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0 Basics of Explosion Protection

Flammable gases, mists and dusts, together with oxygen, form
explosive atmospheres. If such an atmosphere is ignited, an
explosion results, which may cause serious damage to per-
sonnel and equipment.
An explosion can only take place if the following factors are
jointly active:
1. flammable substance (gas, vapour, mist or dust)
in a suitable distribution and concentration,
2. oxygen (from the air) and
3. ignition source.
An explosive atmosphere only occurs if the substance-air mix-
ture lies within a certain concentration range, the explosion
limits. The explosion limits depend on the ambient pressure
and the oxygen concentration of the air.
Explosion Protection
In order to avoid explosions and associated dangers, an op-
erator must incorporate effective explosion protection precau-
tions into his plant.
The principle of integrated explosion requires that explosion
protection measures be taken in the following order:
1. Measures to prevent formation of a dangerous explo-
sive atmosphere.
2. Measures which prevent dangerous explosive atmos-
pheres from igniting.
3. Measures which restrict the effects of an explosion to a
safe level.
So are distinguished:
Primary explosion protection:
all measures which prevent the formation of an explosive
atmosphere;
Secondary explosion protection:
all measures which restrict the effects of an explosion to
an insignificant level.
Classification of Zones
Hazardous areas are classified into Zones, depending on the
composition and presence of an explosive atmosphere. This
enables both selection of suitable equipment and appropriate
electrical installation.
Classification of zones and use of equipment
Zone 0 Equipment with certificate of conformity or type test
certificate; especially approved for Zone 0.
Zone 1 Equipment with certificate of conformity or type test
certificate.
Zone 2 Equipment complying with the basic requirements of
Directive 94/9/EC (Equipment certified for Zone 0 and
Zone 1 can also be used).
Gases, Dusts Definition (94/9/EG)
vapours, explosive
mists atmosphere
is present
Zone 0 Zone 20 permanent,
category 1 G category 1 D long-term
Zone 1 Zone 21 occasional
category 2 G category 2 D
Zone 2 Zone 22 seldom or
category 3 G category 3 D short-period
G = gases, D = dusts
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0 Basics of Explosion Protection
Temperature Classes
Ignition temperature is the lowest temperature of a surface at
which an explosive atmosphere ignites on it. Flammable va-
pours and gases can be classified into temperature classes
according to their ignition temperature.
The maximum surface temperature of a piece of equipment
must always be lower than the ignition temperature of the gas-
air mixture or vapour-air mixture in which it is placed.
Explosion Groups
Explosion protected electrical equipment is divided into 2
groups:
Group I Electrical equipment for mining.
Group II Electrical equipment for all other hazardous areas.
Electrical equipment of group II is further subdivided in groups
IIA, IIB and IIC, depending on the danger level of the gas or
vapour atmosphere in which they are operated. Equipment of
group IIC is suitable for use in the most dangerous atmos-
pheres.
Temperature Classes to IEC
Temperature class Maximum permissible Ignition temperatures Temperature class
IEC / EN surface temperature of of flammable substances NEC 500-3
NEC 505-10 the equipment [C] [C] CEC 18-052
T1 450 450 T1
T2 300 300 450 T2
280 280 300 T2A
260 260 280 T2B
230 230 260 T2C
215 215 230 T2D
T3 200 200 300 T3
180 180 200 T3A
165 165 180 T3B
160 160 165 T3C
T4 135 135 200 T4
120 120 135 T4A
T5 100 100 135 T5
T6 85 85 100 T6
Examples of the Classification of Gases and Vapours into Explosion Groups
and Temperature Classes
T1 T2 T3 T4 T5 T6
I Methane
II A Acetone Ethyl alcohol Gasoline Acetaldehyde
Ethane i-amyl acetate Diesel fuel Ethyl ether
Ethyl acetate n-butane Aviation fuel
Ammonia n-butyl alcohol Heating oils
Benzene (pure) n-hexane
Acetic acid
Carbon monoxide
Methane
Methanol
Propane
Toluene
II B Town gas Ethylene
(coal gas)
II C Hydrogen Acetylene Carbon disulphide
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Types of Protection
In areas where explosive atmospheres can occur despite
the explosion protection measures employed, only explo-
sion-protected electrical equipment may be used. Explo-
sion protected electrical equipment can be manufactured
to IEC protection type levels.
Protection type Basic principle Schematic Principal application
to IEC or EN standard representation
Parts which can ignite an explosive atmosphere
are placed in an enclosure which, if there is an ig-
nition of an explosive mixture internally, will with-
stand the pressure and prevent the explosion be-
ing transmitted to the atmosphere around the en-
closure.
Additional measures are taken to achieve a higher
level of safety and avoid the risk of impermissibly
high temperatures and the occurrence of sparks
and arcs internally or on external parts of electrical
equipment, which in normal use produce neither
sparks, arcs nor dangerous temperatures.
The formation of an explosive atmosphere inside
an enclosure is prevented by using a protective
gas to maintain an internal overpressure relative to
the surrounding atmosphere, and if necessary, the
interior of the enclosure is permanently supplied
with protective gas so that there is dilution of flam-
mable mixtures.
The equipment placed in the hazardous area con-
tains only intrinsically safe circuits. A circuit is in-
trinsically safe if no sparks or thermal effects occur
under established test conditions (including the
normal operating and certain fault conditions),
which could lead to the ignition of a given explo-
sive atmosphere.
Electrical equipment or parts of electrical equip-
ment are immersed in a protective liquid in such a
way that an explosive atmosphere above the sur-
face or outside the enclosure cannot be ignited.
Type of protection by which the equipment parts
that could become an ignition source are fixed in
position and completely surrounded by finely
ground solids, so as to prevent ignition of an exter-
nal explosive atmosphere.
Parts which can ignite an explosive atmosphere
are embedded in a casting compound so that the
explosive atmosphere cannot be ignited.
Electrical equipment is not capable of igniting a
surrounding explosive atmosphere (in normal op-
eration and under defined abnormal operating con-
ditions).
Flame-proof
enclosure
d
IEC 60 079-1
EN 50 018
Increased safety
e
IEC 60 079-7
EN 50 019
Pressurised
apparatus
p
IEC 60 079-3
EN 50 016
Intrinsic safety
i
IEC 60 079-11
EN 50 020
Oil immersion
o
IEC 60 079-6
EN 50 015
Powder filling
q
IEC 60 079-5
EN 50 017
Moulding
m
IEC 60 079-18
EN 50 028
Protection method
n
IEC 60 079-15
EN 50 021
Zone 2
Several protection
methods are
subsumed under the
protection type
All electrical equipment
for zone 2, less suitable
for switchgear and
switching installations
Switchgear for low
powers,
control gear and
indicating equipment,
display equipment,
sensors
Electronic devices
Measurement and
control equipment,
communications
equipment,
sensors, actuators
Switching and
control cabinets,
analysis devices,
large motors
Transformers,
starting resistors
Switchgear and switch-
ing installations, control
and display units, con-
trol boards, motors,
transformers, heating
devices, light fittings
Terminal and connection
boxes, control boxes for
the installation of Ex-
components (which are
protected in another pro-
tection class), squirrel
cage motors, light fittings
Basics of Explosion Protection
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Certification and Marking
Only appropriately certified and marked units may be used in
hazardous areas. Two directives are valid up to year 2003 for
placing on market of explosion protected equipment:
EC Directive 79/196/EEC (until 30.06.2003)
EC Directive 94/9/EC (ATEX 100a)
Duties of the Manufacturer, Installer and Operator
Safety can only be guaranteed in hazardous areas through close
collaboration between operators, installers and manufacturers
of explosion protected plant and components, as well as test
stations, authorities and standardising associations.
The manufacturers of explosion protected equipment must be
responsible for part testing, certification and documentation,
and ensure that each finished device corresponds to the tested
type model.
The installer must comply with the installation requirements and
select and install the electrical equipment in accordance with
its use.
The operator is responsible for the safety of his plant. He must
assess the explosion hazard and undertake zone classifica-
tion. He must ensure that the plant is properly installed and
tested before first use. He must ensure the correct condition by
regular testing and maintenance.
EC Directive 79/196/EEC 94/9/EC
Validity until 30.06.2003 from 01.03.1996
Range of validity for equipment electrical equipment all equipment and protection systems
in hazardous areas gases and vapours gases, vapours and dusts
not for mining including mining
QM system of manufacturer no requirements QM certificate of a notified body
Certificate of conformity conformity or inspection certificate manufacturers declaration
of a notified body of conformity on the basis
of the type examination
Marking laid down by the Directive and the standards
Name or marking of manufacturer
Type marking (e.g.) 6000/562-.... 6000/562-....
Address D-Knzelsau
CE mark, no. of testing authority CE
(e.g. PTB) 0102
Test station, no. of certificate (e.g.) PTB No. Ex-91.C.1045 1) PTB 97 ATEX 2031 1)
Mark according to EC Directive 2) 2)
(free movement of goods)
Group and category of equipment: Group I: M 1 or M 2
Mining (I) I or II Group II: 1 g/D, 2 G/D, 3 G/D
Other hazardous areas (II)
EN marking EEx / Ex EEx / Ex
Protection types (e.g.) d, e, q, ... d, e, q, ...
ib or [ib] 3) ib or [ib] 3)
Subclassification for Group II A or B or C A or B or C
(only for d and i)
Temperature class for II T1 T6 T1 T6
Electrical data V, A, W, Hz V, A, W, Hz
Ambient temperature,
if other than 20 C ... + 40 C, (e.g.) Ta 50 C Ta 50 C
1) With ... X if special conditions are indicated for use etc. 2) New: always present, old: not on Ex components
With ... U for Ex components. 3) Intrinsically safe apparatus: ib / associated apparatus: [ib]
Basics of Explosion Protection