Hornbill Compex Training Units: EX 01,02,03 & 04.

Industrial Training

CompE
Certification Body (JTL) Candidate
Code of Conduct
Acceptance of Scheme Requirements:
The Candidate must agree to:
Comply with the requirements for certificafion:
Make claims for certification only with respect to the scope for which certificafion has been granted;
Not use the certification in such a manner as to bring the certification body (JTL) into disrepute;
Not make any statement regarding the certification which the certification body (JTL) may consider
misleading or unauthorized;
Discontinue the use of all claims to certification that contains any reference to the certification bod (JTL)
or certification, upon suspension or withdrawal of certification, and to return any certificates issued to the
certification body (JTL):
Not use the certificate in a misleading manner
The processing of personal information and results in accordance with the Data Protection Act
1998.

At the registration stage the Candidates must:-

Provide centre's with evidence of qualifications- original certificates or other means of confirming
qualifications i.e. JIB/SJIB Grading Card.
Provide photographic evidence of identification with either a valid passport, electronic driving license or
JIB/SJIB Grading Card.
Once registered onto the CompEx cOurse, abide by the individual assessment centre's own code of
conduct.

Communication:
Candidates must ensure they contact only the assessment centre they attended for information regarding
results or details of failures
Candidates must NOT under any circumstances contact the certification body (JTL) directly for results or
details of failures.

Appeals, Complaints:
Candidates who believe they have grounds for an appeal against a failure should contact the assessment
centre they attended to implement the appeals procedure, the centre will inform the Certification Body
(JTL) who will investigate, review and make a final judgment on individual resulfs.
Candidates who have a grievance against the assessment centre staff or course should contact the
assessment centre they attended, to implement the assessment centre's own complaints procedure. If a
satisfactory outcome is not achieved then they should contact the Certification Body (JTL) by letter or
email explaining the grievance. The Certification Body (JTL) will then arbitrate on the complaint.
Candidates who have a complaint against the assessment centre should inform the Cerfification Body
(JTL) by letter or email of sucha complaint who will then arbitrate on the complaint against the assessment
centre.

1
 Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Training

CompEX Hazardous Area Training

Why Legislate?
Before effective legislation in hazardous areas the situation was far from ideal:
THE SENGHENYDD PIT (After the Explosion)

eday, etober 14th. 1913. when 434 lives were lost.

Senghenydd Colliery 1913: Gresford Colliery 1934:

434 men/boys killed 266 men/boys killed

These cases are the worse examples of deaths and injuries in British industry, unfortunately
they are by far not the only ones relating to hazardous atmospheres.

2
Hornbil
Industrial Training
Compex Training Units: EX 01,02,03 &04.

Why Competency?
Iflegislation alone could prevent such destruction, working in hazardous areas would be
accident free. Even after effective legislation accidents can happen.

Piper Alpha 1988: Bosley Wood mill Dust Explosion 2015:

4 killed 35 injured
167 men killed

No sector is exempt, from multi nationals to individually owned companies the dangers are
the same.

Why Document?
Correct information is as important as competency, the Piper Alpha disaster was a
combination of poor documentation providing the conditions to cause an explosion,
followed by incompetency in dealing with the situation resulting in far greater loss than the
initial explosion warranted.

General Legislation relevant all workplaces including Hazardous Areas

Health & Safety at Work Act 1974

Control of Substances Hazardous to health -

CoSHH

Electricity at Work Act 1989

Notes:.s.

3
 Hornbill Compex Training Units: EX 01,02,03 & 04.
Industrial Training

STandaras tor HGZardous Area Standards for hazardous areas were developed
CUjoment in response to horific industrial accidents or as
2010
IECEx EN E0079 new industry takes on and develops existing
ENSO014 ECT)
technology. Equipment that was produced to
1990 UK

980
BS 46833 UK an earlier standard may still be suitable for
continued use. Therefor people working on this
CP 003
BS1259 equipment should be aware the standards exist
1940 3S 889 and be able to verify that the equipment is safe
S20 ES229
Ktombill to use. Previous standards: ToolbOx Guide P107-110

ATEX
ATEX directives Toolbox Guide P2

5
ATEX directives are set to remove technical barriers to trade within the European
Community and outlines essential technical and safety requirements with which products
have to comply.
1
ATEX 95
TnADe MANUFACTOUNG-
(original ATEX Directive 94/9/EC, now ATEX Directive 2014/34/EU)
Applies to Equipment and its protective systems for use in potentially
explosive atmospheres.
Applies to both electrical and mechanical equipment

UK regulations which put into effect the Directive are "The Equipment
and Protective Systems Intended for Use in Potentially Explosive
Atmospheres Regulations 1996" reissued 2001.
Introduced into British law and was mandatory by July 2003

USIwCeevumeNT.
ATEX 137 (ATEX Directive 1999/92/EC)
Applies to the Health and Safety of workers when working in potentially
explosive atmospheres.
ATEX 137 lays down minimum requirements for protection of
workers
potentially at risk from explosive atmospheres. The Directive defines
requirements for worker safety and details both employer and employee
requirements.
UK Regulations which put into effect the Directive are "The Dangerous
Substances and Explosive Atmospheres Regulations" (DSEAR 2002)
Introduced into British law and was mandatory by July 2006
Free download available on the HSE website. (DC.LI33) HSE.
ATEX lEC
4
CELTFIED
ASSessD
Hornbill Compex Training Units: EX 01,02,03 &04.
Industrial Training

UK- DSEAR 2002

Apply
DSEAR does
Reg. 3-
Application DSEAR
not apply Where to apply DSEAR
Exemptions: Ships, off shore Oil rigs, Coal Mines, Low pressure
gas (boilers cookers etc.)

Reg. 4-Duties
Employers' duties to his employees and others affected by hazardous area under
their control. Employee competence.

Reg. 5- Risk Assessment

Where a dangerous substance is or is liable to be present at the workplace Zone

The hazardous properties of the substance.

Information contained in any relevant safety data sheet.

A
Work that involves more than one dangerous substance. The risk presented AWARNING
INCOMPATIBLE MATERIALS

by such substances in combination with the work processes and substances rls i cam

nretle
used. Also their possible interactions.

The amount of the substance involved.

The arrangements for the safe handling, storage and transport of System
dangerous substances and of waste containing dangerous substances. maintenanc

Activities, such as maintenance, where there is the potential for a high level
of risk.
Avoid lgnition Sources

The likelihood that an explosive atmosphere will ocur and its

persistence

The likelihood that ignition sources, including electrostatic discharges,

will be present and become active and effective

The scale of the anticipated effects of a fire or an explosion

eiz

5
 HornbilI Compex Training Units: EX 01,02,03 & 04.
Industrial Training

Reg.6-Elimination or reduction of Risk

The reduction of the quantity of dangerous substances to a minimum.

The avoidance or minimising of the release of a dangerous substance.
The control of the release of a dangerous substance at source.
Fueicubes (250 to 900 Litres)
The prevention of the formation of an explosive atmosphere, including

the application of appropriate ventilation.

efice lgton
Ensuring that any release of a dangerous substance which may give oper ame
wEdingAC
22%

rise to risk is suitably collected, safely contained, removed to a safe

place, or otherwise rendered safe, as appropriate. Ompr

The avoidance of ignition sources including electrostatic discharges; YophuiE

iectncy
22%
Hot Sutace
and adverse conditions which could cause harmful physical effects.

The segregation of incompatible dangerous substances.

PROTIO vE EOUE
The segregation of incompatible dangerous substances.
Develop control measures to eliminate or control risks and to mitigate
evGMEEa
effects of any incident
UNAE

Figure 1-Risk Control Hierarchy

Reg.7- Places where explosive atmospheres may occur

Classification of work areas where explosive atmospheres may occur and

avoidance of ignition sources in those areas
Co-assess with COSHH (control of substances hazardous to health)

Reg. 8- Arrangements to deal with accident and emergencies

Procedures prepared, including the provision of appropriate first-aid facilities

and relevant safety drills, which shall be tested at regular intervals.
Information on emergency arrangements, including-
() Details of relevant work hazards and hazard identification
arrangements, and
(i) Specific hazards likely to arise at the time of an accident, incident or emergency.

5
Hornbill
Industrial Training
Compex Training Units: EX 01,02,03 & 04.

Reg.8-Arrangements to deal with accident and emergencies (continued)

Suitable warning and other communication systems are established to

enable an appropriate response, including remedial actions and rescue
operations, to be made immediately when such an event occurs.
Where necessary, before any explosion conditions are reached, visual, or
audible, warnings are given and employees withdrawn.
Where the risk assessment indicates it is necessary, escape facilities are
provided and maintained to ensure that, in the event of danger, employees
(Ca)
can leave endangered places promptly and safely.

Reg. 9-Information, instruction and training

Information, instruction and training CompE

Reg. 10- Identification of hazardous contents of containers and pipes

Ensure that the contents of containers and pipes, together with the nature of
those contents and any associated hazards, are clearly identifiable.

Reg. 11 Duty of co-ordination

Where two or more employers share the same workplace (whether on a

temporary or a permanent basis) where an explosive atmosphere may occur.
The employer responsible for the workplace shall co-ordinate the
implementation of all the measures required by these Regulations to be
taken to protect employees from any risk from the explosive atmosphere.

Notes..**
 Hornbil
Industrial Training
Compex Training Units: EX 01,02,03 & 04.

DSEAR- applied to explosive Atmosphere.

Apply- Risk assess -Substitute - Control- mitigate

MOST HIERARCHY OF CONTROLS

Effective
Eliminate or remove the
Elimination
hazard from the workplace.

Replace with less hazardous

Substitution condition, practice or process.

Engineering Physical change that reduces exposure,

Controls isolates worker from hazard.

Administrative Improvements in the way work is done.

Controls

PPE Protect worker with Personal

Protective Equipment.

LEAST
Effective

Knowledge, Skills and Competencies of:

Responsible persons: responsible for the processes involved in the design,
selection and erection of explosion protected equipment
Operatives: selection and erection (Technicians)
Designers: design and selection

Responsible Persons, Operatives and Designers shall be able to demonstrate their

competency and provide evidence of attaining the knowledge and skill requirements
relevant to the types of protection and/or types of equipment involved
Thecompetency of Responsible Persons, Operatives and Designers shall be verified and
attributed, at intervals relevant to national regulations or standards or user requirements.
Verification shall show sufficient evidence that the person:
Has the necessary skills required for the scope of work;
Can act competently across the specified range of activities; and
Has the relevant knowledge and understanding underpinning competency.

Responsible persons

8
Hornbill
Industrial Training
Compex Training Units: EX 01,02,03 & 04.

general understanding of relevant electrical engineering:

understanding and ability to read and assess engineering drawings
practical understanding of explosion protection principles and
techniqueS;
working knowledge and understanding of relevant Standards in explosion protection;
Basic knowledge of quality assurance, including principles of auditing,
documentation, traceability of measurement and instrument calibration.

Operatives
understanding the general principles of explosion protection;
understanding the general principles of types of protection and
marking;
understanding those aspects of equipment design which affect the
protection concept;
understanding content of certificates and relevant parts of this standard;
familiarity with the particular techniques to be employed in the selection and
TALLATTION
erection of equipment referred to in IEC 60079-14: NS
general understanding Inspection& Maintenance requirements of lEC 60079-17
understanding the additional importance of Permit to Work ALNTËNANCE
systems and safe isolation in relation to Explosion Protection

Designers
detailed knowledge of general principles of explosion protection;
detailed knowledge of general principles of types of protection and
marking;
detailed knowledge of those aspects of equipment design which affect the
protection concept,
detailed knowledge of content of certificates and relevant parts of IEC 60079-14;
understanding of practical skills for the preparation and installation of relevant
concepts of protection;
detailed knowledge of additional importance of Permit to Work systems and safe
isolation in relation to Explosion Protection;
detailed knowledge of particular techniques to be employed in the selection and
erection of equipment referred to in this standard;
general understanding of Inspection and Maintenance requirements of EC 60079-17.
Led-Us
iNO.
NSMdcToN
9
 Hornbill
Industrial Training9
Compex Training Units: EX 01,02,03 &04.
IEC 60079-14/ Annex A/A.3.3 Operatives/technicians (included to remind you we will
assess your competency on dealing with documentation as well as practical skills)

Operatives/technicians shall be able to demonstrate their competency and provide

evidence of attaining the knowledge and skill requirements specified in A.2.2 relevant to
the types of protection and/or types of equipment involved. They shall also be able to
demonstrate their competency with documentary evidence in the:
a) use of documentation in4.2
b) production of reports, e.g. inspection reports, to the user as identified in 4.2;
c) practical skills necessary for the preparation and installation of relevant concepts
of
protection;
d) use and production of installation records as identified in 4.2.

THE FOLLOWING COULD SAVE YOUR LIFE

Before you start work plan your exit route

Plan alternative route should this become blocked

Be aware of the hazards around you

Know how to raise the alarm if something happens

Know where the assembly points are

Know who to report to
Know the position of nearest fire extinguishers
Do not attempt to fight fire if it cannot be controlled
with single fire extinguisher.

Make sure you work safely and do not be a danger to those

around you

Fire Triangle

Oxygen Heat and Fuel make up the fire triangle.

Taking any element away will prevent combustion
FUEL

10
 Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Training
Some properties of flammable liquids

Lower Explosive Limit: LEL >io Ne HWf.

Gasses need to be mixed in the correct amounts to be considered a hazard

LEL:-is the concentration of flammable gas or vapour in the air below which no explosion
will occur

Upper Explosive Limit: UEL

Upper Explosive Limit Too rich,
the concentration of flammable gas or
UEL:- is
(UEL) insufñicient oxygen
vapour in the air above which no explosion wll
Ocur. Flammable range
Combustion will only occur if the flammable
mixture comprising fuel, in the form of a gas or Lower Explosive Limit Too weak,
vapour, and air are within certain limits. (LEL) insuficient fuel

The flammable limits of some materials

LEL UEL
Material % by Volume % by Volume

Propane 9.5
Ethylene 2.7 34
-

Hydrogen 75.6
Acetylene 1.5 100
Diethyl Ether 1.7 36

Paraffin 1.7 |5
Carbon Disulphide 60

PE. AH
16. lIC

11
 Hornbil
Industrial Training
Compex Training Units: EX 01,02,03 & 04.

Flash point VAPOos CHANGe OF STATE Toolbox Guide P10

The fire hazard associated with a flammable liquidis

FLASH POINT
usually based on its flash point. The flash point is the
FLASH POINT-Lowest temperature at which
lowest temperature at which a liquid in an open a liquid gives off enough vapors to form
vessel will give off sufficient concentration of an ignitable mixture with air

vapours to form an ignitable mixture with air.

Many common laboratory chemicals have flash points
below room temperature. Ethyl ether for example has
a flash point of 45° C.

Fahrenheit Boiling
0 8. 120 GASOLINE UEL
Flash Point =-40°F 68 RashPoint= 125°
740 TEMPERATURE
Celsius

gnition temperature TG P10

Once the flammability range has been reached,

the vapourS will ignite at the proper ignition
temperature.
The ignition temperature ofa substance is the
lowest temperature necessary to cause the
vapour-air mixture over the liquid to ignite and
continue to burn in the absence of the heat
Source.
Ifthe vapour-air mixture is confined and there iss
an ignition source, an explosion will result.
The ignition temperature is often misleading
because it is a relatively large number, often in
the hundreds of degrees.

12
Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Training

Ignition temperature

However, it only takes a short duration of contact

with a potential ignition source to reach this 253°C
temperature and ignite a flammable vapour.
For example, a spark contacting a few molecules
200°C
of a flammable vapour can raise the temperature
above the ignition point in only a few thousandths
of a second.
A hot light bulb (120°C) or a Car exhaust (110°C)
can ignite some chemicals. Carbon disulphide, for
example, will ignite at a temperature of 80°PC.

The auto-ignition temperature

The auto ignition Temperature means the same

thing as the ignition temperature. The minimum
temperature required to ignite a gas or vapour in air
without a spark or flame being present

Notes:.s

13
 Hornbill1 Compex Training Units: EX 01,02,03 & 04.
Industrial Training
The auto-ignition temperature for some common fuels:
iGNiTION T
Autoignition Flammability Limits
Substance Flash Point ('C) | Temperature (C)| (vol% at 25°C)
Lower pper

Gamba 30 100 50
Metha
Me -188 630
Ethane -135 515
Propane -104 450
n-Butane /4 370
n-Pentane_ 260
n-Hexane 225
n-Heptane
n-Octane 4 220 0.95
n-Nonane
n-Decane 0.75

Ethano 9 365
ISOpiene 395
Dimethyl sufoxide (DMSO) 300
Petrol
L40
Hydrogen 253 S30
Nerosenee
210
Diesel
Naphina2
LPG

Notes:....

Temperature Classification Co DE Toolbox Guide P7

Temperature classification is based upon the maximum temperature which any relevant
part of the apparatus (which may be in contact with an explosive gas) will reach, when
operating within normal design ratings at an ambient temperature not exceeding 40° C.

14
Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Training
Temperature Code Maximum Surface
Temperature
T1 450 °C
T2 300 °C
T3 200 °C
T4 135 °C

TS 100 °C

T6 85 °C
(nelevaub pa) HOW maANY °T TAÉngs
- C + t+0 amben
20equipment emps .Corles tesed on.
Suitable a T Class EQUAL OR LOWER
must have the ignition temperature than of
the gas

Gas/Apparatus compatibility
Ammonia 630-
Methane 595- 600
Hydrogen 560-
500
Propane 470- T1
Gas Ignition Ethylene 425 Apparatus
400
Butane 3665 Temperature
Temperature Classification
300-
Cyclohexane 259-

Diethyl Ether 170

Carbon Disulphide 105 100-

T4for apparatus is usually OK 13S TAMB40°C

xCeption:
Carbon Disulphide, requiring T5
Don't confuse T Class with maximum operating temperature!
SGocP
Gas Sub-Division Gas Ignition Temp °C

ACETONE 35
AMMONIA 630
BENZENE 555
BUTANE 365
Gas T Class CYCLOHEXANE 260
GASOINE 280
Hexanee HEXANE 240
Hydrogen
Propane
T PROPANE
PARAFIN
ETHYLENE
450
210
IIB 425
Ethylene CYCLOPROPANE
HYDROGEN
495
270
SULPHIDE
HYDROGEN 560
ACETYLENE 305
CARBON- 90
DISULPHIDE

15
 Hornbil Compex Training Units: EX 01,02,03 &04
Industrial Training

GAS GROUPS 90
Defines lgnition Energy
IIC More easily ignited
IIB
IA Less easily ignited

Typical gas Gas Group

Hydrogen IIC
ACETYLENE
Ethylene IB

Propane IIA

PE AEH
IIA IIS

Notes...

16
Hornbill
Industrial Training
Compex Training Units: EX 01,02,03 & 04.
Ignition Energy 1000 2000

JAMES PRESCOTT JOULE

gnition energy of flammable gases is calculated hysics 1818 1889
Thermodynamics
in Proved the conservation
o enere 1st Law of TD
Discovered the mechanical
= Micro Joules. equivalent of heat
Joule-Thomson Effect
the basis of refngeration
The Joule is the standard unit of energy, this can Joule's Law of electricity
be electrical, mechanical or chemical energy. eanmednis
honor
he made
Father ef ThermomaiCS his discoveriesas a hobby
Consenvation of energ, the most basic and unhrsal
making such a vital discovery was goven by God to a man of
From an electrical point of view: sincere Christian faith -DE. Heniy M. Morris

1Watt X1 Second =
1 Joule
A Micro Joule is 0.000,001 of a Joule
60 watts
It is apparent that the amounts of energy we are talking about
6Jouls
porsecond
are extremely small.

Gas Group Representative Gas lgnition Minimum lgnition

Temperature Energy (u)

Methane (Firedamp) 595° C 280

IIA Propane 450 260

lIB Ethylene 440° C 95

lIC Hydrogen and 560° C 20

Acetylene

Notes....

17
 Hornbill Compex Training Units: EX 01,02,03 & 04
Industrial Trainin9

Properties of Gases
Compound Vapour LFL UFL Ignition Apparatus
Density Temp C Class Group
Acetone 2.00 2.0 535 IIA
Ammonia 0.59 15 630 IA
Butane 2.05 1.5 8.5 365
Carbon Disulphide 2.64 1.0 60 100
2 IIA
IIC
Cyclohexane 2.90 1.2 7.8 T3
259 ILA
Diethyl Ether 2.55 1.7 36 170 IIB
Ethylene 0.97 2.7 34 425 T2 IIB
Hydrogenn 0.07 4.0 75.6 560
Kerosene 0.7
IIC
5 210 T3 IIA
Methane 0.55 5.0 15 595 /IA
Propane 1.56 2.0 9.5 4500 IIA
iNTELNAToN PAcTectioN CoDS!
Ingress Protection Toolbox Guide P33

IP code uses 2 digits to specify protection.

First digit refers to protection against solid matter.

Second digit refers to protection against liquid.

First numeral Second numeral

Protection against solid bodies Protection against liquid
No protection 0 NO protection
Objects greater then 50mm Vertically dripping ater
Objects greater then 12mm Angled dripping water -75 to 90
Objects greater then 2.5mm Sprayed water
Objects greater then 1.0mm Splashed water
Dust protected Water jets
Dust tight Heavy seas
7 Effects of immersion
Indefinite immersion

MuNMUM
LEMeNT IP54
IN ZONE.

1P5 tP GLANTo WASHER.+ SToPPER

ALL T J0L USE
18
 HIT- Mavn CoDES i2
Hornbill Compex Training Units: EX 01,02,03 & 04.
Industrial Training
Area Classification
Zone 2

One

CoNTNUO

Why Area Classification?

Hazardous areas are classified in zones based on the frequency of the appearance and the
duration of an explosive gas atmosphere.
Area classification is a method of analysing and classifying the environment where
explosive gas/vapour or dust atmospheres may occur so as to facilitate the proper selection
and installation of equipment to be used safely in that environment.
The classification also takes into account the ignition characteristics of the gas/vapour or
dust such as ignition energy (gas group) and ignition temperature (temperature class).

Properties of some gases, vapours and liquids Properties of some gases, vapours and liquids
Ignition Temp. Apparatus Ignition Temp. Apparatus
Compound Compound Temp. ("c)
Temp. C) Class Group Class Group
Hydrogen Sulphide
Ammonia 630
Benzene Kerosene
Butane Methane (Firedamp)
Methane (Industrial)D
Butene 40
Carbon Monoxide Methanol
Chloromethane Natural Gas 700
Diabutylether 85 Pentane L85
Dioxane 3T9 Propane 470
Ethane TownGas*
Etnanol Xylene 464
Formaldehyde 24

Industrial Methane includes methane mixed with not more than 159% *Containing not more than 57% by volume of hydrogen and not more
by volume of hydrogen. than 16% by volume of carbon dioxide, the remainder being a mixture

Why Zoning?

Leak Potential & Presence of lgnition Sources

Hazardous properties of hydrocarbons

Safe selection (& optimization) of Electrical Equipment

Workers safety (ATEX 137)

Notes.

19
Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Training9

Area Classification Toolbox Guide P 8&9

Zone 0

In this zone, an explosive gas/vapour Zone 2

atmosphere is continuously present, or
present for long periods or frequently. Zone 1

Zone 1
In this zone an explosive gas or atmosphere Zone 0
is likely to occur in normal operation.

Zone 2

In this zone, an explosive gas atmosphere is unlikely occur in normal operation and
to
if it does occur, is likely to do so only infrequently
and will exist for a short period
only

Non-
Hazardous
Area

Old Method of

Zone 0 Representation

Notes:..Akas...A.

20
Hornbill
IndustrialTraining
Compex Training Units: EX 01,02,03 & 04.

outoo

Always refer to documentation for

zones
Group and category
ATEX Area ATEX directive
Classification
Guide P 10 & 11
Toolbox
Group I: Mines Group Il: Surface Industry

Category 1 Categony 2Categony 3

M2

Category 1:for zone or

Category 3:for zone 2 or 22

CATEGORY-Equippment (94/9/EC) ZONE-Area (99/92/EC)

1 D/G 2one 20/0

Can be used in all zones, safe during Explosive atmosphere present continuously orfrequently
normaloperation and in case of (more than 1,000 hours/annum).
malfunctions and rare malfunctions.

2D/G -GD Zone 21 /1

Can be used in Zones 21 and 22, safe Explosive atmosphere present occasionaly during normal
during normal operation and operation (more than 10 hours but less than 1,000
malfunctions. hours/annum).

3D/G Zone22/2

Can be used in Zone 22, safe during Explosive atmosphere never present during normal
normal operation. operation, only during malfunctions (more than 0.1 hours
but less than 10 hours/annum).

21
 HornbilI
Industrial
Compex Training Units: EX 01,02,03 & 04.
Training
Gas Clasification Exercise: Pe
IA IB ilc

Gas Ignition Energy Gas Group

Ethylene 95 i16
Hydrogen 20 nc
Propane 280u 2

Acetylene 17 2

Area Classification Exercise:

ZoNE

-Vent pipe

Zowe L

eooeseo902
Separator

Drg&7g

feasible, the separator vent pipe should be grouped with the tank vents to minimize the hazardous
locations on a site.

22
 Hornbill
Industrial Training
Compex Training Units: EX 01,02,03 & 04.

IECEX Area Classification Toolbox Guide P11

IEC 60079-14: 2014

Equipment Protection Levels (EPLS)

EPL Ga Equipment for explosive gas atmospheres, having a 'very high' level of
protection, which is not a source of ignition in normal operation, expected
faults or when subject to rare faults.
EPL Gb Equipment for explosive gas atmospheres, having a high' level of protection,
which is not a source of ignition in normal operation or when subject to faults
that may be expected, though not necessarily on a regular basis.
EPL Gc Equipment for explosive gas atmospheres, having a 'enhanced" level of
protection, which is not a source of ignition in normal operation and which
may have some additional protection to ensure that it remains inactive as an
ignition source in the case of regular expected occurrences (for example failure
of a lamp).

Equipment will be marked with its EPL just like the

CATEGORY under ATEX

ECEX Area
IECEX
Classification
EPL B.S.Zone ATEX Cat.
Ga/Da 0/20 1G/1D
deorzs 2G/2D
Gb / Db 1/21
icn Gc/Dc 2/22 3G/3D

23
 Hornbill
Industrial Training
Compex Training Units: EX 01,02,03 & 04.

IECEX Area Classification Notes:..

Traditional approach to selection of equipment
Conduct Area . Defines Zones
Classification
&Extents

Select Type of
IEC 60079-14: 2014 Protection

iormbil

IEC 60079-14:2007
Zone Equipment Protection Levels (EPLs)

Ga
Ga' or "Gb
ZeNeS 2011E
Ga', 'Gb',

Da
or Ge
A.DS...
Da or Db
Da', Db', or De

Hornbil!

IECEX Area Classification

EPLI Category approach
Conduct Area Defines Zones
Classification
& Extents

Risk Assessment
of Consequences
Determine Select Type of
EPL Protection

24
Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Training
IECEX Area Classification

EPLS may then be determined on the basis

NT
of risk, i.e. taking into account the UNT
NO

consequences of an ignition.
This may, under certain circumstances,
require a higher EPL or permit a lower EPL
than the defined in Table.
Ifthe consequences of an ignition is
perceived to be grave with great loss of life
or equipment perhaps only Ga equipment
may be allowed in a Zone 1 area and either
Ga or Gb equipment allowed in a Zone 2 area.

On the other hand if the risk associated with an ignition is perceived to be small this may
perhaps permit Gb equipment into a Zone 0 and Gc equipment into a Zone 1.

The revised EPLs will be identified on the area

classification drawing.

ATEX Equipment
Zone EPL Category

Ga 1

1 Gb 2

2 GC 3

25
 Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Training
Boundary Signage
DSEAR Regulation 7(3) requires employers to place signs, if
necessary, at the entry points of places that have been
classified as hazardous (i.e. zoned areas). HH AC
The purpose of signs is to warn of areas where an explosive
atmosphere may occur in such a quantity that employees
need to be warned of its presence, so that they can take the
necessary precautions in relation to the risk.

DSEAR Schedule 4. Warning sign

EX
Distinctive features:
Dangeer
Explosive atmosphere
(a) Triangular shape;
(b) Black letters on a yellow background with black edging (the yellow part
to take up at least
50% of the area of the sign).

Sneak Question?
Which of the gas sub divisions does Ethylene fall?
A.I
llB
B. lIA E. 1IC

C. IlID F. 1B

The temperature at which gas/air mixture will ignite spontaneously is

known as:-

A. The flash point E. Cash point

B. The fire point F. Flame path
C. Rupture point GThe ignition temperature
D. The upper ignition temperature H. The flash temperature

26
Hornbill
Industrial Training
Compex Training Units: EX 01,02,03 & 04.

Types of Protection and Where We Can Use Them Toolbox Guide P12

Certification Zone 0 Zone 1 Zone 2

EXia Intrinsic Safety, safe with 2 faults

N
EXib Intrinsic Safety, safe with 1 fault

EXd Flameproof

EXe Increased Safety

EXp Presurisation

V
EXo Oil Immersion

EXq Quartz and Sand Filled V

EXm Encapsulation V

EXn Reduced Risk TOT PAcs I2 V

V
EXic Intrinsic Safety

Flameproof Ex d Toolbox Guide P13

An enclosure containing electrical apparatus or circuits that

is capable of withstanding an internal explosion.
It should prevent the internal combustion communicating
to any external flammable gas or vapour.

Notes: .

27
 Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Training

Flameproof Ex d

(a) Flanged joint INTERIOR

(b) Spigot joint INTERIOR

(c) Screwed joint INTERIOR

As covers are needed to gain

access to the internals of Exd EExd
enclosures, flanged joints are
max. joint width
sometimes permitted.

It is not
possible to machine the
min. length of
faces of the covers to produce a flame path X
perfect join.

A gap or "flamepath" is designed into the product. The "X" and

"Y" dimensions shown are a function
of gas Group and the volume
of the enclosure.
These dimensions have to be tightly controlled both during
production and subsequent on-site maintenance.
If these dimensions are not exceeded the probability that a flame
will reach the surrounding hazardous area is extremely small.

Notes:.

28
Hornbil
Industrial Training
Compex Training Units: EX 01,02,03 & 04.

Flame Path Ex d
For Enclosure volumes of less than 500cm Toolbox Guide P14

Apparatus Group Maximum Permissible Flange

Gap

IIA 0.15mm

IIB 0.15mmn

IIC 0.1mm

500 cm>2000cm3 >2000cm

Minimum
width of joint Y
X IIA lIB IIC IIA IIB IC

12.5mm 0.30 0.20 0.04 0.20 0.15

Flange
25mm 0.40 0.20 0.04 0.40 0.20 0.04

12.5mm 0.30 0.20 0.15 0.20 0.15

Spigot 25mm 0.40 0.20 0.15 0.40 0.20 0.15

40mm 0.40 0.20 0.20 0.40 0.20 0.20

12.5mm 0.45 0.30 0.25 0.30 0.20

Screw 25mm 0.60 0.40 0.25 0.60 0.30 0.25

40mm 0.75 0.45 0.30 0.75 0.40 0.30

Notes:...

29
 Hornbill
Industrial Training
Compex Training Units: EX 01,02,03 & 04.

Flameproof Ex d
Flame path:- A small joint or gap in a flameproof enclosure througgh HMAZARDOUS ATMOSPHERE

which air, gas or the products of an internal explosion may pass.

Juncton
Gaps to be measured with a feeler gauge (Maximum gap for lIC
areas 0.1mm for lIA and I1B 0.15mm.)
Suitable for use in zones 1 and 2
Live maintenance not permitted
No unauthorised modifications to a certified enclosure are
permitted. Toolbox Guide P39

Components not to be removed or modified within flameproof

equipment.
All bolts should be "Spanner Tight"
Adding components to an enclosure should never take place
because of the possibility of increased explosion pressure, as a
result of pressure piling. CTH

This could also lead to an explosion in one part of the enclosure

transmitting a greater explosion in another part of the
enclosure
The removal of components is also to be avoided since an increase in the free internal
volume of the enclosure will result. Making the certification invalid.

Notes:...

30
Hornbill1 Compex Training Units: EX 01,02,03 & 04.
Industrial Training

Zone, ATEX Cat. & EPL Exercise

Fill in the Table with the corresponding Zone, ATEX Category or EPL.

ZoNe Ga
BS Zone - 1 EPL ?
ATEX CAT. 2G BSZone- ?
EPL Gc BSZone- 2?
EPL - Da BS Zone -

2o?
ATEX CAT. - 1G EPL Ga ?

Zone
BS -
20 ATEX CAT.- 1D ?
EPL Gb ATEX CAT. -
2G ?
BS Zone 2 ATEX CAT.- 3G?

Notes:. .

31
 Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Training
Flameproof Obstructions Toolbox Guide P37

Equipment not to be sited nearer an obstacle than stated in the table.

Apparatus Group Minimum Distance

IIA
10mm

IIB
30mm

IC 40mm

Obstructions include: steelwork, walls, weather guards, mounting brackets, pipes or other
electrical equipment
Note: minimum distances may not prove practical as Flanged joint gaps need to
be checked
with feeler gauges

Flameproof Sealing Tape Toolbox Guide P38

IIA apparatus a single wrap of non-setting (Denso tape) permitted.

IIB apparatus consultation with technical authority required.
IIC apparatus not permitted.

Flameproof Painting of Flanges

Seals and gaps should never be painted over indiscriminately. Some paints dry very hard.

In particularaluminium paint should never be used, as some combinations of aluminium

and rust can burn very easily

Notes:..

32
Hornbill1 Compex Training Units: EX 01,02,03 & 04.
Industrial Training

Flameproof Use of Grease

Gaps can be protected by the application of a non-hardening grease

Silicone based greases are generally suitable but should not be used on the
seals of gas detectors-catalytic sensors can be "poisoned" by silicon.
Fixing holes and threads in apparatus subject to corrosion should be
protected by a suitable non hardening grease

Flameproof Adaptors and Reducers

Adaptors and Reducers provide a method of matching electrical thread
forms on hazardous area approved equipment whilst ensuring the
integrity and Ex approval of the installation is maintained.

Adaptors are used where the thread size of the cable gland or
connection device is larger than, or of an equivalent size, to the entry
thread of the enclosure.
Only one thread adaptor to be used per entry

Reducers are used where the thread size of the cable gland or entry device is
smaller than the entry thread of the enclosure.
Only one thread reducer to be used per entry

Notes.. .

33
 Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Training
Increased Safety Ex e Toolbox Guide P17 & 18

This technique relies on constructional safeguards to ensure that the MAZARDOus ATMOsPHERE

apparatus does not normally contain arcing or sparking devices or hot

surfaces that might cause ignition.

Suitable for use in zones 1 and 2.

Live maintenance not permitted.

Minimum of IP 54 to be maintained.

No unauthorised modifications permitted.

The use of high integrity insulation (cable insulation should be maintained up to

the
termination).
Enhanced creepage and clearance distances.
Creepage distance:- the shortest distance along the surface of an insulating material
between two conductive parts.
Clearance distance:- the shortest distance in air between two electrically conducting
parts.

Insulated Barrier

2
Air Gap
Insulating ****Clearance
Conductors Surtace - Creepage
Fig. 5. Definitions of Creepage and Clearance.

Notes:..

34
Hornbill
Training
Compex Training Units: EX 01,02,03 & 04.
Industrial
Increased Safety Exe
Terminals must be constructed with integral locking
devices to avoid inadvertent loosening, which could
lead to the possibility of arcing or sparking.

Some types of terminal such as slot types, may receive and adequately
clamp more than one conductor.
However, unless permitted by the certification, two wires of different
cross sections should not be connected into one terminal unless first
secured within a single compression type ferrule, or the terminal is of
special design.

Terminals are de-rated from their standard industrial current rating in order
to limit the possibility of high temperatures developing.
Where single screw saddle type clamps are used with a single conductor, the
latter should be U-shaped around the screw to permit proper clamping
Fonk

Luminaires with fluorescent lamps and electronic ballasts shall not

be used where temperature class T5 or T6 is required or where the
ambient temperature exceeds 60°C

Lamps (e.g. bi-pins, screw connections on tungsten lamps) using non-conductive materials
with conductive coating shall not be used unless tested with the equipment

Notes..

35
 Hornbill
Industrial Training
Compex Training Units: EX 01,02,03 & 04.

Motors Ex e: In order to meet the protection requirements of a

motor, an
inverse-time delay overload protective device shall be such that will
it
monitor the motor current and also disconnect a stalled motor within
the
time te stated on the marking plate
The overload protection to be used with the motor
has to be of a specific
type and the characteristics of the type are included
with and form part of
the approval certificate.
All Exe machines must withstand stalled rotor current
for 5 seconds from
normal running temperature without damage to the class of
insulation
used in construction.
Refer to IEC 60079-7
D

0c
F 0 Temp
A = Max
B
amb temp
Max design operating temp
C Max temp by insulation
class
D Max temp "T rating"
E = Temp rise curve
"Start up from cold"
F Temp rise curve "Stalled motor"
E <5seconds CUT ofF PowER,
DrscoNECTON TME

figure 1
Etime
Notes:..

36
Hornbil Compex Training Units: EX 01,02,03 & 04.
Training
Industrial

Tool Box Guide Quiz: (Edition

On which pages can you find Zone definitions?

What constitutes a Zone 0?
A place in which an explosive atmosphere consisting of a mixture with air of
flammable substances in the form of gas, vapour or mist is
sN ONTANUOUSY.a er.L.en.lniaDs.2. ******

P****** ********************************************************

On which page can you find Temperature Classification?

What is Temperature Classification?
Temperature Classification is based on the maximum temperature whieh Ca
4t.lsand.pa..ht.Gkegsrena.iekeadt.j....
.dsuk.ada. aueadk.Rpkaskht.g osa.di.
**** *****************************
***********"*********************************

What is T Class T4?

Unless otherwise marked (T Amb.), these temperature classifications are
suitable for an ambient temperature range from Z. to to.

Notes.

37
 HornbilI Compex Training Units: EX 01,02,03 & 04.
Industrial Training9

Pressurised Systems Ex p Toolbox Guide P15

The concept of pressurisation is very simple

It is atechnique where a protective gas is supplied to an

enclosure in order to prevent the formation of an explosive
atmosphere inside the enclosure
Maintains a pressure known as overpressure to prevent the
ingress of flammable atmospheres
It can be used to dilute any potentially flammable material in
the enclosure to a level below the LEL

Characteristics of protective gas

Two sources may be required dependant on risk
Non-toxic and free from foreign bodies
The gas should not normally contain more Oxygen by volume than air

Source should be taken from a non-hazardous area

Temperature should not exceed 40° C

Notes:... Wt..da.zpees. Zes..a.e..

Pressurised Systems Ex p
3 Methods of pressurisation; O

Static pressurisation
Pressurisation with leakage compensation
Pressurisation with continuous flow

38
Hornbill1 Compex Training Units: EX 01,02,03 & 04.
Industrial Training
Static pressurisation:
Apparatus is purged and pressurised outside the hazardous area.

Allowed into hazardous area withouta continuous supply of protective gas.

Application: Transportable data collection equipment.

Pressurisation with leakage compensation:

Where an enclosure cannot be totaly sealed a continuous supply of protective gas is supplied
in sufficient quantity to compensate for any leakages.

Generally used where a source of ignition exists within the enclosure.

Minimum overpressure should be 50 Pascal's or 0.5 millibar.

Enclosure in Zone 2.
No flammable materials are piped into the enclosure.

Enclosure maintained at a pressure just above outside ambient pressure.

Any leakage will be of the protective gas outwards rather than the flammable atmosphere
inwards.

Notes..h...ke..kan...sksrMEL S...nsad

39
 Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Training
Pressurisation with continuous flow:
This is the most complex method though is the method most
associated with FEx p
Requires the enclosure to maintain an internal overpressure with
sufficient continuous flow of protective gas to maintain the
internal atmosphere below the LEL in a worst case leak scenario
Typical applications are enclosures where

Sources of ignition exist- thermal and electrical

Flammable materials are piped into the enclosure so the potential

for release and formation of a flammable atmosphere exists
Example:- Analyser Houses

Controls if Protective Gas Fails

Devices should be fitted to monitor the overpressure or flow of
protective gas
If these fall below the minimum value the çontrols should:
ANM:
1. Raise an Alarm G dscoNNECt
2. Disconnect the Power, dependant on zone of use Gc

Zone 1 Installation
If the
enclosure contains apparatus certified to zone 2 an alarm should be raised and
immediate corrective action taken to restore integrity of the system
Ifthe enclosure contains uncertified ignition capable apparatus then alarm and de-energise
ignition capable components

As long as in doing so you do not create a more dangerous condition (may be time delayed)

Notes:.

40
Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Training
Zone 2 Installation
If the enclosure contains uncertified ignition capable apparatus then an
Alarm should be raised ce wo DiS c©NNeCT.
Immediate action taken to restore integrity of the system G6

m
Purging
Before pressurisation can take place it is necessary to remove any
existing flammable atmosphere
This process is known as purging. The enclosure volume should be
changed by the purge gas at least 5 times before energising.
Zone 2 purging may be omitted if the interior of the enclosure and the
associated supply ducting is proved to be below the LEL

Pressurisation
Suitable for use in zones 1 and 2

No live maintenance permitted

Non certified apparatus can be used inside the enclosure

Marking of Ex p is complex and Technical Authority should be consulted

Cable glands:- non certified but suitable for cable

Tends to be very expensive to install and maintain
Additional requirements for pressurized enclosures
Pressurized enclosures, with only an Ex component enclosure Mialx Puge

certificate (marked with a 'U'), shall not be installed.

They shall always have an equipment certificate for the complete
assembly. terfaceBox Mini-Y-Purge

Notes:.....

41
 Hornbill
Industrial Training
Compex Training Units: EX 01,02,03 & 04.
Pressurisation General
Unless it has been assessed as a whole, the complete installation shall be checked
for
compliance with the requirements of the documentation and this standard.
IEC 60079-14: 2014
The required level of protection 'x', 'y' or 'z' is determined by the EPL requirement
for the
location and whether the enclosure contains an ignition-capable source
of ignition in
accordance with the following table

ZONE 1 2

Enclosure contains ignition-capable

equipment Type px Type px or pz

Enclosure does not contain ignition- No pressurization

capable equipment Type py
required

NOTE IEC 60079-2 requires that type'py' equipment will only contain equipment
to type of protection 'd', 'e', T', 'm', 'nA', 'nC', '0' or 'q'.

Ifhazardous area has been risk assessed and awarded an EPL the table below should be
used, regardless of zone, for selection, erection and maintenance of equipment.

EPL Gb Gc

Enclosure contains ignition-capable

Type px Type px or pz
equipment

Enclosure does not contain ignition- No pressurization

Type py
capable equipment required No P
NOTE IEC 60079-2 requires that type 'py' equipment will only contain equipment
to type of protection 'd', 'e', "', 'm', 'nA', 'nC', '0' or 'q.

42
Hornbill Compex Training Units: EX 01,02,03 & 04.
Industrial Training

Oil Immersion Ex o G Ge Toolbox Guide P24

Use of mineral insulating oil to provide protection with fluid

actually quenching the electrical ark or spark
Circulation of oil around apparatus allows any hot spots to be
dispersed allowing for improved equipment reliability.
Suitable for use in zones 1 and 2
No live maintenance permitted

Sealed enclosure IP66

Potential health hazard with respect to old oil and PCB's

Sand/ Powder Ex qGL Ge Toolbox Guide P26

Technique relies on the apparatus to be protected

having a sand or powder filling. Temperaturregler
Thermostat
TRS5
TS
Any sparking or hot surfaces which exist under the ExKennzoichneung / Ex arking

filling cannot ignite the surrounding atmosphere. Schutzat/ Protecsio 54

Code q stands for quartz medium used in the form

of small glass silica beads. m peraturregler TRi1
EThermosta

Suitable for zones 1 and 2 ExKennzeichmumg Ex

zELM 2 ATEX 007
schutaatProtectio

No live maintenance permitted

Minimum IP 54 required. WHenc USED

EXM
Tool Box Guide Quiz: (Edition cones oF Use
On which page does protection type Ex d start?

Complete the definition given in section 3.2.1

A type of protection in which the parts that can ignite an explosive atmosphere are placed
in an enclosure that can withstand the pressure developed during an internal explosion of

. ...
an explosive mixture and which

... . .. ******.**** ******************************************************************

43
 Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Training
A
RATH
Which sub-section deals with flange gap dimensions of Ex d equipment?.
RAME
******************* .. ?

What are the permissible flange gaps for enclosures of less than 500cm3 fo:

IC equipment? ..9.en?
IIA & IIB equipment?

What are the permissible zones of use for Ex d equipment?

Zones.. ..?

How long should Cylindrical Threads be for Ex d equipment?

M.

Tool Box Guide Quiz: (Edition

What is the minimum number of threads for Ex d equipment?

******

Which table gives information on glands, adapters and blanking elements for Exd
equipment?
Page.......! lable......

Which pages can you find special requirements for installing Ex d equipment?

. to ....?

What does the T.B.G. say regarding the use of grease on Ex d equipment?

Section.. pdge.....**
******************************************************************* ************************************ ********************************
*************************************************************************************************************"********************"************

**********************************************************************************
**********************************************************************

*******************************************************************************************************************************************************

44
 Hornbill
Industrial Training
Compex Training Units: EX 01,02,03 & 04.

Ex d equipment in a
What is the requirement when applying grease bearing textile tape to

.. .. ......
IA gas atmosphere?
************************ .2x S.. K9...0..NON. w..TA... *********************"*********************

. .... ***************************************************************************

***** **********
...***
..
*********nos************************************************************************************

*.. e*****************************************************************************

What is the requirement when applying grease bearing textile tape to Ex d equipment in a
IIC gas atmosphere?

M.IL..
******************************************************************** * ***************************************

Encapsulation Ex m LN nESSIN Toolbox Guide P23

Protection is obtained by encapsulating hot or sparking HAZARDOUS ATMOSPHERE

components to prevent ingress of any explosive gas. It

should cool heat producing components and withstand
maximum temperature during normal and fault conditions.

Apparatus is not readily repairable and usually used for low RESIN

cost throw away items.

No live maintenance permitted. 126 Ex1,2mb IC TS Gb
Zone
Equipment just marked Ex'm may be used in: 120 Ex tb
C TBPC DD IPES
one 21, 22

Zone 1, (Gb, Cat 2) and Zone 2 (Gc, Cat 3)

Sub categories of Ex'm
'ma' may be used in areas requiring EPL 'Ga', 'Gb' and 'Gc',
or Category 1, 2 and 3
may be used in areas requiring EPL 'Gb' and 'Gc' or
'mb
Category 2 and 3
'mc' may be used in areas requiring EPL 'GC' or Category 3

45
 Hornbill Compex Training Units: EX 01,02,03 & 04.
Industrial Trainingg

Ge zove 2 ovtL
Reduced Risk Ex n Toolbox Guide P18

A type of protection applied to electrical Explosion Protected Machines [Product Guidel

apparatus such that, in normal operation it is
TMEIC hods Exn certfication for constant and
not capable of igniting a surrounding variable speed induction machines. Series
certification is held for the complete range or
explosive atmosphere, and a fault likely of motors. The explosion protected (Exn) rating for our
motors as certified by Baseefa and other agencies
causing ignition is not likely to occur.
rings many advantages to our customers
-
High efficiency and energy savings
Suitable for zone 2 only -
Low vibration and noise
-
High Reliability
Easy installation
Live maintenance not permitted - Quick delivery
Meet international standards (IEC,. EN, BS)

Minimum IP 54 required

Notes....

Reduced Risk Ex n

The 'n' standard subdivided into a number of protection types.

is
Type nA: non-sparking
Type nR: restricted breathing enclosures if wAsHèn
Type nL: energy limited equipment (ic)
Type nZ: enclosure with 'n' pressurisation (pz)
Type nC: sparking where the contacts are suitably protected other
than by type
R,Lor Z.

Ex nA non sparking apparatus:- designed to prevent any means of ignition arising.

Examples: -Squirrel cage motors

Terminal boxes
-Light fittings

-Transformers
-Low energy devices (inst. & control)

46
Hornbill Compex Training Units: EX 01,02,03 & 04.
Industrial Training
Ex nC Sparking has different protection concepts
-

Non incendive components

Enclosed break device CICe

Hermetically sealed device

Encapsulated device
Examples Circuit Breaker
Relays
-
Contact Switches
Electric Motors (slip ring, wound rotor)
-
Switches Note: EXnC is being replaced by EXmc

Notes:.

Ex nL:-Energy limited apparatus

Designed tolimit the ignition energy of the circuit (based on concept of intrinsic safety)
Being replaced by "comparable" Ex'ic

Ex nP Overpressure

Concept uses an overpressure within a housing to prevent any potentially flammable

atmosphere entering.

Ex nR Restricted Breathing
Technique relies on the ignition capable part Nexxus II LED Bulkhead
within the enclosure, which although not fully ATEX CATEGORY 3
iernorntioa an arTav of icht e
sealed is constructed in such a way that it iodes (LEDs) providing an instant whte light that s
MsoNe.
enlarge

would take a long time for a flammable The

and
expiosion protecionE
versatile solktion in many applications
hose wnere concits e ec
gas/vapour to penetrate. pecisi
with a heat resistant
corrndion resistant sauminasm

Often applied to luminaires.

Minimum IP 54 required* - EX nR always requires IP washer as part of the protection concept

47
 Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Training9

Luminaires
Luminaires with fluorescent lamps and electronic ballasts shall not be used wheree
temperature class TS or T6 is required or where the ambient temperature exceeds 60°C
Lamps (e.g. bi-pins, screw connections on tungsten lamps) using non-conductive
materials with conductive coating shall not be used unless tested with the
equipment

Note: Same as Ex'e Luminaires.

Notes:..

Intrinsic Safety EX03 Ex Toolbox Guide P20

Definition of Intrinsic Safety

A method of protection based upon the restriction of electrical energy, within the
apparatus and interconnecting wiring that are exposed to a potentially explosive
atmosphere to a level below the minimum ignition energy required to cause an explosion.

Three categories of Intrinsic Safety Ex ia Zones 0,1 and 2

CenriaED ntrinsically safe
Ex ia, Ex ib and Ex ic CSSoHreD with two faults

Ex ib Zones 1 and 2
Difference lies in component integrity of the equipment Intrinsically safe

Continued Intrinsic Safety under Fault conditions auis e

thoe in omponent Ex ic Zone 2
Intrinsically safe

Zones of use erinsk safety is the only protection

in nomaloperation

Live maintenance is permitted

esTnie umT /ENeney

F30 Ex ic Adaptor
Zowes-Ca ia, Giib,
Ccjc
TIves

48
Hornbil
Industrial Training
Compex Training Units: EX 01,02,03 & 04.

EXic isreplacing EXnL they are similar but not the same.
Care should be taken when comparing one to the other.
They may be interchangeable in some circumstances but
not al. This is due to the origin of the different standards.

1 3G Ex nA IIC T4 GC

Notes:. .
Intrinsically Safe System ASEING ?

NON-HAZARDOUS SIDE HAZARDOUSSIDEE ISsystems require documentation for the

complete system, the circuit needs to be
considered as a whole.
Intrinsic
Satety
Barrier
Equipment that is energy storing
S7ones cR
Produces energy ang ee
And is intended for use in intrinsically
ONLY THESE WIRES ARE
INTRINSICALLY SAFE safe circuits
NEEDS TO BE CERTIFIED INTRINSICALLY
SAFE
Cnery
For example; Transmitters, Proximity Switches, Converters and Loudspeakers.

Simple Apparatus
A device not capable of producing energy to a value greater than 1.5V, 100mA, 25mw
or 20J STCken /LAGeL
Switches, Thermocouples, RTD's (Resistance Temperature Devices),
Terminals, Junction Boxes and LED's
CERTIFICATION NOT REQUIRED

NoN- arAEd
49
 Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Training

Temperature classification awarded is normally T4 however JB's switches and

terminals may be T6 because they do not contain heat dissipating components.

Notes:...

Intrinsically Safe System

Certified Apparatus will be marked as Ex ia, Ex ib or Ex ic

If Certification appears in square brackets [Ex ia], [Ex ib] or [Ex ic 05 Protected safety barrier

Then this means that the equipment is associated with equipment

that is intrinsically safe but is not in itself intrinsically safe.

Intrinsically Safe System

Types of Barrier
Non isolated- Shunt Diode Barriers

Isolated Galvanic Barriers

Shunt Diode Barrier ZEnER

A current and voltage limiting device, which uses an infallible resistor to limit
the current to the hazardous area and Zener diodes to limit the voltage.
Commonly known as Zener barriers

50
Hornbill Compex Training Units: EX 01,02,03 & 04.
Industrial Training

Zener Barrier installations require a high integrity earth to function as designed

Barriers are designed to remain safe witha maximum of (Um) 250V applied to
the non-hazardous area terminals.

Notes:. . ******

Shunt Diode Barrier ZENNER

cases the intrinsically safe barriers and
In all FACAOCUS AREA EAREA

equipment MUST be wired per an approved ay eardh

drawing. CLR

Capacitance and inductance of the wiring and

Vo
cables must be included in the loop evaluation
IS systems using zener barriers requirea high
integrity earth Shunt diode satety barrier

Minimum of one 4mm2 (old standard) or two Hazardous Arej

1.5mm conductors required from barrier earth bar wER

in an enclosure to the main IS earth bar sensor L ener Barrier.

*wEh negative ground

azardousAreasateArea
Two conductors are required as good practice to
Condition
enable testing and maintain integrity w w

dunl-o ner Barrer w

stive
to the m ounting tabs for positive redundant
ande
grounding

51
 Hornbill
Industrial Training
Compex Training Units: EX 01,02,03 & 04.

Safe are
Hozerdous area

Dmgore
Pet n

The impedance from the barrier earth bar to the star point of the transformer
should be
less than 10.

Notes..

Galvanic Barriers NO EnnTH

NON HAZ AADOUS AteH.
Concept relies on physical isolation
HAZARDOUS AREA

between hazardous area and safe area Line fauit

Load, alarm
circuits within the barrier Or shutdown
UM circuits
Typical galvanic barriers give 400V isolation
between these circuits Fiold switch is normall
losed open on alarm
In addition to limiting energy and providing Supply

isolation galvanic barriers usually perform

some additional function. Plant reference potential

Switch with Galvanic Isolator

Galvanic Barriers do not require any IS
earthing arrangements.

NoN HAZALDo0S AnEA.

52
Hornbill
Industrial Training
Compex Training Units: EX 01,02,03 & 04.
Installation of Barriers
Normally installed in non-hazardous areas

Normally installed in dedicated enclosures within safe area

Recommended as good practice not to mix Zener and galvanic barriers on the same
mounting rail

Barriers should be mounted so that there is a minimum of 50mm tween safe and
hazardous area terminals

Some manufacturers of equipment mount IS equipment within an

Ex d or Ex e enclosure the type markings then would be of the

form
Ex d [Ex ial] or

Exe [Ex ial]

Notes.....

Installation of Barriers
Provision should be made to terminate cable screens
where used SoM

To increase integrity of system IS and non IS cables should

be kept segregated in barrier enclosure by either
Looming of the cables or running cables in trunking.

Cabling and Wiring for IS Installations

Only insulated cables whose conductor test voltages are at least 500V a.c. or
750 d.c. shall be used in intrinsically safe circuits.
The diameter of individual conductors within the hazardous area shall not be
less than 0.1mm.
Cores of conductors should be identified and made off using crimped
connections

53
 Hornbill Compex Training Units: EX 01,02,03 & 04.
Industrial Training9

Under no circumstances should IS and non IS circuits be mixed in the

same multicore cable
IS and power cables can be run
together on the same cable tray
providing that either the power cables or the IS cable are: 1) Screened
with the screens earthed or 2) Armoured with the armour earthed.
Single core high current carrying conductors should be avoided
Segregation by physical spacing is recommended

Freedom to use ordinary instrument cabling in hazardous areas

Armouring not required but cable must be insulated
Capacitance, Inductance and Reactance /Inductance ratio must be
taken into consideration when cable run in hazardous area exceeds
1000M

Where interconnecting cables incorporate individually screened

conductors, such screens should be insulated from each other in such a
manner that the insulation resistance is not less than 1MO/kilometre.
Core to core to withstand a test voltage of 50OVac or 750Vdc
LAAA
Diameter of individual conductors should not be less than 0.1mm

Creepage and clearance dimensions to be observed. 6mm between

two bare IS conductors. 3mm between an IS conductor to earth

Cable armour bonding

The armour shall be bonded to the equipotential bonding system via the cable gland or
equivalent, at each end of the cable run. Where there are interposing junction boxes or
other equipment, the armour will normally be similarly bonded to the equipotential
bonding system at these points. In the event that armour is required not to be bonded to
the equipotential bonding system at any interposing point, care shall be taken to ensure
that the electrical continuity of the armour from end to end of the complete cable run is
maintained. In any event, there shall be at least one electrical bonding connection of the
armour to the equipotential bonding system. The cable gland for isolating the armour from
earth shall be installed in the non-hazardous area or locations requiring EPL "Gc" or "Dc".

54
Hornbill1 Compex Training Units: EX 01,02,03 & 04.
Industrial Training

Cabling and Wiring for IS Installations

Where non armoured cable is used a non-certified A2 cable gland is
acceptable

GALVAwC ZeNen. TO eATH,

Earthing of conducting screens
Where a screen is required, the screen shall be electrically connected to earth at one point
only, normaly at the non-hazardous area end of the circuit loop.

This requirement is to avoid the possibility of the screen carrying a possibly incendive level
of circulating current.
(2) If anearthed intrinsically safe circuit is run in a screened cable, the screen for that circuit
shall be earthed at the same point as the intrinsically safe circuit which it is screening

an intrinsically safe circuit which is isolated from earth is run in a screened cable, the
(G) If
screen shall be connected to the equipotential bonding system at one point.
on nefen To DAAwING.

Unused cores in cables uenT

(si)
Each unused core in a cable shall either

a) be adequately insulated from earth and from each other at both ends by the use of
suitable terminations, or
the cable have an earth connection (e.g. via the associated apparatus),
b) if other circuits in
be connected to the earth point used to earth any intrinsically safe circuits in the same
cable, but shall be adequately insulated from earth and from each other by the use of
suitable terminations at the other end.
heat-shrink tubing would satisfy this requirement or suitable terminals

Identification of IS Circuits
Common practice for cables to have blue outer sheath
The colour light blue is used to indicate IS and greatly assist in the
identification of cables, IS apparatus and junction boxes
The use of light blue is recommended
1,S./NeNi.S. Net (WSAME ColE
S.NoN i.s. secne GATED ON
THE SAME CAbLe
TAA Y

55
 Hornbill
Industrial Training
Compex Training Units: EX 01,02,03 & 04.

Sneak Question?
What should the earth impedance be, between a Zener barrier earth point and the main
power supply earth?

Junction Boxes
Are by definition simple devices and therefore do not need to be certified, they
need to be identified as simple apparatus.
A label is required to indicate IS equipment is contained in the enclosure

IS and non IS circuits must be kept separatee

A minimum distance of So mm is required

Creepage and clearance distances to be observed.

mm between two bare conductors. IS

mm between an conductor to earth

IS

Cable entry must maintain IP54

If less than 6mm thread entry then IP washer required
For clearance holes an IP washer required

Light blue terminals preferred

Provision must be made for all cable cores including screens

Ifmore than one IS circuit is contained in a junction box within a hazardous area it has to
meet extra requirements, these would be met by using an EX e enclosure. Glands only have
to maintain IP integrity and the enclosure.
If a junction Box contains both IS and non IS circuits a certified enclosure must be used,
certified glands must be used.
IS and non IS ircuits must be kept separate, a minimum distance of 50mm is required.

56
Hornbill
Industrial Training
Compex Training Units: EX 01,02,03 & 04.

In addition to the IS circuit identification label the box must be labelled either:

"WARNING DO NOT OPEN WHEN ENERGISED"

Or:

"WARNING NON-INTRINSICALLY SAFE CIRCUITS PROTECTED BY INTERNAL IP30 COVER"

Terminals
Are by definition simple apparatus and do not need to be certified

Should maintain creepage and clearance distances.

&mm between bare IS conductors.

3mm between an lIS

conductor to earth
Light blue terminals preferred

IS and non-IS circuits must be kept separate in junction box.

A minimum distance of So mm is required

1G?
Intrinsically Safe System

Example- Beacon
IS-mB1Beacon
Above ignition Cure EC2 Beacon Exia RACATE 2084%

28V-660mA Seria No 06 1
Pi 1.2W NARNING:
oG
Pos
european
660mA safety y
Barrier required to
limit the power
Output to 1.2W

12W 42mA
28V

ppper-tuch.a
42mA
Des0
PTE
CE
A39 etxnL C TX

Bclow tgnithon. Cuve AHMoATRKDIR8x

s 42 mA CataCITawCE /1NoCANCCF
S eLOUN NT
57
 Hornbilll Compex Training Units: EX 01,02,03 &04.
Industrial Training

Sneak Question?

According to ATEX 137. Where can Category 2 equipment be used?

A. Zones 0, 20 and less onerous duties
B. Zones 1, 21 and less onerous duties
C. Zones 2 and 22 only
D. Zones 20, 21 and 22 only

Ex components
An Ex component requires additional certification when
incorporated into electrical apparatus or systems intended
for use in potentially explosive atmospheres.
RTIM
Ex components are marked with the symbol "U

Examples
An approved but empty enclosure

A type 'd' push button switch SHAESYE oF 6UroN

A type 'e' terminal block

Some cable glands

ind
ISTB RANGE ENCLOSURE
iS Cn cUT No LAet Noy CernrFeo
Powen CnCuT LAGEL CenTFiED. xtb 1IC C
IP6S
cERT NO: SIRA11ATEX3142U
c No: 1ELNOO021
YEAR OF MANUFACTURE 2011

Notes:...
****

58
 Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Training
Selection of Equipment
¥Determine Zone Likelihood of Gas/ Hazardous Likelihood of Common Protection Basis for
Vapour (above LEL) Area Electrical Equipment
Rating Ignition Source
Classification
duit

Select Type of Protection tolerant)-Exia

for that Zone Likely 2one 1 Rare Intrinsic satety (1 fault
tolerant)- Exib
*Ensure Equipment is Flameproot-Exd
Certified for the Increased satety -ExC
EncapsulatedExm
Relevant gas Group Pressurised Exp ith
shutdown)
*Ensure the Temperature
Classification of the Not likely Zone 2 Unlikely Non sparking-EXn
ExpP (with
Equipment is below the Pressurised
alarm)
ignition temperature of
Most unlikely Non POssible Normal electical equipment
the gas hazardous

X In Addition ensure the

Equipment is Suitably Constructed to withstand the Operating Environmental Conditions

Gland Markings - non certified

Markings on non-certified glands will include

Manufacturer
Gland type in accordance with standard. BS 6121 require the following markings

W Single wire armoured

X Braid armour
Y Aluminium strip armour (unsuitable for hazardous areas)
Z Tape armour
BS EN 50262 requires the following:
A Outer seal only.
B Armour lock only.
C 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
Certification details including the Certifying Body and Certificate number.

59
 Hornbill
Industrial
Compex Training Units: EX 01,02,03 & 04.
Training

Glands for Flameproof apparatus EX d Toolbox Guide P42

Must be certified Exlgor Exde (dual use)

In 2005 and prior, E1WF glands were specified. Certified flameproof to British Standards not
to ATEX Standards.

E (Inner seal, outer seal and armour lock)

1 (Seal material)
w (Single wire armoured)
F (flame proof)

Threaded entry hole 8mm deep minimum

Engaged thread length 5 full threads minimum

Line 1
Manufacturers| Gland Manufacturer's Thread Year of X for Special Conditions OA Notifed
Size Apparatus
Name or Product Type ze Certification ForSafe Use GroupP Body Number
Trademark ldentfication

CMP UK (20) T3CDS (M20) SIRA 06 ATEX1283Xil 2/3GD 0518CE

Testing Station ATEX Certificate Symbol Signifries FullATEX Category / ommunity

ldentficaton Number Gas or Dust Mark
European tandaros sroups

Notes.. .
***

60
Hornbill Compex Training Units: EX 01,02,03 & 04.
Industrial Training
Glands for increased safety apparatus Ex e Toolbox Guide P44

Glands used on new installations must be certified and marked EX@or Exde (dual use)
In 2006 and prior normal E1W glands were permitted in accordance with 1EC 60079-14

An IP sealing washer and locknut are required when less than 5

threads are engaged (6mm approx.)

A serrated washer maybe required to maintain earthing integrity
When glanding on to non-metallic apparatusa banjo is often required
to maintain earth continuity

Glands for Reduced risk apparatus Ex n

Must be certified Exg, ExEx deldual use) or

Ex nR

Prior to 2008, cable glands did not require to be certified

An IP sealing washer and locknut are required when less than 5
threads are engaged (6mm approx.)
A serrated washer maybe required to maintain earthing integrity
When glanding on to non-metallic apparatus a banjo is often required
to maintain earth continuity
Glands for reduced risk, restricted breathing apparatus Ex nR
An I washer isalways required immaterial of the length of thread
IEC 60079-14 2009 states Glands for Ex'nR must be certified for use
in Ex'nR equipment.

Notes:.*. ..dtkene....

61
 Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Training
Type of Gland Gland Gland Gland
Protection Certification Specification Specification Specification
from 2008 from 2007 from 2006 2005 and prior

lameproof EX d or de EX d or de EX d or de ElWF
'd'

Increased EX e, d or de ElW EX e, d ElW eor F ElW e or F

Safety 'e' or de

Reduced Risk Ex n, e, d or ElW EIW ElW

'n' denR

Use of MICC cable glands Toolbox Guide P41

MICC (Mineral Insulated Copper Conductor) may be used in most

applications
Standard pots maybe used with Ex'd, Ex'p and Ex'n equipment
For Ex'e equipment only Ex'e pots maybe used.

Notes.

62
Hornbill
Industrial Training
Compex Training Units: EX 01,02,03 & 04.

Protection Concept Exercise

Certification Name of protection concept? Zone 0 Zone 1 Zone 2

Ex eb

Exib

Ex nc

Ex ia

Ex ob

Exic

Ex mb

Ex db

Exqb

Ex pb

Use of Barrier Glands on Ex d Equipment Toolbox Guide P42

Where there is an internal ignition source

Zones 1 and 2 - type IlIC gas present:- Required
Zone 1-type IA or llB gas present and volume of apparatus greater than 2Litres:- Required
Zone 1-type 1IA or l1B gas present and volume of apparatus less than 2Litres:- Not Required
Zone 2 type lIA or lB gas present and any internal volume Not Required
-

63
 Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Training

Does the
enclosure
contain an Does the gas belong to group IIC ?
ignition
source?

No
Use Barrier Gland.

Isthe volume of
Is the area the enclosure
No
Zone 1 greater than 2
litres

No No

Use Suitable Flameproof Gland

Sneak Question?

In order for combustion of an explosive atmosphere to occur, which items are necessaryy?
AA supply offuel E. A triangle
B. An enclosure F. A zone 0
CA source of ignition G. ATEX equipment
D. Boundary signage (H.) A supply of oxygen

The design ambient temperature range of equipment for use in the UK, will be?
A. T1 D. 35° C max
(B)-20 to +40° C E. T6
C. 45° C max F. -10 to + 50° C

64
Hornbill Compex Training Units: EX 01,02,03 & 04.
Industrial Training
Zones of Use Exercise

Indicate which areas can be

cleaned with this equipment? Cat 3D
Circle items that prevent use
M) T1 IIA T5

EPL GC

IAT2
X
one XX
XX

HCT
XX X

ATEX Smartclean Zone 2

Industrial vacuum cleaner NA T2
3GD EXnA lIB T3 135°C IP65

ATEX
CAT 2G
X

IBT3

EPLG
EPL DO
IIA T2
DDB T1

65
 Hornbill
Industrial Training
Compex Training Units: EX 01,02,03 & 04.

Glands Industrial Type

Hawke 151, 153
Non certified Not for use in Hazardous Areas
Outdoor or Indoor use.
For use with single wire armoured 'W',

Wire braided 'X'

CMP CW20
Steel tape armoured Z'

Elastomer and plastic insulated cables.

Provides armour clamping for all armour/braid types. Deluge
Pepper A, L, E, or C type
protection option available.
Providesa cable retention and low smoke and fume, zero halogen seal
onto the cables outer sheath.

Glands Certified Universal

Hawke 501/453
Certified Flameproof (Type d), Increased Safety (Typefe) and
Restricted Breathing (Type 'nR') indoor and outdoor cable gland for use
in Zone 1, Zone 2, Zone 21 and Zone 22 Hazardous Areas.
CMP Triton
For use with single wire armoured W', wire braided X' and steel tape

armoured Z elastomer and plastic insulated cables.

Providing a Flameproof seal on the cable inner bedding and an
environmental seal on the cable outer sheath
Pepper CR Type

7
ATyeE
Notes:........... *** TP WHLCHCLa.

NS.G..IG...G4ND...

66
 Hornbill1
Industrial Training Compex Training
Units: EX 01,02,03 &

Glands Certified
Barrier
Certified Flameproof
(Type'd'), Increased Hawke 653
Safety (Typee)
Breathing (Type 'nR') and Restridted
cable gland for use in
Zone 1, Zone 2,
Zone 22 Hazardous Zone 21 and
Areas with all types
of armoured cable
compound barrier providing a
seal around the CMP PX2K
cable conductors
environmental seal and an
on the cable outer
To be used on
sheath
cables that are not
effectively filled,
circular, have tape OSonLEN compact and/or
bedding or have hygroscopic fillers. Pepper CR-C Type
Cables that exhibit
cold flow' characteristics.

Glands Certified
Brass non-armoured
Certified Flameproof
(Type@), Increased Hawke 501/421
Safety (Typee)
Restricted Breathing and
(Type 'nR') indoor
and outdoor cable
Zone 1, Zone 2, gland for use in
Zone 21 and Zone
22 hazardous areas
armoured cables. with un-
CMP SS2K
This cable gland
provides a flameproof
seal on the cable
outer sheath of single inner sheath (of
sheathed cable) and a
seal on the cable secondary environmental
outer sheath.
This cable gland Pepper A Type
provides a flameproof
seal on the cable inner
outer sheath of single sheath (or
sheathed cable) and a
seal on the cable secondary environmental
outer sheath.

Notes:...ks. elzh
..Prdeis...EA.K4
******°******

LX n.. d..A.. e...

67
 EX 01,02,03 & 04.
Hornbill Compex Training Units:
Industrial Training

Glands Certified Plastic

non-armoured AZ
use on
certified increased safety Ek elintended for
Plastic cable gland
insulated cables. Made from
non-armoured elastomer and plastic
displacement seal.
and provide a controlled pull resistant
polyamide
1 (21) and Zone 2
(22) hazardous areas.
Zone
Suitable for installation
in

Certified non-armoured
Barrier gland
Glands Restricted Breathing (Type
Increased Safety (Typee') and
(Type 'd')
Certified Flameproof Hazardous Areas with all
Zone 22
Zone 21 and
cable gland for use in Zone 1, Zone 2, conductors
'nR) seal around the cable
compound barrier
cable providing a
types of unarmoured
on the cable outer
sheath.
and an environmental seal
Pepper CR-U Type
CMP PXSS2K
Hawke 623

Glands: 60079-14: 2014

explosion
electrical equipment shall maintain the
cables to the
The connection of
relevant type of protection.
protection integrity of the enclosure you need to use
a
a flameproof
an IS circuit into for flameproof
equipment.
E.G. If you need to gland correct standard
flameproof gland and cable of
the
certified
aza.sA.ndeetk.LPrng.sdZAA..
Notes.,
Notes:.
ear.!e.ac.Sl.la. ..2h%..
es.fbec.,ksa.leiy.eal.aegpea..
Hgrsepie Jlle,
uzalass wh Non-
68
HornbillI Compex Training Units: EX 01,02,03 & 04.
Industrial Training

Glands: 60079-14: 2014

Where the certificate for the cable gland has an 'X' marking, this cable gland shall be only
used for fixed installations.
If anadditional clamping is required to prevent pulling and twisting of the cable
transmitting the forces to the conductor terminations inside the enclosure, a clamp shall be
provided and placed within 300 mm of the end of the cable gland.
Where the equipment is portable only glands without X' marking shall be
used.
Cable glands and/or cables shall be selected to reduce the effects of 'cold
flow characteristic' of the cable.

IP Washers
The Entry Thread Sealing Washers are produced in 2mm Thick White
Nylon as standard which are recommended and meet the specified
requirements of Shell's offshore operations.

Red Fibre Washers can also be supplied but careful consideration should
be given to their use in sub-zero climates where absorption, freezing and
cracking have been known to occur, ultimately impairing the degree of
Ingress Protection attainable.

IP washers can be fitted with glands to EXd equipment providing the entries have parallel
threads.

Notes:..

69
 Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Training
Ingress protection
important to realise that to effect correct installation and maintenance, it is critical to
It is
preserve any item of equipment's ingress protection requirements.
Why is ingress protection a major concern as regards hazardous area equipment?

Consider the implications on standard industrial equipment

should ingress protection become compromised, providing
the overcurrent protection is set and operating correctly the
circuit should loose supply. This although inconvenient is not
normally life threatening. There is however an increased risk
of fire, especially when dust ingress is the problem.
Ifwe translate this problem into a hazardous gas
atmosphere, the gas would have been ignited long before
the problem developed to the extent that it tripped the
breaker or blew a fuse. Think of what causes household gas
explosions, the electrical equipment is not faulty, even in the
act of turning on or off a switch, the energy is far in excess of
what is required to ignite methane.
(The same reasoning can be applied to the correct installation of conductors, heat alone can
ignite gases, as a spark is not necessarily required.)

What should we look for as regards IP protection on hazardous area equipment?

The equipment has the appropriate IP rating required
by the area.
All stoppers / blanks are present and tight, if required
they fitted with an IP washer. They should also be of
the appropriate type for the equipment. (T.B.G. Table
9). The electrical supply should not be connected to
indx
iSTB RANGE ENCLOSURE

equipment with stoppers missing. o618Ex Db

hIC
cERT No: sikIELM OOO021
Batch No:
All cable glands are correct (Table 9), undamaged and YEAROF MANUFACTURE 2011
ABHORS D dLAND
tight.
All covers have the correct bolts, all present and tight.
If covers are removed, any gaskets should be present
and undamaged.
The enclosure should be undamaged.

70
 Hornbil
Industrial Training
Compex Training Units: EX 01,02,03 & 04.

Tool Box Guide Quiz: (Edition

On which page does gland specification for Ex d equipment start? *************".

From which edition of the T.B.G. does the advice for fitting barrier glands to Ex d
equipment alter? ***********

Given that there is now conflicting advice of when to use barrier glands on Ex d
equipment, who is responsible for setting the site rules on this matter?

* ****************************************

Does EEMUA recommend following the original advice or the new advice?. ****************** *

According to the original flow chart what is the minimum standard gland requirement for
a Zone 2 1IC environment for an Exd enclosure that contains sparking apparatus that has
an internal volume of less than 2 Iitres? ***********************************

Where can Ex d IIB be installed?

A. Zone 1 and Zone 2, gas sub-divisions lIB or lIC

B. Zone 1 and Zone 2, gas sub-divisions IA or lIB

C. Zone 1 and Zone 2, gas group IB only

D. Any hazardous location.

Notes:.

71
Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Training
Zones Of Use Exercise

Indicate which areas equipment

can be installed?
Circle items that preyent equipment
Being installed. M1 T1

EPLG AAXX

Zone 1
AA AXXX

AT2 HC T4X
I8
cen be
Lnstalled m |A

Il 2G Ex d IIB T4 one
FAGGIOLATIPUMPS
MACERATA ITALY
S.p.A ATE
otor Matr. 32
CESI 06 ATEX X12G Ex d 1B T4 31
23Vn Vn A Ph KW RPM.
24 Temp.Amb. 45 c
Op.duty Ins.cl. IP6829
coNNECTCABLE FOLLOWING STANDARD EN SO079-0

25
A X X
Targhe elettropompe ATEX

CAN2G
AAAAAA AX XX X
X

AAAXX
H8T X
AX
X

XXXXXXXXXXX

EPL Ga
EPDC
1A T2 PUIBT1

72
Hornbill Compex Training Units: EX 01,02,03 & 04.
Industrial Training
Cables

Should be infallible which means Wire Bradd

Amour
that the likelihood of failing after
correct installation is so small it
Single WeA
can be ignored. Armoured
Amour (SWA)

Extruded bedded cable is

Steel ape
recommended. Amour (STA)

Copper conductors may be used

in any size required. Unarmoured NOma
Unarmoured

Aluminium conductors are not

permitted where CSA is less than 16mm2

Power cables normally PVC/ SWA

Instrument and control cables will be specified by design engineer and indicated on the
system drawings

Cables may be drawn into heavy gauge steel conduit with screwed connections or heavy
flexible conduit with an insulated outer coating
Cables MICC-For Ex'd flameproof applications, a certified Ex'd MICC gland
should be used. A standard MICC termination pot is suitable.
For Ex'e enclosures an increased safety seal pot is required.

Conduit seam welded or seamless solid drawn steel conduit should be

used as preference.
When conduit passes from safe area to a hazardous area a stopper box or equivalent
sealing device to be fitted as near to the boundary as practical

Whenever conduit is used with flameproof equipment, stopping boxes are to

incorporated at the cable entries.
In the steel wire armoured or braided cables are preferable to conduit
UK, in
hazardous areas.

Notes...

73
Hornbil1 Compex Training Units: EX 01,02,03 & 04.
Industrial Trainin9
Cables
Allcables should be marked for identification purposes. Details
of marking requirements should be included in the cO335
documentation. Permanent indelible makers should be used
Crimped terminations are generally preferable to non-crimped terminations,
as there is less risk of stray strands of wire causing circuit faults. Crimped
connections are readily inserted and removed.
Crimping tools of the ratchet type (hydraulic in larger sizes) should be used.
The simple plier type should not be used.
Sufficient terminals should be provided to terminate all cores. Unused
cores should not be left un-terminated
Sufficient length of conductor core should be left to allow for at least one
re-termination (20mm).
When there is insufficient room within the enclosure and also where
MICC conductors are used, the extra length can be accommodated by a
loop formed external to the enclosure
Ex e Increased Safety
The length of the conductor core should be kept as short as practical and no more than half
the diagonal of the enclosure, so that it does not exceed the maximum dissipated power
stated on the enclosure

Standards Toolbox Guide P4 & 107-110

International Standards:- International Electro technical Commission (IEC)

European Standards:- Committee for Electro technical Standards (CENELEC)

National Standards:- British Standards
Standards moving towards harmonisation

Notes.addis..a.sikil.thaeaubt.
***

74
Hornbill Compex Training Units: EX 01,02,03 &04.
Industrial Training

IEC Protection Concept Previous BS Replaced by EN BS EN 60079

Identical to EN Superseded *Superseded ldentical to

IEC
** Replaced *Replaced

60079-0 General BS 5501 part 1 EN 50014 60079-0*

60079-1 a BS 5501 part 5* EN 50018 60079-1*

60079-2 p BS 5501 part 3 EN 50016 60079-2*

60079-5 BS 5501 part 4 EN 50017 60079-5*

60079-6 BS 5501 part 2 EN 50015 60079-6*

60079-7 e BS 5501 part 6* EN 50019* 60079-7*

60079-10 Classification of areas BS 5345 part 2** EN 60079-10 60079-10

60079-11 BS 5501 part 7* EN 50020* 60079-11*

60079-14 Electrical Installations BS 534 5 parts 3-8** EN 60079-14 60079-14

60079-15 n BS 6941** EN 50021* 60079-15

60079-17 Inspection and maintenance BS 5345 parts 3-8** EN 60079-17 60079-17

60079-18 m BS 5501 part 8 EN 50028 60079-18

60079-25 Intrinsic systems BS 5501 part 9* EN 50039 60079-11

60079-31 Dust ignition 't BS 6467** EN 61241 60079-31*

Notes:...

75
 Hornbill Compex Training Units: EX 01,02,03 & 04.
Industrial Training

ATEX Markings
CE marking with the number of the notified body responsible for production

000Sira No. 0518 BASEEFA No. 11800

cEe CE CE Mark
CE
China Export

UKCA will start to appear on ATEX equipment as of January 2021

Mandatory as of January 2023

Product areas covered by the UKCA marking

Toy safety Non-automatic Gas appliances

Pyrotechnics weighing Machinery
Recreational craft instruments
Equipment for use
and personal Measuring outdoors
watercraft instruments
Ecodesign
Simple pressure Lifts
vessels Aerosols
ATEX
Electromagnetic Radio equipment
Low voltage
electrical equipment
compatibility Pressure equipment Restriction of
Personal protective hazardous
equipment substances

Equipment is given a category

Zone 2 Flammable matenial in liquid
safety rating torm

Zone 1
lemmabie material in geseous
with oxYEen and
Zone 0-Equipment Cat 1 ied
vey ngn concentration
in

Zone 0
Flemmable material in gaseou5
Zone 1-Equipment Cat 2 comcen YEen in high

Flammabile material unlikely, or

Zone 2-Equipment Cat 3 for a very short period and in no
concentration

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Hornbill Compex Training Units: EX 01,02,03 & 04.
Industrial Training

Sneak Question?

ATEX Certified equipment has?

A. A crown inscribed with FLP DJA hexagon inscribed Ex

B. A hexagon inscribed IEC E. The CE marking

C. A triangle insc bed LFP F. Two concentric squares

Notes.

Equipment Group Category Suitable for use in..

1G ZONE O (+1+2)
II
(Surface Industry) 1D ZONE 20 (+21 +22)
ZONE 1 (+2)
II
(Surface Industry) 8 ZONE 21 (+ 22)
3G zONE 2
3D ZONE 22

Marking according to Marking according to

Directive 2014/34/EU IEC/CENELEC/CSA standard 60079-0
(previously 94/9/EG) (ATEX)

CE l 2 GEx db eb lIC T4 Gb
CE CE-marking and number Ex Explosion protection marking
of the notified (monitoring) body db Type of protection (flameproof enclosure, level of protection,db)
(0158=DEKRAEXAM GmbH) eb Type of protection (Increased safety, level of protection eb)
(not for equipment category 3)
1IC Equipment group
Explosion protection symbol (Electrical equipment group l1, subgroup C (ypical gas:
Equipment group (equipment for hydrogen), intended for use in areas where an explosive
use in hazardous areas, other than gas atmosphere is to be expected, other than mines
mines susceptible to firedamp) susceptible to firedamp)
Equipment category (category 2) Temperature class
Explosive atmosphere (max.surtace temperature 135 °C)
gas, vapour or mist) Gb Equipment protection level
(EPL Gb; equipment with high protection level)

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 Hornbil Compex Training Units: EX 01,02,03 & 04.
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Apparatus certified by EEC certification body to a CENELEC Standard

recognised by EEC Directives
POWERNE EX POWER PACK
PN400/12 12V 4h

CE 1 2 G EEx ed IIC T6
1180
IP66 amb 200
T
Baseefa 05ATEX0250
+40C to
WARNING: DO NOT OPEN OR CHARGE IN
HAZARDOUS AREA
Year of manufacture: 2007 Serial No: 267111

Certificates where Special Conditions Apply

Certificate will end with the letter X, (in the pastQuahog Custard Handling UK Micro Torch 2AA
the letter B was used and may still be 100 Main St, Bognor Regis
s/n 201199990
Ta-40°C to +50C QUAGATEX144x
encountered on some certificates).
You should always ask to see the certificate to
CE 2G Ex d lIA T4
make sure special conditions have been met.
IECEX and Worldwide Approvals
The single public domain document for ATEX is the manufacturers
Declaration of Conformity (DoC).
This is the only document that the manufacturer is obliged to show to his
customer and the manufacturer has sole responsibility for it. ATEX
In contrast IECEx has been designed from the outset as an ISO/IEC Type5
Certification Scheme relying on a single third party to bring together all ECEX
aspects of design evaluation and production control before issuing a publicly
available certificate.
The certificate is issued by the certification body (IECEx) and not the manufacturer. Also
purchasers of any 1ECEx equipment can check on line certification status from the IECEx
database.

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As of 1st November 2006 the following countries signed up to the IECEX scheme
Australia Germany New Zealand South Africa Canada

Hungary Norway Sweden China India

Romania Switzerland Czech Republic Italy Russia

UK Deenmar apan Serbia and Montenegro

USA Finland Korea Singapore France

Netherlands Slovenia

Documentation
A verification dossier shall be prepared for every installation, containing:
Area classification document
Instructions for erection and connection
Instruction for electrical equipment with suffix *
cmor$ion
Descriptive document for 'IS' systems
Equipment declaration of conformity
Information necessary for inspection
Details of relevant calculations
Details of repairs
Gas/vapour classification
Temperature class or ignition temperature
External influences and ambient temperature
Equipment suitability e.g. Temperature rating, type of protection, IP rating, corrosion
resistance
Material characteristics
KEEP
Types and details of wiring systems CALM
Cable entry systems READ THE
DOCUMENTATION
Drawings and schedules of circuit identification

Notes:...

Sneak Question?
 Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Trainingg

What is the minimum requirement for terminating an SWA cable with an Ex'e'E1W cable
gland intoa steel enclosure having a 10 mm threaded gland plate?

A. Fit gland, earth tag, star washer and internal lock nut
B. Fit gland, external IP washer and internal locknut

Fit gland
D. Fit gland, external seal washer, and internal star washer

ATEX Directive groups and categories. Which of the following is appropriate?

A. Groupl and categories, 2 and 3

Group ll and categories 1, 2 and 3

C. Group l
and categories M1 and M2
D. Group ll and categories M1 and M2

IEC 60079-14: 2014 Dust

Gas Sreups
Apparatus Sreups
Equipment Groups

Three Surface Groups: Three More Surface Groups:

IIA IIA Fibres &Flying's (more than 500uM)
IIB IIB Non-conducting Dust (less than 500uM)
IIC IIC Conducting Dust

Dust

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Industrial Training
Equipment designed for use with flammable gases may not be suitable for use where
combustible dust may be present.
Ingress protection is the principal protection method for dust. Surface temperatures als0
need to be taken into account
There are four types of explosion protected equipment recognised by the IEC which are
applicable to dust. As from November 2013 IEC recognise the changes below.
Ex ia', 'ib', "ic intrinsic safety
-

Ex 'ma','mb', 'mc' - Encapsulation

Ex 'pD' Pressurisation
-

Ex 'ta','tb','tc'&'tD' -
Protection by Enclosure

Light Metals
Installation materials (e.g. Cable trays, Mounting plates, Weather protection) not contain
more than
Locations requiring EPL Ga': ZoweO
10% total aluminium, magnesium, titanium & zirconium, or

7.5% of magnesium, titanium & zirconium

Locations requiring EPL 'Gb': Zove l

7.5% of magnesium, titanium & zirconium

Locations requiring EPL 'GC': Zowe 2
No requirements

Notes:..

Above a Hazardous Area 2014 edelion IeC6oo71-14

Equipment that may produce hot particles or hot surfaces located above a hazardous area
shall be either totally enclosed or provided with suitable guards or screens, to prevent any
ignition sources falling into the hazardous area.

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 Hornbill Compex Training Units: EX 01,02,03 & 04.
Industrial Trainingg
Such items may include:

Fuses that may produce arcs, sparks or hot particles.

Switches that may produce arcs, sparks or hot particles

Motors or generators that have sliding contacts or brushes.
Heaters, heating elements or other equipment that may produce arcs, sparks or hot
particles.

Auxiliary equipment such as ballasts, capacitors and starting8

switches for all types of discharge luminaires.

.All lamps

Static Electricity
Non-metallic installation materials (e.g. plastic covered cable trays, plastic mounting plates
and plastic weather protection) shal be controlled by:
Insulation resistance not exceeding 1 giga-ohm, or
Limit surface area to:

EPL for location Group llA location Group IlB location Group lIC Iocation

0 Ga 5,000mmm 2,500mm 400mm

Gb 10,000mm 10,000mm 2,000mm
GC 10,000mm 10,000mm 2,000mm

Notes: .

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Industrial Training

Isolation and Permits to Work

Isolation of Equipment
Electrical equipment containing live parts which are located in a hazardous
area, shall not be opened without isolating all incoming and (where
necessary because of neutral voltage to earth) outgoing connections
including the neutral conductor.
"Isolation" in this context means withdrawal of fuses and links or locking off
of an isolator switch. The enclosure shall not be opened until sufficient time
has been allowed to permit any surface temperature or stored electrical
energy to decay to a level below which it is incapable of causing ignition
To allow work to be carried out safely, suitable means of isolation shall be
provided for each circuit or group of circuits, to include all circuit
conductors including neutral.
Labelling shall be provided immediately adjacent to each means of
isolation to permit rapid identification of the circuit or groups of
circuits thereby controlled.

What is a permit-to-work system?

W Work-Permit
Exerts from HSE website Guidance on permit-to-work systems HSG250- A guide for the petroleum, chemical and
allied industries.

Full document available as a free download -http://www.hse.gov.uk/pubns/priced/hsR250.pdf

A permit-to-work system is a formal recorded process used to control work which is

identified as potentially hazardous. It is also a means of
communication between site/installation management, plant
supervisors and operators and those who carry out the
hazardous work.
Essential features of permit-to-work systems are:
Clear identification of who may authorise particular jobs (and
any limits to their authority) and who is responsible for
specifying the necessary precautions;

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Training and instruction in the issue, use and closure of permits;

Monitoring and auditing to ensure that the system works as ISIBILITY
intended;
Clear identification of the types of work considered hazardous;
Clear and standardised identification of tasks, risk assessments,
PZW
permitted task duration and supplemental or simultaneous ANC
CE
co
activity and control measures.

When to issue a Permit to Work

Permit-to-work systems are normally
considered most appropriate tO
Non-production work (eg
maintenance, repair, inspection,
testing, alteration, construction,
and Greund Wer/Werk
dismantling, adaptation, modification, Wo
Per ermt

cleaning etc);
Non-routine operations;
jobs where two or more individuals or
groups need to co-ordinate activities
to complete the job safely;
Jobs where there is a transfer of work Note the use and control of the system is enhanced by the colour coding of the permits!

and responsibilities from one group to

another.

Permit systems vary from site to site, it is important to follow the correct procedures
pertaining to the particular site at which you work.

Hot wor Cold work Confined space

warning
DANGERD

KEEP OUT ust be obtained

Electrical Isolation Lifting

A DANGER DANGER
Electrical AUFTING
nazard INPROGRESS

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Hornbill
Industrial Training
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Gas-Free Certiticate Safe work Permit

Permit ignition sources to be used in a hazardous area under
prescribed conditions
Specific location assessed to ensure gas or vapour not
present and not expected to be present, in quantities which
may give rise to flammable concentrations, during specified
period.

Specify start date/time of permit,

Define location of activity,
Specify nature of permitted activity (e.g. Diesel
generator, drilling),
Take and record measurements to confirm absence of
ignitable concentration of flammable gas or vapour,
Specify sampling requirements to
confirm continued absence of
flammable gas or vapour,
Control of possible flammable gas or
liquid sources,

Specify contingency plans for

emergencies,
Specify expiry date/time of permit.

Notes:.. .

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Hornbill
Industrial Training
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Inspection EXO2 & EX04 Toolbox Guide P35-41

IEC 60079-17 applies to users and covers factors directly related to the inspection and
maintenance of electrical installations within hazardous areas only, where the hazard may
be caused by flammable gasses, vapours, mists, dust, fibers or flying's.
IEC 60079-17 supplements the requirements of EC 60364-6 "Electrical Installations for
Buildings."This standard is an attempt to harmonize national wiring standards in
an IEC standard. The latest versions of many European wiring regulations (e.g, BS 7671 in
the UK) follow the structure of IEC 60364 very closely.

Documentation
For the purpose of inspection and maintenance, up-to-date
documentation of the following items shall be available to the
inspector:

a) Zone classification of areas and, if included, the

equipment protection level (EPL) required for each location.
b) Equipment group (1IA, 1B or IC) and Hazardous area
Classification drawing
temperature class requirements.
c) Equipment characteristics e.g.
temperature ratings, type of protection, IP
rating, corrosion resistance.
d) Records sufficient to enable the
explosion protected equipment to be
maintained in accordance with its type of
protection. LEGEND

e Copies of previous inspection records focs oettrapot

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Notes:..

Qualification of personnel
The inspection and maintenance of installations shall be carried out by
experienced personnel, whose training has included instruction on the various
types of protection and installation practices, the requirements of this standard,
the relevant national regulations/company rules applicable to the installation
and on the general principles of area classification.

Appropriate continuing education or training shall be undertaken by personnel on

a regular basis. Evidence of the relevant experience and training claimed shallbe
available.

Grades of Inspection
Visual Inspection

An inspection which identifies, without the use of access equipment or tools, DOCUMES

those defects, such as missing bolts, which will be apparent to the eye.

Close Inspection:

An inspection which encompasses those aspects covered by a visual inspection Foraet

DotDoc
and, in adition, identifies those defects, such as loose bolts, which will be To
apparent only by the use of access equipment, for example steps, (where
necessary), and tools.

Detailed Inspection:

An inspection which encompasses those aspects covered by a Close Inspection

KEEP
and, in addition, identifies those defects, such as loose terminations, which will CALM

only be apparent by opening the enclosure, and/or using, where necessary, DOCUMENT
EVERYTHING!

tools and test equipment.

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 HornbilI
Industrial Trainingg
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Notes: . .

Sneak Question?

Restrictions apply to lamps for Ex'e' and Ex'n' luminaires. Fill in the blanks?

Lamps (e.g. bi-pins, screw

connections on tungsten lamps) using non-CoNOUCIUCmaterials
with conductiveCoaTNG-Sshall not be used unless
eSeE) with the_LQuPMSNT

As regards pressurized EX equipment what level of protection is permitted in locations

requiring EPL 'Gb' (Category '26') where the enclosure does contain ignition-capable
equipment? (EXp_?)

Exp

Types of Inspection
Initial inspection:
Are used to check that the selected type of protection and its installation
are appropriate. They are to be detailed inspections in accordance with IEC
60079-17 tables 1, 2, 3 and 4
ioouSpeelien
Periodic inspection:

May be visual or close in accordance with IEC 60079-17 tables 1, 2, 3

and 4. A
visual or close inspection may lead to the need for further detailed inspection.

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Hornbill
Industrial Training
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Sample inspection:
May be visual, close or detailed and should be used to monitor
the effects of environmental conditions, vibration, inherent
design weakness, etc.

Periodic inspection: Intervals between periodic inspections should not normally exceed
three years without seeking authoritative expert advice.
Movable electrical equipment (hand-held, portable, and transportable)
is particularly prone to damage or misuse therefore the interval
between periodic inspections may need to be reduced from the
maximum recommended 12 months.

Enclosures which are frequently opened (such as battery housings) should

have a detailed inspection at least every 6 months.

EN 50021 ExN V's IEC 60079-15 Exn

Some problems with Exn equipment under new standards
The major problem in performing a direct comparison is the different formats of the
documents. The older standard was written in a "stand alone" style, whereas the later
standard is fully integrated with IEC 60079-0, the "General Requirements" document, and
must be considered with that standard.
Remember that Declaration of Conformity issued from 1st July 2006 should not refer to EN
E FIT Fo Portose
50021 as a harmonised standard RISK ACceSS IT

Notes.. .

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 Hornbill
Industrial Training
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Table 1 -
Inspection schedule for Ex "d", Ex "e", Ex "n" and Ex "t/tD"

Check that:
Ex"d" Ex "e"EUD"
X required tor all types, n type "n only, t = type t and "tD only Grade of inspection

AGENERAL (ALL EQUIPMENT) DcvDcDc v

Equipment is appropriate to the EPLIZone requirements of the location
L
2 Equipment group is correct
A3,C. xxxxxx|
Equipment temperature class is correct (only
tor gas)
4 Equipment maximum surface temperature is correct XXXX
Degree of protection (IP grade) of equipment is appropriate for the level of
protection/group/conductivity
6Equipment circuit identification is correct
7 Equipment circuit identification is available
xxXXx
Enclosure.
are satisfactory
glass parts and glass-to-metal sealing gaskets and/or compounds xxx
There is no damage or unauthorized modifications
10 There is no evidence of unauthorized modifications
11 Bolts, cable entry devices (direct and indirect)
correct type and are complete and
and blanking elements are of the
tight
physical check
Visual checkk
12| Threaded covers on enclosures are of the correct type, are tight and secured
-physical check

Visual check
13Joint surfaces are clean and undamaged and gaskets, if any, are satistactoryy
and positioned correctuy
14 Condition of enclosure gaskets is satisfactory
15| There is no evidence of ingress of water or dust in the enciosure in accordance
with the IP rating
16 Dimensions of flanged joint gaps are:
within the limits in accordance with manufacturer's documentation or
within maximum values permitted by relevantconstruction standard at time
of installation or
within maximum values permitted by site documentation
17 Electrical connections are tignt
18 Unused terminals are tightened
19 Enclosed-break and hermeticaly sealed devices are undamaged
20 Encapsulated components are und amaged
21| Flameproof components are undamaged
22 Restricted breathing enclosure is satisfactory-(type "nR only)
23 Test port, if fitted, is functional--( type "nR" only)
24 | Breathing operation is satisfactory- ( type "nR only)
25 Breathing and draining devices are satisfactory
EQUIPMENT SPECIFIC (LIGHTING)
26 Fluorescent lamps are not indicating EOL effects
27 HID lamps are not indicating EOL effectss
28Lamp type, rating. pin contiguration and position are correct
EQUIPMENT SPECIFIC (MOTORS)
29 Motor fans have sufficient clearance to the enclosure and/or covers, cooling
systems are undamaged, motor toundations have no indentations or cracks.
30| The ventilation airflow is not impeded
xxxx|xxxX
31 Insulation resistance (1R) of the motor windings is satistactory x x IXLI
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Hornbill1 Compex Training Units: EX 01,02,03 & 04.
Industrial Training
Ex "d" Ex "e" Ex "n"
Ex"utd"
Check that:
X = required for all types, n = type "n" only, t = type "t" and "tD" only Grade of inspection
oclvclvlplclv
B INSTALLATION GENERAL

1 Type of cable is appropriate

2 There is no obvious damage to cables xxxxxxxxx
3 Sealing of trunking., ducts. pipes and/or conduits is satisfactory xxxxxxxxx
4 Stopping boxes and cable boxes are correctly filled
Integrity of conduit system and interface with mixed system maintained x x|
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

Fault loop impedance (TN Systems) or earthing resistance (IT systems) is

satisfactory
8 Automatic electrical protective devices are set correctly (auto-reset not
possible)

9 Automatic electrical protective devices operate within permitted limits x|

10
11
Specific conditions of use (if applicable) are complied with
Cables not in use are correctly terminated
x
12 Obstructions adjacent to flameproof flanged joints are in accordance with
|EC 60079-14
13 Variable voltage/frequency installation complies with documentation
INSTALLATION HEATING SYSTEMS
xxxxxx
14 Temperature sensors function according to manufacturer's documents
15 Safety cut off devices function according to manufacturers documents
16 The setting of the safety cut off is sealed XxX|
17 Reset of a heating system safety cut off possible with tool only
18 Auto-reset is not possible
19 Reset of a safety cut off under fault conditions is prevented
20 Safety cut off independent from control system
21 Level switch is installed and correctly set, if required
22 Flow switch is installed and correctly set, if required
INSTALLATION MOTORS

23 Motor protection devices operate within the permitted or time limits.

CENVIRONMENT
Equipment is adequately protected against corrosion, weather, vibration and
other adverse factors
No undue accumulation of dust and dirt
3 Electrical insulation is clean and dry

(D detailed, C close, V = visual)

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Hornbill
Industrial Training
Compex Training Units: EX 01,02,03 & 04.
Table 2- Inspection schedule for Ex "i" installations

Check that: Grade of

inspection
X = required
Dc v
EQUIPMENT

Circuit and/or equipment documentation is appropriate to the EPL/Zone

Equipment installed is that specified in the documentation
BCircuit and/or eguipment category and group correct
4 rating of equipment is appropriate to the Group Ill material present
5 Equipment temperature class is correct
Ambient tem perature range of the apparatus is correct for the installation
7 Service temperature range of the apparatus is correct for the installation

8 Installation is clearly labelled X

SEnclosure, glasS parts and glass-to-metal sealing gaskets and/or compounds are satisfactory X
10 Cable glands and blanking elements are the correct type, complete and tight
physical check
Visual check

11 There are no unauthorized modifications

12 There is no evidence of unauthorized modifications
13 Diode safety barriers. galvanic isolators, relays and other energy limiting devices are of the
approvea type, nstalled in accordance with the certification requirements and securely
earthed where required
14 Condition of enclosure gaskets is satisfactory

15 Electrical connections are tight

16 Printed circuit boards are clean and undamaged

17 The maximum voltage Um of the associated apparatus is not exceeded

BINSTALLATIONN

11cables are instaled in accordance with the documentation

2 Cable screens are earthed in accordance with the documentationn
There is no obvious damage to cables
4Sealing of trunking, ducts, pipes and/or conduits is satisfactory
Point-to-point connections are all correct (initial inspection only)
x
5
6Earth continuity is satisfactory (e.g. connections are tight, conductors are of sufficient cross-
section) for non-galvanically isolated circuits

Earth connections maintain the integrity of the type of protection

8 Intrinsically safe circuit earthing is satisfactory
9Insulation resistance is satisfactory
10 Separation is maintained between intrinsically safe and non-intrinsically safe circuits in
common distribution boxes or relay cubicles
s

11 Short-circuit protection of theDower

power supply is in accordance with
the documentation

12 Specific conditions of use (f applicable) are complied with

13 Cables not in use are correctly terminated
CENVIRONMENT
Equipment is adequately protected against corrosion, weather, vibration and other adverse
tactors

2 No undue external accumulation of dust and dirt

(D detailed. C = close, V = visual)

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Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Training

Sneak Question?

When an Exde flameproof machine is fitted with an Exe terminal box, which gland should be
used?

13 GID
EEx ia llC T5
MC 06.ATEX.8000-001XU

Maxon- Series
MARON CO
nON
8000 Valve
NoreYY MU rusA
esed Shut-ofr Valves

Maxon- Series
MAXON CORPORATION, MUNCIE
8000 Valve ExtEC T
IN 47302 USA
7PA0 2757 Normally Closed Shut-0ff Valve
24VDC 115A 1.6W 200/13.8
SERIAL# NAT/PROP
Model # M..
200S8113DA11-J3BO
T-40 F140
MLX MA
SI
ACT 4 6.9 SAR sOC

CE
CRN OC2221.5C PN :C878085
4,4X,1P6S
NEMA
PAT. NO. 6, 789, 563 & 6, 805, 328

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Notes:..

YCLOPS NDICATORR
XPLOSIONPROOF
SWITCHO
SNAP
O8 HAZAROOUS LOCATIONS
-PURGE
MODEL PScZ-3A
TION1 ASS GROUPSANO
oscOECT SPa
C & D. T6 0S AMCSERES
GouDA 8. CAR
OTLY CLOSED
WN C EEP
2.
Class L Dhsion uniess power s swiched ot nES CMCUurS 30NT
LORSO
Do not dscomect non-hazardous location o250
96 V2A-125 Voc 1/4
knowm to be MICRO SWITCHP-250
US area s
VAC

IC T6 GC
Exe mb tozl T68 C P6 Dc
CE130
0575
D Ex D lpzl A22
3OV-2008-0SL-ATEX-D6T6
CST
LINO

ECEXDNV O8.O525

SOLUTIONS GE
Websier. TX T7538
www.pugesouoneLSA
cm

CYCLOPS
X-PURGE CONTROLLER

Cless 1 Dvision L Group 8. C&D

a0 WARNING
Emperare Cooe T4

2DEx 0 lpxl A21

S C PS L
0575 DNY-2008-SL-ATBX-057o
ECEX DNV CElos23

Serial Na25050E04
VAC. SO/6O Hz.

15 VAC 50/80 2 ES Ai
230 ALARM
CONTACT RATING5 ACOC S0 mA

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Hornbill Compex Training Units: EX 01,02,03 & 04.
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Certification
Where the certification plate or markings on explosion protected
equipment is missing or illegible, alternative methods may be used to
determine traceability to the certification details of the specific
equipment.
The method used could include: additional identification labels which incorporate unique
tag numbers, serial numbers or reference to the installation databases.
The method of attaching or fixing the labelling shall not reduce the integrity of the
equipment

Environmental conditions
Electrical equipment in hazardous area can be adversely affected by
environmental conditions in which it is used. Some of the key elements
to consider are corrosion, ambient temperature, ultraviolet radiation,
ingress of water, accumulation of dust or sand, mechanical effects and
chemical attack
Additional precautions should be taken with the environmental
protection on equipment located on seashore and offshore effected by
salt water, water deluge, high pressure cleaning, sandblasting and heavy
wind conditions

Notes.

95
Hornbil
Industrial Training
Compex Training Units: EX 01,02,03 & 04.

Sneak Question?

When equipment is handed over from the installer, what TYPE of inspection is required?
A. Visual

B. Detailed

Initial
D. Sample

CLOSE inspections on Ex 'e' or 'n' equipment, requires?

A. To check that lamp ratings, type and position are correct

B. To check that electrical connections are tight
C. To check that the electrical insulation is clean and dry

DTo check that the apparatus circuit identification is available

There are three categories of intrinsically safe apparatus ia', ib' and ic. Which one of the
following statements is true?
A. ib is only suitable for Zone 2.
(B) ia is suitable for Zones 0, 1 and 2 and specified gas sub-divisions.
C. ib is suitable for all zones and gas sub-divisions
D. ia is unsitable for Zone 0 and gas sub-division IIc.

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Hornbill Compex Training Units: EX 01,02,03 & 04.
Industrial Training

Sneak Question ?

Which of the following is considered to be reasonably practicable for enciosures

containing EXi circuits?
ATo be labeled that all circuits are intrinsically safe
B. To be fitted with 30A terminals inside.

C. The terminals must be Exe.

D. The ingress protection (IP) to be IP65

Which of the following types of equipment may be connected to an intrinsically safe

Zener barrier?
A. Any apparatus may be connected in the hazardous area
B. Simple apparatus and any type of IS certified apparatus

C.only the apparatus specified in the documentation

XD. The apparatus specified in the documentation and junction boxes

The function of safety units, such as Zener Barriers is to:?

(A. Limit the maximum energy which may be transferred from the power supply to
equipment in the hazardous area.
B. Allow any type of certified apparatus to be used without any other
considerations being necessary.

C. Allow certified and simple apparatus to be used without any other

considerations being necessary.
D. Limit the capacitance and inductance in the hazardous area to safe levels.

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Hornbill
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Equipment Selection Test

No. Equipment Area Suitability
Ex d IAT4 Ethylene 11S
NO
Exia II T6 Zone 0 1G Ga YES
Exde IIC/T6 Carbon Disulphide
(gnition 102°C)
ExnII T3 Zone 1 2G Gb
NOZovzZ
Exíb IIB T6 Zone 0 1G Ga No-dve
Exib IIB T6 Zone 1
2G Gb Yes
Exe IIC T5 Below Ground (Mine) Na Hc
[Exia IIC] Zone 1
2G Gb NO
9 Exd Il:T2 Hydrogen YES
10 Exia IIA T6 Zone 0 1G Ga
YES
11 Exg I1B T3 Propane
12 Exd [ib] IIC T6 Ethylene B
13 Exm IIA T3 Propane Yes
14 Exden [ib]IOT4 Zone 2 3G Ge
15 Exo ILTI Zone 0 1G Ga
16 Exia IIC TS Acetylene
(lgnition 305°C)
*
17 Exp 11T4 Hydrogen ES.
18 Ex@ Exia] T2 Void above the liquid insidea
storage Tanker ZovO| NO
19
[Exia Exia 1 Propane NO
Ex1IA T1 Propane NO
21 Exd IA T6) Acetylene

98
Hornbill
Industrial Training
Compex Training Units: EX 01,02,03 & 04.
Minimum Requirements for E'x Enclosures

Study the information given for the threaded and

clearance holes- Items A to I and decide where
appropriate the need to fit (to minimum requirements)
the four items shown right using SWA cable glands.
Tick the box where required'
OOO
IP
Washer Locknut
Serrated
(Star) Earth Tag
(Banjo)
washer

Ex'e 8mm thick threaded plastic junction box IP54

B Ex'e 3mm thick threaded plastic junction box IP54

Ex'e 6mm thick threaded plastic junction box with

internal earth plate IP65

D
Ex'd 12.5mm thick flameproof enclosure IP54
XX
Ex'e 8mm thick metal clearance hole IP54 X
F
Ex'e Smm thick threaded metal enclosure IP54

I X
G Ex'e 6mm metal plate clearance hole IP65
X
I
H Ex'e 6mm plastic clearance hole with a earth
continuity platelP54

15mm boss entry metal Ex'n restricted breathing

light fitting IP54
X
99
Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Trainingg

Study the information given for the threaded and

clearance holes Items A to I, and decide where
-

appropriate the need to fit (to minimum

requirements) the four items shown right using Serrated
SWA cable glands. (Star) Earth Tag
IP Washer Locknut
Tick the box where required washer (Banjo)

J
Smm thick threaded plastic junction bOx
IP54

K
8mm thick threaded plastic junction box
IP54

ómm thick threaded plastic junction box

with internal earth plate IP54

M 1Omm thick metal threaded Ex ia

Transmitter IP54

N
ómm thick metal enclosure clearance hole
IP54
K
O
8mm thickk threaded metal Thermocouple
IP65

P 1Omm metal plate clearance hole Ex ic

LED Beacon IP65

Q| a
Smm plastic clearance hole with threaded
earth continuity plate IP65

R 1Omm threaded entry Ex ib DP Cell IP54

100
Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Training

CompEx
Complete the crossword below

Across Down
6. What is Exe equipment 1. Grade of inspection
7. What is Exd equipment 2. Name a gas in IIC gas group
9. Unused entries should be what 3. Fine stranded wire should always be ?
11. Glands used on Exd,e,n equipment should 4. X after the number on certified equipment
be what 5. un-used cores should always be ?
12. What should you always use on Exnr 8. I.S. impedance should not exceed
equipment entry hole 9. Preferred colour for I.S. cables
13. How many mods can be done on Exd 10. what is a classed as a Simple device
equipment

101
Hornbill Compex Training Units: EX 01,02,03 & 04.
Industrial Training

Hornbill Hornbill Industrial Training

Doc Title: Appeals Procedure Doc No: CESR 171
Date issued: 27/02/2008 | Date reviewed: 15/07T/08 Rev No: 0
Issued: LDavies Authorised: R.Scaplehorm Pages: 1 of1

APPEALS PROCEDURE

The assessment and verification process at Hornbill Industrial Training is

subject to clearly defined practices and processes; however, it is still
possible that a candidate may raise a concern.

Candidates have the right of appeal if

They are not satisfied with the assessor's judgment of their
competence during the assessment process,
f they feel that the opportunity for assessment is being denied.

The appeal procedure is as follows:

In the first instance you should make contact with the assessor or
internal verifier on 01792 818111 and explain your concerns. He/
she will try to clarify any issues. These discussions will be
documented on the Appeals Form.
The Appeals Form is to be completed by the assessor or internal
verifrer. The candidate should check that the written submission
accurately reflects the nature of the appeal. The Form also provides
details of the action taken and by whom. If the candidate agrees with
the decision then the appeal is conduded and marked as such on the
form.
f, howeve, you are still not satisfied then you can take the matter
up with the Secretary of the Awarding Body explaining fully your
Concerns.
If the Secretary feels your concerns are justified the matter will be
referred to the Awarding Body for adjudication. The decision of the
Board will be final.

102
Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Training

Hornbill
Unit 6
Darcy Business Park
Llandarcy, Neath
SA10 6EJ
Tel: 01792 818111
Industrial Training Fax: 01792 321146
www.hornbill.co.uk

APPEALS FORM

Name of Candidate ****************************************

Course: ***** *******************

Name oT ASsesSsor. .... - .*****************************

Name of Internal Verifier *** *****

Cause for Appeal:

Action Taken:

Appeal Concluded YES NO

If NO,referto Awarding Body

I

fully understand and agree with the above

Signed (candidate). . *************** Date ***********

Signed (for HIT).. ***********************.*.************************** Date

assessment and certification for electrotechnical personnel working in potentsially hazardous or explosive atmospheres
n
Bca Conraca

CompE
APPROVED CONTRACTOR wISTOSN PSOVL

103
Hornbil Compex Training Units: EX 01,02,03 & 04.
Industrial Training

Hornbill Hornbill Industrial Training

Doc Title: Equal Opportunities Policy Doc No: CESR 17
Date issued: 30/02/20D83 Date reviewed: 15/8/08 Rev No: 0
Issued: L Davies Authorised: R.Scaplehorn Pages: 1 of1
EQUAL OPPORTUNITIES POLICY STATEMENT

We are an equal opportunities organisation. We are committed to ensuring that al our candidates
and centre staff (persons) are protected from unlawfu discrimination whilst attending or
deliverin
their course and assessmentt
What is Discrimination?

Direct discrimination occurs where someone is treated less favourably and put ata
disadvantage on discriminatory grounds in relation to his or her attendance and assessment
e to for example sex. raoe cclour. age. nationality. religion. religious or philosophical belief.
ethnic national origin, marital status, civi part ship, disability. educational abity, sexual
orientation or genderre-assignment). Diret discrimination may even occur unintentionally.

Indirect discrimination occurs where the individuas attendance or assessment is subject to an

unjustifed condition which one person finds more difficut to meet although, on the face of it,
the condition or requirement is neutral

Victimisation occurs were an individual is treated less favourably than another person because
she taken acton to assert their statutory rights or assisted another person with
has
informabion in that regard.

Harassment occurs where an individual is subjected to uwanted conduct that has thee
purpose or effect of violating that person's dignity or creates an intmidating. hostile.
degrading. humiliating or offensive emvironment for the individual

Our Commitment

All persons will be treated equally. fairty and with respect.

No person will receive less favourable treatment or will be discriminated against.

All persons have a personal responsibility for the application

of this equal opportunity policy.
which extends to the treatment of all other persons

Any person who believes s/he may have been unfairty discriminated against is encouraged to
use our grievance procedure.

Any person who conducts himself or herself in a discriminatory manner towards another
Personor member of the public will be guity of gross misconduct and will be subject to
disciplínary or legal acbon.

Russell Scaplehom
Managing Director
January 2008

104
Hornbill
Training
Compex Training Units: EX 01,02,03 & 04.
Industrial
INTEGRATED QUALITY, ENVIRONMENTAL & SAFETY

Hornbil
Industrial Training
QESR

Title: DATA PROTECTION POLICY STATEMENT Doc No: QESR_ HIT 1003
DateIssued: 29/09/2013 Date Revised:21/01/2019 Rev No:3
Issued By: Jason Williams Authorised: Russell Page:1 of 1

Scaplehom

DATA PROTECTION POLICY STATEMENT

Hornbil is committed to a policy of protecting the rights and privacy of candidates in
accordance with the Data Protection Act. Hombill needs to process certain information
about its candidates and other individuals it has dealings with for administrative purposes
(e.g. to administer courses, to record progress, to agree awards, to collect fees, and to
comply with obligations to external agencies). To comply with the GDP Regulations
2018, infommation about individuals must be collected and used fairly, stored safely and
securely and not disclosed to any third party unlawfully
The policy applies to all candidates. Any breach of the Data Protection Act 1998 or
Hombill Data Protection Policy is an offence, and, in that event, Hornbill disciplinary
procedures will apply. As a matter of good practice, other agencies and individuals
working with Hornbill, and who have access to personal information, will be expected to
have read and comply with this policy. Itis expected that departments/sections who deal
with external agencies will take responsibility for ensuring that such agencies sign a
contract agreeing to abide by this.
Data Protection Principles:
If you are processing/collecting personal information covered by the Act, you must
comply with the General Data Protection Regulations 2018.
The Data Protection Act 1988 governs the use of personal information through the eight
data protection principles.
These principles require that personal infomation is:
Processed fairly and lawfully
Processed for one or more specified and lawful purposes, and not further
processed in any way that is incompatible with the original purpose
Adequate, relevant and not excessive
Accurate and, where necessary, kept up to date
Kept for no longer than is necessary for the purpose for which it is being used
Processed in line with the rights of individuals
Kept secure with appropriate technical and organisational measures taken to
protect the information
Not transfered outside the European Economic Area (the European Union
member states plus Norway, Iceland and Liechtenstein) unless there is adequate
protection for the personal information being transferred

Russell Scaplehorn
Managing Director
January 20018

QESR_HIT_1003 Rev 3 2019

105
 Hornbil
Industrial Training

Hornbill Industrial Training

T: +44 (0) 1792 818 111| E: [email protected] I
W: hornbill.co.uk
 Hornbill
Industrial Training

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 Hornbil
Industrial Training

Hornbill Industrial Training

T: +44 (0) 1792 818 111 I
E: [email protected] I W: hornbill.co.uk
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