BASIC OF EXPLOSION PROTECTION

Explosion Protection

BY

PRAMOD KALYANI
 BASIC OF EXPLOSION

Explosion protection triangle

Ignition
source
Oxygen
◼ sparks
◼ air
◼ hot surfaces
◼ H2O2
◼ hot gases

Flammable material
• gas
• dust
• vapor
Explosion Limits of selected Gases and Vapours
EXPLOSION PROTECTION

FLAMMABLE RANGE

Gas Representative Gas Ignition Energy

Group (mj)

I Methane 280

II A Propane 260

IIB Ethylene 95

IIC Hydrogen 18
SOURCE OF IGNITION

Hot Surfaces:

If an explosive atmosphere comes into contact with a

heated surface, ignition can occur.

The capability of a heated surface to cause ignition depends

on the type and concentration

of the particular substance in the mixture with air.

This capability becomes greater with increasing temperature

and increasing surface area

Ignition also depends on the size and shape of the heated

body.
SOURCE OF IGNITION

Flames

Flames, even very small ones, are among the most effective
sources of ignition.

No naked flames are permitted in Zone 0 and gases from

flames and other heated gases are not permissible unless
special preventive measures are taken.

In other Zones devices with flames are only permissible if the

flames are safely enclosed
 SOURCE OF IGNITION

Mechanically generated sparks:

As a result of friction, impact or abrasion processes such as grinding,

particles can become separated from solid materials and become
hot owing to the energy used in the separation process. Rubbing
friction, even between similar ferrous metals and between certain
ceramics, can generate hot spots and sparks similar to grinding
sparks….
SOURCE OF IGNITION

Stray electric currents:

Stray currents can flow in electrically conductive

systems or parts of systems as return currents in

power generating systems, especially in the

vicinity of electric railways and large welding

systems.

As a result of magnetic induction (e.g. near

electrical installations with high currents or radio

frequencies)
SOURCE OF IGNITION

Static electricity

The discharge of charged, insulated

conductive parts can easily lead to incendive

sparks….
SOURCE OF IGNITION

Lightning

If lightning strikes in an explosive atmosphere,

ignition will always occur. Even in the absence of

lightning strikes, thunderstorms can cause highinduced

voltages in equipment, protective

systems and components.

The affect of lighting strikes outside the

hazardous area needs to be considered…

SOURCE OF IGNITION

Radio frequency (RF) ignition

Range 1 (104 to 1012Hz)

Electromagnetic waves are emitted by all

systems that generate and use radio-frequency
electrical energy (radio-frequency systems),
e.g.
radio transmitters.
All conductive parts located in the radiation field
function as receiving aerials. If the field is
powerful enough and if the receiving aerial is
sufficiently large, these conductive parts can
cause ignition in explosive atmospheres….
SOURCE OF IGNITION

Radio frequency (RF) ignition

Range 1 (1011 to 1015Hz)

Radiation in this spectral range can,

especially when focused, become a source
of
ignition through absorption by explosive
atmospheres or solid surfaces. Sunlight, for
example, can trigger an ignition if objects
cause convergence of the radiation (e.g.
bottles acting as lenses, concentrating
reflectors)….
SOURCE OF IGNITION

Ionizing Radiation

Electrical equipment which generates ionizing

radiation is admissible provided that the energy

of a radiated pulse or energy flux (power) of

continuous radiation is limited to such a low

value that it cannot ignite the explosive

atmosphere in that the radiation is safely

enclosed.
 SOURCE OF IGNITION

Ultrasonic

In the use of ultrasonic sound waves, solid or liquid

substances absorb a large proportion of the energy emitted by
the electro acoustic transducer. As a result, the substance
exposed to ultrasonic warms up so that, in extreme cases,
ignition may be induced. Ultrasonic waves with a frequency of
more than 10 MHz are not be permitted, For ultrasonic waves
with a frequency up to 10 MHz the power density of the
generated acoustic field shall not exceed1 mW/mm2, unless it
is proved for the case in point that ignition is not possible.
SOURCE OF IGNITION

Adiabatic compression and shock waves

In the case of adiabatic or nearly adiabatic

compression and in shock waves, such high
temperatures can occur that explosive
atmospheres (and deposited dust) can be
ignited. The temperature increase depends
mainly on the pressure ratio, not on the pressure
difference…
SOURCE OF IGNITION

Exothermic reactions, including self

ignition of dusts

Exothermic reactions can act as an ignition

source when the rate of heat generation

exceeds the rate of heat loss to the

surroundings.
SOURCE OF IGNITION

Electrical apparatus

In the case of electrical apparatus, electric

sparks and hot surfaces can occur as sources of

ignition. Electric sparks can be generated, e.g.

when electric circuits are opened and closed;

by loose connections;

by stray currents.
 AREA CLASSIFICATION

EUROPE

IEC ( International Electro

◼NEC( National Electrical Code) technical Commission) for
of USA: Prevalent for areas other Europe
than mines.

◼MSHA (Mine safety & health

administration ):for mines.
 AREA CLASSIFICATION

NEC
Classification on media basis

Class 1: Gases Class 2: Dusts Class 3: Fibers

Presence of hazard
normal vs abnormal

DIV I DIV II DIV I DIV II

Group A: Group A: Group E: Group E:

Acetylene Acetylene Metal Metal
Classification on severity of media

Group B: Group B: Group F: Group F:

Hydrogen Hydrogen Coal Coal

Group C: Group C: Group G: Group G:

Ethylene Ethylene Grain Grain

Group D: Group D:
Propane etc Propane etc
AREA CLASSIFICATION

Classification on location

Classification on severity of
media
 AREA CLASSIFICATION

Degree of Hazard

North American Zones and Divisions

Zone Definitions Division Definitions

Zone 0 Usually hazardous during normal Usually or Frequently

operations (>100 hrs/yr) hazardous vapors present
Div 1 during normal operations

Zone 1 Frequently hazardous during normal

operations

Zone 2 NOT hazardous during normal Div 2 NOT hazardous during normal
operations (<10 hrs/yr) operations
ZONE SYSTEM

ZONE 1
ZONE 2

ZONE 0

ZONE 0
ZONE & EQUIPMENT CATEGORY
Temperature Classes

M a xim u m S u rfa ce E u ro p e a n S ta n d a rd N o rth A m e rica n

T e m p e ra tu re C (IE C ) S ta n d a rd (N E C )
450 T1 T1

300 T2

280 T 2A

250 T2 T 2B

230 T 2C

200 T3

180 T3 T 3A

165 T 3B

160 T 3C

135 T4 T4

120 T 4A

100 T5 T5

85 T6 T6
Temperature Classes

Effect of Dust deposition on Temperature Class

BASIC OF EXPLOSION PROTECTION

Explosion Prevention Methodology

TYPE OF PROTECTIONS FOR ZONE

Marking Type of protection Principle of protection May be

used in

d Flameproof enclosure An propagation of an explosion Zone 1 , 2

(control stations, inside to outside is excluded
motors, fuses, power
electronics)
e Increased safety Avoidance of arc, sparks and Zone 1 , 2
(motors, luminaries) excessive temperature

ia Intrinsic safety Limitation of energy as well as Zone 0, 1 ,

arcs and temperature 2
(radio equipment,
ib automation Zone 1 , 2
technology)
p Pressurization Ex-atmosphere keep at a distance Zone 1 , 2
(switch-and-control from the ignition source
cupboards, analyze-
apparatus,
computers)
m Encapsulation Ex-atmosphere keep at a distance Zone 1 , 2
(coils of motors or from the ignition
relays, solenoid
valves)
o Oil immersion Ex-atmosphere keep at a distance Zone 1 , 2
(transformers, relays,
from the ignition source
control stations,
magnetic contactors)
q Powder filling An propagation of an ignition Zone 1 , 2
(capacitors, inside to outside is excluded
transformers)
APPLICABLE STANDARDS FOR TYPE OF PROTECTION
 TYPE OF PROTECTION FLAMEPROOF Ex ‘d’

Definition as per IS 2148: FLAMEPROOF Ex ‘d’

US- Explosion-Proof, UK- Flame-Proof,

GERMANY - Pressure-Proof

◼ A type of protection in which the parts can ignite an

explosive atmosphere are to be placed in an enclosure,
which can withstand the pressure developed during internal
explosion of an explosive mixture, and which prevents the
transmission of the explosion to the explosive atmosphere
surrounding the enclosure
FLAMPROOF (EXPLOSION-PROOF) PROTECTION (Ex ‘d’)

Important Parameter

FLAME PATH - Width of Joint: shortest path thru flameproof joint

from inside to the outside of an enclosure

GAP - Diametrical Clearance: dist between corresponding surfaces

of flameproof joint.

IEC 60079-1 Table 1 & 2: Minimum width of joint & maximum gap
for Group II A/B &C enclosure.

MESG (max experimental safe gap): maximum gap of a joint 25

mm in width which prevents any transmission of an explosion
during 10 tests made as per IEC 60079-1-1.

IEC 60079-1-1 : Method of test ascertainment of MESG.

FLAMPROOF (EXPLOSION-PROOF) PROTECTION (Ex ‘d’)

Maximum gaps and flame path for gas groups

depends on ignition energies of the gas / vapour and
the volume of the enclosure

For example, for IIB gas group, for 100 Cubic cm

volume, for flanged joints:
◼ Flame Path - 6 mm
◼ Maximum Gap - 0.3 mm

For II C Hydrogen, 100 cubic cm volume, for flanged

joints:
◼ Flame path - 9.5 mm
◼ Maximum Gap - 0.1 mm
FLAMEPROOF EQUIPMENT- CONSTRUCTIONAL REQUIREMENTS

◼USE OF APPROVED MATERIAL WITHOUT THE USE OF INCENDIVE

FRICTIONAL SPARKING

◼EQUIPMENT SHOULD WITHSTAND ROUGH USAGE

◼EQUIPMENT SHALL BE ADEQUATELY STRONG TO WITHSTAND ALL

REQUIRED TESTS

◼THE EFFECTIVE THREADED METAL TO METAL JOINTS SHALL HAVE A

MINIMUM OF 5 FULL UNINTERRUPTED ENGAGED THREADS & A MINIMUM
EFFECTIVE UNINTERRUPTED DIRECT AXIAL LENGTH OF THREADED
ENGAGEMENT OF 9 mm

◼THERE SHALL BE NO INTENTIONAL GAP BETWEEN JOINT SURFACES

◼NO PACKING MATERIAL SHALL BE USED BETWEEN OPPOSED SURFACES TO

FORM A FLAMEPROOF JOINT

◼IF COMPRESSIBLE PACKING MATERIAL OR A GASKET IS NECESSARY TO

SEAL A JOINT (eg. IP) THE PACKING SHALL BE APPLIED AS A SUPPLMENT TO,
BUT SHALL NOT BE INCLUDED IN THE FLAMEPROOF JOINT

◼ANY DISPLACEMENT, DAMAGE, INTEGRATION OR OMISSION OF THE

PACKING SHALL NOT RESULT IN THE FLAMPROOF NATURE OF THE JOINT
BEING ADVERSELY
FLAMPROOF (EXPLOSION-PROOF) PROTECTION (Ex ‘d’)

Flameproof Limit Switch Box Flameproof SOV

EX d typical marking: EEx d IIB T5

 IP Rating

The first digit

The first digit of the IP code indicates the degree that persons are protected against contact with
moving parts (other than smooth rotating shafts, etc.) and the degree that equipment is protected
against solid foreign bodies (dusts) intruding into an equipment.
 IP Rating

Second Digit
The second digit indicates the degree of protection of the equipment inside the enclosure against the harmful
entry of water or moisture (e.g. dripping, spraying, submersion, etc.)
 NEMA Equivalent IP

NEMA
The American form of IP rating is known as NEMA. NEMA is an acronym for National Electrical
Manufacturers Association.
NEMA Application Comment IP
Equivalent

1 Indoors Protected against accidental contact, limited amount of dirt 20

2 Indoors Intrusion of dripping water and dirt

3 Outdoors Protection against dust, rain. No damage when ice forms on the housing 64

3R Outdoors Protection against rain. No damage when ice forms on the housing 22

3S Outdoors Protection against dust, rain and hail. No damage when ice forms on the 64
housing
4 Indoors/Outdoors Protection against splash water, dust, rain. No damage when ice forms on the 66
housing
4X Indoors/Outdoors Protection against splash water, dust, rain. No damage when ice forms on the 66
housing. Protected against corrosion

6 Indoors/Outdoors Protection against dust, water jet and water during temporary submersion. No 67
damage when ice forms on the housing

6P Indoors/Outdoors Protection against water during longer submersion. Protected against corrosion

11 Indoors Protection against dripping water. Protected against corrosion

12, 12K Indoors Protected against dust and dripping water 55

13 Indoors Protected against dust and splash water, oil and non-corrosive liquids 65

NOTE:The NEMA Types meet or exceed the test requirements for the associated IEC Classifications; for this
reason, the table should not be used to convert from IP rating to NEMA.
INTRINSICALLY SAFE EQUIPMENT & CIRCUITS (Ex ‘i’ )

What is intrinsic safety ?

Limitation of electrical energy or thermal effect

under normal or abnormal conditions to cause
ignition of a potentially explosive atmosphere

Definition as per IS 5780

A type of protection which a circuit or part of the circuit is

intrinsically safe when any spark or thermal effect produced
normally is incapable, under prescribed test conditions, of causing
ignition of prescribed gas or vapour
 Intrinsic Safety

Principal

◼ HOW IT WORKS ?
◼ Series resistor limits the current
◼ Zener diode limits fault voltage
◼ Diversion of fault path

Resistor Fuse +
Positive
Zener
Fault
Diode
Path
-
 INTRINSICALLY SAFE EQUIPMENT & CIRCUITS (Ex ‘i’ )

Only electrical protective measure (protection technology by way of power

limitation), the other protective techniques use mechanical means to prevent
ignition from electrical faults (max. 30 volts or 50 mA)

Ex ‘i’ apparatus is the one which has all the circuits within intrinsically safe

Ex ‘i’ circuit is the one which has intrinsically safe barriers with Zenner diodes for
power limitation

Minimum IP 20 ingress protection

INTRINSICALLY SAFE EQUIPMENT- Category- Ex ib

Ex ib equipment shall be incapable of causing ignition in normal operation, with a

single fault and with the following safety factors:

◼ 1.5 in normal operation and with one fault

◼ 1.0 with one fault, if the equipment contains no unprotected switch contacts in
parts likely to be exposed to a potentially explosive atmosphere and the fault is
self-revealing

"Faults" are those in components upon which safety of the installation depends.
Intrinsic safety is the only protection concept which considers failure of the field wiring
TYPE OF PROTECTION INSENTRICALLY SAFE

European Markings
TYPE OF PROTECTION PRESSURISATION Ex ‘p’

PRESSURIZATION TYPE (Ex ‘p’ )

◼A type of protection by which the entry of surrounding atmosphere

into the enclosure of the electrical apparatus is prevented by
maintaining inside the said enclosure, a protective gas at a higher
than that of the surrounding atmosphere

◼The surface temperature of enclosure does not exceed auto

ignition temperature of surrounding flammable gases.

◼Theses enclosures are not capable of withstanding explosion inside

the enclosures.
 PRESSURIZATION TYPE (Ex ‘p’ )

TYPES
Dynamic Pressurization (DP) or pressurization by continuos
circulation of protective gas (purging)

◼ DP is a method of maintaining pressure in an enclosure in which

after purging the protective gas is passed continuously through
the enclosure at a pressure above that of the specified minimum
and discharged to the outside atmosphere

◼ Static Pressurization or pressurization with leakage compensation

◆ Air
supplied & pressurized continuously from a non-hazardous area to
avoid ingress of flammable gases / vapour inside the enclosure
PRESSURIZATION TYPE (Ex ‘p’ )

Pressurized Equipment

Ingress protection minimum IP 4X

Over pressure 1.5 times or 0.2 kPa

Material of construction should be flame retardant, self-

extinguishing and should not be affected by protective gas
PRESSURIZATION TYPE (Ex ‘p’ )

Pressurized Equipment / Panels

A minimum overpressure of 0.2 kPa (2mbar) with reference to

external atmospheric pressure

Air intake from a safe area

Exhaust duct outlet to be located in safe area

Zone 1- can be used if there is no spark in normal service

Zone 1 or 2 -if ejection of spark is prevented by effective device

and rapid suction of external atmosphere is prevented
❖PRESSURIZATION TYPE (Ex ‘p’ )

▪Minimum actions of Failure of Protective

Gas for Ex ‘p’

Area Enclosure does Enclosure

not contain contains I-C
Ignition-capable Apparatus
apparatus
Zone 2 No Action Alarm
required
Zone 1 Alarm Alarm with trip

❖Applications:

•Electrical equipment whose normal operation involves sparks,

arcing & complex assemblies like large motors, switchgears &
control cabinets etc.
TYPE OF PROTECTION INCREASED SAFETY Ex ‘e’

Definition as per IS 6381

A type of protection by which measures are

applied so as to prevent with a minor degree
of security, the possibility of excessive
temperature and the occurrence of arcs or
sparks in the interior and the external parts
of electrical apparatus which does not
produce them in normal service
TYPE OF PROTECTION INCREASED SAFETY Ex ‘e’

❖ Stringiest construction methods to ensure that no sparks, excessive

temperature are produced
• Careful terminal design
• Use of good quality insulation material
• Use of special materials to protect the enclosure against impact, ingress
of dust & moisture
• Can be used for I, II A, B, C gas groups
• Permitted for us in T1, T2, T3 classes only
• Terminal with minimum IP 54 ingress protection

EX d typical marking: EEx e IIA T3

 TYPE OF PROTECTION OIL IMMERSION Ex ‘o’

Defination:
Protection technique in which the equipment or its parts are
immersed in oil in such a way that an explosive atmosphere
which, may be above the oil or outside the enclosure cannot
be ignited.

Oil used shall be mineral oil confirming to relevant standards

Constructional features:
◼ Fully enclosed, leak-proof enclosure
◼ Oil level indicator
Application:
Transformers, Switch gears, Control gears.
TYPE OF PROTECTION POWDER/SAND FILLING Ex ‘q’

❖Equipment enclosure filled with quartz /sand so that in

normal operating condition, any arc occurring within the
enclosure of electrical equipment will not ignite the
surrounding atmosphere

No ignition shall be caused either by flame or by

excessive temperature of the surfaces of the enclosure

❖ Enclosure constructional features:

◼High mechanical strength
◼Ingress protection
◼Powder filled
◼Insulation of enclosed equipment

❖ Applications:

▪Capacitors, electronic sub-assemblies or transformer etc.

 TYPE OF PROTECTION ENCAPSULATION Ex ‘m’

Features

◼ Ensuring exclusion of flammable substance

coming in contact with source of ignition by
encapsulation prevents explosion .

◼ The surface temperature of enclosures or

components mounted inside does not exceed
auto ignition temperature of surrounding
flammable gases.

◼ Either potting with resin or hermetically sealing

achieves encapsulation

◼ Ingress of surrounding ambient is prevented .

◼ Prevalent for small devices & electronic

components.
TYPE OF PROTECTION ENCAPSULATION Ex ‘m’

Applications:

◼ Static coils in ballast, solenoid valves or

motors, relays & other control gear of limited
power & complete PCBs with electronic
circuits.

◼ Control Components like indicating lamps push

button elements & control switches etc.
 TYPE OF PROTECTION NON-SPARKING TYPE EQUIPMENT Ex ‘n’

Features

❖ Equipment construction in such a way that in

normal operation, it is incapable of igniting a
surrounding explosive atmosphere and a
fault incapable of causing ignition

❖ Hermetically sealed type

❖ Restricted breathing type

❖ Careful design of terminals

❖ Applications
◼ Tools
◼ Equipment
TYPE OF PROTECTION ENCAPSULATION Ex ‘m’

Applications:

◼ Static coils in ballast, solenoid valves or

motors, relays & other control gear of limited
power & complete PCBs with electronic
circuits.

◼ Control Components like indicating lamps push

button elements & control switches etc.
ATEX

Faults to be considered

• Category 3 Normal operation- intended

use…within design parameters.

• Category 2 Malfunction- not performing the

intended function

• Category 1 Rare malfunction- 2

independent foreseeable malfunctions that
when combined create an ignition hazard
ATEX

Who does what?

•Electrical Category 1 & 2 Notified Body

•Safety/Protective Systems Notified Body

•Electrical Category 3 Self Certification

•Non-electrical Category 1 Notified Body

•Non-electrical Category 2 Notified Body hold

TCF

•Non-electrical Category 3 Self Certification

 Approval / Testing Agencies In India

▪CMRI (Central Mining Research Instituite),

Dhanbad, BIHAR

▪CCoE (Chief Controller of Explosives),

Nagpur

▪BIS (Bureau Of Indian Standards)

▪DGMS (Director General Mine Safety),

Dhanbad, BIHAR

▪DGFASLI (Director General of Factory

Advice Service and Labour Instituites),
Mumbai
Equipment Approval Procedure INDIA

Drawing and prototype

submittal to CMRI

Tests by CMRI

Approval by CMRI

ISI Certification (Tests by

CMRI) as per applicable
Indian Standards

Approvals by:
• DGFASLI
• CCoE
Equipment Approval Procedure-CE
 Q&A
Thank you for your
interest!