Flameproof Equipment CH 12-17 April 01

CHAPTER 12
CABLE AND CONDUIT ENTRY
12.1 Introduction
Gland must maintain integrity of enclosure

FLAMEPROOF OTHER
Must be certified EEx d IIC Certification usually optional

Generally IP54
The cable entry, whether conduit or cable gland, is required to preserve the integrity of the enclosure which
it enters. The requirements for hazardous area glanding are in addition to any other gland requirements for
cable support, weatherproofing, electrical continuity, securing of cable armour or braid, etc..
For flameproof enclosures the prevention of flame transmission must extend to the conduit or cable
glanding. This may be achieved in some cases by the provision of appropriate flame path lengths and
controlled flame gaps and in others by providing total sealing e.g. pressure tight stopper boxes, MICC
glands, or pressure tight barrier glands. In effect, this means:
Gland entries to flameproof enclosures must themselves be certified;

flameproof and conduit must be of an approved type.
Chapter 12, HAZARDOUS AREA ELECTRICAL EQUIPMENT

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12.2 Flameproof MICC glands
potting compound
swage ring
These are very similar to uncertified glands, but are identified by the coding, which is almost invariably
‘EEx d IIC’. Usually, such glands are dual certified EEx d IIC/EEx e II.
12.3 Flameproof cable entries
Solid cable Non-solid cable
solid filler
extruded air-gaps
bedding
compression gland barrier gland
The following information is required to properly specify flameproof glands for use in hazardous areas:
 The gas group (though almost all glands are 'IIC')
 If the cable is filled to prevent flame propagation
 The type of cable construction
 Whether serving is polymeric or metallic
 Type and thickness of armour
 Cable dimensions; diameter overall, diameter under armour & tolerances
 Cable voltage grade
 Special environmental requirements
 Enclosure screw thread
If the cable core is 'filled', as in cable manufactured to BS5467, BS6346 or BS6116, then it is assumed to
be substantially resistant to the transmission of exploding gas. In this case, a compression gland may
normally be used. However, see section 12.6
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Many other cables in general use, however, have 'non-filled' cores which allow gas to pass readily down the
centre of the cable. To prevent this, cables need to be provided with a means of sealing between cores,
bedding and inner sheath, such as a certified flameproof barrier gland.
Any entry into flameproof equipment must maintain the flameproof properties. This requires that the entry
be sealed against any exploding gas being expelled into the surrounding atmosphere or to cool any which
escapes through allowable paths so that it cannot ignite the surroundings.
12.4 Flameproof Compression Glands

Inner seal clamps cable
and makes
Inner sealaclamps
sealed joint
cable &
makes sealed joint
In a flameproof compression gland, the flameproof properties of the enclosure are achieved by the use of an
elastomeric seal pressing onto the inner bedding of the cable to prevent flame transmission along the cable,
and by the use of carefully machined threads forming a flamepath with the enclosure.

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12.5 Flameproof barrier glands
The cables used for some wiring systems are not designed to be pressure-proof and hence may be damaged
by exploding gas passing down their centre. To prevent this a barrier gland is needed which provides a
solid seal around the cable cores. Various designs exist, some using brass thimble inserts and other using
direct application of epoxy putty to the gland. An alternative to using a barrier gland would be to use a
component approved stopper box in conjunction with an ordinary gland.
12.6 Selection of Flameproof Glands

Start
Internal
Yes source of No
ignition?
Use a Does gas

barrier Yes No Use a
require IIC
gland apparatus? compressio
(or other n
suitable gland
sealing Yes In a zone No (or other
device) 1? suitable
device)
Yes Volume No
>2 litres?
The recommendations for the selection of a flameproof gland are as follows:
1 Firstly, if the cable used is MICC (mineral insulated), then use a certified flameproof "pyro" gland.
If not MICC, it is necessary to know if the cable is filled or unfilled.
2 If the flameproof apparatus has its own certified cable entry device (such as an in-line plug), then a
filled cable can enter straight into this device.
For cable entry using a standard gland, the diagram above should be followed.
3 Unfilled cables always need a barrier gland.

4 Filled cables generally require a compression gland, but do need a barrier gland under certain
circumstances – see next section.
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12.7 When to use a flameproof barrier gland
 With a cable that is not sealed against gas, e.g.

tape-bedded cables
some metal-sheathed cables
 With an enclosure containing a source of ignition (e.g. switch, contactor) and
hazard gas is IIC or
enclosure is >2 litres and in a zone 1
There are two situations in which a barrier gland is required, despite the fact that a filled cable is used: if
the enclosure contains components which spark (Ex d switches, contactors, etc.) and:
either the hazard is a IIC gas
or the enclosure is in a Zone 1 and is more than 2 litres in volume.
12.8 Conduit entry into Ex d enclosures
Conduit must be
 seam-welded or
 solid-drawn
Conduit seals (‘stopper boxes’) are essential
 at or within 450 mm of Ex d enclosure wall
 when conduit passes from hazardous area to non-hazardous area
Direct or indirect entry is allowed into the flameproof enclosure. Any size of conduit is allowed, but there
must be a compound-filled stopper box within 450 mm, according to EN 60079-14. (A stopper box is,
incidentally, also required when conduit passes from a hazardous to a non-hazardous area.) The conduit
may be seam-welded or solid drawn.
12.9 Glanding into non-flameproof enclosures
For non-flameproof equipment….

 use of a certified gland is not obligatory
but
 gland usually should be IP54 minimum
Consider use of a certified gland for

 plastic glands into EEx e enclosures
 MICC glands in EEx e enclosures
With only two exceptions, glands used with enclosures which are not flameproof need not be certified, but
the integrity of the enclosure must not be impaired. However, note that some company codes of practice
exceed the minimum requirements of BS5345 and EN 60079-14 and these codes should be followed when
on such plants. (One example would be the widespread specification of a flameproof compression gland on
all non-flameproof ‘Ex’ equipment). For most non-flameproof methods of protection, ingress protection to
at least IP54 must be achieved - this is an absolute requirement for Ex e.

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Increased safety: BS 5345 Part 4 clause 17.2 requires that certification is required in the following two
increased safety applications:
1 when using an MICC (pyro) cable - the seal must be EEx e certified
2 when using a plastic gland which is not otherwise certified with the equipment
Otherwise, glands which can meet the IP54 requirements are acceptable. EN 60079-14 has no such
requirements, but certification in the two instances listed above is probably the easiest way of proving
compliance.
Ex N/EEx n enclosures: similar entry requirements to Ex e are required, maintaining IP54. Additional
sealing is required on 'restricted breathing' apparatus - no specific gland exists, but a flameproof barrier
gland in conjunction with thread sealant and a suitable IP washer can make an almost gas-tight seal.
Intrinsic safety does not have any specific glanding requirements. Indeed, the enclosure is only required by
the standard to be IP20 ('fingerproof'). However, for operational reasons, weatherproofing will almost
certainly be desirable with the appropriate selection of a gland.
Pressurised apparatus needs to be as leak-free as possible for practical reasons. Most glands can be made
fairly air-tight, the flameproof barrier gland being, perhaps, the best in this respect.
12.10 Adapters and reducers
These are permitted, but

 certified items only for Ex d
 good practice not to use more than one
12.11 Gland features for differing applications
Depending upon the application, the gland may have to serve different functions. Some of the differing
requirements are outlined in the following table:
Gland type
Feature Ex d Ex e Industrial
Adequate mechanical strength   
Mechanically exposionproof   
Good electrical contact between gland & enclosure for proper earthing   
Good electrical contact between gland &armour for proper earthing   
Protected against dust ingress possibly  possibly
Protected against water ingress possibly  possibly
Cores must be sealed against explosion possibly  
Certified   

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CHAPTER 13
In the UK, BS 5345 has been the code of practice for hazardous areas, covering selection, installation,
inspection, maintenance and testing. In 1996, IEC 60079-14 was published, dealing with selection and
installation only (the other aspects are dealt with in other IEC codes). The IEC standard was adopted as a
European and then a British standard (BS EN 60079-14:1997), which, on 1st December 1999, finally
superseded the relevant parts of BS 5345. This chapter is a summary of IEC 60079-14, but the IEC
standard should be taken as the definitive source of reference, not this chapter.
The first 9 clauses contain general requirements applicable to all equipment, as follows:
1 Scope and object

2 Normative references
3 Definitions and terms
4 General
5 Selection of electrical apparatus
6 Protection from dangerous (incendive) sparking
7 Electrical protection
8 Emergency switch-off and electrical isolation
9 Wiring systems
The remaining clauses deal with specific concepts:
10 Additional requirements for type of protection “d” – Flameproof enclosures

11 Additional requirements for type of protection “e” – Increased safety
12 Additional requirements for type of protection “i” – Intrinsic safety
13 Additional requirements for type of protection “p” – Pressurised apparatus
14 Additional requirements for apparatus for use in zone 2
The following 14 sections of this chapter (numbered 13.1 - 13.14) will deal with each of these clauses in
turn.
There are also three annexes:

A Verification of intrinsically safe circuits with more than one associated apparatus with linear
current/voltage characteristics
B Methods of determining the maximum system voltages and currents in intrinsically safe circuits
with more than one associated apparatus with linear current/voltage characteristics (as required by
Annex A)
ZA European standards corresponding to IEC standards
13.1 Clause 1: Scope and object
The standard covers the “design, selection and erection of electrical installations in explosive gas
atmospheres”, whether the equipment is permanent, temporary, portable, transportable or hand-held. All
voltages are covered. The requirements are in addition to those in non-hazardous areas, so, for example in
the UK, the Wiring Regulations apply.
Exclusions: mines where firedamp (methane) is present, flammable dusts, explosives and medical facilities.
Other codes apply to all these locations.
Chapter 13, pHAZARDOUS AREA ELECTRICAL EQUIPMENT

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13.2 Clause 2: Normative references
This section is a list of all other relevant IEC standards. Most of them are in the 79-series, dealing with the
construction of equipment and area classification, but also referenced are standards for ingress protection,
testing, protection against electric shock, conduits, transformers and RCDs.
13.3 Clause 3: Definitions and terms
This clause contains 24 definitions. Some of the more useful are as follows:
3.8-3.20: these define the standardised abbreviations of input and output parameters to be used for
intrinsically safe equipment. They are the same as those in the intrinsic safety construction standard.
However, older equipment will use different abbreviations and chapter 7 of this manual should be consulted.
3.21 - simple apparatus: “Electrical component or combination of components of simple construction with
well-defined construction with well-defined electrical parameters which is compatible with the intrinsic
safety of the circuit in which it is used. The following apparatus is considered to be simple apparatus:
a) passive components, for example switches, junction boxes, resistors and simple semiconductor devices;
b) sources of stored energy with well-defined parameters, for example capacitors or inductors, whose values
are considered when determining the overall safety of the system;
c) sources of generated energy, for example thermocouples and photocells, which do not generate more than
1.5 V, 100 mA and 25 mW. Any inductance or capacitance present in these sources of energy are
considered as in b).”
13.4 Clause 4: General
Clause 4.1: General requirements

 Hazardous areas to be divided into zones 0, 1 and 2
 Locate equipment in the non-hazardous area if possible, or in the zone of lowest risk
 Install in accordance with the equipment’s documentation (note especially lamp wattage)
 After installation, carry out an initial inspection in accordance with IEC 60079-17
 Do a gas check before carrying fluorescent tubes through a hazardous area
 Do no use low-pressure sodium lamps in or above a hazardous area (risk of free sodium ignition
from a broken lamp)
 In exceptional circumstances (research, development, pilot plants, etc.), the requirements of clauses
5-9 need not be met provided the installation is of limited duration, staffed by trained personnel and
measures are taken to prevent the occurrence of an explosive atmosphere (or disconnect equipment
or take other measures). These measures must be documented by someone with the required
experience and knowledge of the risks.
Clause 4.2: Documentation

For installing or extending, the following is required:
 area classification documents
 certificates for equipment with special conditions of installation (e.g. those with an ‘X’ suffix to the
certificate number
 intrinsically safe system documentation
 manufacturer’s or qualified person’s declarations (where applicable)

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13.5 Clause 5: Selection of electrical apparatus
Clause 5.1: Specific information

To select equipment, the following must be available:
 classification (zoning) of the hazardous area
 temperature class or ignition temperature of the gas
 apparatus group of the gas (where applicable, i.e. if Ex d, Ex i, Ex nL or Ex nC equipment is
installed)
 external influences and ambient temperature
Clause 5.2: Selection according to zones

Certain types of equipment are limited to certain zones, as described in Chapter 3 of this manual. For zone
2, there are a number of relaxations, which, in effect, mean that the equipment need not be certified.
However, for uncertified equipment to be installed in zone 2, it must at least be assessed (though not
necessarily by a third party) against the requirements of the construction standard (IEC 60079-
15/EN 50021). In reality, it is easiest for those operating a plant containing a zone 2 to obtain certified
equipment wherever possible. Sometimes, however, such certified equipment is not available or an existing
item of equipment has been modified as a ‘one-off’ to make it comply with the standard. In this case, the
person taking responsibility for the installation should be familiar with the standards listed. The following
uncertified items are sometimes found in zone 2 hazardous areas:
A A compressor, instrument panel, etc. protected by pressurisation
B A good quality non-sparking a.c. induction motor
This is not to say that such installations are ideal: the person who signs off the installation is taking full
responsibility for the compliance of the items with the code of practice. However, as the risk in a zone 2 is
low, such a course of action may be justified. There is no such option for zones 1 or 0.
Clauses 5.3 and 5.4: Selection according to the ignition temperature and apparatus group of the gas
These clauses are covered in Chapter 3 of this manual.
Clause 5.5: External influences

Protect apparatus against:
 chemical, mechanical, vibrational, thermal, electrical and humidity influences
 prevent foreign bodies dropping into ventilation openings of rotating machines
13.6 Clause 6: Protection from dangerous (incendive) sparking
Clause 6.1: Danger from live parts

Prevent contact with bare, live parts (unless intrinsically safe, where this is permitted)
Clause 6.2: Danger from exposed and extraneous conductive parts

Safety depends on
 limiting earth fault currents in frameworks or enclosures
 preventing elevated potentials on bonding conductors

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This clause then specifies requirements for electrical distribution, defining the following systems outlined
below. Note that ‘T’ stands for ‘terra’ or ‘earth’ and ‘N’ stands for neutral.
1 Clause 6.2.1: Type TN system – only TN-S allowed (separate earth and neutral), not TN-C
(combined earth and neutral)
2 Clause 6.2.2: Type TT system (separate earths for power and exposed conductive parts) – if used in
zone 1, then an RCD shall be fitted, but check the earth resistivity is not too high
3 Clause 6.2.3: Type IT system (neutral isolated from earth or earthed through an impedance) –
insulation monitoring device required to indicate the first earth fault. Local bonding
(“supplementary equipotential bonding”) may be necessary
4 Clause 6.2.4: SELV and PELV systems – shall be in accordance with IEC 364-4-41; safety
isolating transformers shall be to IEC 742.
Clause 6.3: Potential equalisation

 All exposed conductive parts must be connected to the equipotential bonding system
 Indirect connections are acceptable provided they are solidly made
 Items such as door and window frames need not be connected if there is no danger of them
becoming ‘live’
 Metallic enclosures of intrinsically safe equipment are exempt unless the documentation states
otherwise
 Installations with cathodic protection are not normally connected to the equipotential bonding
system
 Consider bonding between vehicles and fixed metallic structures
Clauses 6.4 – 6.6

These deal with dangerous sparks from static, lightning and electromagnetic radiation respectively, but call
up national or other standards until such times as IEC standards exist.
Clause 6.7: Cathodically protected metal parts

 This is a method of preventing metal parts (such as steel) from corroding by making the metal
slightly negative with respect to a sacrificial metal rod, which corrodes instead
 May produce incendive sparks, even though at low voltage, on account of the high current available
 Not permitted in zone 0
 There is no IEC standard at present
13.7 Clause 7: Electrical protection

 Not applicable to intrinsically safe circuits
 Consider overload, short-circuits and earth faults when selecting wiring
 Protect transformers against overload which would cause excessive heating
 Short-circuit and earth fault protection devices must not auto-reclose under fault conditions
 Motors must be prevented from operating when one phase is lost
 If automatic disconnection of equipment poses an increased risk, a conspicuous warning device my
be used
 Protect rotating machines against overload if this would cause excessive heating. The protective
device shall be:
“a) a current-dependent, time-lag protective device monitoring all three phases, set at not
more than the rated current of the machine, which will operate in 2 h or less at 1.20 times
the set current and will not operate within 2 h at 1.05 times the set current, or
b) a device for direct temperature control by embedded temperature sensors, or
c) another equivalent device.”

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13.8 Clause 8: Emergency switch-off and electrical isolation
 Means must be provided outside the hazardous area for switching off electrical equipment in case
of emergencies
 Each circuit or group of circuits must have a suitable means of isolation; all phase conductors as
well as the neutral must be isolated – this is more onerous than the requirements for non-hazardous
areas
 Labelling is required immediately adjacent to the means of isolation
 Measures should be taken to prevent inadvertent re-connection
13.9 Clause 9: Wiring systems
Clause 9.1: General

 Aluminium conductors to be 16 mm2 minimum, with suitable connections
 Protect from mechanical damage, corrosion, solvents, heat, vibration, etc. or take measures such as
installation in conduit and the use of armoured, screened or sheathed cables
 PVC insulation becomes very brittle below -5oC
 Unsheathed single core cables must not be used unless protected from damage (e.g. in conduit or
inside an enclosure)
 Beware of insulation exhibiting “cold flow”, which could cause compression fittings to become
loose
 Unused openings of enclosures to be fitted with blanking elements which can only be removed with
the aid of a tool (intrinsic safety exempt from this)
 Precautions (such as sealing, venting or sand-filling) must be taken to prevent flammable gases
passing down trunking, ducts, pipes or trenches
 Wiring crossing a zone boundary must be appropriate to both zones
 Prevent the metallic armouring/sheathing from coming into contact with metal parts. Usually, the
outer cable insulation is enough
 Openings in walls for cables and conduits between hazardous and non-hazardous areas must be
sealed
 Cable joints should be avoided where possible, but, if used, must be suitable for the environment
 Connections should be solidly made (unless inside an Ex d enclosure or in an Ex i circuit)
 Multi-strand cables must be terminated with a lug, core end sleeve or appropriate terminal, not by
soldering alone
 Terminations must not reduce the required separation distances, where these apply
Clause 9.2: Cable systems for zone 0

IEC 60079-14 only permits EEx ia equipment (specific requirements in clause 12) in zone 0.
Clause 9.3: Cable systems for zones 1 and 2

IEC 60079-14 is not highly prescriptive. The emphasis is that the cable should be fire-retardant (unless
laid in sand, for example) and protected against mechanical damage, usually by means of tough outer
insulation; it is not a requirement, for example, that only armoured cable is to be used.
For fixed apparatus, the following are listed:

 thermoplastic sheathed cables
 thermosetting sheathed cables
 elastomeric sheathed cables
 mineral insulated metal sheathed cables

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For portable or transportable apparatus:
 heavy chloropropene or equivalent synthetic elastomeric-sheathed cables
 heavy tough rubber-sheathed cables
 other equally robust cables
For portable apparatus not exceeding 250 V/6A and not exposed to heavy mechanical stresses (e.g. not
hand-lamps, foot-switches, barrel pumps), rather less robust cables may be used:
 ordinary chloropropene or equivalent synthetic elastomeric-sheathed cables
 ordinary tough rubber-sheathed cables
 other equally robust cables
Flexible cables may be

 ordinary tough rubber sheathed flexible cables
 ordinary polychloroprene sheathed flexible cables
 heavy tough rubber sheathed flexible cables or plastic cables of equivalent robustness
 heavy polychloroprene sheathed flexible cables
Clause 9.4: Conduit systems

 Conduit seals to be used when the conduit leaves a hazardous area and with Ex d enclosures
 Pull up tight at all threaded connections
 May be used as a protective conductor if the joints can handle the fault current
 Protect against corrosion
 Sealing compounds must not shrink or be affected by chemicals in the hazardous area
 Minimum 16 mm of sealing compound
 No more than 40% of the cross section to be filled
 Suitable draining device to be fitted to long runs of conduit; cable must be resistant to moisture
 Ensure conduit maintains the ingress protection level of the enclosure
 Make sure thread sealant does not reduce the effectiveness of the earth path, if applicable
13.10 Clause 10: Additional requirements for type of protection “d” – Flameproof enclosures
Clause 10.1: Solid obstacles

The following clearance distances should be provided around flamepaths. This is necessary to allow the
‘cooling by mixing’ mechanism, which is part of the way in which flamepaths quench the flame:
Gas/vapour subgroup Minimum distance (mm)

IIA 10
IIB 30
IIC 40

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Clause 10.2: Protection of flameproof joints
 Joints to be protected against corrosion
 Substances which harden in use must not be used *
 Keep water out of flamepath gaps
 Do not fit gaskets unless supplied with the equipment
 Non-setting grease is permitted, but beware of the effect of silicone greases on flammable gas
detector pellistors
 Non-setting tape (e.g. ‘Denso’ tape) may be used on IIA, IIB and IIC equipment, but only when
used with IIA gases; only one layer is allowed, with a short overlap
* PTFE tape on threads is not specifically addressed, but the principle is that substances which
solidify should not be used. However, the reason for this is that, in the case of a flange joint, for
example, the person maintaining the equipment might not remove all the hardened sealant; in some
cases, the sealant might cause the joint to be damaged when dismantling. As the use of PTFE tape
on threads does not cause either of these problems, its use is permitted by many companies.
Clause 10.3: Cable entry systems (see also chapter 12)

Glands and conduit entries must maintain the flameproof characteristics of the enclosure. The six types of
direct entry listed are:
a cable entry device which is already incorporated as part of the certified enclosure
b certified compression gland
c certified mineral insulated cable entry device
d certified sealing device with a stopper box or sealing chamber, as specified in the documentation
e certified barrier gland
f other means
Figure 1 in IEC 60079-14 (section 12.6 in the preceding chapter) gives the selection procedure when the
cable entry is not included or specified as part of the equipment.
Clause 10.4: Motors supplied at varying frequency and voltage

Unlike Ex e motors, there are two options given to prevent the combination of the motor with a converter
from causing an excessive temperature:
 embedded temperature sensors, as specified in the motor documentation, or other effective
measures
 the motor is tested during the certification process with a specific converter and may only be used
with that converter
Clause 10.5: Conduit systems

 Conduit to be screwed heavy gauge steel, solid-drawn or seal welded, of heavy or very heavy
mechanical strength, or
 flexible conduit of metal or composite material of heavy or very heavy mechanical strength
 minimum 5 threads engagement
 seals within 450 mm of the flameproof enclosure
[Note that BS 5345 did not permit flexible conduit in zone 1, nor did it permit conduit seals to be up to
450 mm from the enclosure; they had to be screwed into the enclosure.]

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13.11 Clause 11: Additional requirements for type of protection “e” – Increased safety
Clause 11.1: Degree of protection of enclosures

 Generally, IP54 minimum
 If there are no bare live parts, IP44 is sufficient.
 Rotating electrical machines with no bare live parts to be IP20 minimum if in a clean environment
and regularly checked
Clause 11.2: Cage induction motors – thermal protection in operation

 Overload protection must disconnect motor within its tE time
 Disconnection times to be verified
 Arduous duty cycles require special consideration
 Embedded temperature sensors as the only means of controlling the temperature are only permitted
if the motor documentation states this
 Soft starts may require additional assessment of thermal protection
 Motors may only be used with variable frequency/voltage convertors which have been type tested
with the motor during certification. [This is a requirement which was not in BS 5345.]
Clause 11.3: Wiring systems

 Glands must maintain IP54; advised that a sealing washer or thread sealant is used unless at least
6 mm of engaged thread
 Care required to maintain required creepage distances when using MICC seals. [In practice, many
users specify dual-certified EEx d/EEx e MICC glands, as the seal then definitely meets the
requirements for both EEx d and EEx e enclosures.]
 Ensure conductors are adequately clamped in terminals – be especially careful where a terminal can
take more than one conductor
 Do not put two conductors into a terminal designed for one unless the two are combined in a
suitable compression-type ferrule
 Do not exceed the ‘load limit’ of junction boxes and other enclosures by fitting too many terminals
or supplying too much current; alternatively, check the calculated power dissipation using the
manufacturer’s parameters
Clause 11.4: Resistance heating devices

 Install in accordance with the documentation to avoid excessive temperature rise
 The temperature protective device, if required, shall de-energise the resistance heating device either
directly or indirectly. It shall be of a type that has to be manually re-set.
 In addition to overcurrent protection, to limit excessive heating from earth fault, TT and TN
systems require an RCD and IT systems require an insulation monitoring device

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13.12 Clause 12: Additional requirements for type of protection “i” – Intrinsic safety
Clause 12.1: Introduction

“A fundamentally different installation philosophy has to be recognised in the installation of intrinsically
safe circuits. In comparison with all other types of installations, where care is taken to confine electrical
energy to the installed system as designed so that a hazardous environment cannot be ignited, the integrity
of an intrinsically safe circuit has to be protected from the intrusion of energy from other electrical sources
so that the safe energy limitation in the circuit is not exceeded, even when breaking, shorting or earthing of
the circuit occurs.
“As a consequence of this principle, the aim of the installation rules for intrinsically safe circuits is to
maintain separation from other circuits.”
Clause 12.2: Installations for zones 1 and 2

 Equipment to be at least Ex ib
 Simple apparatus need not be marked but must comply with the requirements of the intrinsic safety
construction standards (see also clause 3.21 of IEC 60079-14)
 Locate associated apparatus outside hazardous area if possible, otherwise protect with a suitable
method [in practice, this usually means housing in an Ex d or Ex p enclosure]
 Ensure associated apparatus is not connected to anything containing more than 250 V/1500 A [for
most associated apparatus, Um is quoted as 250 V – this is the maximum nominal rms voltage and
transients above this need not be considered]
 Cables to be capable of withstanding 500 V minimum
 Multi-stranded conductors require core-end sleeves and must not have individual strands of less
than 0.1 mm diameter
 Multicores must have at least 0.2 mm insulation, capable of withstanding at least 1000 V pair-to-
pair and protected against damage
 Take account of cable capacitance and inductance when installing cable, taking account of the
worst-case stated values from the manufacturer
 Must not have IS and non-IS in the same cable
 Keep IS and non-IS cables in separate trays if possible, but where not possible, if there is a risk of
invasion due to damage, either the IS or the non-IS cable should be armoured, metal-sheathed or
screened
 Identify IS cables by colour (light blue) if possible; if colour is not used, then either all IS or all
non-IS cables should be armoured, metal-sheathed or screened
 Extra marking required where there is possible confusion between the blue neutral conductor and
IS circuits
 Take account of external electric or magnetic fields using screens and/or twisted cores and/or
generous separation distances
 Bond armour to the equipotential bonding system, usually via the glands, at each end of the cable
run and at interposing junction boxes
 Generally, connect screens to earth at one point only, normally in the non-hazardous area; this is to
prevent circulating currents in the screen. There are, however, three special cases (refer to clause
12.2.2.3) where multiple connections are allowed:
a multiple connection to a substantial, insulated earth conductor – see Figure 2
b the two ends of the screen are assured to be at the same potential
c the screen is connected through small capacitors (e.g. 1 nF, 1500 V ceramic) provided total
capacitance is not more than 10 nF

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Intrinsically-safe Associated apparatus
apparatus
Cable sheath Screen
Insulated Insulated earth

connections conductor Earthing system
Figure 2
Maintain terminal separation between Additional screen

separate earthing(usually 6 mm) and between IS and non-IS
IS circuits
(50 mm)
 IS circuits shall be either isolated from earth (when a galvanic isolator is used) or connected at one
point only (when a zener barrier or a galvanic isolator is used)
 Barrier earth to be to the equipotential bonding system or to the main power system earth by means
of an insulated conductor which is less than 1 , protected against damage and not used by other
non-IS circuits
 Can use a single conductor for the barrier earth (minimum 4 mm2) or, more practically, two
conductors (minimum 1.5 mm2)
 Verify the safety of the whole system (refer to section 7.5 of this manual). [There is much detailed
information given in clause 12.2.5, including the temperature rating of simple apparatus. However,
this is the level of detail used by the certification body and users are rarely required to perform such
calculation.]
Small components are permitted to exceed the limit of 135 oC for a T4 temperature class, as tests have
shown that ignition does not occur until much higher temps are reached when the hot body is small. Table 4
in IEC 60079-14 is the same as that in the IS construction standard.
Total surface area excluding lead wires Requirements for T4 classification

(based on 40oC ambient temperature)
<20 mm2 275oC
20 mm2 10 cm2 200oC
>20 mm 2
Power not exceeding 1.3 W *
* Reduced to 1.2 W with 60oC ambient or 1.0 W with 80oC ambient
Clause 12.3: Installations for zone 0

 All parts of the system must be Ex ia; simple apparatus must also comply
 Galvanic isolation preferred
 Zener barriers permitted if isolated from the mains voltage by a double-wound transformer having a
suitable primary fuse
 Earthing in the hazardous area, if required, shall not be in the zone 0, but as close to the zone 0 as
possible
 Consider the use of surge protection devices
13.13 Clause 13: Additional requirements for type of protection “p” – Pressurised apparatus
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Clause 13.1: Ducting
 Entire installation should be assessed for compliance (unless certified as a whole)
 Ducts tested to 1.5 times the overpressure (200 Pa minimum) – achieve this by closing the outlets
 Ducting materials should not be degraded by the protective or flammable gases
 Protective gas to be from the non-hazardous area (unless supplied by cylinder)
 Locate compressor, ducting and exhaust in non-hazardous area where possible; ducting ideally
should be at an overpressure throughout its length
 Spark and particle barriers required if exhaust is in hazardous area as follows:
Table 5
Zone of exhaust duct outlet Apparatus
A B
Zone 2 Required Not required
Zone 1 Required * Required *
A = apparatus which may produce ignition-capable sparks or particles in normal operation
B = apparatus which does not produce ignition-capable sparks or particles in normal operation
* If the temperature of the enclosed apparatus constitutes a hazard upon failure of pressurisation, a suitable
device shall be fitted to prevent the rapid entry of the surrounding atmosphere into the pressurised
enclosure.
Clause 13.2: Action to be taken on failure of pressurisation (Table 6)
Area classification Enclosure containing apparatus Enclosure containing apparatus

not suitable for zone 2 without suitable for zone 2 without
pressurisation pressurisation
Zone 2 Alarm (1) No action
Zone 1 Alarm and switch off (2) Alarm (1)
(1)
If the alarm system operates, immediate action should be taken, for example to restore the integrity
of the system
(2)
If automatic switch-off would introduce a more dangerous condition, other precautionary measures
should be taken, for example duplication of the protective gas supply
Apparatus with an internal source of release must have an alarm for failure of the protective gas.
Clause 13.3: Multiple pressurised enclosures with a common safety device – refer to IEC 79-2 (the
construction standard)
Clause 13.4: Purging

 Increase manufacturer’s purge time to take account of ducting volume
 Initial purge may be omitted in a zone 2 if a gas check is done
 Protective gas must be non-combustible, non-toxic, substantially pure and below 40oC
 Seal wiring systems etc. to prevent leakage

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13.14 Clause 14: Additional requirements for apparatus for use in zone 2
 Enclosures generally to be IP54 (IP44 if no bare live parts)
 Ingress protection may be provided by location (e.g. in a room without a deluge system), in which
case IP4x and IP2x apply
 No IP rating required for items such as strain gauges, RTDs, thermocouples, energy-limited
apparatus
 Cable entries should maintain IP rating of enclosure [no certification is required]. This is
particularly important with restricted breathing enclosures [a barrier gland is best, but a well-sealed
compression gland is often used]
 Terminations as for Ex e
 Motors with variable speed drives permitted without certification of the combination provided
excessive temperature rise has been considered

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CHAPTER 14
EARTHING AND HAZARDOUS AREAS
14.1 The objectives of earthing
With the exception of lightning protection and possibly prevention of static electricity, earthing is intended
to provide an acceptable environment for both electrical equipment and personnel. The requirements are
threefold, firstly to provide for electrical circuit protection for the electrical equipment, secondly to provide
for protection against electric shock for the personnel and thirdly to provide for the correct function of the
apparatus. The first of these is achieved by providing fault current return paths and the second by
connecting all exposed metalwork together so that personnel are unable to touch parts at dangerously
different potentials. We can conveniently give the first two provisions names:
 electrical protection connections (EPC)

 personnel protection connections (PPC)
The third objective usually includes the provision of a suitable level of electromagnetic compatibility.
The purpose of this paper is to consider the basic objectives in relation to hazardous areas in general and to
consider some specific problems associated with shunt diode barrier devices.
The terms EPC and PPC have the advantage of not referring to 'earthing', 'bonding' or 'conductors' thus
avoiding preconceptions about the objectives and their implementation. A generalised distribution and
utilisation system is presented in Figure 1 and shows these sets of connections. There is inevitably some
overlap between the two functions.
Electrical protection connection

Personnel protection connections
Figure 1 - Generalised distribution and utilisation

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To better understand the objectives consider an installation which cannot be “earthed”. An aeroplane may be
flying at a height of 9000m and a speed of 900kph. It may contain up to 200kW of generating capacity and
distribution systems up to 200Vac and dc. In this environment there is electrical protection for the systems.
There are also people who may be in contact with the electrical equipment, and who do not suffer any
adverse effects from this contact, because of the personnel protection connections. Clearly this installation
cannot be “earthed”.
Electrical protection connections (EPC): These connections are required to carry sufficient fault current
back to the source of supply so that the protective equipment can operate. It is tempting to think that a
connection to earth provides a home for all wayward currents, but this is incorrect. The only place a
current can go is back to the source of supply. This means that the electrical protection connections have to
provide a return path back to the source. Whether this is done via the structure or via conductors does not
change the intent, the choice is influenced by economics (the cost of providing dedicated conductors) and
the level of reliability desired (via structure or copper conductors). Various national and industry codes of
practice have specific guidance in these areas.
Personnel protection connections (PPC): These connections are required to provide equipotential bonding
so that personnel cannot touch parts at dangerously different voltages and thus receive electric shocks.
These differences in voltage may arise from fault currents, which will flow via any available path, or from
static charges. In hazardous areas differences in voltage from both sources have to be limited to very small
values, typically a few volts, so that ignition-capable sparks do not arise. It should be remembered that
sparks of 40J are sufficient to ignite hydrogen/air mixtures. Again it does not really matter whether
mechanical connections to structure are relied upon or whether bonding conductors are used instead. There
are, however, reasons why one implementation will be preferred to another; for example, concrete structures
present a problem in this respect. There is no prima facie reason for including the ground in this potential
equalisation apart from lightning protection, protection of overhead line distribution systems and the
problem of stepping between the structure and the ground.
14.2 The objectives of intrinsic safety
The above combination of electrical and personnel protection connections has minimal effect on non-
intrinsically safe installations. However intrinsic safety has its own rules regarding 'earthing' which have to
be fitted into the above philosophy. Intrinsic safety depends on limiting voltage and current within the
system to low levels so that any sparking which may occur is not ignition capable. It also permits live
working which means that sparking to the surroundings is an acceptable situation and must also be non-
ignition capable. This presupposes that the intrinsically safe system is not only at the same potential (give
or take the system voltage) as its surroundings but also the current limitation in the circuit is not by-passed
by a fortuitous connection to earth. It also pre-supposes that the voltage accessible to personnel is safe
from a physiological standpoint. An acceptable voltage can be assessed from existing limits for safe
systems, e.g. SELV or FELV as defined in BS7671, or by considering the physiology of electric shock from
first principles. In either case most intrinsically-safe installations, which usually do not exceed 30Vdc, are
acceptable.

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The obvious way to maintain the intrinsically-safe circuit at the same potential as its surroundings is to
connect the reference point of the circuit to the surrounding structure. At this point it is important to realise
that sparking to the surroundings during live maintenance is considered acceptable because it is an unusual
occurrence and not likely to coincide with the significant transient potential differences that can occur
between the intrinsically safe circuit and its surroundings when power faults to earth are being cleared by
the circuit protection in power circuits. During normal operation it is assumed that transient potential
differences can exist between the intrinsically safe circuit and its surroundings. To prevent these potential
differences producing unknown dangerous currents in the intrinsically safe circuit it is insulated from its
surroundings everywhere except at the deliberate point of connection to earth (if any).
These ideas become particularly important when shunt diode safety barriers are used as these require a
connection to 'earth' to achieve intrinsic safety. Figure 2 illustrates that the components within the barrier
will limit the voltage and current within the system without connection to 'earth'.
IO ?
UM UO
Figure 2 - Energy limitation by a barrier
However the voltage between the system

and its surroundings is equally important
and for this reason the barrier 'earth'
OK
IO
should be connected so that the voltage
difference between the system and its
surroundings is also defined. This can be UM UO
achieved, as shown in Figure 3, by
connecting the barrier 'earth' to the local
structure or the potential equalisation or
bonding conductors which are provided
for personnel protection. The only To supply reference
additional connection required is one to
carry fault currents back to the source of
supply.
Figure 3 - Principle of protection
Thus the implementation shown Figure 3 achieves the objectives of intrinsic safety, electrical protection and
personnel protection, without prejudicing any of them, in the most general manner.

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The barrier installation which results from following the UK national code of practice is shown in Chapter
7. The barrier earth is connected directly to the “supply reference point”, which is usually understood to
mean the star point of the main distribution transformer.
Figure 5 - German barrier earthing
[There is no Figure 4]
Likewise Figure 5 shows the installation which results from following the German national code of practice.
It can be seen that each is a particular implementation of the general objectives illustrated in Figure 3. The
differences between the two arise from the need to fit barriers and their earthing into pre-existing
installation practices which are themselves different.
Off-shore installations appear somewhere between the two because the greater formality of the bonding of
the structure approximates to a potential equalisation conductor.
Performance under fault conditions: The obvious fault condition is the one which applies excessive
voltage to the barrier and causes the barrier fuse to blow. In this case sufficient current is required to flow
in the barrier 'earth' to blow a fuse which is unlikely to have much more than a 250mA rating. The
minimum current required to do this is about 425mA which the barrier 'earth', even at its maximum
permitted resistance of 1ohm, will carry without difficulty. The maximum current which could flow is that
obtained from the maximum of the mains voltage limited by the cold resistance of the fuse. This will be in
the region of 30A to 70A. Again, even at the maximum permitted resistance of 1ohm for the barrier 'earth',
no significant problems arise.

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The barrier earth also has to deal with
faults to the unfused side of a single Fault current path
channel barrier. This is illustrated in
Figure 6 using the UK installation.
L 1
Now the minimum current required to
blow the fuse cannot be predicted
because it is not the barrier fuse which N 2
is involved. Likewise the maximum
current which could flow is not easy
to predict. For non-intrinsically safe
installations 'earth return' resistances
of 1ohm or less are required at mains
voltage circuits so that circuit
protection is able to operate. This
gives an indication of where the Figure 6 - Fault to unfused side of barrier
maximum of 1ohm for the 'barrier
earth' is derived from. It is vital not
to be tempted into thinking that the barrier 'earth' has to carry only small currents, limited by the
barrier fuse, and is thus of minor importance.

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CHAPTER 15
INSPECTION, MAINTENANCE AND TESTING
15.1 Inspection codes of practice
 Inspection is covered by BS 5345 and EN 60079-17:1997

 3rd edition of EN 60079-17 in preparation
 EN 60079-17 superseded the relevant parts of BS 5345 on 1st December 1999
 Similar philosophy, different in detail
 Code of Practice, not the law
 Following a CoP is the best way to show compliance with H&S@W Act
 Operators should review their inspection procedures to check compliance with
the new CoP
Until the publication of EN 60079-17:1997, BS 5345 was the code of practice used in the UK. The two
codes are very similar in philosophy but have some differences in detail.
Inspection is required to maintain the safety of the equipment, as well as to ensure that it is in working
order. These two requirements are not the same:
operability  safety
15.2 A summary of the main differences between BS 5345 and EN 60079-17
BS 5345 EN 60079-17:1997
Covers selection, installation, inspection and Covers inspection and maintenance only
maintenance [installation covered by EN 60079-14:1997]
Levels of inspection left to operator Defines visual, close & detailed levels of inspection
and gives guidance on applicability
Maximum 2 years between inspections Maximum 3 years
Part 3 clause 19.2 requires gaps in Ex d equipment Clause 5.1.1 allows a visual inspection only
to be measured periodically
The maximum period between inspections may be interpreted somewhat more loosely than every three years
if equipment is assessed on a rolling sample basis. The size and composition of the sample is at the
discretion of the operator, justified by past records.

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15.3 Inspection schedules
Visual inspection - defects apparent without tools

(e.g. missing bolts)
Close inspection - defects apparent with tools but without opening
enclosure
(e.g. loose bolts)
Detailed inspection - defects apparent using tools and opening enclosure
(e.g. loose terminations)
Unlike BS 5345, EN 60079-17 defines three levels of inspection. Both codes also define initial, periodic
and sample inspections.

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15.4: EN 60079-17:1997 Table 1 - Inspection schedule for Ex “d”, Ex “e” and Ex “n” installations
Check that: Ex “d” Ex “e” Ex "n”

Grade of Inspection
(D = detailed, C = close, V = visual)
D C V D C V D C V
A APPARATUS
1 Apparatus is appropriate to area classification * * * * * * * * *
2 Apparatus group is correct * * * * * *
3 Apparatus temperature class is correct * * * * * *
4 Apparatus circuit identification is correct * * *
5 Apparatus circuit identification is available * * * * * * * * *
6 Enclosure, glasses and glass-to-metal sealing gaskets and/or compounds
are satisfactory * * * * * * * * *
7 There are no unauthorised modifications * * *
8 There are no visible unauthorised modifications * * * * * *
9 Bolts, cable entry devices (direct and indirect) and blanking elements are
of the correct type and are complete and tight
- physical check * * * * * *
- visual check * * *
10 Flange faces are clean and undamaged and gaskets, if any, are satisfactory *
11 Flange gap dimensions are within maximal values permitted * *
12 Lamp rating, type and position are correct * * *
13 Electrical connections are tight * *
14 Condition of enclosure gaskets is satisfactory * *
15 Enclosed-break and hermetically sealed devices are undamaged *
16 Restricted breathing enclosure is satisfactory *
17 Motor fans have sufficient clearance to enclosure and/or covers * * *
B INSTALLATION
1 Type of cable is appropriate * * *
2 There is no obvious damage to cables * * * * * * * * *
3 Sealing of trucking ducts, pipes and/or conduits is satisfactory * * * * * * * * *
4 Stopper boxes and cable boxes are correctly filled *
5 Integrity of conduit system and interface with mixed system is maintained * * *
6 Earthing connections, including any supplementary earthing bonding
connections are satisfactory (e.g. connections are tight and conductors are
of sufficient cross section)
- physical check * * *
- visual check * * * * * *
7 Fault loop impedance (TN systems) or earthing resistance (IT systems) is
satisfactory * * *
8 Insulation resistance is satisfactory * * *
9 Automatic electrical protective devices operate within permitted limits * * *
10 Automatic electrical protective devices are set correctly (auto-reset not
possible in zone 1) * * *
11 Special conditions of use (if applicable) are complied with * * *
12 Cables not in use are correctly terminated * * *
13 Obstructions adjacent to flameproof flanged joints are in accordance with * * *
IEC 79-14
C ENVIRONMENT
1 Apparatus is adequately protected against corrosion, weather, vibration
and other adverse factors * * * * * * * * *
2 No undue accumulation of dust and dirt * * * * * * * * *
3 Electrical insulation is clean and dry * *
NOTES
- General: the checks used for apparatus using both types of protection “e” and “d” will be a combination of both columns.
- Items B7 and B8: account should be taken of the possibility of an explosive atmosphere in the vicinity of the apparatus when using
electrical test equipment.

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15.5: EN 60079-17:1997 Table 2 - Inspection schedule for Ex “i” installations
Check that: Grade of Inspection

Detailed Close Visual
A APPARATUS
1 Circuit and/or apparatus documentation is appropriate to area * * *

classification
2 Apparatus installed is that specified in the documentation (fixed
apparatus only) * *
3 Circuit and/or apparatus category and group correct * *
4 Apparatus temperature class is correct * *
5 Installation is clearly labelled * *
6 There are no unauthorised modifications *
7 There are no visible unauthorised modifications * * *
8 Safety barrier units, relays and other energy limiting devices are of
the approved type, installed in accordance with the certification
requirements and securely earthed where required * * *
9 Electrical connections are tight *
10 Printed circuit boards are clean and undamaged *
B INSTALLATION
1 Cables are installed in accordance with the documentation *

2 Cable screens are earthed in accordance with the documentation *
3 There is no obvious damage to cables * * *
4 Sealing of trunking, ducts, pipes and/or conduits is satisfactory * * *
5 Point-to-point connections are all correct *
6 Earth continuity is satisfactory (e.g. connections are tight and
conductors are of sufficient cross-section) *
7 Earth connections maintain the integrity of the type of protection * * *
8 The intrinsically safe circuit is isolated from earth or earthed at
one point only (refer to documentation) *
9 Separation is maintained between intrinsically safe and non-
intrinsically safe circuits in common distribution boxes or relay *
cubicles
10 As applicable, short-circuit protection of the power supply is in *
accordance with the documentation *
11 Special conditions of use (if applicable) are complied with * * *
12 Cables not in use are correctly terminated
C ENVIRONMENT
1 Apparatus is adequately protected against corrosion, weather, * * *

vibration and other adverse factors * * *
2 No undue external accumulation of dust and dirt

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15.6: EN 60079-17:1997 Table 3 - Inspection schedule for Ex “p” installations
Check that: Grade of Inspection

Detailed Close Visual
A APPARATUS
1 Apparatus is appropriate to area classification * * *

2 Apparatus group is correct * *
3 Apparatus temperature class is correct * *
4 Apparatus circuit identification is correct *
5 Apparatus circuit identification is available * * *
6 Enclosure, glasses and glass-to-metal sealing gaskets and/or
compounds are satisfactory * * *
7 There are no unauthorised modifications *
8 There are no visible unauthorised modifications * *
9 Lamp rating, type and position are correct *
B INSTALLATION
1 Type of cable is appropriate *

2 There is no obvious damage to cables * * *
3 Earthing connections, including any supplementary earthing
bonding connections are satisfactory, for example
connections are tight and conductors are of sufficient cross-
section *
- physical check * *
- visual check
4 Fault loop impedance (TN systems) or earthing resistance (IT *
systems) is satisfactory
5 Automatic electrical protective devices operate within *
permitted limits *
6 Automatic electrical protective devices are set correctly *
7 Protective gas inlet temperature is below maximum specified * * *
8 Duct, pipes and enclosures are in good condition * * *
9 Protective gas is substantially free from contaminants * * *
10 Protective gas pressure and/or flow is adequate
11 Pressure and/or flow indicators, alarms and interlocks *
function correctly *
12 Pre-energising purge period is adequate
13 Conditions of spark and particle barriers of ducts for *
exhausting the gas in hazardous area are satisfactory *
14 Special conditions of use (if applicable) are complied with
C ENVIRONMENT
1 Apparatus is adequately protected against corrosion, * * *

weather, vibration and other adverse factors * * *
2 No undue accumulation of dust and dirt

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15.7 Determining inspection frequency and type
EN 60079-17 provides a flow chart to assist in determining inspection type and frequency:
New Type: Initial Determine provisional

plant Grade: Detailed periodic interval
Type: Sample Modify/confirm

Grade: Visual periodic interval
Existing
plant Type: Periodic
Grade: Close
Type: Sample
Grade: Detailed Can an increase in the NO
periodic inspection interval
be justified?
Increase periodic interval

YES
Type: Sample
Grade: Visual Is the periodic
NO interval already
three years?
Type: Periodic
* IC - ignition capable
Grade: Close (IC)*
in normal operation, YES
Visual (Not IC)*
ie where the internal
components of the
Type: Sample
apparatus produce, in
Grade: Detailed
normal operation, arcs,
sparks or surface
temperatures capable
of causing ignition.
Can an increase in NO
the periodic inspection
Carry out safety audit to interval be justified?
recommend new YES
periodic interval
When a large number of similar items are present (e.g. junction boxes), a sample inspection may be carried
out. The results of this can be used to decide sample frequency and size for future inspections. The
maximum recommended interval of 3 years can thus be extended by reference to data accumulated over a
number of years if this data shows that serious faults are very rare. The zone designation is also a factor in
making the decision.
Equally, equipment installed in particularly arduous environments might require frequent inspections on
100% of the items.

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15.8 Recording inspection data
The recording of data should:

 be concise
 be easily referenced
 highlight required actions
 be easily retrieved
There are no formal guidelines for the recording of data, but it should:
 be concise - a “one-sheet-per-item” method of recording may be more efficiently replaced by a
check-list containing many similar items in the same location
 be easily referenced to the equipment – equipment must have a tag before the inspection starts and
inspection is best done by location
 highlight required actions – aspects where the equipment does not comply should be clearly
marked in a way that makes it easy to identify among the mass of data; required action should be
prioritised (see below)
 be easily retrieved at a future date – until the time where inspectors can enter the data directly into
their (intrinsically safe) palmtop computers for later downloading, the summarised information
should be transferred from clipboard to computer to facilitate future retrieval
Prioritising actions: it is helpful to have a scale (say, 1 to 4) to indicate the urgency of the action required.
Thus, for example, action code 1 (e.g. a thermocouple in a zone 0 that is not fed via a barrier or isolator)
requires immediate attention whereas action code 4 (e.g. an uncertified junction box in a zone 2) requires
consideration at the next convenient opportunity but its continued presence may be justified and
documented. Additionally, potential faults (e.g. where the documentation to prove compliance is not
available) should be separately designated (say, P1 to P4).
15.9 Inspection with maintenance
Inspection without maintenance is ineffective so some means of linking the two is required. There are many
ways of achieving this and one is shown below.
Checklists Maintenance Repair

Inspector (faults) Department orders Tradesman
Checklists Copies of
(no faults) Copies of repair Completed
checklists orders repairs
Checklists
Input on all Inspection Fault

installations record Completed record
including file checklists file
modifications

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15.10 Intrinsically safe test meters
There are two general types

low voltage meters
- BS 5345 Part 4 clause 21.1.2 permitted their use “regardless of
the possible presence of flammable atmospheres” if the output
- complies with the limits for simple apparatus
- EN 60079-14/17 do not contain such guidance
high voltage insulation testers (e.g. ‘Meggers’)
- may damage instrumentation
cable capacitance more problematic at high voltage
When a flammable atmosphere might be present, only certified meters should be used. Of the two types
available, the low voltage type makes a negligible difference to the total voltage, current, power and stored
energy in an intrinsically safe circuit if it is within the limits imposed for simple apparatus.
When a flammable atmosphere might be present, only certified meters should be used. The two types
available are:
1 Intrinsically safe low voltage/ current multimeter - BS5345 Part 4, clause 21.1.2 allows the use of
such meters on live I.S. circuits (and, by implication and where safe, live non-I.S. circuits)
“regardless of the possible presence of flammable atmospheres”. [There is no mention of this in
EN 60079-17, which does not cover testing.]
2 Intrinsically safe high voltage insulation tester (e.g. a ‘Megger’). This is not usually to be used on
I.S. circuits and should only be used on other circuits with care as capacitance, notably cable
capacitance, can enhance any spark produced due to insulation breakdown and make it non-
intrinsically safe.
The potential problem with using an I.S. insulation tester in a hazardous area means that its use should be
carefully controlled and operators need to be aware of the possible risks. Care should be taken in using an
insulation tester on long cable runs, particularly where the cable runs through a hazardous area
containing IIC gases like hydrogen. Hydrogen needs less than one eighth the amount of spark energy
compared to a IIA gas.
Where practical, use of an insulation tester should be limited to shutdown situations. Where this is not
possible, it is as well to prove that points where sparking is most likely are free of flammable gas (e.g. at a
junction box). It is not practical to issue a gas-free certificate for an entire cable run where this may be
hundreds of metres. The balance is between the risk of insulation failure leading to an unsafe situation
versus the small but definite risk posed by the instrument itself.
Prior to commissioning, it may be advantageous to make measurements with both high voltage/current
testers and a low voltage/current tester. All results are recorded but subsequent routine testing in the
possible presence of flammable atmospheres is then only done with the low voltage/current multimeter and
the results compared with the initial readings. (Tests made with a low voltage meter may not necessarily
identify certain bad connections or damaged insulation because of the low test current or voltage.)

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15.11 Insulation testing: a worrying calculation!

‘Meggers’ can produce an incendive spark, even though certified, by
charging up the cable to 500V+

Typical cable is 160pF/m (0.16 nF)

Spark energy to ignite a IIC gas is 40uJ

E = ½CV2
Thus, Ccable = 2E/V2
= 2 x 40/(500 x 500)
= 3.2 x 10-4uF
= 320pF
 Cable length = 320/160 = 2 metres!!!!
 Above this, the spark is, theoretically, capable of igniting hydrogen!
The potential problem with using an I.S. ‘Megger’ in a hazardous area means that its use should be
carefully controlled and operators need to be aware of the possible risks. Almost invariably, such devices
have an ‘X’ suffix to the certificate number, indicating special conditions for safe use. Care should be taken
in using a ‘Megger’ on long cable runs, particularly where the cable runs through a hazardous area
containing IIC gases like hydrogen. Hydrogen needs less than one eighth the amount of spark energy to
ignite compared to a IIA gas and even a short cable contains enough capacitance when charged to over
500 V to store enough energy to ignite hydrogen if a spark discharge occurs.
15.12 Insulation testing: points to ponder
 If possible, use only when plant is flammable-free

 Can a low voltage meter be used instead?
 If using a ‘Megger’:
 Do a gas check where a spark is possible
 Do the test in the hazardous area
 Wait the required time for the cable to discharge
 Use solid connections to the cable
 Be extra cautious about use in a IIC area
 Pyro is highly capacitive
Where practical, use of a ‘Megger’ should be limited to shutdown situations. Where this is not possible, it
is as well to prove that points where sparking is most likely are free of flammable gas (e.g. at a junction
box). It is not practical to issue a gas-free certificate for an entire cable run where this may be hundreds of
metres. The balance is between the risk of insulation failure leading to an unsafe situation versus the small
but finite risk posed by the ‘Megger’ itself.

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CHAPTER 16
REPAIRING Ex EQUIPMENT
16.1 General
Routine maintenance is required on most equipment in order that it stays working reliably for long periods.
For electrical equipment in hazardous areas this is further complicated by the fact that failure of the
equipment, which may cause an explosion of the flammable materials to which they are exposed, may not
cause an operational problem.
It is useful to distinguish between maintenance and repair. There is clearly overlap, but it is useful to
define maintenance/overhaul as being limited at most to like-for-like replacements whereas repair goes
beyond this and makes good damage which has occurred to a non-replaceable part of the equipment.
Clearly, the certification (and possibly the safety) of the equipment will lapse if it is maintained and repaired
by those who do not understand the safety principles of the equipment. For maintenance, it is sufficient for
those who have been trained in the principles of hazardous area electrical equipment to undertake the job.
Repair is more specialised and many users do not have the facilities on-site to repair equipment. It should
either be returned to the manufacturer or, if not, only entrusted to a repair facility which is approved to do
the work to the current code of practice (see below).
16.2 Maintenance
The European Code of Practice devoted to maintenance is EN 60079-17:1997 which replaces BS 5345
from 1st December 1999. The requirements of the two codes are very similar, but the detailed differences
are compared below:
EN 60079-17 provides much more guidance on the levels of inspection - see Chapter 16.
16.3 Repair
16.3.1 BS IEC 60079-19:1993 and the BEAMA/AEMT Code of Practice
In 1984 the British Electrotechnical and Allied Manufacturers' Association and the Association of Electrical
Machinery Trades published a code of practice for the repair and overhaul of electrical equipment in
potentially explosive atmospheres. It deals mainly with electrical rotating machines, not because they are
the most important items, but because they are often items of expensive equipment which lend themselves to
being repaired. The failure in these machines is often of a mechanical nature anyhow.
This code has now been reproduced as an IEC standard IEC 60079-19:1993.

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16.3.2 Identification of repaired apparatus
Where the repair affects the integrity of the explosion protection, repaired apparatus should be marked on
the main part in a visible place. This marking should be legible and durable taking into account possible
chemical corrosion. According to Annex A of both the BEAMA and IEC 60079-19 codes, the marking
should include:
 the standard number “IEC 79-19” or the national equivalent ("BEAMA AEMT Code of Practice on
Repairs”)
 the name or registered trade mark of the repairer
 the repairer's reference number relating to the repair
 the date of overhaul/repair

 the symbol R or R
The marking could be on a plate permanently attached to the repaired apparatus.
16.3.3 Removal of electrical apparatus
Where electrical apparatus is removed for maintenance, any exposed conductors which remain should be
mechanically and electrically secured in an appropriate manner so as to prevent the occurrence of an unsafe
condition.
16.3.4 Documentation
In addition to the certificate, other documentation, suitable for the repair and/or overhaul, should be
available, e.g. the appropriate drawings, specifications, etc. The data available for the repair and/or
overhaul should generally include, but need not be limited to, details of:
 technical specification;
 performance and conditions of use;
 dismantling and assembly instructions;
 certification limitations, where specified;
 marking (including certification marking);
 recommended methods or repair/overhaul for the apparatus.
Records of any previous repairs, overhauls or modifications should be kept by the user and made available
to the repairer.
16.3.5 Reclamation procedures
The following main reclamation procedures may be performed - check with the code: copy winding, metal
spraying, electro-plating, sleeving, brazing/welding, metal stitching, machining of stator/rotor cores, re-
tapping threaded holes, re-machining surfaces.

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CHAPTER 17
EQUIPMENT FOR USE IN FLAMMABLE DUSTS
17.1 Combustible dusts
A ‘dust’ can be defined as follows:
‘Small solid particles which settle out under their own weight but may remain suspended for some time’
[BS 6467:Part 2:1988]
The term ‘combustible dust’ describes a particular type of dust (or grit) as follows:-
‘Dust that is combustible or ignitable in mixtures with air’
Many dusts are combustible, ranging from many used in the food industry (flour, cocoa, sugar) to paper fibres,
metal, polymers, coal and others.
Dusts are similar to gases in that they have auto-ignition temperatures in the same range (most are between
150C and 600C for layers and clouds), and can also be ignited by a spark, though the spark ignition energies
are almost invariably much higher than for gases. Therefore, equipment certified for use with flammable gases
can generally be adapted for use with flammable dusts by ensuring that they are dust-tight. This has been the
method used historically (section 17.4) and is still used (section 17.5.1). Equipment protected by its enclosure
only is beginning to come available (section 17.5.2).
17.2 Properties of dusts
 Dust forms layers which do not disperse

 Layers can produce clouds if disturbed
 Flammable clouds are clearly visible
 Two ignition temperatures:
 cloud AIT
- equipment 2/3 of this temperature
 layer AIT
- apply 75 K safety margin when selecting equipment
Dusts have two ignition temperatures, which differ from each other: cloud ignition and a layer ignition. The
cloud ignition temperature is the higher. The ignition temperatures depend on a number of variables (e.g.
particle size), and cannot be measured accurately, so a large (but different) safety factor is applied to these two
ignition temperatures when assessing the suitability of equipment that may become hot in use.
Dust cloud ignition temperature: a safety factor of 1/3 is used. Thus, when the ignition temperature of a dust
cloud is known (e.g. 380°C for lignite), the maximum surface temperature of the apparatus used must not
exceed two thirds of that figure (253°C). In gas and vapour parlance, this requires T3 apparatus, unless the
equipment has been specifically assessed for dusts, in which case the actual surface temperature should be
written on the equipment.

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Dust layer ignition temperature: there are currently no standard tests for dust layer ignition temperature, but
in practice a figure is normally obtained by measuring the ignition temperature of a 5 mm thick layer of dust on
a hotplate. For this reason, it is usually considered necessary to ensure that where dust layers can occur they
do not exceed 5 mm. Because of this uncertainty, when a layer temperature is known, 75 K is deducted as a
safety factor. The layer ignition temperature of lignite, for example, is 225°C and thus the temperature of the
apparatus used would need to be below 150°C (in gas and vapour terms, this is T4 apparatus).
Other Properties: apart from its ability to form layers, dust has a further potential property which can have a
very real effect on safety and that is its ability to conduct electricity. Clearly, if conducting dusts enter
apparatus they can, by creating faults, cause the very ignition sources we seek to avoid. For this reason the
conductivity of the dust layer is important and such things as metallic and carbon dusts (which have resistivities
below the 105 ohm.metre yardstick used to delineate the conducting dust boundary) require special attention to
be given to equipment enclosures. The required level of ingress protection is given in section 17.4 – IP6X is
always sufficient, but sometimes IP5X may be acceptable.
17.3 Area classification for dusts
Current European zoning:

Zone 20 – dust cloud present continuously, or nearly so
Zone 21 – dust cloud may be present in normal operation
Zone 22 – dust cloud unlikely
UK: historically two zones

Zone Z – similar to zone 21
Zone Y – similar to zone 22
Historically, the UK has had just two zones, whereas a 3-zone system is now adopted throughout Europe and
by the IEC standards.
17.3.1 Historical zone Z/Y system
Zone Z is one where a dust is, or may be, present in a cloud during normal processing, handling or cleaning
operations in sufficient quantity to be capable of producing an explosive concentration of combustible dust in a
mixture with air. Zone Z is roughly equivalent to zone 21 (see below).
Zone Y is an area where a dust cloud is unlikely and these areas result from malfunction or careless use of
plant equipment, or disturbance of dust layers. Zone Y is roughly equivalent to zone 22 (see below).
There was no zone designation for inside dust-containment systems.

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17.3.2 Current zone 20/21/22 system according to prEN 50281-1-3
PrEN 50281-1-3 is based on IEC 61241, but the zone definitions below are different in that dust layers are
excluded, but are considered separately as sources of release and as a fire risk.
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
 inside the dust-containment: hoppers, silos, cyclones, filters, etc.
 dust transport systems, except some parts of belt and chain conveyors, etc.
 blenders, mills, dryers, bagging equipment
Zone 21: A place in which an explosive atmosphere in the form of a cloud of combustible dust in air is likely to
occur in normal operation occasionally
 areas outside the dust containment and in the immediate vicinity of access doors subject to frequent
removal or opening for operation purposes when internal explosive dust/air mixtures are present
 areas outside the dust containment and in the proximity of filling and emptying points, feed belts,
sampling points, truck dump stations, belt dump over points, etc. where no measures are employed to
prevent the formation of explosive dust/air mixtures
 areas outside the dust containment where dust accumulates and where, due to process operations, the
dust layer is likely to be disturbed to form explosive dust/air mixtures
prEN 5028181-3 recommends that it will usually be appropriate to define the zone 21 as an area of width 1 m
around the source of release is sufficient, extending vertically downwards to the ground or a solid floor.
Outdoors, the zone may be smaller due to wind and rain. Consideration should be taken of where dust layers
may form and whether they are likely to be disturbed (zone 21 results) or unlikely to be disturbed (zone 22).
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 time only
 outlets from bag filter vents
 locations near equipment that is opened at infrequent intervals or equipment that from experience can
easily form leaks where, due to pressure above atmospheric, dust will be blown out: pneumatic
equipment, flexible connections that can become damaged, etc.
 storage of bags containing dusty product
 areas that are normally classified as zone 21 can fall into zone 22 when measures (e.g. exhaust
ventilation) are employed to prevent the formation of explosive dust/air mixtures
 areas where controllable dust layers are formed that are likely to be raised into explosive dust/air
mixtures
 around a zone 21 that is not contained by walls, floors or other barriers
17.4 Selection of pre-ATEX equipment
Until the introduction of the ATEX Directives (Chapter 4), the selection of electrical equipment for use in
flammable dusts had not been easy since the equipment marking gives little or no information as to its
applicability. In the UK, BS 7535:1992 gives guidance on the selection, installation and maintenance apparatus
in combustible dust zones. It uses the now obsolete two zone (Z/Y) system but also recognises the interior of
the dust containment. Its recommendations can be summarised as follows:

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Old zone New zone Equipment requirements
designation designation
Inside dust containment 20 EEx ia IIC apparatus with IP6X enclosure
Z 21 Equipment suitable for zone 1 with IP6X enclosure
(IP5X for EEx o)
Y 22 Equipment suitable for zone 2 with IP6X enclosure if the dust is
conductive, otherwise IP5X
One problem encountered is that equipment frequently does not state its IP rating, so it is not possible to easily
demonstrate compliance with the IP requirement. It may be necessary to make a judgement or contact the
manufacturer. Flameproof (EEx d) equipment is suitable, even if the dust can get inside, since an internal
explosion of a dust cloud is less easily transmitted to the outside than with a gas explosion. For EEx e
equipment, IP5X (dust-protected but not dust-tight) is a minimum requirement, but it may not meet IP6X
(dust-tight), in which case a build-up of dust inside may cause overheating – the severity of the problem can be
gauged by inspection and a judgement made. Encapsulated (EEx m) equipment is gas-tight and restricted
breathing (EEx nR) equipment exceeds IP6X, so both may be used with flammable dusts after considering its
temperature class. Pressurised (EEx p) equipment is also suitable provided dust cannot enter while the
equipment is switched off.
17.5 Selection of ATEX-certified equipment
17.5.1 Dust-protected equipment also certified for gases
ATEX-certified equipment might have the following information:
EEx e II T3 Ta = -20 - +60oC
nnnn II 2 G (T3)
II 2 D (T 100oC)
‘nnnn’ is the reference number of the Notified Body accrediting the quality system
‘II’ is the Group (I = mining, II = surface industry)
‘2’ is the ATEX Category:
Category 1: zone 0/1/2 use for gases or 20/21/22 for dusts
Category 2: zone 1/2 or 21/22 use
Category 3: zone 2 or 22 use
‘G (T3)’ refers to the temperature class for Gases
‘D (T 100oC)’ refers to the external surface temperature applicable to Dusts
ATEX-certified equipment continues with the approach used historically but specifically states whether it is
certified for dusts or not. If the equipment is marked for gases only, this may be a lack of forward thinking by
the manufacturer: ask the manufacturer whether certification for dust is possible.
It is important to realise that gases will usually be exposed to a higher temperature than dusts because they are
able to penetrate the enclosure and this is reflected in the temperature class. This means that a lower external
surface temperature can be stated for dusts for EEx i, EEx e, EEx nA and EEx nL equipment.
17.5.2 Equipment certified specifically for dusts

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The ATEX Directives also permit equipment to be used in flammable dusts that is not certified for gases. The
relevant standard for such equipment, which is protected by the enclosure, is EN 50281-1-1. [Equipment
marked like this need not necessarily be electrical – the ATEX Directives also require mechanical equipment to
be certified for use with flammable gases and dusts.] The marking would, typically, be as follows:
nnnn II 2 D (T 100oC)
17.6 Standards and codes of practice
The following European standards are published or are being prepared, based on IEC 61241:1997 (formerly
IEC 1241):
1 EN 50281-1-1:1998 - Electrical apparatus for use in the presence of combustible dust –

Part 1-1: Construction and testing (formerly designated prEN 61241-1-1)
2 EN 50281-1-2:1998 - Electrical apparatus for use in the presence of combustible dust –
Part 1-2: Selection, installation and maintenance (formerly designated prEN 61241-1-2)
3 prEN 50281-1-3 – Electrical apparatus for use in the presence of combustible dust –
Part 1-3: Classification of areas where combustible dusts are or may be present
4 prEN 50281-2-1 - Electrical apparatus for use in the presence of combustible dust -
Part 2-1: Method for determining the electrical resistivity of dust layers
(formerly designated prEN 61241-2-1)
5 prEN 50281-2-2 - Electrical apparatus for use in the presence of combustible dust -
Part 2-2: Method for determining the minimum ignition temperatures of dust/air mixtures
(formerly designated prEN 61241-2-2)
Notes:
 1, 2 and 3 deal with zones 20, 21 & 22
 the ‘pr’ prefix indicates a provisional standard; this is a final draft which may be used to enable
feedback to be incorporated into the final version
 The definitions of the dust zones in prEN 50281-1-3 are different to the IEC definitions in that there is
no mention of dust layers in the EN standard. Layers are dealt with as a source of hazard (when
disturbed) and, separately, as a fire risk (if a dust layer forms on a hot surface)
 EN 50281-1-1:1998 gives the requirements for equipment which is not otherwise protected for gases,
i.e. equipment protected by its enclosure; the additional requirements for equipment already certified
for gases are not yet available as European standards. As an interim measure, use BS 7535:1992 in
the UK
 The ATEX 94/9/EC Directive and the 1999/92/EC Worker Protection (‘Use’) Directive also use Zones
20, 21 & 22

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CHAPTER 12

CABLE AND CONDUIT ENTRY

Gland must maintain integrity of enclosure

Must be certified EEx d IIC Certification usually optional

Gland entries to flameproof enclosures must themselves be certified;

Chapter 12, HAZARDOUS AREA ELECTRICAL EQUIPMENT

12.3 Flameproof cable entries

Solid cable Non-solid cable

compression gland barrier gland

12.4 Flameproof Compression Glands

Chapter 12, HAZARDOUS AREA ELECTRICAL EQUIPMENT

12.6 Selection of Flameproof Glands

Use a Does gas

The recommendations for the selection of a flameproof gland are as follows:

3 Unfilled cables always need a barrier gland.

 With a cable that is not sealed against gas, e.g.

12.8 Conduit entry into Ex d enclosures

12.9 Glanding into non-flameproof enclosures

For non-flameproof equipment….

Consider use of a certified gland for

Chapter 12, HAZARDOUS AREA ELECTRICAL EQUIPMENT

12.10 Adapters and reducers

These are permitted, but

12.11 Gland features for differing applications

Chapter 12, HAZARDOUS AREA ELECTRICAL EQUIPMENT

1 Scope and object

The remaining clauses deal with specific concepts:

10 Additional requirements for type of protection “d” – Flameproof enclosures

There are also three annexes:

13.1 Clause 1: Scope and object

Chapter 13, pHAZARDOUS AREA ELECTRICAL EQUIPMENT

13.3 Clause 3: Definitions and terms

13.4 Clause 4: General

Clause 4.1: General requirements

Clause 4.2: Documentation

Chapter 13, pHAZARDOUS AREA ELECTRICAL EQUIPMENT

Clause 5.1: Specific information

Clause 5.2: Selection according to zones

Clause 5.5: External influences

13.6 Clause 6: Protection from dangerous (incendive) sparking

Clause 6.1: Danger from live parts

Clause 6.2: Danger from exposed and extraneous conductive parts

Chapter 13, pHAZARDOUS AREA ELECTRICAL EQUIPMENT

Clause 6.3: Potential equalisation

Clauses 6.4 – 6.6

Clause 6.7: Cathodically protected metal parts

13.7 Clause 7: Electrical protection

Chapter 13, pHAZARDOUS AREA ELECTRICAL EQUIPMENT

13.9 Clause 9: Wiring systems

Clause 9.1: General

Clause 9.2: Cable systems for zone 0

Clause 9.3: Cable systems for zones 1 and 2

For fixed apparatus, the following are listed:

Chapter 13, pHAZARDOUS AREA ELECTRICAL EQUIPMENT

Flexible cables may be

Clause 9.4: Conduit systems

Clause 10.1: Solid obstacles

Gas/vapour subgroup Minimum distance (mm)

Chapter 13, pHAZARDOUS AREA ELECTRICAL EQUIPMENT

Clause 10.3: Cable entry systems (see also chapter 12)

Clause 10.4: Motors supplied at varying frequency and voltage

Clause 10.5: Conduit systems

Chapter 13, pHAZARDOUS AREA ELECTRICAL EQUIPMENT