A guide to the use of electrical equipment in potentially

explosive atmospheres
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Introduction

Potentially Explosive Atmospheres exist where there is a risk of explosion due to

mixtures of gas/air, vapour/air, dust/air or other flammable combinations.

In such areas there is a necessity to eliminate sources of ignition such as sparks,

hot surfaces or static electricity which may ignite these mixtures.

Where electrical equipment has to be used in these areas it must be so designed

and constructed as to not create sources of ignition capable of igniting these
mixtures.

Before electrical equipment can be used in a potentially explosive atmosphere a

representative sample has to be fully tested and certified by an independent
authority such as BASEEFA in the U.K. or UL in the U.S.A.

This information is intended as a guide only and further expert guidance should
be sought before placing into service, maintaining or repairing any item of
equipment in a Potentially Explosive Atmosphere.

Where comparisons are shown between, for example, European and North
American practice this may be an approximation and individual standards/codes
of practice should be consulted for precise details.

MEDC have spent 25 years designing and manufacturing electrical equipment

suitable for use in potentially explosive atmospheres. We deal with all the major
testing and certification authorities throughout the world and have a diverse
range of internationally approved products.

Area Classification

Process plants are divided into Zones (European and IEC method) or Divisions
(North American method) according to the likelihood of a potentially explosive
atmosphere being present.

European & IEC Definition of zone or division North American

Classification Classification
An area in which an explosive mixture is Class I Division 1
Zone 0 (gases)
continuously present or present for long (gases)
 periods Class II Division 1
Zone 20 (dusts)
(dusts)
An area in which an explosive mixture is Class I Division 1
Zone 1 (gases)
likely to occur in normal operation (gases)
Class II Division 1
Zone 21 (dusts)
(dusts)
An area in which an explosive mixture is Class I Division 2
Zone 2 (gases)
not likely to occur in normal operation (gases)
and if it occurs it will exist only for a short Class II Division 2
Zone 22 (dusts) time (dusts)
Class III Division 1
(fibres)
Class III Division 2
(fibres)

Gas Groups (plus dusts and fibres)

There are two main gas groups, Group I – Mining only and Group II – Surface
Industries
These categories are used in European and I.E.C. groupings.
Group I is concerned only with underground mining where methane and coal
dust are present.
Group II gases occurring in surface industries, are sub-grouped according to
their volatility. This enables electrical equipment to be designed to less onerous
tolerances if it is to be used with the least volatile gases.

Typical European/I.E.C. Gas North American Gas

gas/material Group Group
Methane I -
Acetylene IIC A
Hydrogen IIC B
Ethylene IIB C
Propane IIA D
Metal dust - E
Coal dust - F
Grain dust - G

Note : North American legislation now allows Zones to be used to classify areas,
where this practice is used it follows the IEC Zone method.

Temperature

Hot surfaces can ignite explosive atmospheres. To guard against this all Electrical
Equipment intended for use in a potentially explosive atmosphere is classified
according to the maximum surface temperature it will reach in service. This
temperature is normally based on a surrounding ambient temperature of 40
degrees Centigrade (102 degrees Fahrenheit). This temperature can then be
compared to the ignition temperature of the gas(es) which may come into contact
with the equipment and a judgement reached as to the suitability of the
equipment to be used in that area.
Many MEDC products are certified for use in ambient temperatures up to 55
degrees Centigrade, see individual data sheets for details.

Temperature Classification Maximum Surface Temperature

European/I.E.C. North American
T1 T1 450° C
T2 T2 300° C
T2A 280° C
. T2B 260° C
T2C 230° C
. T2D 215° C
T3 T3 200° C
. T3A 180° C
T3B 165° C
. T3C 160° C
T4 T4 135° C
. T4A 120° C
T5 T5 100° C
T6 T6 85° C

e.g. Butane has an ignition temperature of 365 degrees Centigrade, equipment

used in the vicinity of this gas would need a T rating of T2 or higher.

Types of Electrical Equipment Suitable for

use in Potentially Explosive Atmospheres

Different techniques are used to prevent electrical equipment from igniting

explosive atmospheres. There are restrictions on where these different types of
equipment can be used as follows :

European - IEC - Area USA - Area of use

Area of use of use Designation
. Designation Designation Standard
Standard Standard
Flameproof Enclosure – An Zones 1 & 2 Zones 1 & 2 Class 1 Divisions 1
enclosure used to house EExd Exd &2
electrical equipment, which EN50018 IEC60079-1 UL1203
when subjected to an internal
explosion will not ignite a
surrounding explosive
atmosphere.
Intrinsic Safety – A Zones 0, 1 & 2 Zones 1 & 2 Class 1
technique whereby electrical EExi Exi Divisions 1 & 2
energy is limited such that any EN50020 IEC60079-11 UL913
sparks or heat generated by
electrical equipment is
sufficiently low as to not ignite
an explosive atmosphere.
Increased Safety – This Zones 1 & 2 Zones 1 & 2
equipment is so designed as to EExe Exe
eliminate sparks and hot EN50019 IEC60079-7
surfaces capable of igniting an
explosive atmosphere.
Purged and Pressurised – Zones 1 & 2 Zones 1 & 2 Class 1
Electrical equipment is housed EExp Exp Divisions 1 & 2
in an enclosure which is initially EN50016 IEC60079-2 NFPA496
purged to remove any
explosive mixture, then
pressurised to prevent ingress
of the surrounding atmosphere
prior to energisation.
Encapsulation – A method of Zones 1 & 2 Zones 1 & 2
exclusion of the explosive EExm Exm
atmosphere by fully EN50028 IEC60079-18
encapsulating the electrical
components in an approved
material.
Oil Immersion – The Zones 1 & 2 Zones 1 & 2 Class 1
electrical components are EExo Exo Division 2
immersed in oil, thus excluding EN50015 IEC60079-6 UL698
the explosive atmosphere from
any sparks or hot surfaces.
Powder Filling – Equipment is Zones 1 & 2 Zones 1 & 2
surrounded with a fine powder, EExq Exq
such as quartz, which does not EN50017 IEC60079-5
allow the surrounding
atmosphere to come into
contact with any sparks or hot
surfaces.
Non-sparking – Sparking Zone 2 Zone 2 .
contacts are sealed against EExn Exn
ingress of the surrounding EN50021 IEC60079-15
atmosphere, hot surfaces are
eliminated.
Special Protection – Zones 0, 1 & 2 Zones 0, 1 &
Equipment is certified for use *Exs 2
in a Potentially Explosive Exs
Atmosphere but does not
conform to a type of protection
listed above.

* This type of protection is only recognised by National Authorities, not as a

European-wide type of protection.

Selection, Installation and Maintenance of Electrical

Equipment Intended for use in Potentially Explosive
Atmospheres

International and national standards are published giving details of requirements

for the safe use of Electrical Equipment in Potentially Explosive Atmospheres as
follows :
 . International U.K. U.S.A.
General Recommendations BS5345:Part N.E.C. Chapter
EC60079-14
1 5
Classification of Hazardous Areas N.E.C. Chapter
IEC60079-10 .
5
Inspection and Maintenance of
IEC60079-1
Electrical Equipment
Requirements for Flameproof BS5345:Part N.E.C. Chapter
IEC60079-14
Enclosures 3 5
Requirements for Intrinsically BS5345:Part N.E.C. Chapter
IEC60079-14
Safe Equipment 4 5
Requirements for Increased BS5345:Part N.E.C. Chapter
IEC60079-14
Safety Equipment 6 5
Requirements for Purged and BS5345:Part N.E.C. Chapter
IEC60079-14
Pressurised Equipment 5 5
Requirements for Non-Sparking BS5345:Part
IEC60079-14 .
Equipment 7
Requirements for Equipment BS5345:Part
IEC60079-14
with Special Protection 8

MEDC advise that all Explosion-proof electrical equipment is maintained, by

suitably trained personnel, in accordance with the Manufacturers'
recommendations.

Any spare parts used should be purchased from the original Manufacturer and
repairs should be carried out by the Manufacturer or under his supervision, in
order that the item remains in conformance with the certification documents.

The Certification Process

All Electrical Equipment, intended for use in a Potentially Explosive Atmosphere,

should be certified as suitable for such use.

The methods of obtaining certification differ in detail, see below, between each
certifying body or group of bodies (e.g. CENELEC). Basically this process consists
of supplying a representative sample of the equipment along with a set of
drawings to a recognised test/certification body e.g. BASEEFA who in turn test
the equipment against a recognised Standard e.g. EN50018 and issue a
Certificate. The user of the equipment can then refer to this Certificate to enable
him to safely put the item into service in a zone appropriate to the Certification.

European Practice – after 1st July 2003

After the above date the ATEX Directive comes into force throughout the EEC.
This becomes a mandatory requirement for all equipment intended for use in a
hazardous area. The fundamental difference between current practice and ATEX
certification is that ATEX addresses the essential safety requirements for
hazardous area equipment and uses Standards as part of the method of
conforming to these. Amongst other documentation required by certifying
authorities will be Technical Manuals in order that the user is informed of
installation methods etc.

ALL EQUIPMENT, BOTH ELECTRICAL AND MECHANICAL, INTENDED TO BE

PUT INTO SERVICE WITHIN THE EEC AFTER 1ST July 2003, WILL HAVE
TO HAVE BEEN CERTIFIED IN ACCORDANCE WITH THE ATEX DIRECTIVE.

In practice this means re-certification of all currently certified electrical

equipment.

MEDC have started this process and all relevant equipment will be covered by the
implementation date of 1st July 2003.

It should be noted also that MECHANICAL equipment is covered by the ATEX

Directive so for the first time items such as gearboxes will have to carry ATEX
certification.

The equipment coding will be as the current practice plus an additional code as
follows:

ExII2G i.e.

Ex – Explosion proof in accordance with ATEX.

II – Group II surface industries.

2 – category 2 equipment (suitable

.....for use in Zone 1) note: Category 1 is suitable for Zone 0.
Category 3 is suitable for Zone 2.

G – suitable for atmospheres containing gas ( D is suitable for atmospheres

containing dusts).

Equipment will be CE marked when certified to ATEX.

European Practice – Current – until 30th June 2003

The method is basically as above. In addition all electrical equipment intended for
use in the European Economic Community (EEC) must comply with
Electromagnetic Compatibility regulations (EMC) and manufacturers must issue,
on request, an EC Declaration of Conformity in accordance with the EMC
regulations.

When certified, an item of equipment and its' certificate, carry a code e.g.
EExdIIBT4. This can be broken down as follows:

E – European certificate in accordance with harmonised standards

Ex – Explosion-proof electrical equipment

d – flameproof enclosure type of protection

II – Group II surface industries

B – gas group B

T4 – temperature class T4 (135 degrees centigrade surface temperature).

North American Practice

Sample equipment and supporting documentation are submitted to the

appropriate authority e.g. .U.L., F.M., C.S.A.

The equipment is tested in accordance with relevant standards for explosion

protection and also for general electrical requirements e.g. light fittings.

After successful testing a listing is issued allowing the manufacturer to place the
product on the market.

The product is marked with the certification details such as the gas groups
A,B,C,D the area of use e.g. Class 1 Division 1

World-wide Certification

Most countries outside Europe or North America use the IEC Standards as a basis
for their own national standards.

The Russian Federation certifies equipment to GOST standards, these closely

follow CENELEC practice.

There is a scheme in place which will when fully adopted allow for internationally
recognised certification to become a reality, this is the IEC EX SCHEME. This uses
the IEC standards and IEC recognised test and certification bodies to issue
mutually recognised test reports and certificates. The scheme is in its infancy and
its level of success cannot yet be measured.

Ingress Protection

2 digits are used to denote the level of ingress protection that a piece of
apparatus enjoys :–
(The first digit denotes the level of protection against solid objects and the second
against liquids)

. Solids . Liquids
0 No protection. 0 No protection.

1 Protected against solid objects 1 Protected against vertically falling

up to 50mm, e.g. hands. drops of water.
2 Protected against solid objects 2 Protected against water spray up
up to 12mm, e.g. fingers. to 15 degrees from vertical.
3 Protected against solid objects 3 Protected against water spray up to
up to 2.5mm, e.g. tools. 60 degrees from vertical.
4 Protected against solid objects 4 Protected against water sprays from
over 1mm, e.g. wires. all directions.
5 Protected against dusts. 5 Protected against water jets from
 (No harmful deposits). all directions.
6 Totally protected against dust. 6 Protected against strong water jets
from all directions, e.g. Offshore.
7 Protected against immersion between
. . 15cm and 1m in depth.
8 Protected against long immersion
under pressure.

North American practice is to use NEMA standards to describe ingress protection,

i.e.:

NEMA 3 is similar to IP 54
NEMA 4 is similar to IP 55
NEMA 4x is similar to IP 56
NEMA 6 is similar to IP 67