Professional Documents
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Government
Appointed
ATL
T0104
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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
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
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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.
Based on
Application (technically)
SANS 10086-2
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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
Periodic
Sample
Inspection
of
a
proportion
of
the
electrical
equipment,
systems and installations
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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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*
Zone
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
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2*
3*
4,5
6*
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7, 8
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
12
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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
16
17
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18
1B
INSTALLATION
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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
8*
9*
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11*
12*
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
Minimum
distance
(mm)
10
30
40
1C
ENVIRONMENT
1*
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Ex rating __________
Grade of inspection
Check that:
Detailed
Close
Visual
2A EQUIPMENT
1
Circuit or equipment (or both) category and group are correct ....................
Enclosures, glass parts and glass-to-metal sealing gaskets and/or compounds are
satisfactory
There are no 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
2B INSTALLATION
1
Earth continuity is satisfactory (for example, connections are tight and conductors are of
sufficient cross-sectional area) ....................................................................
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
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*
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*
3*
4*
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6*
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
11*
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2B
INSTALLATION
1*
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8*
The intrinsically safe circuit is isolated from earth or earthed at one point (see
the documentation)
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10
11*
12
2C
ENVIRONMENT
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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)
THANK YOU
QUESTIONS ?
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Annex A
Equipment selection
A.2
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.
Copyright of this material belongs to
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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)
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
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
using optical radiation
Intrinsically safe
SANS 60079-28
iD
Equipment remains
functioning in Zones
20, 21 and 22
SANS 60079-5
Fieldbus intrinsically
safe concept (FISCO)
Equipment remains
functioning when
explosive
atmosphere present
Equipment remains
functioning in Zones
0, 1 and 2
SANS 60079-11
Equipment remains
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EPL
Type of protection
Group
I
Normal
Group
II
According to
standard
Conditions of
operation
functioning in Zones
21 and 22
Group
III
Gc
Dc
Normal
Code
Encapsulation
Protection by
enclosure
Pressurized enclosures
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
Pressurized enclosures
nC
pz
SANS 60079-15
SANS 60079-2
Fieldbus non-incendive
concept (FNICO)
Protection of
equipment and
transmission system
using optical radiation
Intrinsically safe
Encapsulation
Protection by
enclosures
Pressurized 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
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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A.3
Gas, vapour or
dust
(sub)division
Permitted
equipment group
IIA
IIB
IIC
II or IIC
IIIA
IIIB
IIIB or IIIC
IIIC
IIIC
Underground
mines
Gas and vapour,
Surface
Dust, Surface
A.4
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
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