forward these existing requirements with a few changes and additions, for example the inspection of work equipment and specific new requirements for mobile work equipment. Many aspects of PUWER should therefore be familiar to you. The Regulations require risks to people's health and safety, from equipment that they use at work, to be prevented or controlled. In addition to the requirements of PUWER, lifting equipment is also subject to the requirements of the Lifting Operations and Lifting Equipment Regulations 1998.2 What does PUWER do? In general terms, the Regulations require that equipment provided for use at work is Suitable for the intended use; Safe for use, maintained in a safe condition and, in certain circumstances, inspected to ensure this remains the case; Used only by people who have received adequate information, instruction and training; and accompanied by suitable safety measures, eg protective devices, markings, warnings. Course Notes Page 6 of 71Compex Foundation TTE> 18 December 2014 - Version 1 MHOR The MHOR Regulations in Brief The employer's duty is to avoid Manual Handling as far as reasonably practicable if there is a possibility of injury. If this cannot be done then they must reduce the risk of injury as far as reasonably practicable. If an employee is complaining of discomfort, any changes to work to avoid or reduce manual handling must be monitored to check they are having a positive effect. However, if they are not working satisfactorily, alternatives must be considered. The regulations set out a hierarchy of measures to reduce the risks of manual handling, These are in regulation 4(1) and as follows: + Avoid hazardous manual handling operations so far as reasonably practicable; + Assess any hazardous manual handling operations that cannot be avoided; + Reduce the risk of injury so far as reasonably practicable The guidance on the Manual Handling Regulations includes a risk assessment filter and checklist to help employers assess manual handling tasks. A revised version of the MHOR was published in March 2004. It also includes a checklist to help you assess the risk(s) posed by workplace pushing and pulling activities. In addition, employees have duties to take reasonable care of their own health and safety and that of others who may be affected by their actions. They must ‘communicate with their employers so that they too are able to meet their health and safety duties. Employees have general health and safety duties to: * Follow appropriate systems of work laid down for their safety + Make proper use of equipment provided for their safety ‘+ Co-operate with their employer on health and safety matters ‘+ Inform the employer if they identify hazardous handling activities + Take care to ensure that their activities do not put others at risk PPE REGS Employers have basic duties concerning the provision and use of personal protective equipment (PPE) at work and this document, explains what you need to do to meet the requirements of the Personal Protective Equipment at Work Regulations 1992 (as amended). What is PPE? PPE is defined in the Regulations as ‘all equipment (including clothing affording protection against the weather) which is intended to be worn or held by a person at work and which protects him against one or more risks to his health or safety’, eg safety helmets, gloves, eye protection, high-visibility clothing, safety footwear and safety harnesses. Hearing protection and respiratory protective equipment provided for most work situations are not covered by these Regulations because other regulations apply to them. However, these items need to be compatible with any other PPE provided. Course Notes Page 7 of 71Compex Foundation TTE> 18 December 2014 - Version 1 Cycle helmets or crash helmets worn by employees on the roads are not covered by the Regulations. Motorcycle helmets are legally required for motorcyclists under road traffic legislation. What do the Regulations require? The main requirement of the PPE at Work Regulations 1992 is that personal protective equipment is to be supplied and used at work wherever there are risks to health and safety that cannot be adequately controlled in other ways. The Regulations also require that PPE: * Is properly assessed before use to ensure it is suitable; * Is maintained and stored properly; + Is provided with instructions on how to use it safely; and + Is used correctly by employees Can | charge for providing PPE? An employer cannot ask for money from an employee for PPE, whether it is returnable or not. This includes agency workers if they are legally regarded as your employees. If employment has been terminated and the employee keeps the PPE without the employer's permission, then, as long as it has been made clear in the contract of employment, the employer may be able to deduct the cost of the replacement from any wages owed. MHSWA REGS ‘The MHSW regulations have been put in place in order that you take care of all those you work in conjunction with - employees, contractors, clients or customers. The aim of the regulations is to reduce damage by assessing all potential risks and to create action plans for emergencies Compliance with industry specific regulations will normally be sufficient. However, where MHSW Regulations go further than those of more specific legislation, extra measures will be required in order to comply. Who do the regulations apply to? Employers have a duty to asses all risks for all workers, including mobile and home workers Seafarers and young people performing temporary or short-term work in family businesses or domestic service are exempt from protection. ‘A summary of the regulations: (for employers): * You must review risk assessments periodically and make modifications if there are any significant changes in working practices or equipment; + If safety procedures can ever be improved, appropriate steps should be taken accordingly; * You are expected to take reasonable steps to familiarise yourself with the hazards and risks in your workplace; * Work must be organised. A set pattern of rules and regulations usually means more systematic work and less chance of accidents; Course Notes Page 8 of 71Compex Foundation TTE> 18 December 2014 - Version 1 ‘+ Training should be given in such a way that hazardous situations can be avoided. For example: Lengthening of working day, removal of taking screening breaks etc for meeting deadlines should be avoided; + You must ensure that the significant hazards are identified, and that the actual working practices are addressed and if need be, changed so as to reduce any risk ELECTRICITY AT WORK REGULATIONS The Electricity at Work Regulations 1989 (SI 1989/635) (as amended) (the Regulations)* came into force on 1 April 1990. The purpose of the Regulations require precautions to be taken against the risk of death or personal injury from electricity in work activities. PERSONS ON WHOM DUTIES ARE IMPOSED BY THESE REGULATIONS REGULATION 3 1) Except where otherwise expressly provided in these Regulations, it shall be the duty of every- a) Employer and self-employed person to comply with the provisions of these Regulations in so far as they relate to matters which are within his control; and b) Manager of a mine or quarry (within in either case the meaning of section 180 of the Mines and Quarries Act 1954(1)) to ensure that all requirements or prohibitions imposed by or under these Regulations are complied with in so far as they relate to the mine or quarry or part of a quarry of which he is the manager and to matters which are within his control 2) It shall be the duty of every employee while at work- a) To co-operate with his employer so far as is necessary to enable any duty placed on that employer by the provisions of these Regulations to be complied with; and b) To comply with the provisions of these Regulations in so far as they relate to matters which are within his control SYSTEMS, WORK ACTIVITIES AND PROTECTIVE EQUIPMENT REGULATION 4 1) All systems shall at all times be of such construction as to prevent, so far as is reasonably practicable, danger. 2) As may be necessary to prevent danger, all systems shall be maintained so as to prevent, so far as is reasonably practicable, such danger. 3) Every work activity, including operation, use and maintenance of a system and work near a system, shall be carried out in such a manner as not to give rise, So far as is reasonably practicable, to danger. 4) Any equipment provided under these Regulations for the purpose of protecting persons at work on or near electrical equipment shall be suitable for the use for Course Notes Page 9 of 71Compex Foundation TTE> 18 December 2014 - Version 1 which it is provided, be maintained in a condi properly used. STRENGTH AND CAPABILITY OF ELECTRICAL EQUIPMENT n suitable for that use, and be REGULATION 5 No electrical equipment shall be put into use where its strength and capability may be exceeded in such a way as may give rise to danger. ADVERSE OR HAZARDOUS ENVIRONMENTS REGULATION 6 Electrical equipment which may reasonably foreseeably be exposed to- a) Mechanical damage; b) The effects of the weather, natural hazards, temperature or pressure; ©) The effects of wet, dirty, dusty or corrosive conditions; or d) Any flammable or explosive substance, including dusts, vapours or gases, Shall be of such construction or as necessary protected as to prevent, so far as is reasonably practicable, danger arising from such exposure. MEANS FOR CUTTING OFF THE SUPPLY AND FOR ISOLATION REGULATION 12 1) Subject to paragraph (3), where necessary to prevent danger, suitable means (including, where appropriate, methods of identifying circuits) shall be available for- a) Cutting off the supply of electrical energy to any electrical equipment; and b) The isolation of any electrical equipment. 2) In paragraph (1), “isolation” means the disconnection and separation of the electrical equipment from every source of electrical energy in such a way that this disconnection and separation is secure. 3) Paragraph (1) shall not apply to electrical equipment which is itself a source of electrical energy but, in such a case as is necessary, precautions shall be taken to prevent, so far as is reasonably practicable, danger. PRECAUTIONS FOR WORK ON EQUIPMENT MADE DEAD REGULATION 13 ‘Adequate precautions shall be taken to prevent electrical equipment, which has been made dead in order to prevent danger while work is carried out on or near that equipment, from becoming electrically charged during that work if danger may thereby arise. Course Notes Page 10 of 71Compex Foundation TTE> 18 December 2014 - Version 1 PERSONS TO BE COMPETENT TO PREVENT DANGER AND INJURY REGULATION 16 Bs 767) DSEAR Course Notes No person shall be engaged in any work activity where technical knowledge or experience is necessary to prevent danger or, where appropriate, injury, unless he possesses such knowledge or experience, or is under such degree of supervision as may be appropriate having regard to the nature of the work. This is the British Standards published by the IET (Institute of Engineering and Technology ) and the BSI ( British Standards Institute ) for all electrical installations under 1000V. Now in its 17th Edition/ amendment 1. It is a comprehensive list of regulations, tables, charts etc covering every aspect of cable calculations, capacity of conductors, installation methods and so on. It is over 400 pages and takes some getting used to reading , never mind finding what you set out to find, If you are an electrician you will already know this all to well ! There is also a set of Guidance Notes published again by the IET which go into greater depth for certain areas such as Inspection and Testing, Special Locations and so on. If you do need to know more for doing your own work | would recommend the On Site Guide book which is again Published by the IET, but has all the basics for working safely and correctly in accordance with 857671. The 17th edition, released in January 2008 and amended in 2011, is the latest edition of BS7671, and became effective for all installations designed after 1 July 2008 One of the more significant changes is (chapter 41) that 30 mA RCDs will be required for socket outlets that are for use by ordinary persons and are intended for general use. This improves the level of protection against electrical shock in the UK to a level comparable to that in other EU countries. The 17th edition incorporates new sections relating to micro-generation and solar photovoltaic systems. Dangerous Substances & Explosive Atmospheres Regulations 2002 DSEAR is concerned with protection against risks from fire, explosion and similar events arising from dangerous substances used or present in the workplace. They set minimum requirements for the protection of workers from fire and explosion risks related to dangerous substances and potentially explosive atmospheres. The Regulations apply to employers and the self-employed at most workplaces in Great Britain where a dangerous substance is, or could be, present. DSEAR is part of the HASWA. ATEX Regulations came into force On the 1*July 2003. Existing Plants had until 2006 to for full compliance. DSEAR Requirements Do you carry out regular and adequate inspections at the workplace? Do you consider non-electrical items? Have you looked into consideration mitigation against the effects of an explosion! Have you got in place procedures in case of an emergency or accident? Have you got in place documentation and control procedures required for DSEAR? Statutory Instrument 2002 No. 2776. Page 11 of 71Compex Foundation TTE> 18 December 2014 - Version 1 The Dangerous Substances and Explosive Atmospheres Regulations 2002(DSEAR) were made under the Health and Safety at Work etc Act 1974 (HSW Act) and their main provisions came into force on 9 December 2002. The Regulations apply to workplaces {as defined in regulation 2) in Great Britain. These workplaces, which cover most sectors of industry and commerce, are also subject to the HSW Act. A limited number of requirements concern explosive atmospheres and these came into force on 30 June 2003; their application is subject to transitional arrangements. The Regulations implement two European Directives: the safety aspects of the Chemical Agents Directive (a) 98/24/EC9 (CAD) and the Explosive Atmospheres Directive 99/92/EC10 (ATEX 137) requiring similar legislation throughout the European Union (EU) on work involving hazardous chemical agents and explosive atmospheres. DSEAR requires the establishment to have a strategy for prevention of explosions. This requires that the organisational measures taken at the workplace. This is a form of System management and control of an Explosive Atmosphere. The primary purpose of DSEAR is to protect the safety of workers and others who may be at risk from dangerous substances that can cause a fire, explosion or similar energy-releasing event, such as a runaway exothert set out as follows: Regulations 1 to 4 deal with preliminary Regulations, scope and definitions. sues, i.e. the date of entry into force of the Regulation 5 requires employers and the self-employed to assess risks to employees and others whose safety may be affected by the use or presence of dangerous substances at work. Regulation 6 sets out how the risk to safety from dangerous substances should be eliminated or reduced. Regulation 7 contains specific requirements to be applied where an explosive atmosphere may be present (in addition to the requirements in regulation 6). Regulation 8 requires the provision of arrangements to deal with accidents, incidents and emergencies. Regulation 9 requires the provision of information, training and instruction on dangerous substances. Regulation 10 requires the identification of pipes and containers where these contain dangerous substances. Regulation 11 addresses the need to coordinate explosion protection measures where ‘employers share the same workplace. Regulations 12-16 deal with the application of the Regulations outside Great Britain, exemptions from the Regulations, and amendments to and removal of other legislation. Regulation 17 sets out the transitional arrangements for workplaces and work equipment where explosive atmospheres may occur. Course Notes Page 12 of 71Compex Foundation TTE> 18 December 2014 - Version 1 (@) The health aspects of CAD are implemented separately through the Control of Substances Hazardous to Health Regulations 2002, the Control of Lead at Work Regulations 2002 and the Control of Asbestos at Work Regulations 2002. DANGEROUS SUBSTANCES WARNING SIGNS DSEAR introduces an approach to reduce any risk, ELIMINATION METHODS 1. Substitution 2. Control 3. Mitigation You should try to avoid the use altogether of hazardous substances or processes. If this cannot be done, suitable control measures should be applied to prevent fires, explosions and adverse events occurring. Adverse events, process going out of control. If having applied control measures there is still a risk if fire or explosion occurring, mitigate by protecting persons from detrimental effects. Course Notes Page 13 of 71Compex Foundation TTE> 18 December 2014 - Version 1 DANGEROUS SUBSTANCE ASSESSMENT Duty of Co-ordinatior Competence Training Emergencies and Accidents Equipment and Inspectio! Ignition Assessment Area Classification — — se Risk Assessments, ss : ye Locations ATEX ATEX (ATmospheres EXplosive) Main Purpose of the Directive; “to remove technical barriers to trade within the European Community and outlines essential technical and safety requirements" The main change in Atex 95 is that non-electrical hazards are now brought within the scope of the directive, Pump, mechanical seals, reducer, coupling, guard coupling and motor must be in accordance. For new equipment, Compliance with the ATEX directive has been a legal requirement in all European Union member states since 1st July 2003. For equipment sold before 1st July 2003; Equipment compliance with the ATEX directive is a legal requirement in all European Union member states by Ist July 2006. The end-user must complete with a notified organisation, an inflammation risk assessment document relating to the use of each piece of equipment in potentially explosive atmospheres. Course Notes Page 14 of 71Compex Foundation TTE> 18 December 2014 - Version 1 ith trans Introduced into British Law March 1996 ion periods. ATEX Regulations came into force on the 1* July 2003 Became fully into force on 1* July 2006. (Existing Plants compliance). All hazardous areas must now conform to ATEX 95 & ATEX 137. Applies to both electrical & mechanical equipment. Statutory Instrument 2002 No. 2776. ATEX DIRECTIVE 95 Equipment and its protective systems for use in potentially explosive atmospheres. The ATEX Directive (94/9/EC) known as ATEX Directive 95 concerning Equipment and Protective Systems intended for use in potentially explosive atmospheres is mainly of interest to the equipment manufacturer and supplier although there are some aspects (mainly associated with the availability of spares and stock items) which will be of concern to the equipment user. Atex Directive 137 The UK regulation which puts into effect this directive is DSEAR. UK regulations which put into effect thi ctive are: ‘+ Equipment and protective systems intended for use in potentially explosive atmospheres FEBRUARY 2002 ‘+ ATEX Directive 137(was 118). The UK Regulations which puts into effect this directive is DSEAR. + The ATEX 137 Directive Is aimed at ensuring the health and safety of workers whilst in their place of work. This directive categorises the workplace into zones. Zones provide a measure of the probability of the presence of a dangerous mixture with air of any flammable gas or combustible dust. ‘+ Covers health and safety protection of workers. ‘+ Duties are placed on the employer. ‘+ Intended to ensure that workers enjoy a minimum level of protection throughout all member states. ATEX 137 - EMPLOYERS OBLIGATIONS Prevent formation and ignition of flammable atmospheres Control effects of explosions Conduct Risk Assessments Classify work place into zones Maintain an explosion protection document Use ATEX 95 equipment Training of staff Identify areas with signage Course Notes Page 15 of 71Compex Foundation TTE> 18 December 2014 - Version 1 THE WARNING SIGN The requirement for a warning sign is in line with the EC Safety Signs Directive. The purpose of this directive is to encourage the standardisation of safety signs throughout the member states so that signs, wherever they are seen, have the same meaning. Directive 99/92/EC requires that, where necessary, locations where —_ explosive atmospheres may occur shall be marked with warning signs at their point of entry. The warning sign must have certain distinctive features. It must be triangular in shape, utilise black lettering on a yellow background with black edging. The yellow background must constitute at least 50% of the area of the sign. Other explanatory data may be added to the sign. ATEX MARKINGS Meets ATEX Directive 95 (for use in explosive atmospheres) EUROPEAN STANDARDS - COMMITTEE FOR ELECTRO TECHNICAL STANDARDISATION (CENELEC) CENELEC is the European Committee for Electro technical Standardisation and is responsible for standardisation in the electro technical engineering field. CENELEC prepares voluntary standards, which help facilitate trade between countries, create ew markets, cut compliance costs and support the development of a Single European Market. IEC - Standards dealing with electrical apparatus for hazardous areas are numbered in the series 79 - xx e.g. 79 - 14 this refers to electrical apparatus for explosive gas atmospheres, Part 14: Electrical Installations in hazardous areas (other than mines) Standards relating to this course are: 60079-0 General Requirements. 60079-10-1 Classification of areas (gas). 60079-14 Installation, design, selection & erection. 60079-17 Inspection & maintenance Course Notes Page 16 of 71Compex Foundation TTE> 18 December 2014 - Version 1 INTERNATIONAL STANDARDS ~ INTERNATIONAL ELECTRO TECHNICAL COMMISSION (IEC) Founded in 1906, the IEC (International Electro technical Commission) is the world’s leading organisation for the preparation and publication of International Standards for all electrical, electronic and related technologies. These are known collectively as “electro technology”. IEC provides a platform to companies, industries and governments for meeting, discussing and developing the International Standards they require. All IEC International Standards are fully consensus-based and represent the needs of key stakeholders of every nation participating in IEC work. Every member country, no matter how large or small, has one vote and a say in what goes into an IEC International Standard. THE RISK ASSESSMENT A risk assessment is an important step in protecting jm your workers and your business, as well as complying fg with the law. It helps you focus on the risks that really matter in your workplace - the ones with the potential Five steps to risk to cause real harm. assessment A risk assessment is simply a careful examination of what, in your work, could cause harm to people, so that you can weigh up whether you have taken enough precautions or should do more to prevent harm. Workers and others have a right to be protected from harm caused by a failure to take reasonable control measures. Step 1 Identify the hazards Step 2 Decide who might be harmed and how Step 3 Evaluate the risks and decide on precautions Step 4 Record your ings and implement them Step 5 Review your assessment and update if necessary Course Notes Page 17 of 71Compex Foundation TTE> 18 December 2014 - Version 1 Training uo aes ‘ia? esr Sup Sow te: iiSheeaner mn emanates Course Notes Page 18 of 71Compex Foundation TTE> 18 December 2014 - Version 1 UNIT 2: AREA CLASSIFICATION CAUSES OF EXPLOSIONS EXPLOSION An explosion can occur if there is a combination of a flammable material, oxygen and a source of ignition. If one component is missing no exothermal reaction will occur. Prerequisites for an explosion EXPLOSIVE MATERIAL A flammable material which is present as a gas, vapour or dust is called an explosive material. In the case of vapours or dusts, an explosive atmosphere is created if the drop or particle size is smaller than | mm. Vapours, aerosols and dusts occurring in practice have particle sizes between 0.001 and 0.1mm. Dusts with larger particle sizes are not flammable. Combustion will take place if all three elements, in one form or another, are present, the gas/air mixture is within certain limits and the source of ignition has sufficient energy. The removal of one element is sufficient to prevent combustion as is the isolation or separation of the source of ignition from the gas/air mixture. These are two techniques used in explosion protected equipment. Other protection techniques allow the three elements to co-exist and either ensures that the energy of the source of ignition is maintained below specific values, or allows an explosion to take place and contain it within a robust enclosure. These techniques are addressed in the various sections of this manual. Course Notes Page 19 of 71CompEx Foundation 18 December 2014 - Version 1 ft IGNITION SOURCES. Welding Burning (naked flame) Radiation (sun on metal surfaces) Electro Statics: Lightning Nylon Clothes Water Jetting (Typically 10kV) Aerosols (Typically SkV) NATURE OF THE HAZARD Equipment group II "Surface installations" Hazardous areas Equipment group | "Mining installations” Areas with a firedamp hazard = coal-mining ‘THE GAS GROUP Group | Mining (Methane and Coal Dust) Group II Non Mining/Above ground This course is intended for Group Il gases and NOT for Group | Mining (MI & M2). HAZARDOUS AREAS ‘A Hazardous Area is considered to be an area where an explosive atmosphere is or maybe expected to be present, which requires special precautions to be taken for the construction, installation and use of electrical equipment. For the standard it is considered to be a three dimensional space. Course Notes Page 20 of 71Compex Foundation TTE> 18 December 2014 - Version 1 AREA CLASSIFICATION The aim of Area Classification is: To reduce to an acceptable level the possibility of a flammable atmosphere and an electrical source of ignition coinciding Undertaken by personnel from several disci chemical and civil engineering. ines including electrical, mechanical, DSEAR requires operators to undertake a full risk assessment of existing workplaces. There are many codes of practice which specify methods of grading areas of Hazard, a few typically are: EI’ Energy Institute (Formally the Institute of Petroleum ‘IP’) A.P.1. (American Petroleum Institute) Recommended Practice for Classification of area, etc. 60079-10-1 Classifi ation of Hazardous Areas The Nature of the Hazard: It's Gas Group It's Flash Point The Ignition Temperature LEL and UEL Values Potential source of release The extent of the release Group I! Gases Group Il gases are divided into sub-divisions based on one or both of two test methods: MESG (Maximum Experimental Safe Gap): The maximum clearance between two parallel metal surfaces that has been found, under specified test conditions, to prevent an explosion in a test chamber from being propagated to a secondary chamber containing the same gas or vapour at the same concentration. MIC (Minimum Igniting Current) Ratio: The ratio of the minimum current required from an inductive spark discharge to ignite the most easily ignitable mixture of a gas or vapour, divided by the minimum current required from an inductive spark discharge to ignite methane under the same test conditions. Group IIA - Propane (least easil Group IIB - Ethylene Group IIC - Hydrogen (very easily ignited) ignited) ‘THE FLASH POINT By definition flashpoint is: ‘the lowest temperature at which sufficient vapour is given off a liquid, to form a flammable mixture with air that can be ignited by an arc, spark or naked flame’. ‘THE IGNITION TEMPERATURE. Ignition temperature is defined as: ‘the minimum temperature at which a flammable material will spontaneously ignite’. Course Notes Page 21 of 71Compex Foundation TTE> 18 December 2014 - Version 1 raining fr ineustry Ignition temperature, formerly known as auto-ignition temperature, is an important parameter since many industrial processes generate heat. Careful selection of electrical equipment will ensure that the surface temperatures produced by the equipment, indicated by the T-rating, will not exceed the ignition temperature of the flammable atmosphere which may be present around the equipment. ‘TEMPERATURE CLASSIFICATION Temperature classification is based on the maximum temperature which any relevant part of the apparatus, (which maybe in contact with an explosive gas) will reach, when operating within normal design ratings, (-20'c to + 40'c) TEMPERATURE CLASS Temperature class roiates to the hot surtace 1gniion tamperature of a panicutr expose almonohere. must not be gxcunaes by tho lomparature clasetcates oe earn Intended to be used in thal atmosphere, Hot surfaces can ignite ‘atmospheres Explosion Protected UEL and LEL Values EL - Upper Explosive Limit Is the concentration of flammable gas or vapour in the air above which the gas atmosphere is not explosive. LEL - Lower Explosive Is the concentration of flammable gas or vapour in the air below which the gas atmosphere is not explosive. Course Notes Page 22 of 71Compex Foundation TTE> 18 December 2014 - Version 1 RZ OVol% ‘cars ae pesca {— Explosion —— ey iaweeee nae OVol % J es POTENTIAL SOURCES OF RELEASE Defines how likely it is that a hazardous concentration will be present in any given Geographical location commonly referred to as the ‘Zone’. The extent of the zone is determined by chemical and physical parameters. In general the greater the release rate, the larger the zone. Extent of Zone Geometry of release - from open pool mechanical seal or flange Release velocity - process pressure, liquid or gas Concentration Ventilation Relative Density; If a flammable material is released, it is important to know whether the material will rise or fall in the atmosphere. The different flammable materials are compared with air and allocated a number to denote their relative density with air. Since air is the reference, its relative density is 1 so that for a material twice as heavy as air, its relative density will be 2, Therefore, materials with a relative density less than unity will rise in the atmosphere, and those greater than unity will fall in the atmosphere. Materials which rise in the atmosphere can collect in roof spaces, and those which fall, such as butane or propane, can drift along at ground level and possibly into a non- hazardous location, or may collect in locations lower than ground level without ever dispersing. Such locations should be well ventilated in order to avoid ignition due to a stray spark or a discarded cigarette. Knowledge of where a flammable material will collect ensures that gas detectors when fitted will be located at the correct level and ventilation is directed accordingly. Course Notes Page 23 of 71CompEx Foundation 18 December 2014 - Version 1 <1 >41 AREA CLASSIFICATION MATERIAL, Ethylene Hydrogen Acetylene Diethyl Ether Paraffin Carbon Disulphide The result of an Area Classification Study is an ‘Area Classification Diagram’ which is a graphical representation of the plant showing the hazardous areas (zones). Non-Hazardous area DEFINITIONS. ZONE 0 A place in which an explosive atmosphere c mixture with air or flammable substances ii gas vapour or mist is present continuoush Periods or frequently. ZONE A’ place onsisting of a in the form of ly or for long in which an explosive atmosphere consisting of a mixture with air or flammable substances in the form of gas vapour or mist is likely to occur in normal operation occasionally Course Notes Page 24 of 71CompEx Foundation 18 December 2014 - Version 1 ZONE 2 A place in which an explosive atmosphere consisting of a mixture with air of flammable substances in the form of gas, vapour or mist is not likely to occur in normal operation but, if it does occur, will persist for a short period only Non-Hazardous area ‘An area associated with a plant which is designated free from flammable materials and atmospheres, as designated on an area classification drawing. Always consult the drawing key. EQUIPMENT SELECTION GROUP Il GAS SUBDIVISION iplosion Pretec nition Equpment ‘pet eles Remoaohe® The safest method is....to install electrical equipment in Safe Area Does equipment certification indicate any Special Conditions of use ‘X’ Course Notes Page 25 of 71Compex Foundation TTE> 18 December 2014 - Version 1 Apparatus can be protected against the ingress of liquids and solid matter (inc. dust) with the use of barriers & seals. Apparatus that is intended for use in areas where these may be present will carry a ‘code which indicates to what level the apparatus is protected, The code is known as the: - |.P Code (Ingress Protection Code) INGRESS PROTECTION The IP Code defined in international standard 1EC 60529 classifies the degrees of protection provided against the intrusion of solid objects (including body parts like hands and fingers), dust, accidental contact, and water in electrical enclosures. It consists of the letters IP (for “international protection rating” sometimes also interpreted as "ingress protection rating”) followed by two digits and an optional letter. The standard aims to provide users more detailed information than vague marketing terms such as "waterproof. The digits (characteristic numerals’) indicate conformity with the conditions summarised in the tables below. Where there is no protection rating with regard to one of the criteria, the digit is replaced with the letter X. For example, an electrical socket rated |P22 is protected against insertion of fingers and will not be damaged or become unsafe during a specified test in which it is exposed to vertically or nearly vertically dripping water. IP22 or IP2X are typical minimum requirements for the design of electrical accessories for in-door use. Course Notes Page 26 of 71CompEx Foundation 18 December 2014 - Version 1 Training for inch amiss aa eee ae 3 eg 3 St on nt pg {= rene wo YZ mm Sa pened 4 aS" wee 4 bron gd nist tad xen atom 5 posgeneaa] Om 5 soenes Fn Pen | " : : 6 ‘Strong hosing jets| 6 No ingress of dust. | Dusttight trom all divections | = 7 Ponca SAE] Sms [omer Course Notes H Page 27 of 71Compex Foundation TTE> 18 December 2014 - Version 1 UNIT 4: CERTIFICATION ATEX product certification (or EC Type Examination) is the check on the design specification of a product in relation to a series of relevant standards laid out under the directive, It involves a detailed process of examination, testing and assessment of equipment intended for use in potentially hazardous areas, with the end result being the issue of an ATEX certificate and report, confirming and demonstrating that the product is safe to use (within certain parameters) within potentially explosive atmospheres. The certification process must be undertaken by a Notified Body who issue ATEX certificates and conduct periodic surveillance of quality management systems. Certification is the process of assessing a design to a specification set down ina Standard Apparatus certified to CENELEC Standards will bear the code Eex Older apparatus certified to a National Standard will bear the code Ex ‘Component Certificate Certificate of Assurance Certificate of Conformity Certificates where special conditions of use apply COMPONENT CERTIFICATE Not a full certification and apparatus to which this certificate appears will need additional protection before use in a hazardous area. ‘Components’: means any item essential to the safe functioning of equipment and protective systems but with no autonomous function.” Certificate number will end in the letter “U"; components do not require the CE mark A Component Certificate needs always additional certification before bringing into service. You could recognise a component certificate through its name and through a 'U' behind its certificate number. ‘U’ is German ‘Unvollstandig’ and means incomplete certification. Only the component is certified, but not - without further action. + suitable for installation in hazardous areas. Not completed component certification has a way of protection- and a group marking. No temperature class is mentioned on this type of certificate. Examples of component certified products are terminals, switchgear, remote I/O. Often additional enclosures are required, however empty enclosures belong also to the examples of component certified products. CERTIFICATE OF ASSURANCE Apparatus certified to National Standard or CENELEC Standard by a Notified body outside the EEC. If you manufacture products intended for use in potentially explosive atmospheres, you must provide assurance that your equipment will not cause an explosion during routine operation. Demonstrating compliance with the ATEX Directive 94/9/EC will provide that assurance. It is mandatory for these products to bear both the Distinctive Course Notes Page 28 of 71Compex Foundation TTE> 18 December 2014 - Version 1 ‘Community Mark (the Ex Mark in hexagon) and CE marking before being sold in the Eu. CERTIFICATE OF CONFORMITY Apparatus certified by an EEC Notified Body to a CENELEC Standard recognised by EEC Directives. The Declaration of conformity should include: Name & address of the manufacturer (or their authorised representative). A description of the equipment and its intended use. All relevant provisions fulfilled by the directive (i.e. relevant product marking, T-class and gas groups). Name & Address of the Notified Body who certified the equipment (if applicable), Product Certificate Number (if applicable) i.e, SIRAOGATEX1234 Reference to the harmonised standards used to certify the equipment. Reference to other harmonised directives adhered to (if applicable). Signature of the “responsible person”, For components (i.e. unfinished parts) an attestation of conformity is required and this must contain details of the characteristics of the component, how the component is to be incorporated into the finished equipment such that it will meet the provisions of the ATEX Directive. What Is the difference between a Declaration of Conformity and a Certificate? A Declaration of Conformity is the document that the manufacturer must enclose with (or attach to) any equipment or protective system that is being sold in compliance with the requirements of the ATEX Directive 94/9/EC. The manufacturer has sole responsibility for creating this document and must do so in accordance with the detailed list of contents given at Annex X in the directive. The declaration complements the CE Marking which is applied to the product on the manufacturer's responsibility. A Certificate is normally the output of a process known as "Certification". There are many types of certification schemes, but they all involve the use of a third party certification body which is independent from the manufacturer and purchaser of the product (or service) that is the subject of certification. ‘An ATEX product which has been subject to “certification” will normally have two documents: The "EC-Type Examination Certificate” is issued by an ATEX Notified Body (NB) following test and examination of a prototype, in accordance with Annex Ill of the directive. The name of the NB is incorporated in the certificate number marked on the product. A production document, usually a "Quality Assurance Notification” (QAN) is issued following a review of production capability, in accordance with Annexes IV and/or Vil of the directive, and is subject to periodic review based on regular surveillance. Alternatively, "Verification" may be followed for this production phase, where the Course Notes Page 29 of 71Compex Foundation TTE> 18 December 2014 - Version 1 Notified Body examines each item of manufactured equipment. The NB number (1180 for Baseefa) is included in the marking, adjacent to the CE marking. Where the certification has been carried out on a voluntary basis (for example for Category 3 equipment where certification is not mandated by the directive), the document is simply known as a "Type Examination Certificate". Notified Bodies offer this added service to assist manufacturers where a customer wants more assurance than is given by the minimum legal requirements of the directive. The existence of a certificate eases the manufacturer's task in writing his Declaration of Conformity, but where the directive allows the use of "Internal Control of Production” module (Annex Vill), the manufacturer is entitled to base his declaration entirely on the technical file he has developed himself. WHERE SPECIAL CONDITIONS OF USE APPLY Certificate will end with the letter 'X’, in the past the letter 'B' was used and maybe still encountered on some certificates. This denotes ‘special certification conditions’. These details are given on the certificate and on the installation leaflet. The conditions usually relate to cable entry, operation, lamps and maintenance conditions and must be observed by the user. Always inspect/ask to see certificate to ensure alll special conditions have been met. Course Notes Page 30 of 71CompEx Foundation 18 December 2014 - Version 1 TTE> UNIT 5: EQUIPMENT SELECTION The ATEX Directives introduced Categories of equipment numbered 1, 2 & 3 followed by D (Dust)/or G (Gas). In 2006 IEC 60079 introduced EPLs (Equipment Protection Levels) which mirror the ATEX categories. 0 continuously, for a long period, frequently 1 occasionally 2 2 rarely and for a short period 3 Where only the zones are identified in the area classification documentation, then the relationship between categories/EPLs and zones should be followed. 0 1 ‘Ga’ 1 1or2 ‘Ga’ or ‘Gb’ 2 1,20r3 ‘Ga’, ‘Gb’ or ‘Ge’ Equipment Protection Levels (EPLs) EPL Ga (Equivalent to Atex Cat 1) Equipment for explosive gas atmospheres, having a ‘very high’ level of protection, which is not a source of ignition in normal operation, expected faults or when subject to rare faults. 1EC 60079 - 11 Encapsulation IEC 60079 - 18 ‘Two independent types of protection ‘each meeting EPL ‘Gb’ IEC 60079 - 26 Protection of equipment and transmission systems using optical radiation 1EC 60079 - 28 EPL Gb (Equivalent to Atex Cat 2) Equipment for explosive gas atmospheres, having a ‘high’ level of protection, which is not a source of ignition in normal operation or when subject to faults that may be expected, though not necessarily on a regular basis. Course Notes Page 31 of 71CompEx Foundation 18 December 2014 - Version 1 CAT2 ‘Gb’ Flameproof enclosures ‘a’ | ec 60079-01 Increased safety ‘e | tec 0079-07 Intrinsically sate aw | tec 60079 11 Encapsulation ‘m’ mb’ | IEC 6079-18 ll immersion ‘0° | tec 60079-06 Pressurized enclosures oe} IEC 60079 - 02 Powder filing IEC 60079 - 05 Fieldbus intrinsically safe concept (FISCO) EC 60079 - 27, Protection of equipment IEC 60079 - 28 EPL Gc (Equivalent to Atex Cat 3) Equipment for explosive gas atmospheres, having a ‘enhanced’ level of protection, which is not a source of ignition normal operation and which may have some additional protection to ensure that it remains inactive as an ignition source in the case of regular expected occurrences... ._(for example failure of a lamp). intrinsically safe ‘ic’ | EC 60079 - 11 Encapsulation ‘me’ | IEC 60079 - 18 Non-sparking ‘wor ‘nA’ | IEC 60079 - 15 Restricted breathing ‘nk’ | IEC 6079-15 cAT3 | ‘Get | Energy limitation ‘nt | IEC 60079 -15 Sparking equipment ‘nc’ | IEC 60079 ~ 15 Pressurized enclosures ‘pz’ | IEC 60079 -2 Fieldbus non-incendive concept (FNICO) IEC 60079 - 27 Protection of equipment and transmission systems using optical radiation Peer reenter Page 320171 Course NotesCompex Foundation TTE> 18 December 2014 - Version 1 Training for ncustry IEC 60079-14:2007 (EPL APPROACH) Traditional approach to selection of equipment Conduct Area Classification Defines Zones & Extents Select Type of Protection i 2 : g Conduct Area Classification Defines Zones & Extents Risk Assessment of Consequences Determine EPL Select Type of Protection jer, where a risk assessment, taking into account the consequences of an ignition, has been carried out and the resulting EPL requirements differ from the norm, the required EPL/Categories are to be marked on the Area Classification Drawing. Why EPL? (Atex categories) Historically it has been acceptable to install equipment into specific zones based on the type of protection. In some cases it has been shown that the type of protection may be divided into different levels of protection that can be correlated against each Zone. A better risk assessment would consider all factors. When using a risk assessment approach, instead of the inflexible approach of the past linking equipment to Zones, the inhé ignition risk of the equipment is clearly indicated, no matter what type of protection is used. Course Notes Page 33 of 71Compex Foundation TTE> 18 December 2014 - Version 1 An example using a risk assessment approach: Plant operators often make intuitive decisions on extending (or restricting) their Zones in order to compensate for this inflexibility. A typical example is the installation of “Zones 1 Type” navigation equipment in Zone 2 areas of offshore oil production platforms, so that the navigation equipment can remain functional even in the presence of a totally unexpected and prolonged gas release. On the other hand, it is reasonable for the owner of a remote, well secured, small pumping station to drive the pump with a "Zone 2 Type" motor, even in Zone 1, if the total amount of gas available to explode is small and the risk to life and property from such as explosion can be discounted. The situation became more complex with the publication of the first edition of IEC 60079:26 which introduced additional requirements to be applied for equipment intended to be used in Zone 0. Prior to this, Ex i dered to be the only technique acceptable in Zone 0. It has been recognised that it is beneficial to identify and mark all products according to their inherent ignition risk. This makes equipment selection easier and a risk assessment approach, more appropriate. Course Notes Page 34 of 71Compex Foundation TTE> 18 December 2014 - Version 1 UNIT 6: LABELLING All equipment certified for use in hazardous areas must be labelled to show the type and level of protection applied. ATEX equipment labelling follows a defined, systematic method in which the assessment of the following categories can be interpreted by the letters and numbers: Equipment group (use in mines with pit gas hazards: Group | versus all other explosion hazards areas: Group Il) Equipment category according to ATEX 95a (equipment safety for Group II) Type of atmosphere (for Group Il) Ignition protection type Explosion group Temperature class or maximum permissible surface temperature In Europe the label must show the CE mark and the code number of the certifying body. The CE marking is complemented with the Ex mark, followed by the indication of the Group, Category and, if group Il equipment, the indication relating to gases G or dust D. For example: Ex Il 1 G Explosion protected, Group 2, Category 1, Gas Specific type or types of protection being used will be marked. ATEX (European Union) i 4 type of explosive atmosphere (Group G: Gas, vapour, mist D: Dust (Group ) M1 : energised M2 : de-energised Equipment Category (Group i) 1.2.3 Equipment Group 1:'Mining Non-Mining EU Explosive Atmosphere Symbol Identification number of Notified Body responsible for surveillance CE mark (European Compliance) New Marking - EPL's (Explosion Protection Levels) The introduction of the EPL's and changes in the EN 60079 and EN 61241 series standards has introduced new marking requirements. GAS (SURFACE) The gas group that was previously (Il) for increased safety in surface applications is now IIA, IIB or 1IC, depending upon the certification. Course Notes Page 35 of 71Compex Foundation TTE> 18 December 2014 - Version 1 Training DusT Grouping has also been applied to dusts where the marking is differentiated from gases by the addition of another | i.e. IIA, IIIB or IIIC. Explosion Protection Levels The explosion protection levels are identified by their lettering IEC/CENELEC (Global/Europe) | deeeticto Maximum external surface temperature Apparatus Group Type of protection Explosion protection symbol ‘Ambient temperature range of -20°C to +40°C unless stated on label Equipment Protection Level (EPL) Temperature Classification (Group W) Apparatus Group : : ‘Aternate marking format possible ® ice ot erotecson Ce Re ee eee eR a Explosion protection symbol Course Notes Page 36 of 71Compex Foundation TTE> 18 December 2014 - Version 1 UNIT DEFINE FLAMEPROOF (EEx d) ITION (IEC 60079-1) ‘An enclosure in which the parts which can ignite an explosive gas atmosphere are placed and which can withstand the pressure developed during an internal explosion of an explosive mixture, and which prevents the transmission of the explosion to the explosive gas atmosphere surrounding the enclosure. Flameproof is one of the original methods of explosion protection developed for use in the mining industry. It has a wide range of applications, typically junction boxes, lighting fittings, electric motors etc. The letter'd', which symbolises this type of protection, is from the German word ‘druckfeste’ (kapselung), which roughly translated means ‘pressure tight’ (enclosure). Design does not prevent gas/vapour entering the apparatus. Flameproof apparatus, when properly installed in the intended location, enables components such as switches, contactors and relays etc. to be safely used in hazardous areas. Flameproof is the only one of the nine different methods of explosion protection in which an explosion is permitted. This explosion, however, must be contained by the robustly constructed flameproof enclosure. Covers are required to be tool removable, and secured with all the specified fasteners in place, The enclosure is certified along with the arrangement and its contents, no modifications are permitted. EEx d: FLAMEPATH/JOINT ‘A place where the corresponding surfaces of two parts of an enclosure, or the conjunction of enclosures, come together and which prevents the transmission of an internal explosion to the explosive gas atmosphere surrounding the enclosure. When reassembling flameproof equipment, care should be taken to avoid getting dirt, paint etc into the joints. This will prevent the joints (flamepath) being closed correctly. Course Notes Page 37 of 71Compex Foundation TTE> 18 December 2014 - Version 1 JOINT TYPES Exd Flameproof enclosure iN LYS | Flanged Joint Threaded Joint Spigot Joint Gaps to be measured with a feeler gauge. Maximum gap for IIC (Hydrogen) areas 0.1mm, < 0.5Lt. WA & 118 0.15mm Flanged joints are allowed in a lIC area if gap is reduced 0.04mm. Spigot joints are preferred for lIC gasses with volumes greater than 500mm3. No intentional gaps are required in flamepaths for flameproofing, however, it is required to have a gap for example on motor shafts. ENCLOSURE Suitable for use in areas requiring EPL Gb and Gc or Category 2 and 3 only. The equipment grouping and temperature classification defined in IEC 60079-0 for the use of electrical equipment in explosive gas atmospheres apply to flameproof enclosures. The subdivisions A, B and C for electrical equipment of Group II also apply. Live maintenance not permitted. Course Notes Page 38 of 71Compex Foundation TTE> 18 December 2014 - Version 1 No unauthorised modific Ins to a certified enclosure are permitted; Certified equipment may not be modified in any way, other than as indicated on the certificate. Modification may invalidate the certificate. Unauthorised modifications or changes include: Use of wrong size or type of hole sealing plug. Use of wrong type of cable entry gland. Use of any constructional screw for any purpose other than that originally intended. Attaching cable brackets using cover fixing bolts. Drilling additional holes in any part of certified EExd equipment. Drilling holes to attach cable brackets. Use of any gasket other than specified. Use of hardening sealants or tape. Changing the layout of components in enclosure or adding additional items not included in the EExd certificate. PRESSURE PILING Components not to be removed from flameproof equipment - pressure piling. Results of an ignition, in a compartment or subdivision of an enclosure, of a gas mixture precompressed; For example, due to a primary ignition in another compartment or subdivision. Course Notes Page 39 of 71Compex Foundation TTE> 18 December 2014 - Version 1 UNIT 8: INCREASED SAFETY (EEx e) DEFINITION (IEC 60079-7) A type of protection in which additional measures are applied so as to give increased security against the possibility of excessive temperatures and of the occurrence of arks and sparks in normal service or under specified abnormal conditions. The explosion protection concept Increased Safety was invented in Germany where it has been widely used for many years. It is has become popular in the UK mainly because it has a number of advantages for certain applications over the traditional flameproof method of explosion protection. America has traditionally relied on the use of explosion-proof enclosures in hazardous locations, and the prospect of using an Increased Safety enclosure, which is not designed to withstand an internal explosion, as an alternative, has probably been viewed with a little trepidation. This method of protection has a good safety record and comparable with the other methods of protection. The letter ‘e" which symbolises this method of protection is taken from the German phrase Erhohte Sicherheit, which roughly translated means ‘increased security’. Typical applications are induction motors, lighting fittings and Junction boxes. This type of protection can only be applied to electrical equipment, or components of electrical equipment, which do not produce arcing or sparks in normal operation. The equipment is also designed so that it does not exceed specific temperatures during normal operation (and in specified abnormal operation. The equipment is robust in construction and tested to ensure that it meets the requirements of impact testing in the standard (BS EN 60079-7). Suitable for use in areas requiring EPL Gb and Gc or Category 2 and 3 only. The equipment grouping and temperature classification defined in IEC 60079-0 for the use of electrical equipment in explosive gas atmospheres apply to increased safety enclosures. The subdivisions A, B and C for electrical equipment of Group Il also apply. Live maintenance not permitted. Equipment will have warning label affixed, DO NOT OPEN WHEN ENERGISED. Minimum of IP 54 to be maintained (if cable entry less than 6mm thick). Refer to glanding. No unauthorised modifications permitted. Course Notes Page 40 of 71Compex Foundation TTE> 18 December 2014 - Version 1 EEx e TERMINATIONS. Certified EExe terminal assemblies are to be used. The use of high integrity insulation material employed which has been tested for thermal stability and a high resistance to tracking. Cable insulation should be maintained right up to the metal of the termination. The temperature de-rating of terminals from industrial standard in order to limit the possibility of high temperatures developing. Enhanced creepage and clearance distances Creepage Distance 6mm - The shortest distance along the surface of an insulating material between two electrically conductive parts. Clearance Distance 3mm - The shortest distance in air between two electrically conducting parts. Clearance a ey Creepage Distance [fn Course Notes Page 41 of 71Compex Foundation TTE> 18 December 2014 - Version 1 Clearance and Creepage Paths to Extend to Adjacent Clamping Screw Clearance 29.75mm Creepage Path 30.6mm Clearance and Clearance Path 7 Creepage Path Runs Creepage Paths Extends from End of Bott Between Locating Rivet & 4.0mm to Assembly Rail Assembly Rail 20.5mm, 278mm Course Notes Page 42 of 71Compex Foundation TTE> 18 December 2014 - Version 1 UNIT 9: REDUCED RISK (EEx n) DEFINITION (IEC 60079-15) A type of protection applied to electrical equipment such that, in normal operation and in certain specified abnormal conditions, it is not capable of igniting a surrounding explosive atmosphere. Suitable for use in areas requiring Gc or Category 3 only. Since the presence of a flammable gas or vapour is less likely in Zone 2, the constructional requirements for electrical equipment used in these hazardous locations are not as strict as those for equipment used in Zone 1. A method of protection which falls into this category is type ‘n’ apparatus, which is basically similar to increased safety type “e” apparatus except that there is a relaxation in the constructional requirements. Additional, the requirements of IEC 60079-15 are intended to ensure that a fault capable of causing an ignition is not likely to occur. Live maintenance not permitted. ‘An example of a specified abnormal condition is a luminare with a failed lamp. The equipment grouping and temperature classification defined in IEC 60079-0 for the se of electrical equipment in explosive gas atmospheres apply to increased safety enclosures. The subdivisions A, B and C for electrical equipment of Group Il also apply. The principal design features for type ‘n’ apparatus are as follows. 1) Enclosures and motor fan guards, where exposed to high risk of mechanical damage, to have resistance to impact of 3.5); 2) Minimum ingress protection IP54 where an enclosure has exposed live parts internally; 3) Use of certified terminals; 4) Terminals manufactured form high quality insulation material; 5) Specified creepage and clearance distances incorporated into the design of the terminals; 6) Terminal locking devices to ensure conductors remain secure in service. Enconure Ine, Course Notes Page 43 of 71Compex Foundation TTE> 18 December 2014 - Version 1 SUB DIVISIONS OF TYPE EEX N APPARATUS, EEx nA Non-sparking Apparatus. Designed to prevent any means of ignition arising. Electric Motors/Cage Motors Terminal Boxes Light Fittings Transformers If sparking occurs it; will occur in a hermetically sealed device & will occur in an enclosed break device. TYPE EEx nC ENCLOSED BREAK DEVICE A type n enclosed break device incorporates electrical contacts. It is able to safely withstand an internal explosion of any flammable gas that may have entered inside. This technique is used in, for example, the lamp holders of type ‘n’ apparatus. The example below shows a typical lamp holder in which there are two sets of contacts. One set of contacts is enclosed in what is effectively a flameproof enclosure in which the free internal volume must not exceed 20 cm’. This enclosure is designed to withstand an internal explosion and the voltage and current limitations are 600 V and 15 A respectively. NB Net volume of Enclosed-Break Device NOT to exceed 20 em* HERMETICALLY SEALED DEVICE Sparking contacts may be safely enclosed within a hermetically sealed enclosure. The seal may be by soldering, brazing or the fusion of glass to metal. ‘A device which prevents an external gas or vapour gaining access to the interior by sealing of joints by fusion, e.g. welding, soldering, brazing, or the fusion of glass to metal. The example of hermetic sealing shown below is a reed switch which comprises a set of contacts hermetically sealed within a glass envelope. Course Notes Page 44 of 71Compex Foundation TTE> 18 December 2014 - Version 1 Glass Envelope ‘Switehing Contacts ENCAPSULATED DEVICE An encapsulated device has similarities to hermetically sealed device. External connections are normally by flying leads or terminals. ENERGY LIMITED EQUIPMENT Eex nL. Where circuit components restrict the maximum available energy in a circuit to a level incapable of causing gas ignition. Now being replaced by EEx ic EEx nR RESTRICTED BREATHING ENCLOSURES Technique relies upon the ignition capable part within an enclosure which, although not fully sealed, being constructed in such a way it would take a long time for a flammable gas/vapour to penetrate. Designed to restrict the entry of gases, this technique is often applied to luminaires where, because of the high temperatures developed, the air within the enclosure expands and will develop an increase in pressure (thus excluding any entry of a potential explosive atmosphere), when the luminaire is switched off and cools down, the enclosure regulates the slow ingress of air across the gaskets. It is important therefore to maintain |.P. ratings, minimum of |.P 54. An IP washer is always required immaterial of thread length. Terminals. Certified terminal assemblies are required to be used. Course Notes Page 45 of 71CompEx Foundation 18 December 2014 - Version 1 fc for industry UNIT 10: GLANDING GLANDING INTO Eex d ENCLOSURES Must be certified New revision of IEC 60079 - 14 (2007) requires ‘newly installed’ glands to meet IEC 60079 - 0 Glands certified with an 'x’ can only be used for fixed installations Selected to reduce cable cold flow characteristics Many of cables exhibit ‘cold flow’ of the inner sheath bedding. That is, the material will flow away from pressure applied to it, such as that of a Cable Gland inner seal of the compression or displacement type, hence creating an inefficient seal. Must be certified The threaded part should be at least 8mm in length and comprise at least six full threads. Engaged thread length five full threads minimum. Course Notes Page 46 of 71Compex Foundation TTE> 18 December 2014 - Version 1 raining fr ineustry Blanks Examples of blanking elements for unused apertures Insige ‘ousae Blanks (Plugs) must be certified for the apparatus. "Ex d’ Plugs go in 'Ex d’ Equipment. A blanking element shall not be used with an adapter. GLANDING INTO Eex e/n ENCLOSURES Prior to December 2007 EEx'e’ only required glands to meet type of protection requirements ‘Ingress Protection and Mechanical Impact Strength’. New revision of IEC 60079-14 (2007) requires ‘newly installed’ glands to meet IEC 60079 - 0 Glands certified with an ‘x’ can only be used for fixed Selected to reduce cable cold flow characteristics. Course Notes Page 47 of 71Compex Foundation TTE> 18 December 2014 - Version 1 : Cees An IP sealing washer and a locknut are required when less than five threads are engaged (6mm thread length). A serrated washer maybe required to maintain earth Ss integrity. © ceed When glanding into non-metallic apparatus a banjo is often required to maintain earth continuity. Blanks Blanks (Plugs) must be certified for the apparatus. EEx e or EExd plugs go in EEx e Equipment. Course Notes Page 48 of 71Compex Foundation TTE> 18 December 2014 - Version 1 UNIT 11: INTRINSIC SAFETY “A protection technique based upon the restriction of electrical energy within apparatus and in the interconnecting wiring that may be exposed to a potentially explosive atmosphere, to a level below that which can cause ignition by either sparking or heating effects’. BASIC PRINCIPLES OF 1.5. Intrinsically safe circuits achieve safety by maintaining very low energy levels such that hot surfaces will not be produced, and electrical sparks, if they occur, will have insufficient energy to ignite the most easily ignitable concentration of a flammable mixture. This is achieved by limiting the voltage and current supplied to the apparatus in the hazardous area. To maintain safety, it is of paramount importance that these levels of voltage and current are not exceeded under normal, or even fault conditions. The circuit parameters, i.e. voltage, current, resistance, inductance and capacitance are factors which have to be considered in the design of an IS circuit. Consultation with the characteristic ignition curves given in the construction standard, and reproduced in this section, and the application of appropriate safety factors, will ensure that safe values are established for these parameters during the design stage. INTRINSICALLY SAFE SYSTEM 1 *——|___ HAZARDOUS AREA ae SAFEAREA > 1 1 en a fared Tl Perens Certified | — Associated | Typical pear Control ina Safe Area | Equipment Intrinsically Safe Circuit 1 Intrinsically Safe System Typical uses: Instrumentation, control circuits, low power apparatus Course Notes Page 49 0f 71Compex Foundation TTE> 18 December 2014 - Version 1 raining fr ineustry Difference lies in components integrity of the equipment Continued Intrinsic Safety under fault conditions. EEx Suitable for use in areas requiring EPL Ga,Gb and Gc or Category 1, 2 and 3. Live maintenance permitted EEx “ib” Suitable for use in areas requiring EPL Gb and Gc or Category 2 and 3. Live maintenance permitted EEx Suitable for use in areas requiring EPL Gc or Category 3. Live maintenance permitted Course Notes Page 50 of 71Compex Foundation TTE> 18 December 2014 - Version 1 UNIT 12: PRESSURISATION “A method of protection using the pressure of a protective gas to prevent the ingress of an explosive atmosphere to a space that may contain a source of ignition and where necessary, using continuous dilution of an atmosphere to a space that contains a source of emission of gas, which may form an explosive atmosphere" CHARACTERISTICS OF THE PROTECTIVE GASES Course Notes The technique of pressurising and purging enclosures of electrical apparatus is to prevent the ingress of a flammable atmosphere, Purging is a widely accepted protection concept for explosion protection. It is accepted world-wide (using European ‘Standards, NFPA or IEC Standards) and is relatively straightforward to comprehend. Explosion protection is achieved by keeping the potentially explosive atmosphere away from any source of ignition (thermal or electrical). The potentially ignition capable apparatus is mounted inside an enclosure, the enclosure is then pressurised to a positive pressure relative to the atmospheric pressure (a positive pressure of 0.Smbar is all that is required). As long as this positive pressure is maintained, no gas (or even dust) will be able to enter the enclosure: hence the internal equipment cannot be exposed to a potentially explosive gas. There is however a chance that an explosive gas mixture may have entered the enclosure prior to the positive pressure being achieved. To ensure that the enclosure is pressurised with a non-explosive gas (i.e. Air or Nitrogen) the enclosure is ‘purged’ to flush out the existing contents and ensure that all areas of the enclosure contain only the purging gas (purging of internal dusts have not yet been considered). It normally takes between 5 and 10 volume changes to ensure that the enclosure is ‘purged’. (In Europe the first edition purge standard defined five air changes as a minimum, in North America the minimum is defined as 10 air changes). It is a condition of certification for Zone 1 equipment that power cannot be applied to the equipment until the ‘purging’ (a specified flow of purging gas for a specified time) has been completed. To ensure continuity in the effect of the purging, the maximum leakage rate for the enclosure is also specified. When the purging has been completed, power can still not be applied until the specified positive pressure (at least 0.5 mbar) has been achieved. In the event of a failure to complete the purging cycle (drop in flow or incomplete duration) or if the enclosure pressure drops below the specified positive pressure, power to the equipment shall be removed (for Zone 1) or an alarm indication shall be given (Zone 2). In the event either of these conditions, the entire purging cycle starts again with the full purge time duration. The control of the automatic purging and pressurization is normally by a ‘Purge Control Unit’ (PCU). The PCU is required to measure flow and pressure, and must fail-safe in all conditions. Overview; + Normally ‘air’ but can be an Inert Gas * Two sources may be desirable dependant on the risk * Non-toxic, free from foreign bodies * The gas should not normally contain, by volume, more oxygen than in air * Source should be taken from a non-hazardous area ‘+ Temperature not normally exceed 40°C Page 51 of 71Compex Foundation TTE> 18 December 2014 - Version 1 rn ev oS aS | Minimum 0.5 milliBar above VE atmospheric ic pressure, "——— Hazardous Area a a - safeAres —s Cc 7 — 1 i= oo tF eo OZ siiesss So 0+ —+ ena cee) Three types of enclosure px, py and pz. Suitable for use areas requiring EPL Gb and Gc or Category 2 and 3. The equipment grouping and temperature classification defined in IEC 60079-0 for the use of electrical equipment in explosive gas atmospheres apply to oil immersion enclosures. The subdivisions A, B and C for electrical equipment of Group I! also apply. No live maintenance permitted Non certified apparatus can be used Marking of EEx p is complex and the Technical Authority should be consulted Course Notes Page 52 of 71Compex Foundation TTE> 18 December 2014 - Version 1 EPLicat | Enclosure contains ignition | Enclosure does not contain capable equipment inition capable equipment GbiCat 2 Type'px’ Type'py" raed . Type 'py’ Sheets eee (no pressurisation required) 'Py’ equipment will only contain type of equipment to protection d,e, I,m, nA, nC, 0, or q Suitable spark and particle barriers may be required LOSS OF PRESSURISATION Action to be taken when the pressurisation with the protective gas fails for electrical apparatus without an internal source of release. ‘Area Enclosure contains apparatus | Enclosure contains apparatus classification | not suitable for zone 2 without | suitable for zone 2 without pressurisation pressurisation Zone 2 Alarm Zone 1 Alarm and switch off Alarm NOTE: Restoration of pressurisation should be completed as soon as possible, but in any case within 24h. During the time that the pressurisation is inoperative, action should be taken to avoid the entry of flammable material into the enclosure. Provided that pressurised apparatus is switched off automatically upon pressurisation failure, an additional alarm may not be necessary for safety, even in a Zone | hazardous area. If power is not switched off automatically e.g. in a zone 2 hazardous area, an alarm is the minimum action that is recommended if combined with immediate action by the operator to restore the pressurisation or switch off the apparatus. Apparatus within the enclosure suitable for the external zone need not be switched off when pressure fe Course Notes Page 53 of 71Compex Foundation TTE> 18 December 2014 - Version 1 UNIT 13: EEX 0,q &m EEx 0 OIL EMERSION BS EN 60079-6 (50015), IEC 60079-6. HAZARDOUS ATMOSPHERE —_—_—_—SS) EPL ("Gb"), Category 2 ATEX Equipment All electrical parts are submersed in either non-flammable or low: flammability oil which prevents the external atmosphere from contacting the electrical components. ow EExq POWDER FILLED BS EN 60079-5 (50017), IEC 60079-5. HAZARDOUS ATMOSPHERE EPL ("Gb"), Category 2 ATEX Equipment. EEE] This method is similar to the oll- immersion method of protection, except that the segregation is accomplished by filling the enclosure with powdered material so that an arc generated inside Powder the enclosure will not result in the ignition of the dangerous atmosphere. EEx m ENCAPSULATION HAZARDOUS ATMOSPHERE si ee RESIN The protection method is based on the segregation of those electrical parts that can cause the ignition of a dangerous mixture in the presence of sparks or heating, by potting in resin that is resistant to the specific ambient conditions ma-Zone 0,1 & 2. mb-Zone 1 &2 Course Notes Page 54 of 71Compex Foundation TTE> 18 December 2014 - Version 1 UNIT 14: CABLES Electrical equipment in hazardous areas may be wired using cable having metallic or non-metallic sheath, or conduit. The use of cable is generally predominant and one reason is its ease of installation compared to conduit. BS 7671 includes several tables for the current carrying capacities of wires and cables in various installation types, these values are recommended unless the contract specifies otherwise. Cables for potentially explosive atmospheres have to be sufficiently reliable that the likelihood of failure after correct installation is so small that it can be discounted, The surface temperature of cables should not exceed the temperature class requirements of the installation. Cable systems and accessories should be installed in positions that prevent them from being subject to mechanical damage, corrosion, chemical attack, heat and other detrimental environmental conditions. Selection of the wiring system and cable type must consider these influences and where exposure to such conditions are avoidable, protective measures such as minimising the risk of mechanical damage by the use of appropriate armoured cable types should be considered FIXED APPARATUS Cables shall be sheathed with thermoplastic, thermosetting or elastomeric mate Circular, compact, extruded, bedding fillers (if any) should be non hydroscopi Cables manufactured from thermoplastic, thermosetting, elastomeric or mineral insulated insulating materials may be used in fixed wiring installations. Cables ‘commonly used in the industry are of the EPR/CSP type. Mineral insulated metal sheathed (MIMS) cable is also suitable for use in hazardous areas, but its aluminium variation requires careful consideration before use. Aluminium conductors must only be connected to suitable terminals and have a cross- sectional area (csa) not less than 16 mm’. Course Notes Page 55 of 71Compex Foundation TTE> 18 December 2014 - Version 1 SY CONTROL FLEX Available sizes: 0.5mm?, 0.75mm?, 1.0mm?, 1.5mm, 2.5mm?, 4.0mm?, 6.0mm, 10.0mm*, 16.0mm?, Description: Two Three, four, five core up to 25 core PVC / PVC insulated, galvanised steel wire braided multi core. Approved to BS 6500. Stranded, number coded copper conductor. Uses: Used as connecting cable, as measuring, checking and control cable in machine tool manufacturing, plant engineering and on assembly lines and production lines. Suitable for fixed installation (tray work) or flexible applications without exposure to tensile load. Due to the galvanised steel wire braiding, these cables can even be used under adverse operating conditions or when exposed to high mechanical strain. XLPE STEEL WIRE ARMOURED Available sizes: 1.0mm?, 1.5mm?, 2.5mm?, 4.0mm?, 6.0mm?, 10.0mm?, 16.0mm?, 25.0mm* and larger Description: 2/ 3-core (6943X) and 4-core (6944X); *up to 48 core galvanised Steel Wire Armoured Cable. Black XLPE sheathed, PVC insulated. Approved to BS 5467. Available in copper or aluminium (above 16mm? only) Uses: General circuit wiring (on tray work or ladder or clipped direct) where there is an increased risk of mechanical damage; underground cable routes CABLE TERMINATIONS Normally one cable per terminal (Cable terminations as per the manufacturers’ documentation) EEx e TERMINATIONS, Cable insulation to be maintained right up to the metal of the terminal. Course Notes Page 56 of 71Compex Foundation TTE> 18 December 2014 - Version 1 GENERAL. All cables, cores and terminals should be marked for identification purposes by Permanent indelible methods (cable markers). All cable wiring and identification should be documented. Crimped terminations are generally preferable to bare copper (there is a risk of stray strands causing circuit faults), crimped connections are more readily inserted and removed. Crimping tools of the hand ratchet type are to be used, hydraulic in larger size cable. Note; the simple plier type often results in slack joints. The good general rule is only one wire per terminal, some terminals have special conditions applied and the manufacturer's documentation will need to be referred to. For the provision of re-terminating cables, enough length of conductor core should be left to allow for at least one termination. UNUSED CORES Are not to be left un-terminated Course Notes Page 57 of 71Compex Foundation TTE> 18 December 2014 - Version 1 UNIT 15: NON ELECTRICAL APPARATUS Non electrical equipment that can achieve its intended operation without electrical power, a spring or stored energy. The non electrical certification is covered by risk assessment. This is based on the protection concept to prevent ignition. There are seven recognised concepts of explosion protection for non-electrical ‘equipment within Europe. The seven concepts are similar to the electrical protection concepts and are detailed in the European EN 13463 series of standards as follows ¢ = Constructional Safety (EN 13463-5) g = Inherent Safety (EN 13463-4) b = Control of Ignition Sources (EN 13463-3) p = Pressurisation (EN 13463-7) d = Flameproof (EN 13463-3) k = Liquid immersion (EN 13463-8) fr = Flow restricting (EN 13463-2) Course Notes Page 58 of 71Compex Foundation TTE> 18 December 2014 - Version 1 Constructional Safety | | 0,1,2 1 Constructional measures are applied so as to protect against the possibility of ignition from hot surfaces, sparks and adiabatic compression generated by moving parts. Inherent Safety ga | 12 2 Prevention of arcs, sparks and hot surfaces in normal operation. Control of ignition b ] 1,2 2 ‘Automatic/manual ignition prevention measures, to prevent potential ignition sources becoming effective. Pressurisation p [12 2 Excludes the hazardous atmospheres by 50Pa (0.5 milli Bar)positive pressure of inert gas. Flameproof a [12 2 Explosion containment will not allow transmission of an internal explosion to the surrounding environment. Liquid immersion k ] 42 2 ‘A type of protection in which potential ignition sources are made ineffective. Flow Restriction fr [2 3 Flow restricting enclosures are simple enclosures which will prevent, with adequate probability, the atmosphere inside the enclosures becoming explosive. ‘c’ is most frequently used in the mechanical concepts. Itis nearly always the most suitable and most effective measure. Course Notes Page 59 of 71Compex Foundation TTE> 18 December 2014 - Version 1 : UNIT 16: INSPECTION EMERGENCY SWITCH OFF AREA Must be located outside the Hazardous area where all the Electrical power can be isolated to all equipment in the Hazardous Area. ISOLATION For hazardous areas the neutral is considered to be a LIVE conductor, therefore must be isolated. (double pole isolation). PERMIT-TO-WORK AND SAFE ISOLATION Candidates attending the 5-day CompEx course are required to carry out four practical assessments in the simulated hazardous areas. During these assessments, candidates must demonstrate their ability to work safely by ensuring that all precautions are taken to prevent ignition of a flammable gas which, for the purpose of the assessments, it is assumed may be present at any time. WORK PERMIT In order to ensure that safety is maintained, candidates must operate within the control of a work permit - which must be requested from the Assessor / Authorised Person. In association with the work permit, a gas-free certificate must be endorsed by the Assessor/Authorised Person at all instances when, for example, a particular action is likely to produce a source of ignition. Such situations occur when electrical test instruments and/or portable electric tools are used. SAFE ISOLATION The Electricity at Work Regulations 1989 require those in control of part or all of an electrical system to ensure that it is safe to use and that it is maintained in a safe condition, Course Notes Page 60 of 71Compex Foundation TTE> 18 December 2014 - Version 1 Unsuitable test probes, leads, lamps, voltage indicators and multimeters have caused arcs due to: a) Inadequately insulated test probes (typically having an excessive length of bare metal at the contact end) accidentally bridging a live conductor and adjacent earthed metalwork; or b) Excessive current drawn through test probes, leads and measuring instruments. This happens when a multimeter is set to the wrong function, e.g. set on a current or resistance range when measuring voltage. INSPECTION DEFINITION ‘An action comprising careful scrutiny of an item, carried out with either visual partial dismantling or dismantling in order to arrive at a reliable conclusion as to the ion of an item. equipment where the certificate number has a suffix marking of "X". The certification and instruction documents shall be studied to ascertain the specific BS EN 60079-17:2007 Explosive atmospheres. Electrical installations inspection and maintenance. Electrical installations in hazardous areas possess features specially designed to render them suitable for operations in such atmospheres. It is essential for reasons of safety in those areas that, throughout the life of such installations, the integrity of those special features is preserved. The inspection and maintenance of installations should only be carried out by experienced personnel whose training has included instruction on the various types of protection and installation practices, the relevant rules and regulations, and on the general principles of area classification. Appropriate continuing training should be undertaken on a regular basis. QUALIFICATION OF PERSONNEL The inspection and maintenance of installations shall be carried out only by experienced personnel, whose training has included instruction on the various types of protection and installation practices, the requirements of this standard, the relevant national regulations/company rules applicable to the installation and on the general principles of area classification. Appropriate continuing education or training shall be undertaken by personnel on a regular basis. Evidence of the relevant experience and training claimed shall be available. Course Notes Page 61 of 71Compex Foundation TTE> 18 December 2014 - Version 1 GENERAL. Before plant or equipment is brought into service, it shall be given an initial inspection. To ensure that the installations are maintained in a satisfactory condition for continued use within a hazardous area, either a) regular periodic inspections, or b) Continuous supervision by skilled personnel, and, where necessary, maintenance shall be carried out. Following any adjustment, maintenance, repair, reclamation, modification or replacement, the equipment or relevant parts of equipment concerned shall be inspected in accordance with the relevant items of the detailed inspection tables Where the certification plate or markings on explosion protected equipment is missing or illegible, alternative methods may be used to determine traceability to the certification details of the specific equipment. The method used could include: additional identification labels which incorporate unique tag numbers, serial numbers or reference to the installation databases. The method of attaching or fixing the labelling shall not reduce the integrity of the equipment. Course Notes Page 62 of 71Compex Foundation TTE> 18 December 2014 - Version 1 TYPES OF INSPECTION © Initial + Periodic + Sample INITIAL INSPECTION The purpose of an initial inspection is to ensure that the apparatus is suitable for the hazardous area in which it has been installed During the act of installation no item of equipment has invalidated its certification Detailed inspection carried out. The best time to carry out an Initial Inspection is: Immediately after installation Before plant is operational Before location becomes hazardous PERIODIC INSPECTIONS Even if the apparatus is initially installed correctly there is no guarantee it will remain in this condition, due to the effects of environmental corrosion, vibration, plant and operational changes. In addition to initial inspection some form of routine/periodic inspection is required The frequency of a periodic inspection: Determined by Responsible Engineer (not normally exceeding three years) Operation conditions Environment Normally up to a close inspection PERIODIC INSPECTIONS PERSONNEL Regular periodic inspection requires personnel who: a. Have a knowledge of area classification/EPL and sufficient technical knowledge to understand its implications for the location under consideration; b. Have technical knowledge and understanding of the theoretical and practical requirements for electrical equipment and installations used in those hazardous areas; c. Understand the requirements of visual, close and detailed inspections as they relate to the installed equipment and installations. Competencies and training may be identified in relevant national training and assessment frameworks. Such personnel will need to be sufficiently independent of the demands of the maintenance activities, for example, so as not to prejudice their ability to reliably report the findings of the inspection. Course Notes Page 63 of 71Compex Foundation TTE> 18 December 2014 - Version 1 SAMPLE INSPECTION This is an inspection that reflects a proportion of the installed apparatus Size of sample determined by purpose of inspection Used to monitor effects of environmental conditions, vibration, possible design weakness Can be visual, close or detailed. ‘THREE GRADES OF INSPECTION + Visual + Close = Detailed VISUAL INSPECTION An inspection which identifies, without the use of access equipment or tools, those defects which are apparent to the eye. Check points; 1) Is equipment fit for zone? 2) X on certification number, require to see the certificate as special conditions for use apply. 3) Bolt missing. 4) Ave all blanks in place? Remember always use the inspection tables to IEC 6079-17. Course Notes Page 64 of 71Compex Foundation TTE> 18 December 2014 - Version 1 Specific conditions of use Specific conditions of use apply to any type of certified explosion protected equipment where the certificate number has a suffix marking of "x". The certification and instruction documents shall be studied to ascertain the specific conditions of use. CLOSE INSPECTION ‘An inspection which encompasses those aspects covered by a visual inspection and in addition those defects apparent by the use of access equipment and tools, i.e. loose bolt. Close inspections do not normally require the equipment/enclosure to be opened or de-energised. Check points; 1) Is equipment gas group and temperature rating fit for area 2) Are all bolts tight? 3) Are glanding arrangements correct? 4) Are glands tight (check by hand only). Remember always use the inspection tables to IEC 60079-17. Cable gland The check-tightening of cable glands under close inspection can be effected by hand without the need to remove weather-proofing tape or shrouds. Detailed inspections may necessitate that the cable glands are dismantled only where the integrity of the glands cannot be ascertained by close Inspection. Course Notes Page 65 of 71Compex Foundation TTE> 18 December 2014 - Version 1 DETAILED INSPECTION An inspection that encompasses those aspects covered by a close inspection and in addition identifies defects only apparent by opening the enclosure/ equipment, where the necessary tools and test equipment are required, i.e loose terminations. Full inspection covers removed. Remember always use the inspection tables to IEC 60079-17. Course Notes Page 66 of 71Compex Foundation TTE> 18 December 2014 - Version 1 UNIT 17: DUST There are some basic rules to be observed to see whether a dust is capable of causing a dust explosion. + The dust must be of a combustible nature. + The dust be capable of becoming airborne. + There must be an ignition source present. ‘+ The Atmosphere must contain sufficient oxygen to support and sustain combustion Reference to the table for ‘gas ignition energy’ will suggest that dust ignition requires considerably more energy than the gases considered and the layer ignition temperature is generally above the ignition temperature of most flammable gases. Where equipment is used in a gas/dust atmosphere it must be suitable. From June 2006, equipment installed in a Dust area must be certified for a Dust environment. EQUIPMENT GROUPS * Group | Mining ( Methane) * Group Il Above Ground ( ATEX Gas & Dust) ( IEC Gas) * Group Ill Above Ground ( IEC Dust) From 2006 All equipment must be specifically marked for dust: Eg IID or Ill (From. 2007 IEC Brought in Group Ill). ; ‘ EU (60079-0) Ec (61241-0) | US (NEC 500) De eater IEC (60079-0) | US (NEC 506) | EU(61241-0) | CA (CEC Section 18) Metal dusts mc N/A D Class ll, Group E Carbonaceous dusts 6 D D Class Il, Group F Non-conductive dusts 1B D D Class ll, Group G Fibres and flyings WA D D Class il Course Notes Page 67 of 71Compex Foundation TTE> 18 December 2014 - Version 1 Training for ncustry Dust Fire & Explosion Pentagon ignition Source Dispersion of Dust Particles Confinement of Dust Cloud Combusti PRINCIPLES OF A DUST EXPLOSION Primary Explosion Secondary Explosion Zone 20 Funnel in sack ‘emptying station Zone 21 Immediate vicinity {radius 1m) ‘around loading opening Zone 22 Area outside Zone 21 due to dust deposits Course Notes Page 68 of 71Compex Foundation TTE> 18 December 2014 - Version 1 Zone 20 Continuous release inside a dust containment enclosure gives rise to Zone 20 - a place in which an explosive atmosphere, in the form of a cloud of combustible dust in air, is present continuously, or for long periods or frequently for short periods. For example, a mill or pneumatic conveying system. Zone 21 Primary grade of release gives rise to Zone 21 - a place in which an explosive atmosphere, in the form of a cloud of combustible dust in air, is likely to occur occasionally in normal operation. For example, bagging points and inspection ports that are frequently opened. Zone 22 Secondary grade of release gives rise to Zone 22 - a place in which an explosive atmosphere, in the form of a cloud of combustible dust in air, is not likely to occur in normal operation but, if it does occur, will persist for a short period only. For example, leaks from incorrectly fitted lids or spillages. Protection against Ingress of Dust. IP rating based on BS EN 60529. ( Standard) Some dusts are electrically conducting and consequently any dust which could get into a machine and settle across live parts presents a dangerous situation. By careful construction techniques and the use of seals etc. it is possible to prevent dust and/or water entering equipment. Based on the 3 Zone approach of Zones 20, 21 & 22 the ingress protection required is as follows: Zone 20 or 21 IP6x Zone 22 and electrically conducting dust IP6x Zone 22 and non conducting dust IPSx Course Notes Page 69 of 71Compex Foundation TTE> 18 December 2014 - Version 1 UNIT 18: EXTRA INFO PERMIT TO WORK A permit to work is required prior to carry out any work. Different companies operate different systems. Permit to work are a vital part of a safe system of work for maintenance activities. The Permit to Work should cover in detail all the work and precautions to be taken. Have formal written Permit to Work procedure to carry out work in Hazardous areas. TooLs All tools are to be in sound condition, free from defects and suitable for use in a potentially explosive atmosphere. The suitability of tools and instruments may require a formal risk assessment. PROHIBITED EQUIPMENT Matches or other forms of ignition are prohibited from being carried into a potentially explosive atmosphere, except in exceptional circumstances where their use is covered by a “fire permit’ Battery operated pacemakers, watches, certain hearing aids and certified intrinsically safe equipment and instruments are permitted in hazardous areas. ‘TRANSPORTABLE, PORTABLE AND PERSONAL EQUIPMENT Precaution shall be taken to ensure that movable electrical equipment (portable, transportable and hand-held) is used only in locations appropriate to its type of protection, equipment group and surface temperature. NOTE: Ordinary industrial movable equipment, welding equipment, etc. should not be used in a hazardous area unless its use is managed under a safe work procedure (see IEC 60079-14) and the specific location has been assessed to ensure that there is no explosive atmosphere present. Heavy duty sheath - Robust construction 1.0mm squ minimum size Earth conductor - if necessary incorporated within sheath Flexible armour not sole CPC Portable equipment - 250v and not exceeding 6A. Ordinary polychloroprene, rubber or synthetic elastomeric cable Not allowed where exposed to heavy mechanical stress, for example hand lamps, barrel pumps, etc. ‘* Maintenance of flexible cables ‘+ Flexible cables, flexible conduits, and their terminations are particularly prone to damage. ‘+ They shall be inspected at regular intervals and shall be replaced if found to be damaged or defective. + Moveable/Portable Equipment Inspection + Hand-held portable equipment is particularly prone to damage or misuse and therefore the intervals between detailed inspections may need to be reduced Course Notes Page 70 of 71Compex Foundation TTE> 18 December 2014 - Version 1 ‘© Generally twelve monthly close inspection intervals should be used and recorded ‘+ Six monthly detailed for equipment with battery casing for example frequently opened housings ‘+ In addition visual checks by the user prior to use Course Notes Page 71 of 71