Hazardous Areas Materials

ELECTRICAL MAINTENANCE
HAZARDOUS AREAS MATERIALS
EXP-MN-SE190-EN - Hazardous Areas Materials
In this course you are going to learn :

How to recognize, identify the different Standards in markings
The interpretation, the meaning of all terms indicated on nameplate of an
apparatus Ex type
The different classifications for apparatus installed in H.A.
How to define Hazardous Areas (dimensions, type of risk,)
The different method used for protection of materials in H.A.
How to select the appropriate material and where to install it according to
type and zone of H.A.
Rules and safety measures to adopt in H.A. regarding the electrical (and
instrumentation) devices
Operation and Maintenance of all type of apparatus installed in H.A.
2 EXP-MN-SE190-EN - Hazardous Areas Materials
INTRODUCTION
3 - EXP-MN-SE190-EN Slides Hazardous Areas
Introduction
If as site electrical personnel, you are doing such work, you need
training..
Introduction
Example of marking for the four Standards
Introduction
We are going to understand the identification in different Standards the 4
following identications are for the same apparatus in the 4 Standards
Old Cenelec reference: EEx d IIC T4
E: Certified to the Cenelec Standard

Ex: Explosion protection
d: protection concept
IIC: Apparatus group (gas group), IIC = group of Hydrogen
T4: Temperature classification, T4 = 135C for maximum surface temperature
Old USA NEC 500 ref : Cl 1 Div 1 Gr B T4 or Class 1 Division 1

Group B T4
Class 1: classification of Hazardous Area, class 1 = gas

Division 1: for installation in division 1 area (equivalent to zone 0 + zone 2)
Gr B: gas group, B = group of Hydrogen
T4: Temperature classification, T4 = 135C for maximum surface temperature
Introduction
New marking ATEX: CE xxxx II 2 G
EEx d IIC T4
CE: or EC for European Community

xxxx: identification of the official service (LCIE, Ineris, Baseefa,.)
II 2 G for all material to be installed in explosive atmosphere with
: explosion protection marking
II: material group for surface mounting, surface use
2: category, material for installation in zone 1
G: type of explosive atmosphere, G = gas, vapour or mist
EEx d IIC T4 specificity of electrical (and instrumentation) material, same meaning as
for previous identification
New marking USA - NEC 500: Class 1 Zone 1 AEx d IIC T4
Class 1: classification of Hazardous Area, class 1 = gas (same as NEC 500)

Zone 1: material for installation in zone 1 (same zones as Europeans)
AEx: American Ex for material to be installed in Hazardous Areas
d: protection concept adoption (partially) of the European system
IIC: Apparatus group (gas group), IIC = group of Hydrogen Adoption of the European
identification (with NEC 500 the letters order was reversed see further)
DEFINITION HAZARDOUS AREAS
Definition Hazardous Areas

What is an explosion
nuclear explosions
explosion of a pressurized container
explosions related to the presence of inflammable substances,
explosions related to the presence of dust,
explosions caused by explosives,
miscellaneous explosions

Explosive atmosphere mechanism
Three elements are necessary to trigger an explosion:
Fuel material / Hazardous material
Oxidising agent / air or oxygen
Energy
Definition of terms
Explosive atmosphere
Potentially explosive atmosphere
Explosion risk atmosphere
Blast
Detonation

the lower limit: LEL (Lower Explosion Limit)
the upper limit: UEL (Upper Explosion Limit)
LEL: Concentration in air of flammable well defined gas, vapours or

mist under which a gaseous explosive atmosphere is not present.
UEL: Concentration in air of flammable well defined gas, vapours or
mist above which a gaseous explosive atmosphere is not present.
Some examples of
LEL and UEL

Temperature Phases
Flash point
The lowest temperature at which a liquid gives off sufficient vapour to reach its LEL in the
gas phase (in atmospheric condition).
Auto-ignition temperature (AIT)

The auto-ignition temperature is the lowest temperature above which an explosive
atmosphere will ignite spontaneously (at atmospheric pressure) - without need of ignition
source
In dust, to be differentiated
a cloud of dust
a layer of dust, reference being taken for a 5 mm thickness

Critical points for some gases and dusts

Various phenomena may produce sufficient energy to cause an explosion.
For example:
static electricity,
sparks or electric arcs,
aluminothermical sparks (impact-induced reaction between iron oxide and aluminium),
friction, mechanical impacts,
inductive heating, Joule effect, solar radiation (after focusing),
flames,
shock wave,
radiation (laser, microwave, ultraviolet, infrared).
etc.,

Effect of concentration in air (Hydrogen Propane) and Pressure (for
Hydrogen)
Spark energy required is function of type of gas and its pressure (+ temperature)
STANDARDS HAZARDOUS AREAS
Standards for Hazardous Areas

Two initiators of Standards: European and North American

European Standards (Initial ones)
European International Standards IEC

ATEX 95 Directive 95 Directive 94/9/EC: marking on apparatus + certifications
ATEX 137 Directive 1999/92/EC : for workers fsafety
Evolution of
Standards
+ American
Standards
old : NEC 500
new : NEC 505
New 505 having adopted
ZONE DELIMITATIONS
Zone Delimitations
Types of releasing sources - For gaseous, vapours atmosphere surface
equipment Gas groups (all Standards)
Continuous: danger duration >= 1 000 hrs/yr. - Generates a zone 0
(Cenelec and NEC 505) a category 1 (IEC ATEX Directive) a Division 1
(NEC 500)
1st degree: 10 hrs/yr. < danger duration < 1 000 hrs/yr. - Generates a zone
1: (Cenelec and NEC 505) a category 2 (IEC ATEX Directive) a Division
1 (NEC 500 zone 0 and 1 is a common division 1)
2nd degree: danger duration < 10 hrs/yr. - Generates a zone 2 (Cenelec
and NEC 505) a category 3 (IEC ATEX Directive) a Division 2 (NEC 500)
Zone Delimitations
For Dust atmosphere - Same classification of areas, with a (slightly)
different marking
Same classification of areas, with a (slightly) different marking
Zone 0, 1, 2 becoming respectively zones 20, 21, 22 (Cenelec and IEC)
Divisions 1, 2 identical for NEC 500 NEC 505 send back to NEC 500
Categories 1, 2, 3 identical for ATEX 95
Letter D appears in the marking instead of letter G for ATEX 95
It is a matter of Class for marking of NEC 500 and NEC 505 (Class I for Gas,
class II for Dust, Class III for Fibres). Remind: NEC 505 applies only for Gas
atmosphere
No difference for Cenelec marking, as this differentiation does not appear
Zone Delimitations
Determination of zones (examples)
Discuss / detail those 3

conditions for the same
product, same process but
with different protections
principles
Zone Delimitations
Protection provided by operating in a closed circuit
Protection provided by using inert gases
Zone Delimitations
Protection provided by aspiration at the source of release
Protection provided by a pressure reduction

Maintaining the pressure of an enclosure at a value lower than that of the surrounding
environment prevents the diffusion of inflammable gases and vapours to outside from
that same enclosure.
The environment, which is then safe, can therefore contain standard electrical
equipment or any other potential source of ignition without the equipment presenting a
risk.
In principle, this is a similar solution to that of protection provided by aspiration at the
source of release which simply creates a low pressure of limited extent.
Zone Delimitations
Protection provided by overall aspiration
Protection provided by pressurisation
Zone Delimitations
Concerning the safety of our pressurised technical rooms:
use of airlock doors for normal access, Please do not use emergency exit door as
permanent access in and out. Air lock is there to keep the air pressure inside. And do
not leave the doors open!!
no windows, I have seen work request for installation of windows in room inside the
plant where operators are regularly present
minimum pressure difference: 50 Pascal's (Pa). It is why in (many) technical rooms, you
can find a pressure gauge, the water gauge, inclined type or more simply a U tube
filled with coloured water (50 Pa = 5 mm water)
flushing with not less than 5 times (per hour) the internal volume of the room and
associated ducting, HVAC has to be efficient
use of a protection device which may either be a flow rate controller, a pressure
difference controller, or both,
in the event of a failure an alarm must be activated or the premises shut-down. Do not
bypass the alarm which occurs often when the doors are kept open.
safety equipment must be used for those elements of the electrical installations which
must remain on when pressurisation is released (e.g. standard fighting, emergency
fighting, telephone, safety devices etc.). Reason for having safety lighting, telephone set
, etcof the explosion proof type when all the other equipments are normal type.
Zone Delimitations
Classification according to IP code - Definitions of Areas dimensions
consider the Gas density making differentiation between heavier and
lighter than air
Onshore facilities - Heavier than air gas in open air - 2nd degree source
Zone Delimitations
Onshore facilities - Heavier than air gas in open air - 1st degree source
Zone Delimitations
Onshore facilities - Lighter than air gas in open air - 2nd degree source
Onshore facilities - Lighter than air gas in open air - 1st degree source
Zone Delimitations
Offshore facilities - Heavier than air gas in open air
Zone Delimitations
Offshore facilities - Lighter than air gas in open air
Zone Delimitations
Technical rooms containing sources of atmosphere explosives
Detail this
configuration of
technical rooms
having (so) many
different zones
classifications
Answers / details
are in the main
course
CLASSIFICATIONS
Classifications
Explosive sources
classification as per
Cenelec
In red the marking of
gas classification in
the different
Standards
Classifications
Explosive sources
NEC 500
In the example we are
in Class 1, for Gas
reverse order compared
with Cenelec..
Classifications
Explosive sources
IEC ATEX 95 Directive
Classifications
Explosive sources
NEC 505
Same as Cenelec
Classifications
Summary explosive sources classification between standards
Classifications
Classifications
Enlightened in red is the marking for zones (for installation)
Zones 0, 1 and 2 in gaseous atmosphere (European and NEC 505)

Zones 20, 21 and 22 in dusty atmospheres (European only)
Not appearing on official marking
Only marked as in Category with ATEX 95 but marked zone x with NEC 505
Example of how it was marked on European products

Classifications
Enlightened in red is
the Temperature Class
marking in the
different Standards
Common Standard for
everybody
Only NEC 500 has subgroups
Classifications
If Maximum Surface Temperature > 450C: special marking
If ambient temperature <-20C or > 40C: special approval
The temperature corresponding to a 'class' T1 to T6 is the MST (Maximum
Surface Temperature). It is the certification by the vendor (and one
certifying authority) that the surface temperature of the device (junction
box, lighting feature,) could reach (at maximum) in the worst conditions
(explosion, fire inside the apparatus)..
In direct relation (and not to mix) with the Self Ignition Temperature. (SIT)
Example:
In practice, the MST class is selected at 80% of the SIT (Safety Guard)
Acetylene has SIT at 305C,
305 x O.8 = 244C,
The equipment installed in acetylene atmosphere must be at least of class T3 (200C), T1
and T2 do not fit, but T4 to T6 would be of course accepted.
Classifications
Example: a gas ranked in T1 group means that its SIT is widely above the
material MST which is 450C (fro T1 group). However, think also of Safety
gap and when in doubt, take the material with the lowest MST (T6 85C)
covering all types of atmospheres.
Classifications
Enlightened in red is the protection letter (other letters of course are existing
No protection concept for NEC 500
Protection concept is linked with installation in a zone
Protection Concept (in gas atmosphere) are letters:

e: increased safety (or non sparking) d: flameproof (explosion proof)
n: non incendive q: powder filling i intrinsic safety p: pressurised
m: moulded / encapsulation o: oil immersion
Classifications
Protection Concepts for installation of electrical equipment in Gas
Classifications
Protection Concepts for installation of electrical equipment in Dust
Classifications
Protection Concepts for non electrical equipment and machinery
Specific
Class III for
NEC 500
Classifications
Types of protection Concepts for Gases
Classifications
Types of protection Concepts for Gases (cont)
Classifications
The mode flameproof d - Basic principles
Enclosures must be sufficiently strong to withstand the internal explosion,
Joints and gaps have critical dimensions, (function of gas group see in following)
Covers have warning labels if the enclosure contains parts that store energy or achieve
temperatures in excess of the temperature classification,
Fasteners must conform to dimensional and strength requirements,
Enclosure materials must be fully specified, and non-metallic materials must be fully
defined and have a suitable thermal index (TI),
Cable and conduit entries must meet constructional requirements so that the flameproof
properties are maintained.
d - Flamepaths, gaps, flanges and threaded joints
Classifications
d - Cable entry devices
Direct entry by Cable and cable gland
Direct entry by conduit and sealing fitting
Indirect entry via Ex enclosure - generally of e type (next protection concept)
Classifications
d - Cable entry devices (cont)
Cable glands have to conform to the requirements of threaded joints. 5 fully engaged
threads are required, but 6 are usually provided.
When the wiring is done with conduits, a sealing fitting must be used, material and
compound to be agreed of being flameproof type
Clearance holes are not

allowed in flameproof
enclosures.
Classifications
Complementary requirements for type d enclosures
Flameproof does not mean waterproof (common confusion) see the IP protection
Flameproof joints must be protected against corrosion.
The use of gaskets is only permitted when specified in the manufacturer documentation.
Make sure that all covers and fittings are secure and that all bolts are in place
Ensure that the ground connections from the enclosure to the plant remain secure
Gasket, anti-condensation space heater, etc., must not be added to enclosures which
have not been designed for
Drilling additional holes is strictly forbidden
Holes which are not used must be blanked using appropriate plugs (of d type
engraved on the plug)
Spare parts used must be strictly identical to original ones
Applications of d apparatus
Not used on large volumes
Calibration and maintenance problems, long time required to open. (Do not open the
enclosure under voltage)
Used generally for electric appliances
Explosion proof and flameproof What is the difference for the 2 terms?
Classifications
The mode increased safety e - basic principles
Increased safety is intended for products in which arcs and sparks do not occur in
normal or under fault conditions
Enclosures must be constructed such that they can withstand the mechanical impact test
and provide a specified degree of ingress protection
Terminals must be generously dimensioned for the intended connections and ensure
that the conductors are securely fastened without the possibility of self-loosening.
Clearance between bare conductive parts must not be less than the values specified for
the rated voltage.
Creepage distances must not be less than the values specified for the rated voltage and
the comparative tracking index (CTI) of the insulating material.
Electrical insulating materials must have mechanical stability up to at least 20 K above
the maximum service temperature.
Temperatures of parts of equipment must be limited so as not to exceed values that
could affect the thermal stability of the material and the temperature classification of the
equipment.
See Maintenance chapter (at end) for details
The mode increased safety e - applications

rotating machines (induction motors) - luminaries - transformers - heating devices
terminal boxes - terminal assemblies
Classifications
The mode increased safety e - Electrical motors:
Protective device shall be installed in the winding (temperature switches, temperature
sensors), this is a mandatory request for e type electrical motors. A motor having its
Temperature Protection device(s) disabled is no more of an e type.
The mode increased safety e - Junction boxes

Ex e enclosures that contain bare conductive parts require an ingress protection of
IP54.
Additional holes must be drilled strictly in accordance with current safety regulations
and the permissive number of holes
Holes not used must be blanked using appropriate plugs (marked Ex e).
Classifications
The mode increased safety e - Junction boxes Terminals
Always use the built-in terminals and connectors, do not replace, and do not add.
Terminals are part of the box, they are ordered with
Ex e junction boxes have a maximum surface temperature which is settled by what is
normally inside the enclosure
Main characteristic of terminals in e junction boxes is the guarantee, by the
manufacturer, that each connection is secured and cannot be loosed
clamping yoke,
tension clamp and
Insulation Displacement. Connection (IDC)
Enclosures are allocated a maximum dissipated power figure, which is used to calculate
the number of terminals that can be fitted
Classifications
Parallel Ex e and Ex d electrical equipments
Classifications
The Ex ed apparatus
All sparking devices such as switches, contactors, lamps, thermal relays, batteries etc.
are packaged individually in a flameproof enclosure. The electrical connection is made
via Ex e terminals included in the design or by means of an encapsulated cable.
These components are then installed in an Ex e enclosure.
Classifications
The mode increased safety e - cables entry devices
Cable glands must maintain at least IP54. Threaded entries with minimum 6 mm thread
Metal cable glands do not require certification but should comply with a recognised
standard (engraved Ex e)
Plastic cable glands require an EC type examination certificate by a notified body.
Unused entries must be fitted with suitable stopping plugs. (marked Ex e)
Additional holes must be drilled strictly in accordance with current safety regulations
Earhing of cable entries:
either an internal metal cruciform plate (generally in brass),
or alternatively a thick (could be also in brass) plate which is normally supplied with threaded
entries for the cable glands.
Classifications
The mode Intrinsic Safety i : it concerns an electrical circuit, an electrical loop
being made intrinsically safe in its part inside hazardous areas, by limiting the
energy under the ignition/sparking point . Any apparatus, any device installed in H.A.
cannot be i by itself. It needs a safety barrier installed in a safe area
See comments in main course
i basic principles
The type of protection Intrinsic Safety is based on the principle of current and voltage limitation
within an electric circuit.
The type of protection Intrinsic Safety is particularly used in measurement and control technology,
as no high currents, voltage and capacities are required here.
i Terms and Definitions

Intrinsically safe electrical circuit: an electric circuit in which neither a spark nor the effect of heat
can cause a certain explosive atmosphere to ignite.
Intrinsically safe electrical apparatus: electrical apparatus in which all circuits are intrinsically
safe.
Associated electrical apparatus: electrical apparatus which contains circuits some of which are
intrinsically safe and some are not, and which is designed such that the non-intrinsically safe
circuits cannot negatively influence the intrinsically safe circuits.
Classifications
i principles and examples
Classifications
i Minimum Ignition Energy see previous chapter / slides
Example to illustrate the i associated with M.I.T.:
Lets consider the worst atmosphere requiring the minimum of energy to ignite, the
value being 1 W (one watt).
The instrumentation circuits are in 24V and current loops between 4 and 20 mA with
maximum (and limited by the safety barriers) values at 30 V and 30 mA
Maximum power which can be delivered: 30 x 0.03 = 0.9 W, just under 1 W. It is why
instrumentation is using 24 V and 20 mA as reference maximum values it is as simple
as that but of course do not forget that we need power limitation devices (or voltage
limiter + current limiter).
Categories ia and ib
Classifications
i Characteristics of IS circuits the system IS is
the only method for which safety is guaranteed when the equipment is faulty
the only method usable for zone 0 ("ia")
permits simple components such as switches, TCs, RTDs, to be used without
certification but with appropriate barriers
limited to low energy application:
permits live maintenance and adjustment (with the safety barrier on line of course)
is the most widely used concept in process measurement and control nowadays
(transmitter, positioner, converter, hand portable radio, multimeter)
one loop = one safety barrier
See Instrumentation course EXP-MN-SI160 for more detail on i

protection concept, especially for Safety Barriers
Classifications
The mode Powder filling q
Protection is provided by immersing the ignition-capable parts in a fine powder, usually
quartz.
The mode Oil immersion o

Protection is provided by immersing the apparatus in oil so that an explosive
atmosphere cannot be ignited by the arcs and sparks generated under the oil.
The mode Encapsulation m

Protection is provided by encapsulating any hot or sparking components with a material
that prevents the ingress of explosive gas and cools any heat produced by the
components.
Classifications
The mode Pressurised p
Operation principle: isolates the electrical parts from the external atmosphere by
maintaining a pressure within the equipment enclosure at a level higher than the
external atmosphere
Pressurization: be sure that the enclosure is tight enough to maintain the pressure
(Minimum value # 50 Pa) - Power cannot be turned on until the purge cycle has been
completed - (Purge volume 5 times the enclosure volume)
Protective gas supply: should be suitable for the equipment (air or nitrogen) - Should
be from a clean dry source - Ducting system should be free of leak and the inlet duct in
a Non Hazardous location
In case of components at a temperature > the ignition temperature: include a
warning about opening the door after a waiting time to allow for hot components to cool
down
For NEC 500 there are three grades of "purging"

Type Z: reduces the classification within an enclosure from Division 2 to Non-Hazardous
Type Y: reduces the classification within an enclosure from Division 1 to Division 2
Type X: reduces the classification within an enclosure from Division 1 to Non-Hazardous
Classifications
The mode non incendive n
Can be associated with Apparatus for zone 2 as they are designed to comply with
category 3 G equipment according to ATEX 95
n - Non-sparking apparatus
The risk of the occurrence of arcs, sparks or hot surfaces during normal operation has
been minimised by constructional means. The equipment is marked with 'nA'
n - Sparking apparatus: arcs, sparks or hot surfaces do occur during

normal operation
Apparatus with protected contacts 'nC'

Energy-limited apparatus and circuits 'nL'
Restricted-breathing enclosures 'nR'
Simplified pressurisation 'nP'
Cable entry devices
Classifications
The type of protection for dust
Classifications
Pressurized enclosure pD
The concept is basically the same as for gas. Special attention is placed on the
presence of dust when opening and closing the enclosure.
Moulding mD
With this type of protection, a piece of electrical equipment that generates sparks or
heats up excessively can be encapsulated in a casting compound
Intrinsic safety iD
The concept is basically the same as for gas atmospheres. For apparatus installed in
dust containment, barriers of the type 'ia' must be used.
Protection by enclosure tD
Protection by enclosures is based on limiting the maximum surface temperature of
the enclosure and restricting the ingress of dust by using dust-tight or dust-protected
enclosures. (tD not currently used)
The degrees of dust protection are defined as:
Dust-tight enclosure (IP 6X)
Dust-protected enclosure (IP 5X)
Classifications
Installation in Dust Atmosphere
Installations in dust atmospheres shall be designed and apparatus installed with a view
to providing ease of access for cleaning.
Types of cables
All common types of cable can be used if they are drawn into screwed, solid-drawn or
seam-welded conduits. It is also possible to use cables that are inherently protected
against mechanical damage and are impervious to dust
Cable installation
not exposed to the friction effects

collect the minimum amount of dust and are accessible for cleaning
reduce the current-carrying capacity of the cables if layers of dusts are present
pass through a floor, partition must be made dust proof
dust proofing of connected equipment must be maintained
Cable entry devices

The requirements for the entries in category 1D and 2D dust explosion protection
equipment are basically the same as for increased safety in gas. The only difference is
the IP rating, IP6X for zone 20 and zone 21.
Classifications
The type of Protection for non electrical equipment and machinery
OTHER CERTIFICATIONS
Other Certifications
IP types of protection (ingress protection) according to EN 60529 (IEC 529)
Types of protection for enclosures to ANSI / NEMA 250 (USA)
Enclosure for indoor non-hazardous locations
Enclosure for outdoor non-hazardous locations
Enclosure for hazardous locations
USA Standard differentiates

three application classes
Paralleling IEC 60529 and NEMA 250
These degrees of protection cannot be equated exactly with those of the IEC since
NEMA takes account of additional environmental influences (e.g. coolants, cutting
coolants, corrosion, icing, hail). The comparison table is therefore intended as a nonbinding guideline.
For each electrical apparatus* installed in Hazardous Areas zone 0, 1 and
2 (as per old standard but of course still on line with ATEX 95 and
NEC 505) and in addition to the above, already seen marking /
identifications, there must be a certification marking on the apparatus
itself and an individual certificate (signed piece of paper) delivered with
the equipment.
Example 1 of Marking and Certification
For electro valve material, Asco / Joucomatic made
And associated with this marking are the official documents, the Certification paper(s).
(They are always in 3 or 4 pages) not reproduced in this slides
Example 2 of Marking and Certification
This example is intentionally from an ancient piece of equipment anterior at ATEX 95
Directive but applying the Cenelec / IEC standards for Certification.
Same about the papers
Who issues the Certificate of Conformity?
The certificates of conformity according to ATEX are issued by organisations which are
recognised by all the Member States of the European Union.
See list on the main course
What does this mean for the manufacturer?

Obtaining the certificate:
- gives proof of the conformity of equipment with the Certificate standards;
- authorises the manufacturer to issue a copy of the Certificate;
- gives the testing authorities delivering the certificate free access to the manufacturer's
production units.
The marking of a certified product must specify:
- the name of the manufacturer or his registered trademark;
- the description of the manufacturer's product;
- its identification by means of the code (eg : Ex d IIC T4);
- the name or logo of the testing authority;
- the reference to the type examination certificate according to ATEX 94/9/EC and/or
the IECEX number for an IEC certification.
What are the obligations of the person installing the equipment?
He must select electrical apparatus certified for use in explosive atmospheres under
specific conditions.
He must install them according to each zone defined by the user.
What are the obligations of the user?

He is responsible for using certified equipment in hazardous areas.
He must carry out regular maintenance work and ensure the safety of the installation
and staff.
Marking Examples
ATEX 95 Standard
Cenelec (old) Standard
Marking Examples
INSTALLATION - MAINTENANCE OPERATION
Installation Maintenance - Operation

Installation in Zone 1 - Equipotential bonding
Full equipotential bonding is achieved by connecting not only the housings of the
electrical equipment into the equipotential bonding, but also all other accessible,
conductive structural parts such as building construction, metal containers, piping etc.
The connections for equipotential bonding must be reliable, e.g. using

secured screw terminals.

Installation in Zone 1 - Cables and conductors
As per Standards
Intrinsically-safe equipment in Zone 1

Selection of equipment: only intrinsically-safe equipment of category 1G or 2G with
protection level "ia" or "ib" may be used
Note: associated electrical equipment with type of protection "Intrinsic safety" must be
positioned outside the hazardous area.
Requirements of cables and conductors: Cables and conductors in intrinsically-safe
circuits must always be insulated and withstand a test voltage of at least 500 V AC
between conductors and between a conductor and ground - Cables and conductors of
intrinsically-safe circuits must be marked, e.g. by means of a light blue cable sheath
Routing of IS cables

Zone 1 - The IS cables - Intrinsic safety mainly for instrument cables
Dielectric tests must be performed, by the manufacturer, on cables in accordance with
EN 50020
Use types (A, B, C or D) in accordance with EN 50020
The cable length must be such that the values of L and C stated in certificate SYS
are not exceeded
There are specific calculations of L (reactance) and C (capacitance) for instrument
cables (See course EXP-MN-SI160)
Cables and wiring of IS circuits shall be identified by marking or by bright blue colour
code
All IS wiring shall be kept separate from N-IS wiring (use different cable trays)
All IS cables and terminals shall be kept separate from NIS cables and terminals (at
least 50 mm for terminals and 8 mm for cables)
In enclosures containing different IS circuits, the terminals of each circuit shall be at
least 6 mm from the others or be separated by insulating or grounded metal partitions

Zone 1 - For diodes barriers
the ground path must have less than 1 ohm resistance from the farthest barrier to the IS
grounding electrode
all ground path connections must be secure, permanent, visible and accessible for
routine inspection

Zone 1 - Proof of intrinsic safety
Proof of the intrinsic safety of a circuit is that the electrical characteristic data on the
type test certificate or in the operating instructions of the equipment are observed.
Protection concept in zone 1 (remind)

For Cenelec / IEC ATEX 95 and NEC 505 (Zone 1 Category 2)
Apparatus with standardised type of protection: ib, d, e, p, m, o, q
Apparatus will need certification
For NEC 500 - Class 1 div 1:

Apparatus with type of protection: ia, d, p (type X or Y) or Intrinsic Safety Explosion proof
Pressurised (type X or Y) as letters are not recognised in NEC 500

Installation in Zone 0 - Protection concept in zone 0
IS apparatus of ia category

Apparatus with type of protection: ia, d, p (type X or Y) or Intrinsic Safety Explosion proof
Pressurised (type X or Y) as letters are not recognised in NEC 500
Installation in Zone 2 - Protection concept in zone 2

All equipment certified for zones 0 and 1
Apparatus with type of protection "n

Apparatus incapable of creating sparks or hot surfaces capable of ignition
Equipment with type of protection: m, o , n, p (type Z) or hermetically sealed oil immersion non incendive / sparking - pressurised (type Z)

Installation in Zones 20, 21, 22
All equipment for Zone 20 must be specially approved for this use. The equipment must
correspond to category 1D. (with marking)
The equipment for Zone 21 must correspond to category 2D or 1D. Such marking
must appear on the apparatus
The equipment for Zone 22 must correspond to category 3D, 2D or 1D.
Cabling in H.A. Main general rules all zones

Protect grounding conductors against corrosion and mechanical hazards (this to avoid
sparks with loosed connections)
Ground metallic structures, to avoid sparks
Use cables with Un >= 1 000 V (NF C 15100) in LV power distribution
Add 15 % to standardised section of cables (table 52 D NF C 15100)
Protect cables from mechanical hazards (cable tray, metallic armour or rigid conduit)
Outer sheath must be resistant to chemicals and non flame propagating (category C2
NF C 32070 / IEC 332)
Power cable tape steels (armour) should be earthed at both ends
Bare cables are forbidden in HA

Cabling in H.A. Main general rules all zones (cont)
Conduit or other trunking containing wiring shall be installed in such a manner that the
flammable atmosphere can not be transmitted from a HA to a NHA (use of sealing fittings
is mandatory)
Cable systems: Only cable glands which have been specially certified for this
purpose (d or e) may be used for this type of entry.

Terms Operation and Maintenance
responsibility of the user
the user must carry out maintenance and repairs as necessary without delay
Faults
It must be reported by the user to the supervisory authority (and manufacturer)
Repairs
It is prohibited, to work on live electrical equipment in hazardous areas. Working
on intrinsically-safe circuits is an exception
Works recommendations - worker's skills

Unfamiliarity with the recognised general principles and regulations for installation (in
Hazardous Areas) may cause a potential explosion risk.

Personnel qualification and work carried out in explosion risk zones
(C18510)
no work can be earned out on live equipment, including the replacement of a bulb
or a fuse, and even in extra low voltage installations, without measures being taken to
avoid the risk of explosion.
continuously monitor the atmosphere
continuous ventilation with atmospheric monitoring,
The inspection and maintenance of equipment should only be carried out by
experienced personnel, having received appropriate training
Personnel must be kept informed and up to date through periodical training
sessions.
Authorised operation
work must not be carried out on live equipment, (as first rule)
if this is impossible, a permission to work in an explosive atmosphere should be
awarded which removes any risk.
Work may be carried out on intrinsic safety circuits when the equipment is live.
However, any work carried out on the electrical parts of an installation other that the
connection box and connection terminals that requires their opening, must only he
carried out after checking that there is no explosion danger

Maintenance and safety regulations for "d" explosion proof material
Explosion-proof seals must be in good condition. These seals must not be painted,
All the nuts and bolts must be correctly fitted to these casings.
The casing must not be modified in any way
Specifications relating to what may be contained within the casing must be respected
Casings must not be opened when the power is on, if an explosion risk is present
Cable glands must be correctly fitted
All flameproof joints (flat joint, cylindrical joint threaded joint) must be in a visibly
flawless condition
Rusted joints may not be cleaned using abrasive materials or wire brushes, but only
using chemical means, e.g. with reducing oils.

Maintenance and safety regulations for "d" explosion proof material (cont...)
cable glands used must be suitable for the particular type of protection of the enclosure
(explosion groups IIA, IIB, IIC)
seal inside the gland must be in good condition
All unused openings in the flameproof enclosure must be closed by approved
sealing plugs. The common thread between enclosure and sealing plug forms a
flameproof screwed joint, just as in a gland.
Inspection windows: no scratches, no moisture on the surface
Earth connection: The condition of the external connector of the potential equalisation
cable must be checked for metal enclosures.
Moisture: Dirt and moisture in the interior of the flameproof enclosure must be carefully
removed. If enclosure gaskets show signs of damage, these should be immediately
replaced.

Maintenance and safety regulations for "e" increased safety material
Principle of e:
No arc, no hot point on the casing and secured terminals
The e equipment is only safe when the following requirements are respected:
use of high quality insulation material
use of reliable connections
application of maximum temperature limitations
high index of protection for the casing
compliance with minimum distance for leak lines* and distances in air**
* Leak lines: It is the shortest distance between two conductive elements measured
along the surface of the insulating parts. (or minimum distance required between two
conductors embedded in an insulation material and according to Voltage)

Maintenance and safety regulations for "e" increased safety material (Cont...)
** Distance in air: In order not to trigger an explosion by ionising the air between two
components at different voltages, the minimum distances to be respected are as follows
Maximum temperature: Both for normal heating conditions and in the event of an
expected overload, the maximum allowable temperature for the insulation must not be
exceeded.
Casing:
IP 54 if they contain live, bare elements and special breaking devices
IP 44 if there are no live, bare pieces, and, if making or breaking requires a tool
This casing should only be used with certified elements (indicated by their labelling)
and manufacturer's recommended parts;
Entries / Cable gland: "labelled" cable glands should be used (showing Ex e)
CONCLUSION
99 -EXP-MN-SE190-EN
EXP-MN-SE190-EN- Hazardous
Slides Hazardous
Areas Materials
Areas
Conclusion
What you have learnt in this course:
Introduction to Hazardous Areas
Definition of Hazardous Areas
Standards in Hazardous Areas
Zone Delimitations
Hazardous Areas Classifications
Installation, Maintenance and Operation

Hazardous Areas Materials

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Hazardous Areas Materials

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ELECTRICAL MAINTENANCE

HAZARDOUS AREAS MATERIALS

EXP-MN-SE190-EN - Hazardous Areas Materials

In this course you are going to learn :

3 - EXP-MN-SE190-EN Slides Hazardous Areas

4 EXP-MN-SE190-EN - Hazardous Areas Materials

5 EXP-MN-SE190-EN - Hazardous Areas Materials

E: Certified to the Cenelec Standard

Old USA NEC 500 ref : Cl 1 Div 1 Gr B T4 or Class 1 Division 1

Class 1: classification of Hazardous Area, class 1 = gas

6 EXP-MN-SE190-EN - Hazardous Areas Materials

CE: or EC for European Community

New marking USA - NEC 500: Class 1 Zone 1 AEx d IIC T4

Class 1: classification of Hazardous Area, class 1 = gas (same as NEC 500)

7 EXP-MN-SE190-EN - Hazardous Areas Materials

DEFINITION HAZARDOUS AREAS

8 - EXP-MN-SE190-EN Slides Hazardous Areas

Definition Hazardous Areas

9 EXP-MN-SE190-EN - Hazardous Areas Materials

Definition Hazardous Areas

10 EXP-MN-SE190-EN - Hazardous Areas Materials

Definition Hazardous Areas

LEL: Concentration in air of flammable well defined gas, vapours or

Definition Hazardous Areas

Auto-ignition temperature (AIT)

12 EXP-MN-SE190-EN - Hazardous Areas Materials

Definition Hazardous Areas

13 EXP-MN-SE190-EN - Hazardous Areas Materials

Definition Hazardous Areas

14 EXP-MN-SE190-EN - Hazardous Areas Materials

Definition Hazardous Areas

15 EXP-MN-SE190-EN - Hazardous Areas Materials

STANDARDS HAZARDOUS AREAS

16 - EXP-MN-SE190-EN Slides Hazardous Areas

Standards for Hazardous Areas

17 EXP-MN-SE190-EN - Hazardous Areas Materials

Standards for Hazardous Areas

18 EXP-MN-SE190-EN - Hazardous Areas Materials

Standards for Hazardous Areas

European International Standards IEC

19 EXP-MN-SE190-EN - Hazardous Areas Materials

Standards for Hazardous Areas

New 505 having adopted

20 EXP-MN-SE190-EN - Hazardous Areas Materials

21 - EXP-MN-SE190-EN Slides Hazardous Areas

22 EXP-MN-SE190-EN - Hazardous Areas Materials

23 EXP-MN-SE190-EN - Hazardous Areas Materials

Discuss / detail those 3

Protection provided by using inert gases

25 EXP-MN-SE190-EN - Hazardous Areas Materials

Protection provided by a pressure reduction

Protection provided by pressurisation

27 EXP-MN-SE190-EN - Hazardous Areas Materials

29 EXP-MN-SE190-EN - Hazardous Areas Materials

30 EXP-MN-SE190-EN - Hazardous Areas Materials

31 EXP-MN-SE190-EN - Hazardous Areas Materials

32 EXP-MN-SE190-EN - Hazardous Areas Materials

33 EXP-MN-SE190-EN - Hazardous Areas Materials

34 EXP-MN-SE190-EN - Hazardous Areas Materials

35 - EXP-MN-SE190-EN Slides Hazardous Areas

36 EXP-MN-SE190-EN - Hazardous Areas Materials

37 EXP-MN-SE190-EN - Hazardous Areas Materials

38 EXP-MN-SE190-EN - Hazardous Areas Materials

39 EXP-MN-SE190-EN - Hazardous Areas Materials