Electrical & Instrumentation

CompEX

EX Fundamentals

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Trainer : Abdulhamid Hamad
Introduction to Ex Equipment

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ESR/ESOP|March 2021
 Introduction to Explosion Proof Ex Equipment

Introduction
In the 19th century, electrical equipment was introduced into industry and households.
Immediately afterwards, the occurrence of methane and coal dust in hard coal
mining prompted the development of the basics of electrical explosion protection.

Explosions can cause :

• Loss of life and

• Serious injuries
• Significant damage.

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 Introduction to Explosion Proof Ex Equipment

Definition
What is an explosion?

An explosion is defined as a sudden reaction

involving rapid physical or chemical decay
accompanied by an increase in temperature
or pressure or both.

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 Introduction to Explosion Proof Ex Equipment

What is Hazardous Locations?

A “hazardous area” is defined as an area in which the

atmosphere contains, or may contain in sufficient quantities,
flammable or explosive gases, dusts or vapors. In such an
atmosphere a fire or explosion is possible when three basic
conditions are met.

Fuel Oxygen Ignition

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 Introduction to Explosion Proof Ex Equipment

Protection Principle

1. Preventing releases of dangerous substances, which can create explosive

atmospheres.

2. preventing sources of ignition are two widely used ways of reducing the risk.

Using the correct equipment can help greatly in this

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Statutory Regulation and Standards

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 Statutory Regulation
Statutory Regulation and Standards
and Standards

Standards For Ex Protection?

For basic information on how equipment can be protected in hazardous areas.

Protection is a two part exercise:

1) The equipment must be designed and manufactured to appropriate

standards for a chosen “Type of Protection”.

2) Then must be installed, inspected, maintained and repaired taking

into account further standards for these activities

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 Statutory Regulation
Statutory Regulation and Standards
and Standards

Standards For Ex Protection?

Instruction in the form of legislations have been adopted to prevent explosion

through careful consideration for all the following activities :

• Design
• Manufacturing
• Installing
• inspection,
• Maintenance
• Repairing

Above are also a subject to the requirements of two European Community

Directives stated by ATEX .

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 Statutory Regulation
Statutory Regulation and Standards
and Standards

What is ATEX about?

• The ATEX Equipment Directive is

primarily concerned about TRADE.

• It applies minimum Essential Health

and Safety Requirements (EHSRs) to
avoid concerns over safety being a
barrier to trade.

• Thus all Ex Equipment sold or

installed in the EEA after June 2003
must comply with ATEX 94/9/EC

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 Statutory Regulation
Statutory Regulation and Standards
and Standards

What is ATEX?

ATEX is the name of the framework for controlling explosive atmospheres and
the standards of equipment and protective systems used in them.

(ATEX is for ATmosphères EXplosives meaning Explosive Atmosphere ) .

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 Statutory Regulation
Statutory Regulation and Standards
and Standards

ATEX EX Logo?

This Hexagon Logo with “Ex” marked inside is as per specification of ATEX

❑ The very presence of this LOGO on any product clearly indicates that the
product is not ordinary and due safety procedures must be followed in its:-

• Selection (manufacturing)
• Installation
• Operation
• Maintenance

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 Statutory Regulation
Statutory Regulation and Standards
and Standards

ATEX Directives?

It is based on the requirements of two European Directives:

1. Directive ATEX 100a (94/9/EC) Equipment Directive

On the approximation of the laws of Members States concerning equipment

and protective systems intended for use in potentially explosive
atmospheres.

2. Directive ATEX 137 (99/92/EC) Workplace Directive

On minimum requirements for improving the health and safety protection of

workers potentially at risk from explosive atmospheres.
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 Statutory Regulation
Statutory Regulation and Standards
and Standards

IEC Standard covering EX requirements?

• 60079-14 Explosive atmospheres :

Part 14: Electrical installations design, selection and erection

• 60079-17 Explosive atmospheres :

Part 17: Electrical installations inspection and maintenance

• 60079-19 Explosive atmospheres :

Part 19: Equipment repair, overhaul and reclamation

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 Statutory Regulation and Standards

Quiz
Q1: What are the main two principles to avoid explosion ?

Q2: What are the two main principles stated by Explosion Protection
standards ?

Q3: What is ATEX?

Q4: How many Directive stated by ATEX ?

Q5: Tell number of ATEX directives?

Q6: What is the difference between ATEX and IEC Standards ?

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Fire Triangle and Ignition Sources

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 Fire Triangle and Ignition Sources

What is an Explosive Atmosphere?

An explosion is any uncontrolled combustion wave. In order to create an

explosion, three components have to be met :

1. A source of fuel (e.g. methane or gasoline vapors).

2. Enough oxygen (greater than 10-15%) to oxidize or burn the fuel.
3. A source of heat (ignition) to start the process.

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 Fire Triangle and Ignition Sources

Sources of explosive mixture Release?

In order to know where the gas may or may not be present a study is
conducted which identifies all possible sources of release:-

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 Fire Triangle and Ignition Sources

Sources of Ignitions

• Flames;
• Use of cigarettes/matches etc;
• Cutting and welding flames;
• Hot surfaces; Hot process vessels;
• Space heating equipment;
• Mechanical machinery;
• Electrical equipment and lights
• Spontaneous heating;
• Friction heating or sparks;
• Impact sparks;
• Sparks from electrical equipment;
• Stray currents from electrical equipment
• Electrostatic discharge sparks:
• Lightning strikes.
• Electromagnetic radiation of different wavelengths
• Vehicles, unless specially designed or modified 19
 Fire Triangle and Ignition Sources

Condition of Explosive Atmosphere

For any mixture of a combustible gas or vapor with an oxidizer there is a critical
ignition energy.

• If one releases less than that critical

amount of energy into the mixture, there
will not be a self-propagating explosion.

• If one releases at least the critical amount

of energy, the combustion wave will
become self-propagating as a plane wave,
resulting in an explosion.

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 Fire Triangle and Ignition Sources

Condition of Explosive Atmosphere

Energy Levels for ignition

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 Statutory Regulation and Standards

Quiz
Q1: What are the three things that can create explosion all together ?

Q2: Where do you expect find flammables or gas leaks ?

Q3: Count two of spark sources that can ignite gases ?

Q4: What is the concept of “critical ignition energy”?

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Hazardous Area Classification

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 Hazardous Area Classification
Hazardous Area Classification

Zone System

Hazardous areas are classified into zones based on an assessment of the

frequency of the occurrence and duration of an explosive gas atmosphere, as
follows:

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 Hazardous Area Classification
Hazardous Area Classification

Extent of Zone

• Geometry of release – from open pool mechanical seal or flange

• Release velocity –
process pressure, liquid or gas

• Concentration

• Ventilation

• Relative Density

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 Hazardous Area Classification
Hazardous Area Classification
Zone System

Zone 0:
An area in which an explosive gas atmosphere is present continuously or for
long periods in normal operation;

Zone 1:
An area in which an explosive gas atmosphere is likely to occur in normal
operation;

Zone 2:
An area in which an explosive gas atmosphere is not likely to occur in
normal operation and, if it occurs, will only exist for a short time.

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 Hazardous Area Classification
Hazardous Area Classification

• Zone 0:
For more than 1000 hour/year

• Zone 1:
For more than 10 hours, but less than 1000 hour/year

• Zone 2:
For less than 10 hour/year, but still sufficiently likely as to require controls over
ignition.

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 Hazardous Area Classification
Hazardous Area Classification

Zone System

Areas with a danger of gas explosions

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 Hazardous Area Classification
Hazardous Area Classification

Zone System

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 Hazardous Area Classification
Hazardous Area Classification

An area that is not classified as Zone 0, 1, 2 is deemed to be:

➢ non-hazardous area

➢ Unclassified area

➢ Safe area

Normal industrial electrical equipment may be used.

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 Statutory Regulation and Standards

Quiz
Q1: How many Zones are classified for Hazardous Areas ?

Q2: Do you know more of Zone Classification?

Q3: What is the difference between Non-Classified Area and Safe Area ?

Q4: What is the most dangerous Zone and where it possible to be found?

Q5: What is the second most dangerous Zone and where it possible to be
found?

Q6: Is zone 2 particularly considered Safe area?

Q7: How can you identify classified areas at Hazardous area Drawings?
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MFD Site Hazardous Area Drawings

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 BGC Site Hazardous Area Drawings

Hazardous Area Classification Drawing

Hazardous area are pointed in a special

drawing imposes special agreed marking
and hashing patrons on a Layout
drawing.

These hashes pointing the level of

danger presented by the area.

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 BGC Site Hazardous Area Drawings

Hazardous Area Classification Drawing

Hazardous area drawings can provide you:
• Overall Layout drawing
• Process Unit area Layout Drawing (Horizontal)
• Process Unit area Layout Drawing (Vertical)

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 BGC Site Hazardous Area Drawings

Hazardous area Classification legend :

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 BGC Site Hazardous Area Drawings

Hazardous Area Classification Drawing

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 Statutory Regulation and Standards

Quiz
Q1: What is the zone inside a tank which is empty of any flammable liquid?

Q2: What is the zone inside a tank under the level of the flammable liquid?

Q3: What is the zone inside a tank just above the level of the flammable
liquid?

Q4: What is the zone above a tank that contain a flammable liquid?

Q5: What is the zone around a tank on ground level?

Q6: What is the zone inside a bit located in the ground level around a tank?

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Gas Group & Grouping Criteria

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 Gas Group & Grouping Criteria

Explosive Limits
To produce a flame, a sufficient amount of gas or vapor must exist. But too much
gas can displace the oxygen in an area and fail to support combustion.

o UEL - Upper Explosive Limit

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

o LEL - Lower Explosive Limit

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

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 Gas Group Gas
& Grouping
Group &Criteria
Grouping Criteria

Explosive Limits

• Any gas or vapor concentration that falls between these two limits is in the
flammable (explosive) range.

• Different substances have different flammable range widths — some are very
wide and some are narrower, a wider range are generally more hazardous

• 50% LEL reading means the sampled gas mixture contains one-half of the
amount of gas necessary to support combustion. 40
 Gas Group Gas
& Grouping
Group &Criteria
Grouping Criteria

Explosive Limits

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 Gas Group Gas
& Grouping
Group &Criteria
Grouping Criteria

Equipment Group
Electrical apparatus for potentially explosive atmospheres is divided into 2 groups
Group I:
Devices for use in underground mining and the connected surface installations
which are endangered by mine gases (methane) and/or combustible dusts.

Group II:
Devices for use in all other areas which might be endangered by a potentially
explosive atmosphere.

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 Gas Group Gas
& Grouping
Group &Criteria
Grouping Criteria

Gas Groups
Gases have been placed in groups based on their ignition temperatures and
explosion pressures:
o Group IIC : Suitable to work where gas persistence like :
• Hydrogen
• Acetylene

o Group IIB : Suitable to work where gas persistence like :

• Acetaldehyde
• Ethylene

o Group IIA : Suitable to work where gas persistence like :

• Acetone
• Ammonia
• ethyl alcohol
• Gasoline
• Propane 43
 Statutory Regulation and Standards

Quiz
Q1: What is UEL for explosive gases ?

Q2: What is LEL for explosive gases ?

Q3: Which flammable is more dangerous , one of higher UEL or lower LEL ?

Q4: Which flammable is ore dangerous in term of UEL and LEL ?

Q5: What is the UEL and LEL of Nitrogen ?

Q6: Why we have two group classification of equipment?

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Equipment Level of Protection

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 Equipment Level of Protection

Equipment Protection Levels « EPL »

A system of equipment protection levels has been introduced to clearly indicate

the inherent ignition risk of equipment. no matter what type of protection is used.

The EPL is a level of protection assigned to equipment based on its

likelihood of becoming a source of ignition

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 Equipment Level of Protection
Equipment Level of Protection

Equipment Protection Level : ATEX designation

• Categories are assigned to the equipment groups in Directive 94/9/EC.

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 Equipment Level of Protection
Equipment Level of Protection

Equipment Protection Level : IEC designation

• EPL is assigned to the equipment groups .

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 Equipment Level of Protection

Equipment Protection Levels

«ATEX ‘Category ’ vs IEC ‘EPL’ »

Gas Group II : Gas and Liquides

o 1G or Ga
o 2G or Gb
o 3G or Gc

o 1D or Da
o 2D or Db
o 3D or Dc

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 Statutory Regulation and Standards

Quiz
Q1: How many systems might you know for marking equipment level of
protection ?

Q2: Which system is adopted by ATEX?

Q3: AS per ATEX , what would be the coding of equipment EPL suitable
to keep working in Zone 1 in case of gas release accident?

Q4: AS per IEC , what would be the coding of equipment EPL suitable to
keep working in Zone 1 in case of gas release accident?

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Equipment Surface Temperature

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 Equipment Surface Temperature

Flash Point Temperature

At normal ambient temperature, flammable materials in a gaseous state when
released into the atmosphere will mix with air.
If the material is in a liquid state at ambient temperatures, then knowledge of the
Flashpoint is necessary to determine if there is a possibility that a flammable
mixture will result.

Definition

“The minimum temperature of a liquid, at

which, sufficient vapor is given off from the
surface of that liquid in still air such that it
may form an explosive gas-air mixture”.

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 Equipment Surface Temperature
Equipment Surface Temperature

Ignition Temperature
This is the temperature at which a substance will ignite without any external source
of ignition.

The potentially explosive atmosphere can be

prevented from igniting if the surface
temperature of the item of equipment is
lower than the ignition temperature of the
surrounding gas.
This is also known as:

• Auto Ignition Temperature (AIT)

or
• Spontaneous Ignition Temperature
(SIT).
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 Equipment Surface Temperature
Equipment Surface Temperature

Flashpoint and Ignition Temperature

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 Equipment Surface Temperature
Equipment Surface Temperature

Equipment Surface Temperature

The T class indicates the maximum temperature of surfaces which could ignite an
external explosive atmosphere

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 Equipment Surface Temperature
Equipment Surface Temperature

Equipment Surface Temperature

• If that hazardous is, say, Carbon Disulphide CS2, then all equipment used must meet
the “T6” rating. This means that all equipment used must not have a surface
temperature of greater than 85˚C.

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 Equipment Surface Temperature
Equipment Surface Temperature
Which T –Class is suitable for which Gas ?

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 Equipment Surface Temperature
Equipment Surface Temperature

Surface Temperature Sources

Hot surfaces can occur due to for example:

• Poor connections;

• Overloads; Surface Temperature Coupling misalignment

• Stuck bearings;

• V-belts;

• Rotating parts

Hot Seal Hot Bearing

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 Statutory Regulation and Standards

Quiz
Q1: For a certain Flammable , How many temperatures need to
recognize?

Q2: Why is important to know about Surface temperature?

Q3: What is the benefit of Surface temperature to inspection activities ?

Q4: T1 is the highest or the lowest Surface temperature ?

Q5: What is the value of T6 ?

Q5: Which one is more Safe T1 or T6 , why ?

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Concept of EX Protection

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 Concept of EX Protection
Concept of EX Protection

Concept of Protection : Standards

❑ 60079-1 Explosive atmospheres - Part 1: Equipment protection by flameproof enclosures 'd‘

❑ 60079-2 Explosive atmospheres - Part 2: Equipment protection by pressurized enclosures 'p‘
❑ 60079-5 Explosive atmospheres - Part 5: Equipment protection by powder filling 'q‘
❑ 60079-6 Explosive atmospheres - Part 6: Equipment protection by oil immersion 'o‘
❑ 60079-7 Explosive atmospheres - Part 7: Equipment protection by increased safety 'e‘
❑ 60079-11 Explosive atmospheres - Part 11: Equipment protection by intrinsic safety 'i‘
❑ 60079-13 Explosive atmospheres - Part 13: Equipment protection by pressurized room 'p'
❑ 60079-15 Explosive atmospheres - Part 15: Equipment protection by type of protection 'n'
❑ 60079-18 Explosive atmospheres - Part 18: Equipment protection by encapsulation "m"

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 Concept of EX Protection
Concept of EX Protection

Types of EX Protections

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Concept of EX Protection
Concept of EX Protection

Intrinsic Safe Protection Exi

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 Concept of EX Protection
Concept of EX Protection

Intrinsic Safe Protection I.S : Exi

A type of protection based on the restriction of electrical energy within apparatus

and of interconnecting wiring exposed to the potentially explosive atmosphere to
a level below that which can cause ignition by either sparking or heating effects.

Intrinsic safety is achieved by maintaining very low energy levels:

• Limit the voltage and current supplied to the hazardous area, typically not
exceeding 30V or 100mA.
• Hot surfaces will not be produced
• Electrical sparks, if they occur, will have insufficient energy to ignite the
flammable mixture.
• Voltage, current, resistance, inductance and capacitance are all factors that
must be considered in the design of the circuit.

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 Concept of EX Protection
Concept of EX Protection

I.S Principle of Protection : Exi

• Zener Diode limit the voltage below 30V

• Resistor limiting the current below 100mA.

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 Concept of EX Protection
Concept of EX Protection

Types of Intrinsic Safe Protection

There are three main sub types to Ex i protection:

• Type Ex ia : protection allows for the occurrence of two faults during

operation

• Type Ex ib : protection allows for the occurrence of one fault during

operation

• Type Ex ic : protection allows for the occurrence of no fault during

operation

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 Concept of EX Protection
Concept of EX Protection

Intrinsic safety Loop Concept

The concept of Intrinsically safe circuit is the presence of an intermediate device
that separates the level of the safe zone signal and the hazard zone signal level

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 Concept of EX Protection
Concept of EX Protection

Intrinsic safety Loop Concept

During a potential fault, excess

energy could be transmitted to the
hazardous area and if a spark occurs
could create an explosion.

IS zener barriers drive excess energy

to ground or by other means protect
the device in the hazardous area from
ever creating an explosion. Limited to
about 1watt or less in most instances.

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 Concept of EX Protection
Concept of EX Protection

Apparatuses types :

• Complex System Apparatus

• Simple Apparatus

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 Concept of EX Protection
Concept of EX Protection

Simple Apparatus

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 Concept of EX Protection
Concept of EX Protection

Simple Apparatus
Simple apparatuses do not need certification , only manual is required or safety
certificate

Apparatus Certification needs

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 Concept of EX Protection
Concept of EX Protection

Associated Apparatus

The installation of a (Zener barrier) or (Galvanic isolator) interface does NOT make
a circuit intrinsically safe

Associated apparatus must be installed in a non-hazardous location.

Example apparatus,
• Power supply modules
• Interface units

❑ Associated apparatus can be installed without any further protection ,

Example Marking:[Ex ia] IIC
❑ Associated apparatus can be installed within Ex d, Ex px, Ex pz or Ex nR
enclosures. Example Marking: Ex d [ia] IIC T5
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 Concept of EX Protection
Concept of EX Protection

Barrier as an Associated Apparatus

The installation of a (Zener barrier) or (Galvanic isolator) interface does NOT make a
circuit intrinsically safe without a specific conditions.
Associated apparatus must be installed in a non-hazardous location.

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 Concept of EX Protection
Concept of EX Protection

For Which Zone “Exi” is suitable?

Ex ia
Intrinsically safe
with two fault Ex ib
Intrinsically safe
Ex ic
Zones 0, 1 and 2 with one fault
Safe in normal
use no faults
Zones 1 and 2
Zone 2 only

Faults (Failures) considered are of the components within the interface upon
which the safety of the installation depends
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 Concept of EX Protection
Concept of EX Protection

Two designs achieving Exi protection:

Exi Barriers are used to create intrinsic safe protection and they are coming
into two major designs:

1. Zener Barrier

2. Galvanic Barrier

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 Concept of EX Protection
Concept of EX Protection

1. Zener Barrier

Fuse: sand filled or Resistor: Wire wound or

ceramic type metal film

2/3 Max
Safe
Area
2/3 Max
Hazardous
Area

• Protection against overvoltage & overcurrent

• Infallible components (fail safe)
• Encapsulated components (non-replaceable)

How should you test a suspected faulty barrier?

Disconnect from the circuit and measure the
resistance between the input and output terminals. 76
 Concept of EX Protection
Concept of EX Protection

Protection against Short Circuit and Overvoltage

Safe Area Hazardous
Area

• The resistor within the

barrier prevents Isc
excessive current from
entering the hazardous
area.

Safe Area Hazardous

Area
• The breakdown of the zener
diode and the subsequent
rupturing of the fuse prevents If
excessive voltages from
entering the hazardous area.
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 Concept of EX Protection
Concept of EX Protection

Protection against Overvoltage

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 Concept of EX Protection
Concept of EX Protection

Protection against Overvoltage

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 Concept of EX Protection
Concept of EX Protection

Exi variations
Ex ia
Ex ib
Ex ic

Ex ia – safe with 2
faults – Zones of use
0, 1 & 2 Ex ib – safe with 1
fault – Zones of use 1 Ex ic – safe with 0
&2 fault – Zones of use 2

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 Concept of EX Protection
Concept of EX Protection

Earthing

• Zener barriers require a high-integrity earth.

• Must be insulated from surrounding metalwork, i.e. plant earth.
• Connected directly to main earth point, i.e. transformer star point or earth
rod.
• Resistance between the barrier earth bar and main earth point ≤ 1Ω.
• Earth conductors must have appropriate cross-sectional area for carrying
the maximum fault current at least 4mm2 if using single conductor
otherwise it is better to use 2 separate conductors each of 1.5mm2 so that
each one connected to earthing rode of less than 1Ω.

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 Concept of EX Protection
Concept of EX Protection

Earthing

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 Concept of EX Protection
Concept of EX Protection

Earthing

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 Concept of EX Protection
Concept of EX Protection

Earthing

This mesh forms the equipotential bonding system, a

connection down to which will provide ideal conditions
for furnishing the necessary earth connection to zener
barriers.

Or,
Separate earth rods are permitted, but there remains the need to maintain less than one
ohm (R1 + R2) to the main power system earth which can be difficult to ensure. It can be
possible for earth fault currents in the power system to cause unwanted voltages to
appear at the barrier earth.

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 Concept of EX Protection
Concept of EX Protection

Earthing
Even if such special provision is not made, then the common grounding of the metal
enclosures of plant equipment, motors, luminaires, switchgear and structural components
of the building will together usually constitute an equipotential bonding system suitable for
the connection of zener safety barriers.

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 Concept of EX Protection
Concept of EX Protection

Disadvantages of the Zener Barrier

• Requires high integrity earth.
• Direct connection between the safe and hazardous area circuits.
• Hazardous area apparatus must be capable of withstand 500V IR test to
earth.

So, what is the alternative ?

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 Concept of EX Protection
Concept of EX Protection

2. Galvanic Isolation
Isolation

IS
Hazardous Relay
area
Non-hazardous
area
Supply

• Safety achieved by electrical separation.

• Component approved transformer and relay.
• Ensures prevention of high voltage invasion to IS circuits.
No specific earthing requirements
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 Concept of EX Protection
Concept of EX Protection

Galvanic Isolation

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 Concept of EX Protection
Concept of EX Protection

Simple Devise

• A simple device or apparatus does not generate or store more 1.2V or

100mA or 20mJ or 25mW.

• Such devices are incapable of causing ignition, and need no compliance to

explosion proof or intrinsic safety.

❖ Devices generating energy:

• Thermocouples
• Photocells
❖ Devices storing energy:
• Capacitors
• Inductor
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 Concept of EX Protection
Concept of EX Protection

Basic I.S System: Energy Storage

Inductance and capacitance can effect the security of IS systems.

Total L & C of cables and field apparatus must not exceed the values specified
on interface device.

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Video

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 Concept of EX Protection
Concept of EX Protection

Basic I.S System: Generating energy

Devices which generate energy or sources of stored energy must not generate
more than:

( 1.5V, 100mA , 20mJ and 25mW )

Thermocouple

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 Concept of EX Protection
Concept of EX Protection

Segregation of IS & non-IS Cables

• Adequate separation, 2 inches of air space from other installations.

OR
• Placing of the IS cables inside metal conduit ,
OR
• Use armoured, metal sheathed or screened cables for either the IS or non-IS
cables.
• Can be separated by a grounded metal or insulated partition.
IS and non-IS circuits must not share the same cable

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 Concept of EX Protection
Concept of EX Protection

Unused Cable Cores

Unused cable cores should be :

• Terminated to separate terminals at both ends; OR
• Connected to the same earth point as the IS circuits.

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 Concept of EX Protection
Concept of EX Protection

Enclosures Containing IS & non-IS

Creepage/Clearance Distances can be maintained by either spatial separation

or partition plates.

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 Concept of EX Protection
Concept of EX Protection

Enclosures Containing IS & non-IS

Combining wiring for IS and non-IS circuits can also be combined in single enclosures as
long as proper segregation and identification methods are employed...

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 Concept of EX Protection
Concept of EX Protection

Enclosures Containing IS & non-IS

The requirements for 50mm segregation

applies not just to the terminals but also
all of the interior wiring.

97
97
 Concept of EX Protection
Concept of EX Protection

Enclosures Containing IS & non-IS

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 Concept of EX Protection
Concept of EX Protection

Inspection of IS Earths
1 Check that the IS earth bars are correctly mounted on insulating blocks.
2 Check that the IS earth bars are firmly supported.
Check that the IS earth bars are protected against accidental connection to any non-IS earth
3
(e.g. supporting rack or cubicle i.e., the power non-IS earth)
4 Check that the IS earth bars are labelled ‘Intrinsically Safe Earth’.
5 Check that the IS earth bars are connected together in accordance with the approved drawings.
Check that the cables connecting IS earth bars have the correct conductor size (refer to
6
drawings) and an insulating sheath which is undamaged
7 Check that the cable connections to the IS earth bars are clean and tight.
Check that the main IS earth bar is connected back to the substation or switch room earth bar in
8
accordance with the approved drawing(s).

Check that the cables connecting the main IS earth bar to the substation or switch room earth
bar have the correct conductor size (preferred two) (refer to drawings) and an insulation sheath
9
which is undamaged along its full length and not in contact with un-armoured cables. These
cables should be inspected along their entire route.

Check that cable connections to the main IS earth bar and the substation or switch room earth
10
bar are clean and tight. 99
 Statutory Regulation and Standards

Quiz
Q1: What is the concept of intrinsically safe (I.S.) protection ?

Q2: How many types of barriers used for achieving intrinsic safe
protection?

Q3: Where we have to install the barrier to keep the concept valid?

Q4: which barrier does need very good quality earthing resistance of less
than Ohm?

Q5: What is the distance shall separate I.S. from non I.S. circuits?
100
Concept of EX Protection
Concept of EX Protection

Flame Proof Protection Exd

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 Concept of EX Protection
Concept of EX Protection

Flame Proof Protection : Ex d

Type of protection in which components that could ignite a potentially

explosive atmosphere are fitted in an enclosure that will contain the pressure
of an explosion, preventing ignition of flammable gas outside the enclosure.

It has a wide range of applications, typically junction boxes, lighting fittings,

electric motors etc.

• Zones of Use: 1 & 2

• Equipment Protection Level: Cat 2 / EPL Gb
• Ambient Temperature: -20oC to +40oC unless marked
otherwise

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 Concept of EX Protection
Concept of EX Protection
Flame path : Enclosures

Flameproof is the only one of the nine different methods of explosion protection in
which an explosion is permitted. The enclosure must be strong enough to contain
an explosion pressure of 150 psi peak.

• Flameproof enclosures are not gas tight and a gas or vapour will enter the
enclosure where, for example, joints or cable entries exist.

Standards specify that there shall be no intentional gap at the joints of

flameproof equipment, gaps will normally exist due to manufacturing
methods 103
 Concept of EX Protection
Concept of EX Protection

Flame Proof Protection : Ex d

• the gaps at the joints and threads of cable entries must be long (25mm) / narrow
to cool the flames/hot gases
• Average roughness Ra of the flame path surfaces must not exceed 6.3 m.
• The enclosure must be strong enough to contain an explosion pressure of 150 psi
peak.
• Lamps, circuits and sparking devices are contained within flameproof enclosure
• Wiring enters enclosure via flameproof cable gland or flameproof barrier.

104
Video

105
ESR/ESOP|March 2021
 Concept of EX Protection
Concept of EX Protection

Enclosure Flame Path Joints

• Flanged joints

• Spigot joints

• Threaded joints

An adequate flame path length is normally

achieved with a thread engagement of 5 full
threads.

106
 Concept of EX Protection
Concept of EX Protection

Flame Path Joint Types : Rotating Equipment

joints on motor are protected by “ Flamepath”

107
 Concept of EX Protection
Concept of EX Protection

Flame Path Joint Types : Rotating Equipment

• Cylindrical (shaft gland) joint

108
 Concept of EX Protection
Concept of EX Protection

Flame Path Joint Types : Rotating Equipment

• Labyrinth joint for shafts (d)

109
 Concept of EX Protection
Concept of EX Protection

Obstruction of Flame path

The Code of Practice recommended that obstruction

of flameproof enclosures, particularly those with
flanged joints, should be avoided.

The minimum distances between the flame path opening and an obstruction
are:
Group Distance
IIA 10 mm
IIB 30 mm
IIC 40 mm 110
 Concept of EX Protection
Concept of EX Protection

Enclosure Unused Cable or Conduit entries

It is important that unused cable/conduit entries in flameproof enclosures are

closed using appropriate stoppers as specified in the standards or supplied by the
manufacturer.

111
 Concept of EX Protection
Concept of EX Protection

Enclosure Unused Cable or Conduit entries

These must be ‘component certified’

metal stoppers which are fully engaged
by 5 full threads.

Stopper Unacceptable
Plastic stoppers are unacceptable

112
Concept of EX Protection
Concept of EX Protection

Increased Safety Protection Exe

113
 Concept of EX Protection
Concept of EX Protection

Increased Safety Protection : Ex e

A protection method in which increased measures are taken to prevent the
possibility of excessive HEAT, ARCS or SPARKS occurring on internal or
external parts of the apparatus in normal operation’.

Zones of use: 1&2

Ambient temperatures
Increased Safety enclosures are normally designed for
use in ambient temperatures in the range -20 °C to
+40 °C unless otherwise marked.

114
 Concept of EX Protection
Concept of EX Protection

Increased Safety Protection : Ex e

Ex e Principal
Design Features
Enclosures and Certified
motor fan guards Minimum Terminals Specified Terminal
have resistance to IP54 creepage locking
impact of 3.5J and devices
clearance
distances
115
 Concept of EX Protection
Concept of EX Protection

Increased Safety Ex e
Typical applications are induction motors,
lighting fittings and junction boxes.

Special design features are incorporated in

the apparatus by the manufacturer as follows.

• Mechanically strong enclosure resistant to

impact - tested to 4 or 7 joules impact
energy depending on application.

• Ingress protection against solid objects

and water - at least IP 54.
116
 Concept of EX Protection
Concept of EX Protection
Increased Safety Ex e

INCREASED SAFETY EEX E MOTORS

• These motors are similar in appearance to standard industrial motors

• These motors are not designed to withstand an internal explosion

• The motors have special design features to prevent arcs, sparks and
excessive temperatures occurring both internally and externally

117
 Concept of EX Protection
Concept of EX Protection

Increased Safety Ex e

• Terminals manufactured from high quality insulation material.

• Specified creepage and clearances incorporated in design of terminals.
• Terminal locking devices to ensure conductors remain secure in service.
• Terminal population of enclosure limited by circuit design.
• Close excess current circuit protection.

118
 Concept of EX Protection EX EX Protection
Concept of

Increased Safety Ex e

• Specified creepage and clearances incorporated in design of terminals.

• Terminal population of enclosure limited by circuit design.

119
 Concept of EX Protection EX EX Protection
Concept of

Increased Safety Ex e

• Specified creepage and clearances

120
 Concept of EX Protection
Concept of EX Protection
Increased Safety Ex e
Terminal locking devices

• Cage Type

• Post Type

• Screw Type

121
 Concept of EX Protection
Concept of EX Protection

Increased Safety Ex e

Terminal locking device

It is essential that conductors are
securely connected in the terminals to
prevent sparks occurring as a result of
loose connections.

122
 Concept of EX Protection
Concept of EX Protection
Increased Safety Ex e
Rating of increased Safety terminal
The terminals are de-rated so that the maximum current for Increased Safety applications is
nearly half that for standard industrial applications, to keep surface temperatures within
prescribed limits.

123
 Concept of EX Protection
Concept of EX Protection

Increased Safety Ex e

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

1. Mounting rail
2. Terminals - certified components
3. End plate
4. End bracket
5. Distance sleeve
6. Partition
7. Copper cross-connection
8. Zinc plated screw
9. Copper cross-connection
10. Copper cross-connection 124
Concept of EX Protection
Concept of EX Protection

Protections
Exo , Exp , Exm and Exn

125
 Concept of EX Protection
Concept of EX Protection

Oil Immersion : Ex o

Parts that could ignite a potentially explosive atmosphere are immersed in oil or
another non-combustible, insulating liquid to an extent that gas or vapor above
the liquid or outside the enclosure cannot be ignited by arcing, sparks, hot
components (such as resistors) or hot residual gases from switching operations
beneath the surface of the liquid.

Important Design Parameters

• Stipulated insulating liquids (e.g., oil)

• Assurance that the liquid remains in good condition with regard to dirt and
viscosity
• Assurance and possibility of checking on safe oil level – On heating and
cooling – Leak detection
• Restriction to non-portable equipment

126
 Concept of EX Protection
Concept of EX Protection

Oil Immersion : Ex o
• The basic principle as shown above is to immerse the electrical parts in
mineral oil, which will prevent any exposure of the arcing or sparking to the an
explosive atmosphere.

• It will also quench arcs and limit the temperature rise on electrical parts.
• Standards for oil immersion protection, Ex-o,
require that all parts capable of producing arcs or
sparks must be immersed in the oil at a depth not
be than 25 mm.

• A method to check the oil level must be provided ,

e.g., by a sight glass or by some other reliable
methods.
Locations : Zone 1 & 2 Suitable

127
 Concept of EX Protection
Concept of EX Protection

Purging and Pressurization : Ex p

Ex p is sub divided into 3 types of protection:

• Ex px: converts inside of enclosure to non-hazardous from Zone 1 outside.

• Ex py: converts inside of enclosure to Zone 2 from Zone 1 outside.
• Ex pz: converts inside of enclosure to non-hazardous from Zone 2 outside.

Ex ‘px’ Ex ‘py’ Ex ‘pz’

128
 Concept of EX Protection
Concept of EX Protection

Encapsulation : Ex m
Encapsulation is a type of protection whereby parts that are capable of igniting
an explosive atmosphere, by either sparking or heating, are enclosed in a
compound is such a way that the explosive atmosphere cannot be ignited under
operating or installation conditions

• Resistors, capacitors, opto isolators, diodes etc., must not operate at more
than 2/3 of their rated voltage.

• Voids and air pockets other than those for relays or other devices must be
avoided

129
 Concept of EX Protection
Concept of EX Protection

Non Sparking Protection : Ex n

Ex nA Non-Sparking is a lesser degree of protection than Exe, where as standard

industrial equipment that under normal operation will not produce arcs, sparks or
surface temperature high enough to cause ignition of the surrounding gas vapor
mixture.
This can be further categorized as follows:

Ex nC - Where components used in construction are non-incendive

Ex nA - Where components used in construction are non-sparking
Ex nR - Where components used are tightly enclosed to restrict the breathing
and prevent ignition
Ex nL - Where components used in construction do not contain enough energy
to cause an ignition
Zones of Use: 2 only
Equipment Protection Level: Cat 3 / EPL Gc
Ambient Temperature: -20oC to +40oC unless marked otherwise
130
 Concept of EX Protection
Concept of EX Protection

Non-Sparking Protection : Ex n
Reduced Risk Protection : Type of Protection ‘nR’

Implication for lighting design is the use of higher wattage fixtures and using
fewer of
them for particular areas most notably for floodlights and wellglass
applications...

Per 90079-0, all glands to be used in conjunction

with Ex n equipment must be suitable and certified
as Ex nR
The gland to enclosure interface needs to
maintain the sealing for the restricted breathing.
131
 Concept of EX Protection
Concept of EX Protection

Non-Sparking Protection : Ex n
Reduced Risk Protection : Type of Protection ‘nR’

Ex nR Equipment marking

• It is not Allowed to open such lighting

fixture while energized to prevent the
ingress of gas / dust,

• Maintenance of good seals and tight

securing bolts is vital.

132
 Concept of EX Protection
Concept of EX Protection

Non-Sparking Protection : Ex n
Reduced Risk Protection : Type of Protection ‘nC’

Type ‘nC’ protection may be provided by one of the following,

Enclosed break devices,

Incorporates make/break contacts that may ignite an explosive atmosphere,
but is constructed to withstand an internal explosion without suffering
damage and prevents it igniting the surrounding external explosive
atmosphere.

Hermetically sealed devices,

The external atmosphere cannot gain access to the interior of the device, the
seal is made by fusion, for example soldering, brazing, welding or the fusion
of glass to metal.
133
 Concept of EX Protection
Concept of EX Protection

Concept of Protection : Hybrid Ex Protection Techniques

The light fitting is rated Ex dem using :

• Ex d flameproof for the disconnect switch and lamp holders

• Ex e Increased safety for the housing & terminal,
• Ex m for encapsulation of the ballast..

Final product rated for (Ex d ,Ex e, Ex m) to be Ex dem

134
 Concept of EX Protection
Concept of EX Protection

Concept of Protection : Hybrid Ex Protection Techniques

The control panel below is using :

• Ex d for flameproof operators...

• Ex e increased safety for the housing and terminals

Final product rated Ex de..

135
 Concept of EX Protection
Concept of EX Protection

Which EX protection method is the most cost effective solution?

Generalities– If Zone 1 locations
❑ Ex ‘e’ Increased Safety is typically the way to go if at all possible due to weight,
cost and ease of maintenance

❑ Ex ‘d’ used when ‘e’ protection is not practical, i.e. Motor Starters, Circuit
Breakers, etc.

❑ Hybrid ‘e’ & ‘d’ usually the best concept where you take the best of both and
combine the two.

❑ Lighting –Zone 1 :
• HID lighting is going to always be Ex ‘d’ construction,
• fluorescents are more likely to be Ex ‘e’ plastics.
• LED’s have have been designed using both protection concepts.

❑ Instrumentation circuits for Zone 1 are typically I.S. 136

 Concept of EX Protection
Concept of EX Protection

Protection Selection

137
EX Enclosures

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 EEXd, EEXe & EEXi Enclosures

Ex Enclosures
EX enclosures are specially made for use in hazardous environments. They are
designed, manufactured and tested to international standards. All certificates,
such as ATEX/IECEx, are issued by the manufacturer under license from a test
authority.
Exia
EX enclosures are made of either:

• Aluminum,
Exe
• Polycarbonate
• Polyester.

Exd Exd

Exd
Minimum specified ingress protection is IP 54 139
 EEXd, EEXe &EEXd, EEXe & EEXi Enclosures
EEXi Enclosures

Flame Proof Enclosures

Modification of flameproof enclosures

A. Replacement components should always be exactly the same as the original

specified components in order to avoid infringement of the certification.

Original Replacement of ‘A’ Replacement of ‘A’

arrangement with a larger item with a smaller item

• Component larger or smaller than the original will affect the internal
geometry of the enclosure.

• Pressure piling is a possibility if a larger component is fitted, and

increased volume will result if a smaller component is fitted. 140
 EEXd, EEXe &EEXd, EEXe & EEXi Enclosures
EEXi Enclosures

Flame Proof Enclosures

Modification of flameproof enclosures

B. Adding components is also forbidden because of the

possibility of increased explosion pressure as a result of
pressure piling.
Addition of component ‘C’

C. The removal of components should also be avoided since an

increase in the free internal volume will result.

Removal of component ‘B’

141
 EEXd, EEXe &EEXd, EEXe & EEXi Enclosures
EEXi Enclosures

Modification of flameproof enclosures

C. Drilling and tapping of cable gland/conduit entries should only be carried out
by the manufacturer of the enclosure, or his approved agent.
D. The strength of a flameproof enclosure may be impaired if the number and
size of entries exceeds that permitted in the original design certified by the
test authority.
E. Gaskets can only be replaced; they must not be added
retrospectively if not included as part of the original design.

F. The use of unauthorized sealants should also be avoided

when it is required to maintain or improve the IP rating.

G. Modifying an Ex d enclosures include accidentally

damaging the flameproof gap where the end user scratch
or damage the flanges.

142
 EEXd, EEXe &EEXd, EEXe & EEXi Enclosures
EEXi Enclosures

Flame Proof Enclosures

Modification of flameproof enclosures

The certification of the equipment is

no longer valid if any modification is
carried by the end user

143
 EEXd, EEXe &EEXd, EEXe & EEXi Enclosures
EEXi Enclosures

Ex Enclosures : Bolts used for Exd enclosure

The requirements for bolts, screws and studs used in the construction of a
flameproof enclosure must meet the following requirements:
• Have non-slotted heads – bolts cannot be tightened properly with a
screwdriver.
• Bolts shall be recessed type
• Be of the correct length, nominal diameter and thread form.
• They must also be made of the same material. EG. You can not put a brass
bolt in if all the others are SS.
• Be tight –if all bolts are not tight, the specified air gap may be increased during
an internal explosion.
• Bolt’s holes should be inspected for damaged threads.
• Remove any dirt from the bottom of a blind hole

144
 EEXd, EEXe &EEXd, EEXe & EEXi Enclosures
EEXi Enclosures

Flame Proof Enclosures

Thread Engagement
All cable/conduit entries into Ex d enclosures should be threaded – Clearance
holes are not permitted.

" All threaded devices, such as glands, stoppers, adapters or conduit,

MUST be threaded into the enclosure by a MINIMUM of 5 FULL threads."

• Thread adaptors are allowed to be used if required,

• Where are they required, there shall be no more than one per entry.

145
 EEXd, EEXe &EEXd, EEXe & EEXi Enclosures
EEXi Enclosures

Flame Proof Enclosures

Sealing Unused Entries

Stopper/blank plugs must be Ex d certified

Stopper/blank plugs should not be used with thread adaptors

146
Ingress Protection (IPXX) Environmental
Protection

147
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 Ingress Protection (IPXX)

Ingress Protection (IP)

Ingress Protection Another consideration in the protection of equipment in
hazardous areas is the safeguarding against the ingress of solid foreign objects
and water. This is known as the degree of ingress protection and is commonly
referred to as the IP Code.

• This is defined in IEC Standard 60 529 and the following chart illustrates the
two-digit code used.

148
 Ingress Protection (IPXX)
Ingress Protection (IPXX)

Ingress Protection (IP)

149
EX equipment Marking

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 EX equipment Marking
EX equipment Marking

EX equipment Marking

151
 EX equipment Marking
EX equipment Marking

EX Equipment : Typical Name plate

152
 EX equipment Marking
EX equipment Marking

EX equipment Marking

Example of more detailed

interpretation of ATEX Marking system

153
 EX equipment Marking
EX equipment Marking

EX equipment Marking

154
 EX equipment Marking
EX equipment Marking

EX equipment Marking

155
 EX equipment Marking
EX equipment Marking

EX equipment Marking

156
Method of EX Electrical Installations

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 Method of EX Electrical
Method of EXInstallations
Electrical Installations

Hazardous Area Classification Equipment Selection

It is helpful if we break down a typical electrical installation into suitable parts for
consideration at the design, selection and erection stages, giving a general case.

158
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

Methods of installation :

▪ Cable system with indirect entry

▪ Cable system with direct entry

▪ Conduit system

159
Method of EX Electrical
Method of EXInstallations
Electrical Installations

Arcing &
Sparking
Arcing &
Sparking

Ex d Enclosures

Direct Entry Indirect Entry

160
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

Method of Electrical Installation

▪ Cable system with direct entry

Direct entry comprises a single

flameproof chamber within which
components such as switches, relays
or contactors may be installed.

161
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

Method of Electrical Installation

▪ Cable system with indirect entry

Flameproof apparatus with indirect entry has two separate chambers, one of
which contains only terminals for connection of the conductors of incoming
cables or conduit.

162
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

Method of Electrical Installation Indirect Entry

Direct Entry

163
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

Method of Electrical Installation

Ex d Apparatus with Indirect
Entry to Ex e Terminal Box

Compound Sealed Entries

Note: Barrier gland not required with these arrangement.

Ex e Terminal Box
Ex d Indirect Entry
Apparatus Types 164
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

Cable Glands

There is no IEC Standards for cables for use in Hazardous Areas

Single wire armour

(SWA)

Wire braid armour

Steel tape armour

Unarmoured
165
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

Used type of Cables

Factors to consider when installing in
hazardous areas:

• Cables shall be of non-hygroscopic.

• Cables shall have properly extruded

bedding

A hygroscopic substance is one that readily

attracts water from its surroundings, through
either absorption or adsorption.

* This will allow gases or flammable liquids to

enter the EX protected equipment.*
166
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

Cable Glands

The use of suitable glands which are tested to be adequately safe must be
used to prevent the transmission of:-

• flame
• explosion pressure
• process fluids
• moisture
• dust

In addition, any gland must:-

• provide anchorage for cable via armor (2 tones)

• protect cable cores and armor against corrosion from weathering
• solidly earth the armor
167
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

Purpose of using Gland

• To create positive entry for cable that might have different types of armours
• To Prevent Spread of gas coming through the cable
• To prevent spread of the fire in case of explosion 168
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

Cable Gland types

There are different types of glands provided by cable gland manufacturers.
Not all are suitable for use on Ex d installations. The Four principle types
suitable are:-

• Stuffing Glands
(Used where no mechanical cable protection is required)

• Sealing Glands
(ordinary type certified Ex d)

• Barrier Glands
(used to prevent transmission of flame through the cable)

169
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

Glands
Stuffing Glands
General purpose stuffing glands are suitable for use with all types of un-
armoured cables, providing mechanical cable retention and an
IP66/IP67/IP68 environmental displacement seal onto the cable's outer
sheath.

The gland is suitable for both indoor and outdoor installations.

170
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

Glands

Sealing Glands
A Sealing Gland maintains the flameproof properties of the enclosure at a
cable entry hole. These are fitted where a “filled” cable is used,

Its features are that it provides a

pressure seal and anchor to
prevent the cable being blown out
of the gland. In addition it must
seal the cable sheath to prevent
access to moisture that can
corrode the armoring.

If fitted incorrectly this can be a

weak part of the installation.
171
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

Glands
Barrier Glands
A Barrier gland should be fitted where a non-filled cable is used and where an
explosion or process fluid must be prevented from moving through the cable.

In addition to the sealing gland

requirements the Barrier gland
cannot allow explosions to
travel up the cable because
the cores are sealed using a
hardened epoxy resin plug to
stop transmission through the
cores.

172
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

Glands

Barrier Glands

Where equipment has an internal source of ignition

While in these Zones with these Gases present a
Barrier Gland is Required

• Zones 1 & 2 with a type IIC gas

• Zone 1 with type IIA, IIB or IIC gas and the internal volume of Ex d apparatus is 2L
or greater in size.

It is Not Required to have a Barrier Gland if there is no internal source of ignition

173
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

Glands

• Only Ex d or flameproof glands are allowed for Gas groups IIA, IIB and IIC
gasses in Zone 2 locations if the cable meets the requirements according to
the standards. This also applies for fire damp in mines.

• No direct entry of an Ex d gland is permitted in a Zone 1 location with Gas

Group IIC present as well as IIA and IIB Gasses under certain conditions.

• Indirect Cable Entry into Ex d Enclosures by making use of Ex e and Ex d

enclosures

174
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

Cable Glands

Compound filled
gland (barrier)

Standard gland
(displacement seal)

Compound filled
gland (barrier)

Cable glands for Ex d equipment must be Ex d certified

175
Method of EX Electrical
Method of EXInstallations
Electrical Installations

Gas Seals

176
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

What cable gland would we use on the I.S. cable?

Ex d
Ex d [ ia ] Gland

177
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

Gland Accessory Requirements :

IP Washer

Wall thickness < 6mm Wall thickness 6mm or > will achieve
requires IP washer to IP54, IP washer required for anything
maintain IP54 above IP54

Clearance holes require IP washers regardless of wall thickness.

Wall thickness ≤ 3mm requires a

serrated washer and locknut (anti-
vibration). 178
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

▪ Conduit system

• This technique is included in the CENELEC standard and the IEC

standards as one of the entry methods into flameproof enclosures.

• The design and testing requirements are contained in the CENELEC

and IEC Standard IEC 60079-1.

• Either tapered (NPT) or parallel (straight or metric) threads are

acceptable.

179
Video

180
ESR/ESOP|March 2021
 Method of EX Electrical
Method of EXInstallations
Electrical Installations
▪ Conduit system

Tubular metal sheath into which insulated conductors may be drawn as

necessary; There are two main forms:

• Solid Drawn’ or
• Continuous Welded’

• Either tapered (NPT) or parallel (straight or metric) threads are

acceptable.

181
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

▪ Conduit system

Conduit Seals – Purpose

o Prevent explosion from traveling throughout the conduit

system

o Limit enclosure volume

o Minimize gases or vapors from moving from a

hazardous (classified) location to an unclassified
location through connecting raceways or from
enclosure to enclosure

o Stop pressure piling – buildup of pressure inside

conduit lines caused by pre-compression as the
explosion travels through the conduit 182
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

▪ Conduit system

o Conduit seals shall be installed

within 18” of the enclosure

o Only explosion –proof unions,

couplings, reducers, elbows,
capped elbows, and conduit
bodies similar to L,T and cross
types not larger than trade size of
the conduit are permitted between
seal and enclosure

183
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

▪ Conduit system : Sealing Fitting with drain point

184
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

▪ Conduit system : Sealing Fitting with drain point

Conduit Seals - Purpose

o Stop pressure piling – buildup of pressure inside conduit lines caused

by pre-compression as the explosion travels through the conduit

Pressure piling
describes phenomena related to
combustion of gases in an enclosure. As
the flame front propagates along the tube,
the unburned gases ahead of the front are
compressed, and hence heated. This
results in a high pressure / high temp in
the second enclosure, which if ignited,
causes a far larger explosion.
185
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

▪ Conduit system : Sealing Fitting with drain point

Pressure piling

186
 Method of EX Electrical
Method of EXInstallations
Electrical Installations

▪ Conduit system

187
EX Equipment
Inspection

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ESR/ESOP|March 2021
 Method of EX Electrical Inspection

Introduction

Electrical installations (consisting of electrical components & systems) in

Hazardous Areas are specially designed with special features & properties, so that
the safety aspect & safety requirements remain intact.

These specially designed & built-in features make these Electrical installations
suitable for operation in hazardous Areas.
It is essential that, throughout the life of such installations, the integrity of those
special features is preserved.

This important requirement calls for a well structured procedure to carry out :-

• REGULAR PERIODIC INSPECTIONS , OR

• CONTINUOUS SUPERVISION BY SKILLED PERSONNEL

189
 Method
Method of EX of EX
Electrical Electrical Inspection
Inspection

Inspection, maintenance and repair of explosion-proof equipment

❑ Grades of inspection
◼ Visual inspections
◼ Close inspections
◼ Detailed inspections

❑ Types of inspection

◼ Initial inspections
◼ Periodic inspections
◼ Sample inspections
◼ Continuous supervision
190
 Method
Method of EX of EX
Electrical Electrical Inspection
Inspection

There are three grades of Hazardous Area Inspections:

Visual Hazardous Area Inspections

Visual hazardous area inspections identify without the use of access equipment or tools,
those defects, such as missing bolts, which will be apparent to the eye.

Close Hazardous Area Inspections

Close hazardous area inspections encompasses those aspects covered by a visual
inspection, and in addition, identifies those defects, such as loose bolts, which will be
apparent only by the use of access equipment, for example, steps (where necessary) and
tools. Close inspections do not normally require the enclosure to be opened, or the
equipment to be de-energized.

Detailed Hazardous Area Inspections

Detailed hazardous area inspections will encompass those aspects covered by a close
inspection and, in addition, identify those defects, such as loose terminations, which will
only be apparent by opening the enclosure and/or using where necessary, tools and test
equipment.
This inspection may require the enclosure to be opened, equipment to be de-energized
191
and dismantling of cable glands where applicable.
 Method
Method of EX of EX
Electrical Electrical Inspection
Inspection

Wiring Inspection

• All cables must be routed to avoid mechanical damage, corrosion, or

chemical damage.

• Prevent the transfer of flammable gases, vapours, liquids or dusts from a

hazardous area to a safe area or between hazardous areas. Use trenches,
barrier glands, conduit with seals or transits.

• Cable terminations should be secure to prevent lose connections forming

heat.

• Unused cores to be connected to earth or adequately insulated. Insulation

tape is not permitted. Use heat shrink.

• To prevent separation of core wire strands, terminals should have a lug

(Crimped or soldered) one termination per terminal unless designed for more
connections by the manufacturer. 192
 Method
Method of EX of EX
Electrical Electrical Inspection
Inspection

Equipment Inspection
Sample of check list required for each inspection grade based on the type of
the Ex protection

193
 Method
Method of EX of EX
Electrical Electrical Inspection
Inspection

How to use the Chart

SUPPOSE YOU ARE DOING INSPECTION ON Exe Equipment
Cancel the others Exd & Ex n

194
 Method
Method of EX of EX
Electrical Electrical Inspection
Inspection

How to use the Chart

SUPPOSE YOU ARE DOING CLOSE INSPECTION
Cancel the others Visual V & Detailed D

195
 Method
Method of EX of EX
Electrical Electrical Inspection
Inspection

How to use the Chart

Now you now exactly what activity you need to do within this type of
inspection , just look to starred activities

196
 Method
Method of EX of EX
Electrical Electrical Inspection
Inspection

How to use the Chart

If find a dust in side the encloser for example , then your code is : C2

197
 Method of EX Electrical Inspection
Equipment Inspection
Check list required for each inspection grade based on the type of the Ex protection

198
 Method of EX Electrical Inspection

Equipment Inspection (Continued)

Check list required for each inspection grade based on the type of the Ex protection

199
Examples of EX deficiencies observed at Oil
& Gas industry sites

200
ESR/ESOP|March 2021
Examples of EX deficiencies observed at industry

201
Examples of EX of
Examples deficiencies observed
EX deficiencies at BGC
observed at industry

202
Examples of EX of
Examples deficiencies observed
EX deficiencies at BGC
observed at industry

203
Examples of EX of
Examples deficiencies observed
EX deficiencies at BGC
observed at industry

204
Examples of EX of
Examples deficiencies observed
EX deficiencies at BGC
observed at industry

205
Examples of EX of
Examples deficiencies observed
EX deficiencies at BGC
observed at industry

206
Examples of EX of
Examples deficiencies observed
EX deficiencies at BGC
observed at industry

207
Examples of EX deficiencies observed at industry

208
Cable not glanded properly
Examples of EX deficiencies observed at industry

209
Cracked Enclosure
Examples of EX deficiencies observed at industry

210
Incorrect cable gland
ESR & ESOP

Course Name|Date

211