Ex Inspaction

(Pty) Ltd
Government
Appointed
ATL
CERTEX Appointed Ex Laboratory
T0104
Reg No: 1999/027771/07

PO Box 467
Olifantsfontein
1665
Tel: +27 (11) 316 4601

Fax: +27 (11) 316 5670
E- mail: info@explolabs.co.za
Inspection of in-service Explosion Protected Equipment - Unsafe

Conditions and Cures
Presented by
Johannes Auret, Explolabs and CERTEX

SAFA SYMPOSIUM 2011 CTICC
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Testing and Certification Certification Mark for Explosion Protected (Ex) Equipment
Area Classification / Explosion Risk Assessment Inspection of New or In-service Ex Equipment &
Installations Management System for Ex Installations Consultation Presentations & Workshops
Training Courses
INSPECTION OF IN-SERVICE EXPLOSION PROTECTED EQUIPMENT

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INDEX
TOPICS
Page
1. Introduction...................................................................................................................... 3
2. Questions to be answered ............................................................................................... 3
3. Definition of Inspection .................................................................................................. 3
4. Standards / Info Basis...................................................................................................... 3
5. GRADES of inspection .................................................................................................... 4
6. TYPES of inspection ........................................................................................................ 5
7. Generic Inspection Sheets ............................................................................................... 6
8. Conclusions ................................................................................................................... 25
Annex A Equipment selection.......................................................................................... 26
Copyright of this material belongs to
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1. Introduction
The inspection of Explosion Protected (Ex) Equipment, together with appropriate
maintenance and repair, is critical for safety. This paper highlights the differences
between electrical and Ex inspections and presents some solutions based on
standards covering the subject and best practice from experience.
2. Questions to be answered
1. Q: What is the PURPOSE of an Ex inspection ?
2. Q: We know we need to inspect in-service Ex equipment at least once in
2 years (periodic inspection).
- What Grade of inspection must be used (V/C/D).
3. Q: When must additional inspections be done ?
4. Q: Who is competent to do inspections ?
3. Definition of Inspection
Action comprising careful scrutiny of an item carried out either without dismantling, or
with the addition of partial dismantling as required, supplemented by means such as
measurement, in order to arrive at a reliable conclusion as to the (suitability and)
condition of an item.
4. Standards / Info Basis

Legal Compliance
Standard
SANS 10086-1
Based on
Application (technically)
Old version (Edition 2) of IEC

60079-17
SANS 10086-2
SANS 10086-1, adapted for

underground mining
All surface installations in

hazardous areas (under both the
OHS Act and the MHS Act)
All underground mining
installations in hazardous areas
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NOTE that information taken from SANS 60079-17 Edition 4 (IEC 60079-17 Edition 4)
is used on the next pages (updated versions of the examples listed in
SANS 10086-1).
NOTE that this presentation is based on the above national standards. Individual
companies may have stricter requirements.
5. GRADES of inspection
SANS 60079-17 defines visual, close, and detailed inspections.
visual inspection (V): An inspection that identifies, without the use of access
equipment or tools, those defects, for example, missing bolts, which will be apparent
to the unaided eye. Visual inspections do not require the enclosure to be opened, or
the equipment to be de-energized.
close inspection (C): An inspection that encompasses those aspects covered by a
visual inspection and, in addition, identifies those defects, for example, loose bolts,
which will be apparent only by the use of access equipment, for example, steps
(where necessary) and tools. Close inspections do not require the enclosure to be
opened, or the equipment to be de-energized.
detailed inspection (D): An inspection that encompasses those aspects covered by
a close inspection and, in addition, identifies those defects, for example, loose
terminations, which will only be apparent by de-energizing the equipment and opening
up the enclosure, or using, where necessary, tools or test equipment (or both).
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6. TYPES of inspection
TYPES of inspection are as follows.
Inspection
Type
Initial
Explanation
Purpose
Inspection of all electrical

equipment, systems and
installations before they
are brought into service.
Periodic
Inspection of all electrical

equipment, systems and
installations carried out
on routine basis. At least
once in 2 years.
To check that selected

type of protection and
installation is correct. If
supplier
has
quality
control, only explosion
protection
features
affected by installation
need to be checked, e.g.
flameproof joints on Ex d
terminal box.
To establish if the
explosion protection of
the item and installation is
still intact.
Sample
Inspection
of
a
proportion
of
the
electrical
equipment,
systems and installations
To monitor the effect of

environmental conditions,
vibrations , inherent
design weaknesses, etc.
Interpretation:
To
complement
Periodic
inspections by detecting
accelerated
wear
or
damage that may only be
detectable by a Detailed
inspection.
Inspection
Grades
(V/C/D) applicable
D (full or partial).
Example
1:
New
installation.
Example 2: Replacement
motor.
V or C.
A visual or close periodic
inspection might reveal the
need for a detailed
inspection.
Example: Equipment in
service and operates
normally (fault free).
V, C or D.
Example 1: Check 10% of
motor
stop-starts
for
cracks
on
insulators,
damaged seals.
Example 2: Check the
high-quality
earth
impedance
for
safety
barriers on PT loops.
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7. Generic Inspection Sheets

7.1 Introduction
Using the preceding definitions, generic inspection sheets from SANS 60079-17
Edition 4 (IEC 60079-17 Edition 4) may be used for practical inspection.
(Reminder: These are updated versions of the examples listed in SANS 10086-1).
Depending on the sophistication of the inspection staff, these can be used, or specific
checklists (suitable for specific equipment, e.g. fluorescent luminaries of a particular
make and model, or Ex nA motors) can be compiled.
The inspections sheets address three areas of compliance, i.e. the equipment, its
installation and its environment. Equipment inspection requires the explosion
protection rating and suitability to be first evaluated, then its condition.
The inspection sheets make provision for the three grades of inspection, i.e. Visual
(V), Close (C), Detailed (D).
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7.2 APPLICATION Ex ed indicator stop-start station (D)
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Inspection schedule for Ex d, Ex e and Type n installation

(D = detailed, C = close, V = visual)
Equipment description _____________ Tag no ________ Ex rating __________
1
2
Ex d
3
4
Ex e
Type n
Grade of inspection
V D C V D C V
Check that:
D C
EQUIPMENT
Equipment is appropriate to EPL/Zone requirement of the location .....
X X X X X X X X X
Equipment group is correct ..................................................................
X X
X X
X X
Equipment temperature class is correct ...............................................
X X
X X
X X
Equipment circuit identification is correct .............................................
X
X
X
Equipment circuit identification is available ..........................................
X X X X X X X X X
Enclosure, glasses and glass-to-metal sealing gaskets and/or compounds are
X X X X X X X X X
satisfactory
7 There are no uncertified modifications .................................................
X
X
X
8 There are no visible uncertified modifications ......................................
X X
X X
X X
9 Bolts, cable entry devices (direct and indirect) and blanking elements are of the
correct type and are complete and tight
X X
X X
X X
- physical check ...................................................................................
- visual check .......................................................................................
X
X
X
X
10 Flange faces are clean and undamaged and gaskets, if any, are satisfactory
.............................................................................................................
11 Flange gap dimensions are within permitted maxima ..........................
X X
12 Lamp rating, type and position are correct ...........................................
X
X
X
13 Electrical connections are tight ............................................................
X
X
14 Condition of enclosure gaskets is satisfactory .....................................
X
X
15 Enclosed-break and hermetically sealed devices are undamaged .......
X
16 Restricted breathing enclosure is satisfactory ......................................
X
17 Motor fans have sufficient clearance to enclosure or covers (or both) ..
X
X
X
18 Breathing and draining devices are satisfactory ....................................
X X
X X
X X
1B INSTALLATION
1 Type of cable is appropriate .................................................................
X
X
X
2 There is no obvious damage to cables ................................................
X X X X X X X X X
3 Sealing of trunking, ducts, pipes or conduits (or both) is satisfactory ...
X X X X X X X X X
4 Stopping boxes and cable boxes are correctly filled ............................
X
X
X
X
5 Integrity of conduit system and interface with mixed system is maintained
.............................................................................................................
6 Earthing connections, including any supplementary earthing bonding,
are of sufficient cross-section
X
X
- physical check ...................................................................................
X
- visual check .......................................................................................
X X
X X
X X
X
X
X
7 Fault loop impedance (TN systems) or earthing resistance (IT systems) is
satisfactory ..........................................................................................
8 Insulation resistance is satisfactory ......................................................
X
X
X
9 Automatic electrical protective devices operate within permitted limits .
X
X
X
10 Automatic electrical protective devices set correctly (no auto-reset) ....
X
X
X
11 Specific conditions of use (if applicable) are complied with ..................
X
X
X
12 Cables not in use are correctly terminated ...........................................
X
X
X
X X X
13 Obstructions adjacent to flameproof flanged joints are in accordance with IEC
60079-14 .............................................................................................
14 Variable voltage/frequency installations are as per documentation ......
X X
X X
X X
1C ENVIRONMENT
X X X X X X X X X
1 Equipment is adequately protected against corrosion, weather, vibration and
other adverse factors ...........................................................................
2 No undue accumulation of dust and dirt ...............................................
X X X X X X X X X
3 Electrical insulation is clean and dry ....................................................
X
X
NOTE 1 General: The inspection for equipment that use types of protection "e" and "d " shall be a combination of columns
2 and 3.
NOTE 2 Account shall be taken of the possibility of an explosive atmosphere in the vicinity of the equipment, when
electrical test equipment is used.
1A
1
2
3
4
5
6
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1A
EQUIPMENT
1*
Equipment is appropriate to EPL/Zone requirement of the location
EPL/Zone is provided from the area classification process. EPLs are

determined by explosion risk and are mostly directly related to the allocated
zones.
Group
Zone
In underground mines, within

180m from working faces,
return airways etc.
II
Minimum Equipment
Protection Level (EPL)
Ma
Equipment remains
functioning when explosive
atmosphere present
Mb
Equipment isolated when
explosive atmosphere
present
Ga
Gb
Gc
20
Da
21
Db
22
Dc
III
If more than one EPL, all must comply.
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2*
Equipment group is correct

Selected to suit the explosive atmosphere group (related to spark ignition
properties i.e. minimum ignition energy). Normally determined during area
classification.
3*
Equipment temperature class is correct

Based on explosive atmosphere temperature class (related to heat ignition
properties i.e. auto-ignition temperature) or minimum ignition temperature.
Normally determined during area classification.
4,5
Equipment circuit identification is available (correct if detailed inspection)

The purpose of this requirement is to facilitate the correct isolation of
equipment whenever work is to be carried out. This can be achieved in a
variety of ways, for example:
a) Equipment is fitted with a permanent label which specifies the source of
supply.
b) Equipment is fitted with a tag number or the cable is fitted with a cable
number adjacent to the equipment.
6*
Enclosure, glasses and glass-to-metal sealing gaskets and/or compounds are

satisfactory
All enclosures must be able to handle reasonable impact, to prevent creation of
ignition sources.
Ex d equipment Enclosure must withstand internal explosion, including window
glass/polymer parts.
Ex e and Type n equipment Enclosure must provide IP54 rating if containing

bare live parts.
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7, 8
There are no (visible) uncertified modifications

Modifications = The explosion protection is affected! If not, the certified state of
the equipment remains valid (painting).
9*
Bolts, cable entry devices (direct and indirect entry) and blanking elements are
of the correct type and are complete and tight
- physical check
- visual check
Cable glands, adaptors and plugs must have the same explosion protection as
the enclosure to which connected. The check-tightening of cable glands under
close inspection can be effected by hand without the need to remove weatherproofing tape or shrouds. Detailed inspections may necessitate that the cable
glands are dismantled only where the integrity of the glands cannot be
ascertained by close Inspection.
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10
Ex d Flange faces are clean and undamaged and gaskets, if any, are
satisfactory
Faces must be rust-free and without deep pits, scratches or marks, e.g. caused
by screwdriver to remove lid. A thin layer of grease (not silicone rubber) after
removing loose rust is ideal protection.
11
Ex d Flange gap dimensions are within permitted maxima

Generally speaking, the biggest flange gap that will be permitted is 0,4mm. A
feeler gauge can be carried along. It should be possible to confirm a
completely tight fit visually on smaller enclosures.
NOTE 1 - It is normally considered not necessary to check the diametric
clearance of spigot, shaft, spindle and threaded joints, unless there is
evidence of wear, distortion, corrosion or other damage.
NOTE 2 - When reassembling flameproof enclosures, all (inspected) joints
shall be thoroughly cleaned and may be lightly smeared with a suitable grease
to prevent corrosion and to assist weather-proofing. Blind bolt-holes shall be
kept clear of grease. Only non-metallic scrapers and non-corrosive cleaning
fluids shall be used to clean flanges. Fasteners on Ex d external flanges must
not protrude.
12
Lamp rating, type and position are correct
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Lamps with higher power ratings or other types of lamps may get hotter than
the approved lamp type. Some lamps will have a specific condition of use in
terms of position/orientation, for example the lens of a highbay light fitting
normally pointing downwards will get hotter if the light is pointed up.
13
Ex e, Type n Electrical connections are tight
Loose connections can cause sparks or hot spots.

14*
Ex e, Type n Condition of enclosure gaskets is satisfactory.
IP54 rating of enclosures containing live bare parts must be ensured.

15
Type n Enclosed-break and hermetically sealed devices are undamaged

Enclosed-break and hermetically sealed devices are part of Ex nC equipment
and must respectively contain an internal explosion and provide a gas-tight
seal.
16
Type n Restricted breathing enclosure is satisfactory

Restricted breathing devices are part of Ex nC equipment and must only allow
a low exchange rate between internal and external atmosphere.
17
Motor fans have sufficient clearance to enclosure or covers (or both)

To prevent frictional heat.
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18
Breathing and draining devices are satisfactory

Ex d equipment B&D devices contains at least one flameproof joint.
Ex e and Type n equipment B&D devices must provide IP54 rating if
enclosure contains bare live parts.
1B
INSTALLATION
Type of cable is appropriate

Cables used for fixed wiring in hazardous areas shall be appropriate for the
ambient conditions in service. Cables shall be:
a) sheathed with thermoplastic, thermosetting, or elastomeric material.
They shall be circular, compact, have extruded bedding and fillers, if
any, shall be non hygroscopic, or
b) mineral insulated metal sheathed, or
c) special, e.g. flat cables with appropriate cable glands.
Such cables must be flame retardant.
Flexible cables in hazardous areas shall be selected from the following:
ordinary tough rubber sheathed;
ordinary polychloroprene sheathed;
heavy tough rubber sheathed;
heavy polychloroprene sheathed;
plastic insulated and of equally robust construction to heavy tough
rubber sheathed flexible cables.
Cables shall preferably be substantially compact ( round and filled). If not so
for Ex d connections, then use barrier gland.
There is no obvious damage to cables
Sealing of trunking, ducts, pipes or conduits (or both) is satisfactory

Openings in walls for cables and conduits between different hazardous areas
and between hazardous and non-hazardous areas shall be adequately sealed,
for example by means of sand seals or mortar sealing to maintain the area
classification where relevant. Trunking, ducts or pipes connecting differently
zoned areas must be sealed, for example by a sealing compound or sealing
devices. For trenches, adequate venting or sand-filling may be used.
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Stopping boxes and cable boxes are correctly filled
Integrity of conduit system and interface with mixed system is maintained
Earthing connections, including any supplementary earthing bonding, are of

sufficient cross-section
- physical check
- visual check
Bonding connections must prevent self loosening and corrosion which may
reduce the effectiveness of connection.
Metallic enclosures of intrinsically safe or energy-limited apparatus generally
need not be connected to the equipotential bonding system.
7
Fault loop impedance (TN systems) or earthing resistance (IT systems) is

satisfactory
Intrinsically safe resistance measuring equipment may be used, or the
measurement may be carried out under a hot work permit if absence of
explosive atmospheres in the areas affected can be guaranteed.
8*
Insulation resistance is satisfactory

The insulation resistance for equipment and associated cabling up to 500 V
(excluding safety extra-low voltage, SELV, electrical systems) shall be
measured at 500 V d.c. The insulation resistance shall generally be at least 1,0
M.
9*
Automatic electrical protective devices operate within permitted limits

The following electrical protection is compulsory and must therefore comply
with the above:
Wiring Protection against overload and from the harmful effects of short-circuits
and earth faults.
All electrical equipment Protection against the harmful effects of short-circuits
and earth faults.
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Multi-phase electrical equipment (e.g. three-phase motors) Protection against

loss of one or more phases where this can cause overheating to occur.
Motors and transformers must be protected against overload.
Resistance heating devices must be protected against overcurrent and earthleakage or earth-fault currents.
In circumstances where automatic disconnection of the electrical equipment
may introduce a safety risk which is more dangerous than that arising from the
risk of ignition alone, a warning device (or devices) may be used as an
alternative to automatic disconnection provided that operation of the warning
device (or devices) is immediately apparent so that prompt remedial action will
be taken.
10
Automatic electrical protective devices set correctly (no auto-reset)

Short-circuit and earth-fault protection devices shall prevent auto-reclosing
under fault conditions.
11*
Specific conditions of use (if applicable) are complied with

Specific conditions of use are determined by the ATL as part of explosion
prevention and stipulated in the equipment certificate. They address the user
as they comprise essential information for the installation, use, and
maintenance of the equipment must be complied with by the user. They can
either be shown in full on the equipment lable or if there is a lack of space, be
referenced by including an X suffix after the certificate number.
12*
Cables not in use are correctly terminated
If unused cable are not removed, the cores of the hazardous area end of such
unused cables shall either be connected to earth or be adequately insulated by
means of terminations suitable for the type of protection, for example isolating
and capping both ends. Insulation by tape alone is not permitted.
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13
Obstructions adjacent to flameproof flanged joints are in accordance with

SANS 60079-14
Minimum distance are as follows:

Gas
group
IIA
IIB
IIC
14
Minimum
distance
(mm)
10
30
40
Variable voltage/frequency installations are as per documentation

Ex motors must be type-tested together with the VSD. Ex d, Ex p, Type n
and Ex tD motors can alternatively be installed with a temperature sensing
system. The maximum temperature of Type n motors operating with VSDs
can alternatively be calculated.
1C
ENVIRONMENT
1*
Equipment is adequately protected against corrosion, weather, vibration and

other adverse factors
No undue accumulation of dust and dirt
Electrical insulation is clean and dry
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7.3 APPLICATION Ex i level gauge (D)
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Inspection schedule for Ex i, Ex iD and Ex nL installations

Equipment description _______________ Tag no ___________
Ex rating __________
Grade of inspection
Check that:
Detailed
Close
Visual
2A EQUIPMENT
1
Circuit or equipment (or both) documentation is appropriate to area classification
Equipment installed is that specified in the documentation - Fixed equipment only
Circuit or equipment (or both) category and group are correct ....................
Equipment temperature class is correct ......................................................
Installation is clearly labelled .......................................................................
Enclosures, glass parts and glass-to-metal sealing gaskets and/or compounds are
satisfactory
There are no unauthorized modifications ....................................................
There are no visible unauthorized modifications .........................................
10
Safety barrier units, relays and other energy limiting devices are of the approved type,
installed in accordance with the certification requirements and securely earthed, where
required
Electrical connections are tight ....................................................................
11
Visible printed circuit boards are clean and undamaged .............................
2B INSTALLATION
1
Cables are installed in accordance with the documentation ........................
Cable screens are earthed in accordance with the documentation .............
There is no obvious damage to cables ........................................................
Sealing of trunking, ducts, pipes or conduits (or both) is satisfactory ..........
Point-to-point connections are all correct ....................................................
Earth continuity is satisfactory (for example, connections are tight and conductors are of
sufficient cross-sectional area) ....................................................................
Earth connections maintain the integrity of the type of protection ................
11
The intrinsically safe circuit is isolated from earth or earthed at one point (see the
documentation) ...........................................................................................
Separation is maintained between intrinsically safe and non-intrinsically safe circuits in
common distribution boxes or relay cubicles ...............................................
As applicable, short-circuit protection of the power supply is in accordance with the
documentation ............................................................................................
Special conditions of use (if applicable ) are complied with .........................
12
Cables not in use are correctly terminated ..................................................
9
10
X
X
X
2C ENVIRONMENT
1
2
Equipment is adequately protected against corrosion, weather, vibration and other adverse
factors .........................................................................................................
There is no undue accumulation of dust and dirt .........................................
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2A
EQUIPMENT
1*
Circuit and/or equipment documentation is appropriate to the EPL/zone

requirements of the location
The essential documents are the ATL-certified installation (loop) drawing and
the ATL certificates for individual equipment used in the loop.
EPL/Zone is provided from the area classification process. EPLs are
determined by risk and are mostly directly related to the allocated zones
2*
Equipment installed is that specified in the documentation - Fixed equipment

only
3*
Circuit or equipment (or both) category and group are correct

Levels of protection (EPLs) available for intrinsic safety equipment are ia, ib
and ic. EPL/Zone is provided from the area classification process. EPLs are
determined by risk and are mostly directly related to the allocated zones.
Equipment group is selected to suit the explosive atmosphere group (related to
spark ignition properties i.e. minimum ignition energy). Normally determined
during area classification.
4*
Equipment temperature class is correct

Only the instrument (equipment exposed to explosive atmosphere) has a
temperature rating.
Installation is clearly labelled

The compulsory labeling of equipment must be checked to ensure that the
equipment actually fitted is that specified. Further, the tag numbers must
correspond with the tag numbers used in the control room basement,
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6*
Enclosures, glass parts and glass-to-metal sealing gaskets and/or compounds

are satisfactory
IP ratings are sometimes essential.

7, 8
There are no (visible) unauthorized modifications

This includes exchanging one type of device with a similar (but not identical)
unit, e.g. a new series.
Safety barrier units, relays and other energy limiting devices are of the
approved type, installed in accordance with the certification requirements and
securely earthed, where required
(Shunt-diode safety) barriers require a high-quality earth connection in order to

provide protection.
10
Electrical connections are tight

Loose connections can cause loss of protection, e.g. earth connection on
barrier, earthing of screens and redundant cores.
11*
Visible printed circuit boards are clean and undamaged
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2B
INSTALLATION
1*
Cables are installed in accordance with the documentation
The insulation properties and inductance and capacitance values of the

specified cable are critical for safety.
2*
Cable screens are earthed in accordance with the documentation

Generally, screens are earthed at one point i.e. in the safe area. They must
however not be cut off.
There is no obvious damage to cables
Sealing of trunking, ducts, pipes or conduits (or both) is satisfactory

Openings in walls for cables and conduits between different hazardous areas
and between hazardous and non-hazardous areas shall be adequately sealed,
for example by means of sand seals or mortar sealing to maintain the area
classification where relevant. Trunking, ducts or pipes connecting differently
zoned areas must be sealed, for example by a sealing compound (e.g.
expansion foam) or sealing devices. For trenches, adequate venting or sandfilling may be used.
Point-to-point connections are all correct
This check only needs to be done during the initial inspection.
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Point-to-point generally refers to a connection restricted to two endpoints. In

this case, the termination points of conductors. The reliability of a termination
is influenced by the termination method. For example, soldered, bolted or
screwed connections may have infallibility status.
6*
Earth continuity is satisfactory (for example, connections are tight and

conductors are of sufficient cross-sectional area)
For an earthed (shunt-diode safety) barrier, earthing conductor must be at least
x2 1.5mm2 or x1 4mm2.
Earth connections maintain the integrity of the type of protection

Check continuity of essential earth connections, e.g. transformer screen earth,
barrier relay frame earth.
8*
The intrinsically safe circuit is isolated from earth or earthed at one point (see
the documentation)
This check is only needed on a sampling basis.

Insulation from or connection to earth, as required by the loop design, to be
verified. Not necessary to test if a fault is self-revealing. If shunt-diode safety
barrier (Zener barrier) earths have to be disconnected for such a test, ensure
that loops are first de-energized.
9
Separation is maintained between intrinsically safe and non-intrinsically safe

circuits in common distribution boxes or relay cubicles
Clearance of at least 50mm is required, or insulating or earthed barriers.
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10
As applicable, short-circuit protection of the power supply is in accordance with

the documentation
Output voltage restricted to Um shown on the label of the associated
apparatus; normally 250V. The prospective short-circuit current of the supply
shall not be greater than 1500A.
11*
Specific conditions of use (if applicable) are complied with

Specific conditions of use are determined by the ATL as part of explosion
prevention and stipulated in the equipment certificate. They address the user
as they comprise essential information for the installation, use, and
maintenance of the equipment must be complied with by the user. They can
either be shown in full on the equipment lable or if there is a lack of space, be
referenced by including an X suffix after the certificate number.
12
Cables not in use are correctly terminated

All screens, armour and conductors of redundant cables must be earthed
inside the hazardous area using an explosion protected junction box. In the
safe area, follow standard isolation protocol.
2C
ENVIRONMENT
Equipment is adequately protected against corrosion, weather, vibration and

other adverse factors
There is no undue accumulation of dust and dirt
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8. Conclusions
1. Q: What is the PURPOSE of an Ex inspection ?
A: To preserve the explosion protection features (and certification).
2. Q: We know we need to inspect in-service Ex equipment at least once in
2 years (periodic inspection).
- What Grade of inspection must be used (V/C/D).
A: V and C are prescribed.
3. Q: When must additional inspections be done ?
A: Firstly, Initial inspection before putting replacement equipment or
equipment that has been opened for calibration or routine servicing back in
operation. Partial or comprehensive, for example only the terminal box of a
repaired motor.
Secondly, sample inspections must complement periodic inspections to reveal
hidden damage due to equipment design weaknesses and environmental
conditions. Premature failure can generate ignition sources.
4. Q: Who is competent to do inspections ?
A: The OHS Act requires inspectors to have appropriate competence.
Operatives shall possess, to the extent necessary to perform their tasks, the
following competencies according to SANS 60079-17:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
understanding of the general principles of explosion protection;

understanding of the general principles of types of protection and
marking;
understanding of those aspects of equipment design which affect the
protection concept;
understanding of certification of Ex equipment and installations;
understanding of the additional importance of Permit to Work systems
and safe isolation in relation to Explosion Protection;
familiarity with the particular techniques to be employed in the inspection
and maintenance of Ex equipment;
comprehensive understanding of the selection and erection requirements
of Ex equipment and installations;
general understanding of the repair and reclamation requirements of
SANS 10086-3;
use and availability of certification documentation;
practical skills necessary for the inspection and maintenance of relevant
concepts of Ex protection.
THANK YOU
QUESTIONS ?
CCO
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Page 26 of 29
Annex A
Equipment selection
A.1 Information required

In order to select the appropriate electrical equipment for hazardous area caused by
gases, vapours or dusts, the following information is required:
Classification of the hazardous area including the equipment explosion
protection level (EPL) requirements where applicable;
Where applicable, gas, vapour or dust classification in relation to the group or
subgroup of the electrical equipment;
Temperature class or ignition temperature of the gas or vapour involved;
Minimum ignition temperature of the combustible dust cloud, minimum ignition
temperature of the combustible dust layer and minimum ignition energy of the
combustible dust cloud;
External influences and ambient temperature.
A.2
Selection according to EPL
Statistical approach and Zones

In the past, a statistical approach to equipment selection was followed:
probability of a fire or explosion occurring can be expressed as:
The
pe = pg x pi
Where
- pe is the probability of a fire or explosion occurring;
- pg is the probability that an explosive atmosphere will be present in a particular
place at a particular time (given by the zone); and
- pi is the probability that the above explosive atmosphere can be ignited.
pe and consequently the product pg x pi must be acceptably low. (A probability of 10-5
is considered acceptable, refer to Hickes and Brown). This means that if the
probability of an explosive atmosphere being present increases, the probability
that it can be ignited must decrease and vice versa. Equipment protection is
selected in accordance with the zone in this approach.
Risk-based approach
The equipment selection standard now also allows for a risk-based approach. In a
risk-based approach, the consequence of an explosion is also taken into account,
together with the probability of an explosion. This means quite simply that under
certain circumstances, the occurrence of an explosion is more tolerable (or less
tolerable) than normal.
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Page 27 of 29
Example: A typical example is of two neighbouring plants of similar design, but due to
differences in the materials being handled, the one is Zone 1 and the other Zone 2.
Some engineers will decree that Zone 1 equipment is used even in the Zone 2 plant,
because the danger exists that the wrong replacement equipment will be selected
from stores during a breakdown.
Equipment Protection Level (EPL)
To facilitate the risk-based approach, the concept of Equipment Protection Level

(EPL) was introduced. The EPL for each explosion protection technique has been
determined, based on its likelihood of becoming a source of ignition. The EPL ranges
from a Very High to b High to c Normal and distinguishes between explosive gas
(G), dust (D) and mine (M) atmospheres.
The table below shows the relationship between types of protection and EPLs.
Protection
afforded
Very High
EPL
Group
I
Ma
Type of protection
Group
II
Same as Ga
High
Intrinsically safe
Encapsulation
Da
Very High
High
Mb
Gb
Db
ia
ma
SANS 60079-11
SANS 60079-18
Two independent type

of protection each
meeting EPL Gb
Protection of
equipment and
transmission systems
using optical radiation
Intrinsically safe
iD
SANS 60079-11
Encapsulation
mD
SANS 60079-18
Protection by
enclosure
Same as Gb
tD
SANS 60079-31
Flameproof enclosures
SANS 60079-1
Increased safety
Intrinsically safe
e
ib
SANS 60079-7
SANS 60079-11
Encapsulation
m
mb
SANS 60079-18
Oil immersion
SANS 60079-6
Pressurized enclosures
p, px
or py
q
SANS 60079-2
Powder filling
High
According to
standard
Conditions of
operation
Group
III
Ga
Very High
Code
SANS 60079-26
SANS 60079-28
SANS 60079-27
Protection of
equipment and
transmission systems
Intrinsically safe
SANS 60079-28
iD
Equipment remains
functioning in Zones
20, 21 and 22
Equipment deenergised when

explosive
atmosphere present
Equipment remains
1 and 2
SANS 60079-5
Fieldbus intrinsically
safe concept (FISCO)
Equipment remains
functioning when
explosive
atmosphere present
Equipment remains
0, 1 and 2
SANS 60079-11
Equipment remains
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Page 28 of 29
Protection
afforded
EPL
Type of protection
Group
I
Normal
Group
II
According to
standard
Conditions of
operation
21 and 22
Group
III
Gc
Dc
Normal
Code
Encapsulation
Protection by
enclosure
Intrinsically safe
Encapsulation
mD
tD
SANS 60079-18
SANS 60079-31
pD
ic
mc
SANS 61241-4
SANS 60079-11
SANS 60079-18
Non-sparking
SANS 60079-15
Restricted breathing
n or
nA
nR
Energy limitation
nL
SANS 60079-15
Sparking equipment
nC
pz
SANS 60079-15
SANS 60079-2
Fieldbus non-incendive
concept (FNICO)
Protection of
equipment and
transmission system
Intrinsically safe
Encapsulation
Protection by
enclosures
Equipment remains
functioning in Zone
2
SANS 60079-15
SANS 60079-27
SANS 60079-28
iD
mD
tD
SANS 60079-11
SANS 60079-18
SANS 60079-31
pD
SANS 61241-4
Equipment remains
functioning in Zone
22
Selection
If risk is normal, which is mostly the case, the probability of an explosion is the only
controlling factor and a direct relationship between EPL and Zone exists that is used
to select equipment:
Table A.1 Equipment protection level (EPLs) where only zones are assigned
Zone
0
Minimum Equipment Protection Level

(EPL)
Ga
Gb
Gc
20
Da
21
Db
22
Dc
Where in exceptional circumstances, the risk is not normal, a higher or lower EPL
than that defined in the table may be required.
It is recommended that the required explosion protection levels (EPLs) are recorded
on the area classification drawing, even if the risk-based approach has not been
followed.
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Page 29 of 29
A.3
Selection according to equipment grouping
Relationship between gas/vapour subdivision and equipment subgroup

Environment
Gas, vapour or
dust
(sub)division
Permitted
equipment group
IIA
II, IIA, IIB or IIC
IIB
II, IIB or IIC
IIC
II or IIC
IIIA
IIIA, IIIB or IIIC
IIIB
IIIB or IIIC
IIIC
IIIC
Underground
mines
Gas and vapour,
Surface
Dust, Surface
A.4
Selection according to the ignition temperature of the gas or vapour
The electrical equipment shall be so selected that its maximum surface temperature will not
reach the ignition temperature of any gas or vapour which may be present.
Relationship between the equipment temperature classes and surface temperatures
and ignition temperature
Temperature
class required
by the area
classification
Ignition
temperature of
gas or vapour
(C)
T1
Suitable equipment
temperature class
>450
Maximum
surface
temperature of
equipment
(C)
450
T2
>300
300
T2 - T6
T3
>200
200
T3 - T6
T4
>135
135
T4 - T6
T5
>100
100
T5 - T6
T6
>85
85
T6
T1 - T6
CCO
ONNSSUULLTTIINNG
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CERTEX Appointed Ex Laboratory

Reg No: 1999/027771/07

Tel: +27 (11) 316 4601

Inspection of in-service Explosion Protected Equipment - Unsafe

Johannes Auret, Explolabs and CERTEX

INSPECTION OF IN-SERVICE EXPLOSION PROTECTED EQUIPMENT

Copyright of this material belongs to

INSPECTION OF IN-SERVICE EXPLOSION PROTECTED EQUIPMENT

4. Standards / Info Basis

Old version (Edition 2) of IEC

SANS 10086-1, adapted for

All surface installations in

Copyright of this material belongs to

INSPECTION OF IN-SERVICE EXPLOSION PROTECTED EQUIPMENT

Copyright of this material belongs to

INSPECTION OF IN-SERVICE EXPLOSION PROTECTED EQUIPMENT

Inspection of all electrical

Inspection of all electrical

To check that selected

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To monitor the effect of

INSPECTION OF IN-SERVICE EXPLOSION PROTECTED EQUIPMENT

7. Generic Inspection Sheets

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INSPECTION OF IN-SERVICE EXPLOSION PROTECTED EQUIPMENT

7.2 APPLICATION Ex ed indicator stop-start station (D)

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INSPECTION OF IN-SERVICE EXPLOSION PROTECTED EQUIPMENT

Inspection schedule for Ex d, Ex e and Type n installation

Copyright of this material belongs to

INSPECTION OF IN-SERVICE EXPLOSION PROTECTED EQUIPMENT

Equipment is appropriate to EPL/Zone requirement of the location

EPL/Zone is provided from the area classification process. EPLs are

In underground mines, within

If more than one EPL, all must comply.

Copyright of this material belongs to

INSPECTION OF IN-SERVICE EXPLOSION PROTECTED EQUIPMENT

Equipment group is correct

Equipment temperature class is correct

Equipment circuit identification is available (correct if detailed inspection)

Enclosure, glasses and glass-to-metal sealing gaskets and/or compounds are

Ex e and Type n equipment Enclosure must provide IP54 rating if containing

Copyright of this material belongs to

INSPECTION OF IN-SERVICE EXPLOSION PROTECTED EQUIPMENT

There are no (visible) uncertified modifications

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INSPECTION OF IN-SERVICE EXPLOSION PROTECTED EQUIPMENT

Ex d Flange gap dimensions are within permitted maxima

Lamp rating, type and position are correct

Copyright of this material belongs to

INSPECTION OF IN-SERVICE EXPLOSION PROTECTED EQUIPMENT

Ex e, Type n Electrical connections are tight

Loose connections can cause sparks or hot spots.

Ex e, Type n Condition of enclosure gaskets is satisfactory.

IP54 rating of enclosures containing live bare parts must be ensured.

Type n Enclosed-break and hermetically sealed devices are undamaged

Type n Restricted breathing enclosure is satisfactory

Motor fans have sufficient clearance to enclosure or covers (or both)

Copyright of this material belongs to

INSPECTION OF IN-SERVICE EXPLOSION PROTECTED EQUIPMENT

Breathing and draining devices are satisfactory

Type of cable is appropriate