Ex Basic Toolbox Guide
Ex Basic Toolbox Guide
Ex Basic Toolbox Guide
TOOLBOX GUIDE
NO PART OF THIS TOOLBOX GUIDE MAY BE COPIED OR REPRODUCED IN ANY FORMAT WHATSOEVER. THIS
INCLUDES PHOTOCOPYING, SCANNING AND ELECTRONIC STORAGE
2.0 ZONES
Source of release
Grade of release
Zones
3.0 EX Equipment
Equipment Groups
Gas groups
Temperature classification
Glands
Cables
Earthing
5.0 INSPECTION
Grade of inspection
Type of inspection
6.0 STANDARDS
European ATEX Directives
IEC International standards
American NEC standards
1.0 BASIC INFORMATION
COMPETENCY.
Technicians need to be competent to work in hazardous areas and one way of proving competence is to
attend a hazardous area training programme.
PERMITS.
A permit to work is required before any work is carried out in a hazardous area. Different companies
operate different systems and training must be provided by the employer.
SAFE ISOLATION
Company policy must be followed to ensure equipment is to be worked on is not “LIVE” There is one
exception to this rule and that is where I.S. intrinsically safe circuits may be worked on live. Always seek
advice.
TOOLS
All tools must be good condition, free from defects and suitable for use in a hazardous area.
PROHIBITED ITEMS
The following are not permitted in a hazardous area:
• cigarette lighters
• matches
• anything with a battery in it, for example mobile phones, radios, personal CD / MP3
players, car key-rings with central locking remote controls
• electrical test meters unless intrinsically safe or certified and suitable for the area
classification
• torches, unless intrinsically safe or certified and suitable for the area classification
• PPE, including boots and coveralls, which could give rise to static
HOT WORK
Hot work including welding, burning, drilling, grinding etc. should only be carried out safely under the
permit to work system.
ENVIRONMENTAL CONDITIONS
Electrical equipment can be affected by environmental conditions such as:
• corrosion
• ambient temperature
• water ingress
• vibration
• exposure to chemicals
INGRESS PROTECTION
IP 66 is required for offshore installations. The first number 6 refers to the ingress of matter or particles of
dust or dirt and is complete protection against the ingress of dust. (Dust Tight) The second 6 refers to the
ingress of liquids and is protection against powerful water jets and conditions on ships decks in heavy seas
This is the IP Table
EXPLOSIVE LIMITS
Explosive limits are the upper and lower percentages of gas in air which will burn if ignited.
Lower explosive limit (LEL) is the concentration of gas in air below which the mixture is not explosive.
Upper explosive limit (UEL) is the concentration of gas in air above which the mixture is not explosive.
Between the LEL and UEL the mixture will burn and is explosive.
Flash point is the lowest temperature a liquid will give off a vapour that can form an explosive atmosphere.
Ignition temperature (auto ignition temperature) is the lowest temperature at which a material will ignite
and burn.
2.0 ZONES
Where flammable gases may be present the area must be zoned and shown on hazardous area classification
drawings. The basics for establishing zones are to identify the source of release of the flammable gas,
vapour or mist and then to determine the grade of release.
The source of release is the point from which a flammable gas, vapour or mist can be released into the
atmosphere and the grade of release is the expected possibility it may occur.
ZONE 1 is a place where an explosive atmosphere in the form of gas, vapour or mist is expected to occur in
normal operation
ZONE 2 is a place where an explosive atmosphere in the form of gas, vapour or mist is not expected to
occur in normal operation but if it does will not last for long.
3.0 EX EQUIPMENT
Group I equipment is designed for use in underground mines where methane is present and does not
concern us.
Group II equipment is designed for use above ground so all electrical equipment data plates on offshore
installations will always include the mark II.
GAS GROUPS
Group II equipment is further divided into 3 gas groups IIA, IIB and IIC
TEMPERATURE CLASSIFICATION
Temperature classification is based on the maximum surface temperature that can be reached by any part of
the equipment that could ignite an explosive atmosphere. The temperature class of the equipment must
always be below the ignition temperature of the gas.
Temperature class of Maximum surface
apparatus temperature of
apparatus ˚C
T1 450
T2 300
T3 200
T4 135
T5 100
T6 85
ARCING Making or breaking of switches, loose contacts and broken wires can all produce
arcing
SPARKING Usually associated with rotating equipment such as motors and generators.
HOT SURFACES Motors, transformers and solenoid valves
b) Gas group
c) Temperature classification
GLANDS
Glands may be certified Exe, Exd or dual certified Exde which is suitable for both Exe and Exd. Glands are
usually brass but can also be nickel and chromium but never aluminium.
Where a deluge seal is included on the gland make sure it is replaced over the gland joint after glanding the
cable. Avoid placing any strain on the cable when glanding and finishing off.
GLAND MARKINGS
W single wire armour
Y aluminium strip armour (not suitable for hazardous areas)
Z tape armour
X braided armour
A outer seal
B armour lock
C equals A + B
D inner seal and armour lock
E inner seal, outer seal and armour lock
BARR inner barrier seal, outer seal and armour lock
CABLES
All cables must be fitted with circuit identifications. This is to enable safe and effective isolation of the
equipment when work is to be carried out.
The connection of cables and conduits to the electrical equipment must be made in accordance with the
type of protection. Care should be taken that there is no armour visable outside the body of the gland. This
is to ensure ingress protection is maintained by clamping the outer seal of the gland to the outer insulation
of the cable. Where armour is showing the cable must be reglanded
TERMINATING CABLES
Crimped terminations should be used as they provide a good connection and there is less risk of loose
strands of wire causing short circuits. They are also easy to remove and insert. Hand ratchet type crimping
tool must be used to fit crimps and not the simple plier type which often result in bad connections coming
loose.
CABLE MATERIALS
Copper conductors may be used in any size required. Aluminium conductors are NOT permitted unless
their cross sectional area is greater than 16mm.
CABLE ARMOUR
Galvanised steel wire armour is acceptable for use with mulit core cables
Braided armour may be used but if it is aluminium braiding, exposed braiding must be avoided to prevent
sparking with rusty or corroded steel.
JOINTING
Cable runs in hazardous areas should not be jointed whenever possible. Where this is unavoidable, joints
must be made in a certified junction box that is suitable for the zone.
UNUSED CORES
In multi-core cables, the hazardous area end of each unused core shall either be connected to earth or be
terminating in spare or unused terminals. Insulation by tape alone is not recommended.
CONDUIT SYSTEMS
For added protection from mechanical damage, cables may be run in heavy gauge steel conduit.
Conduits must be fitted with stopper boxes where it enters or leaves a hazardous area and where it enters
flameproof Exd equipment. When conduit contains three or more cables, the total cross-sectional area of
the cables shall be not more than 40 % of the cross-sectional area of the conduit. This is to prevent
bunching and overheating.
EARTHING
Earthing on offshore installations refers to an electrically continuous path from a conducting body to the
main earth point of the power supply.
BONDING
Bonding is different and refers to the electrical connection between exposed conductive parts (metal parts
of equipment which could become live in the event of a fault)
PROTECTIVE CONDUCTORS
A protective conductor is the main earth conductor from a piece of electrical apparatus in the field back to
the main earth at the power supply.
These are the recommended minimum earth conductor sizes according to IEC
Up to and including 6mm² Same as phase conductor but not less than
2.5mm² if protected otherwise 4mm²
16mm² – 35mm² 16mm²
Over 35mm² 0.5 X phase conductor size
A type of protection where the enclosure can withstand the effects of an internal explosion without damage.
It will also prevent the explosion passing outside and igniting an explosive atmosphere that may be present.
PRESSURE PILING
Pressure Piling in an Exd enclosure is a result of the ignition of compressed gas. This happens when you
have two enclosures joined together by conduit and an explosion takes place in one of the enclosures and
the explosion is forced into the other enclosure. This can increase the size of any explosion.
STOP-ENDS
Sealing plugs or stop-ends for un-used cable entries must be certified Exd
GASKETS
Must be approved by the manufacturer and made from metallic of non-flammable material. Removing
gaskets or changing them for home-made types will invalidate the certificate of conformance.
USE OF TAPE
Non-hardening textile tape such as DENSO may be used to protect joints, gaps and flanges from water and
the weather. This is permitted when the equipment is gas group IIA. When the equipment is IIB advice
must be sought from the manufacturer. When the equipment is IIC and the area classification is IIC tape is
not permitted but if the area classification is IIA or IIB it is allowed.
USE OF PAINT
Flamepaths must never be painted before assembly. It is allowed to paint gaps and joints after assembly.
Aluminium paint must never be used.
USE OF GREASE
Flamepaths can be protected from corrosion by use of non-hardening grease. Silicon based grease is
permitted but not on gas detectors! Grease may also be used on threads and exposed screws and bolts to
protect from corrosion.
GLANDS
Glands must be Exd or Exde. There is one occasion where the cable may be indirect entry and the terminal
box is Exe, then the gland could be Exe, Exd or Exde.
Where the equipment is associated apparatus and is Exd(i) the gland must still be Exd or Exde as above.
A type of protection where additional measures are applied in the construction, to give increased safety
against high temperatures and arcs and sparks.
Exe equipment has strict rules for installation that must be followed. These will be stated on the certificate
of conformity and in the manufacturer’s instructions and could include:
These rules must be strictly followed as they could be vital to the type of protection.
INGRESS PROTECTION
This is the protection against the ingress of water, dust and dirt. The minimum IP rating for offshore is
IP66. To meet the ingress protection requirement on Exe equipment, an IP washer must be fitted between
the gland and the body of the enclosure. An IP washer is not required in a threaded entry which has more 5
fully engaged threads or more than 6mm of engaged thread
GLANDS
Glands must be Exe or Exd. Stop ends and sealing plugs fitted to unused cable entries must be Exe or Exd
and be fitted with an IP washer unless there is a minimum 6mm engaged threads the same as for the gland.
Where an external earth tag or banjo is fitted it must be fitted after the IP washer. IP washer must be on
first.
TERMINATIONS
More than one conductor is permitted into one terminal if they are the same size and same cross section
area. Two wires of different cross section are not permitted into one terminal.
CABLE INSULATION
Should be maintained right up to the metal of the terminal.
JUNCTION BOXES
The manufacturer’s instructions must be followed for terminal type, size and numbers of terminals,
conductors size and current ratings.
MICC CABLE
For MICC cable (mineral insulated copper conductor) Exe certified pots are required to maintain core
separation.
A type of protection where, in normal operation is not capable of igniting an explosive atmosphere.
nA is for non-sparking
nC is for sparking apparatus in which the contacts have extra type of protection
nR is for restricted breathing
nL is for energy limiting
nZ is for enclosures with pressurization.
A restricted-breathing enclosure is an enclosure that is designed to restrict the entry of gases but not totally
prevent it.
Energy-limited apparatus is where the circuits and components are constructed to limit the energy.
Hermetically sealed is where sparking contacts are kept away from an explosive atmosphere by means of
sealing with either fusion between glass and metal (used on light fittings) soldering, welding or brazing.
Enclosed break is a device with electrical contacts that will withstand an internal explosion without
suffering damage.
Encapsulated is a device that it is totally immersed in a hard compound so that it is sealed to prevent entry
of gas. Electrical connections are usually provided by flying leads.
Energy limiting is where the maximum energy contained within a circuit is restricted so it is not capable of
causing ignition of an explosive atmosphere.
GLANDS
Exn does not require certified glands
IP WASHERS
The same requirements as Exe. Cable entry into an unthreaded holes with Less than 6mm threads required
an IP washer.
A type of protection where a positive pressure is maintained inside an enclosure or room to prevent the
entry of gasses. Pressure is higher inside than outside.
PRESSURISING GAS
Nitrogen may be used or air. If air is used it should be drawn from a non hazardous area free from gasses. If
nitrogen is used there is a danger of asphyxiation or suffocation.
WARNING NOTICES
Should be fitted warning personnel not to leave enclosures or doors open that could result in loss of
pressure.
SPARK ARRESTORS
Outlet ducts should be located in a non hazardous areas but where this is not possible, spark or flame
arrestors must be fitted.
GLANDS
Certified glands are not required but care should be taken that the glands maintain the ingress protection
and are fitted correctly to prevent the loss of pressure.
A type of protection where the energy within a circuit is limited to such low levels that ignition of an
explosive atmosphere is not possible.
SAFETY BARRIERS
There are two types of safety barriers, shunt diode (zener) and galvanic isolated and they are located in the
safe area. Zener barriers prevent any over voltage or over current getting into the hazardous area by
diverting them to earth and blowing fuses.
Galvanic barriers allow transfer of energy and signals without any direct wiring. This is achieved by the use
of two coils the way a transformer opearates.
SIMPLE APPARATUS
This is electrical components of simple construction which are compatible with the intrinsic safety of the
circuit.
The following are considered to be simple apparatus:
• passive components like switches, junction boxes, resistors and simple semiconductor devices
• sources of generated energy, for example thermocouples and photocells, which do not generate
more than 1,5 V, 100 mA and 25 mW
EARTHING OF SCREENS
Screens should be earthed at one end only and usually at the supply end.
GLANDS
Certified glands are not required on Exi equipment. If the equipment is Exd(i) then the enclosure is Exd and
Exd glands are required.
MICC CABLE
If mineral insulated copper conductor cable is used, Exe pots are required to maintain core separation.
MULTICORE CABLES
I.S. and non I.S. circuits must not be run in the same multi-core cable.
I.S. MAINTENANCE
Some work may be carried out with the equipment LIVE. Work on I.S. equipment in hazardous areas
should be limited to adjustment and calibration and taking electrical measurements as long as the test
equipment is certified as I.S. or the area is verified as gas free with a hot work permit.
ENCAPSULATION. Exm
Type of protection where ignition capable parts are enclosed or encased in a hard setting compound so that
an explosive atmosphere cannot be ignited.
Inspection plays a critical part in ensuring safety to personnel, plant and the installation so it is important
that EX equipment is inspected regularly. The international standard for inspections is IEC60079-17. The
Inspection and Maintenance of Electrical Installations in Hazardous Areas.
QUALIFICATION OF PERSONNEL
The inspection of EX equipment should only be carried out by experienced personnel, whose training has
included instruction on the different types of protection and the rules and regulations of area classification.
Continuing education or training must be undertaken by personnel on a regular basis and evidence of
experience and training must be available.
GRADES OF INSPECTION
VISUAL INSPECTION
An inspection carried out without the use of step ladders or tools and used to identify defects which are
clearly visible such as mechanical damage or missing bolts.
CLOSE INSPECTION
A close inspection is an external inspection and does not require the equipment to be opened or isolated.
Used to identify defects such as loose bolts and loose glands and so tools, steps and ladders may be
required.
DETAILED INSPECTION
This is both external and internal inspection and normally requires electrical isolation. It includes all the
close inspection checks and in addition, will identify defects such as loose terminations and water ingress.
TYPES OF INSPECTION
Initial inspection is for new equipment
Periodic inspections are carried at regular intervals or periods
Sample inspections are used when there are a large number of items which are all identical. It is an
inspection of a percentage of the installed equipment and may be visual, close or detailed.
6.0 STANDARDS
Directive 94/9/EC (more commonly known as ATEX 95 or the Manufacturer’s Directive) is intended to
assist the free movement of goods throughout Europe. It does this by removing the need for separate testing
in each country.
Directive 1999/92/EC (more commonly known as ATEX 137 or the Worker Protection Directive) places
the responsibility on employers to identify hazardous areas, zones the areas and only use certified
equipment in zones.
Ex equipment manufactured in Europe will be marked ATEX in the certificate number. For example
04 ATEX 2344.
The IEC 60079 is an international set of standards governing electrical apparatus for explosive gas
atmospheres and is created and regularly updated by the International Electrotechnical Commission (IEC).
The IEC is a world wide organization responsible for setting the standards for electrical installations in
explosive atmospheres.
America does not use zones, they use classes and divisions which are basically the same as zones. There
are three Classes:
America does not use 3 zones. Instead they have 2 divisions. Division 1 and Division 2 usually shown as
DIV 1 and DIV 2. DIV 1 is the same as zone 1 and DIV 2 is the same as zone 2
America has four gas groups, A, B, C and D. The following tables shows the differences compared to IEC.
GAS GROUPS
GROUP A IIC
GROUP B IIC
GROUP C IIB
GROUP D IIA