Hazardous Locations

eBook

Guide to Explosive
Atmospheres &
Hazardous Locations
 Testing and Certification
We certify products for compliance with IECEX,
the European Union’s ATEX Directive, the National
Electrical Code (NEC) in the U.S. and the Canadian
Electrical Code (CEC) in Canada. Some of the
standards we test to include those of CENELEC, CEN,
IEC, ANSI, UL, CSA, MIL Specs and FM.
We offer the Ex Mark and the CE Mark to show
compliance with EU requirements for Explosive
Atmosphere regulations. Conducting IECEx
certification in parallel offers global access for
countries outside of North America and Europe. In
addition, when your product complies with North
American product safety standards, it is eligible to
bear our ETL Listed Mark that is fully accepted by
Authorities Having Jurisdiction (AHJs)
across North America.
Intertek is one of only a handful of Notified Bodies
that can offer the full scope of ATEX Certification,
from large electrical machines to non-electrical
approval for Zone 0. We offer:
• ATEX Notified Body for product testing,
assessment, inspection and certification for all
equipment (electrical and non-electrical), Safety
Systems, Components and Protective Devices
• UKAS Accredited ATEX Certificates
• IECEx Certificates of Conformity
• Quality Assurance Notification (ATEX Quality
Modules)
• Quality Assurance Registration (IECEx QA Module)
• ATEX Technical file review and lodging
Intertek also offer full CE Marking testing
and assessment at our in house accredited
laboratories, minimising time and cost to market.
Fast Compliance
Being able to test ATEX, CE and
IECEx and certify at the same time
is always the fastest and least
expensive compliance route...
2 Guide to Explosive Atmosheres and Hazardous Locations Intertek
• Our knowledge of CENELEC, CEN, IEC, ANSI, ISA,
CSA, MIL Specs and FM standards is second to
none
• We are the Accepted Certification Body and Ex
Testing Laboratory within the International IECEx
Certification Scheme, which facilitates international
trade by eliminating the need for multiple national
certifications
• ETL and cETL Listing, Intertek’s certification
marks, which are accepted by Authorities Having
Jurisdiction (AHJs) throughout North America, are
available based on local testing
• Intertek’s Global Market Access information is
constantly being updated through our network of
laboratories in over 100 countries
Site Safety Services
Intertek is a leading expert in DSEAR and ATEX 137
compliance and explosion risk reduction with unique
services and skills.
Our global blue-chip client base use Intertek’s
expertise to implement, train and verify that risk is
reduced to acceptable levels and adequately managed
thereafter. We provide:
• High level consultancy including writing
specifications for suppliers and users
• Design control and management of hazardous
area projects
• Area Classification and DSEAR (ATEX) Risk
Assessment
• Equipment and Plant Inspections
• Assistance in the design, supply and installation of
safety and mitigation systems
• Full support, service levels agreements and ATEX
137 / DSEAR Compliance

FAST: Our challenge is to get your products to market
faster and safer! We offer an industry busting 2
week pick up time to get your products into test with
minimal delay.
SPECIALIST: You need to work with a company that
has the size, flexibility and credentials to provide you
with everything you need in one seamless project.
Intertek is here to partner with you from design to
final certification. We share our expertise with you to
deliver your product to the markets you require, on
time and in budget, to train your people and to make
your hazardous locations safer.
GLOBAL: Our Global Hazardous Locations solution
has helped many product manufacturers understand
the requirements needed to meet customer or
market specifications. We have numerous test and
assessment locations world-wide and a large and
experienced team with over 50 dedicated Hazardous
Locations staff.
We are one of the very few providers that can offer
Global Access to all hazardous locations markets,
including our unique GMAP services (Global Market
Access Program) and full CE and performance testing
services.
Intertek has one of the largest dedicated teams of test
and certification engineers in the USA and Europe.
We react quickly, quote competitively and deliver the
highest levels of service available.
Intertek Guide to Explosive Atmosheres and Hazardous Locations
Training
Intertek is an ATEX Notified Body, DSEAR/ATEX 137
implementation specialist and CompEx Training
Centre. We have the largest set of CompEx Training
facilities in the UK and have a satellite training facility
in Sasolburg South Africa.
Intertek also offers a global training solution with the
CompEx mobile facility, designed for our customers
outside the UK, we bring the training to you..
CompEx is a recognised qualification for ATEX and
IEC electrical installation and inspection. It consists of
practical training and assessment in a realistic working
environment and is rapidly becoming a required
qualification worldwide.
We take great pride in the enthusiasm and knowledge
of our trainers who can draw from practical
experience at all times to keep the courses interesting,
relevant and practical.
In addition to theoretical
training, Intertek is the only
ATEX Notified Body to also
be a licensed CompEx Training
Centre. Through our mobile training
rigs we can offer a truly global solution
to your training needs.
3
 Typical ATEX and IECEx Marking [*ATEX only]

0359 II 2 G Ex d IIC T4 Gb
*Complies *Specific *Environment Temperature
with Marking for Type of Class (T1-T6)
European Explosion *Equipment Protection (and/or T135°C)
Directive Protection Category Explosion Group Equipment
Protection Protection
*Notified *Equipment
Level
Body Number Group

Equipment Group [ATEX and IECEx]

Equipment Protection Required Protection
Equipment Group EPL Atmosphere
Category Level Performance & Operation
I (Mines with • Two Faults, Remain
M1 Ma Methane & Dust Very High
firedamp) energised and functioning
I (Mines with • Severe normal operation,
M2 Mb Methane & Dust High
firedamp) De-energise in exp. atm.
II (all other areas) 1 a Gas, Vapour, Mist, Dust Very High • Two Faults
II (all other areas) 2 b Gas, Vapour, Mist, Dust High • One Fault
II (all other areas) 3 c Gas, Vapour, Mist, Dust Low • Normal operation

Equipment Categories &

Zoning Definitions
Protection Levels
Equipment
Gas Dust ATEX
Definitions Protection Typical Zone Suitability
IEC 60079-10-1 IEC 60079-10-2 Category
Levels
0 A place in which an explosive atmosphere 1G Ga Equip. suitable for Zones 0,1,2

20 is continually present 1D Da Equip. suitable for Zones 20,21,22

1 A place in which an explosive atmosphere 2G Gb Equip. suitable for Zones 1,2

is likely to occur in normal operation
21 occasionally 2D Db Equip. suitable for Zones 21,22

2 A place in which an explosive atmosphere 3G Gc Equip. suitable for Zone 2

is not likely to occur in normal operation,
22 but if it does only occus for short periods 3D Dc Equip. suitable for Zone 22

4 Guide to Explosive Atmosheres and Hazardous Locations Intertek

Protection Concepts [ATEX and IECEx]
Typical Typical
Type of Protection Symbol IEC Standard Basic concept of protection
IEC EPL Zone(s)

Electrical equipment for gases, vapours and mists (G)

Op pr Gb 1,2 IEC 60079-28
Inherently safe protected by
Optical Radiation Op sh Ga 0,1,2 IEC 60079-28
shutdown
Op is Ga 0,1,2 IEC 60079-28
Increased safety e Gb 1,2 IEC 60079-7 No arcs, sparks or hot surfaces.
Type ‘n’ (non-sparking) nA Gc 2 IEC 60079-15 Enclosure IP54 or better
Flameproof d Gb 1,2 IEC 60079-1 Contain the explosion, quench
Type ‘n’ (enclosed break) nC Gc 2 IEC 60079-15 the flame
Quartz/sand filled q Gb 1,2 IEC 60079-5 Quench the flame
Intrinsic safety ia Ga 0,1,2 IEC 60079-11
Limit the energy of sparks and
Intrinsic safety ib Gb 1,2 IEC 60079-11
surface temperatures
Intrinsic safety ic Gc 2 IEC 60079-11
Pressurised px Gb 1,2 IEC 60079-2
Pressurised py Gb 1,2 IEC 60079-2
Pressurised pz Gc 2 IEC 60079-2
Type ‘n’ (sealing & hermetic sealing) nC Gc 2 IEC 60079-15
Type ‘n’ (restricted breathing) nR Gc 2 IEC 60079-15 Keep the flammable gas out
Encapsulation ma Ga 0,1,2 IEC 60079-18
Encapsulation mb Gb 1,2 IEC 60079-18
Encapsulation mc Gc 2 IEC 60079-18
Oil immersion o Gb 1,2 IEC 60079-6

Electrical equipment for combustible dusts (D)

Standard protection for dusts,
Enclosure t Da 20,21,22 IEC 60079-31
rugged tight enclosure
Similar to t, but with some
Intrinsic safety iD Da 20,21,22 IEC 61241-11 relaxations if circuit inside is
intrinsically safe
maD Da 20,21,22 Protection by encapsulation of
Encapsulation IEC 61241-18
mbD Db 21,22 incendive parts

Db 21,22 Protection by pressurisation of

Pressurised pD IEC 61241-2
Dc 22 enclosure

Non-Electrical equipment
General - - 0,1,2 EN 13463-1 Low potential energy
Relies on tight seals, closely
Flow restricted enclosure fr - 2 EN 13463-2 matched joints and tough
flameproof enclosure d - 1,2 EN 13463-3 enclosures to restrict the
breathing of the enclosure
Ignition hazards eliminated by
Constructional safety c - 0,1,2 EN 13463-5
good engineering methods
Control equipment fitted to
Control of ignition sources b - 0,1,2 EN 13463-6
detect malfunctions
*EN 13463-7
withdrawn Enclosure is purged and
Pressurisation p - 1,2 & replaced pressurised to prevent ignition
by use of sources from arising
IEC60079-2
Enclosure uses liquid to
Liquid immersion k - 0,1,2 EN 13463-8 prevent contact with explosive
atmosphere
Intertek Guide to Explosive Atmosheres and Hazardous Locations 5
 Temperature Classification
Max. Surface
NEC® 500 CEC® NEC® 505 IEC - Group II
Temperature
450º C (842ºF) T1 T1 T1
300º C (572ºF) T2 T2 T2
280º C (536ºF) T2A
260º C (500ºF) T2B
230º C (446ºF) T2C
215º C (419ºF) T2D
200º C (392ºF) T3 T3 T3
180º C (356ºF) T3A
165º C (329ºF) T3B
160º C (320ºF) T3C
135º C (275ºF) T4 T4 T4
120º C (248ºF) T4A
100º C (212ºF) T5 T5 T5
85º C (185ºF) T6 T6 T6
Note: For Group I (CENELEC/IEC) applications, electrical apparatus has fixed temperature limits i.e., 150º C and 450ºC.

Useful Standards
Topic IEC Standard
Area Classification - Gases, Vapours and Mists IEC 60079-10-1
Area Classification - Combustible Dusts IEC 60079-10-2
Electrical Equipment Installation IEC 60079-14
Electrical Equipment Inspection and maintenance IEC 60079-17
Electrical Equipment Repair and Overhaul IEC 60079-19

Groups [ATEX and IECEx]

Group Environment Location Typical Substance
Gases, Vapours
I Coal Mining Methane (Fire damp)
and Coal Dust
IIA Methane, Propane etc.
Gases, Vapours Surface and other
IIB Ethylene
and Mists locations
IIC Hydrogen, Acetylene etc.
IIIA Combustible flyings
Combustible Surface and other
IIIB Non-conductive
Dusts locations
IIIC Conductive

6 Guide to Explosive Atmosheres and Hazardous Locations Intertek

Typical NEC® Marking
NEC® 500 NEC® 505

Class I, Division 1, Groups A&B T4 Class I, Zone 0, AEx ia IIC T4

Temperature Protection Temperature

Area Class Area Concept Class
Hazard Classification Hazard Classification
Class Gas Class Code
Group Approved to
US Standards Gas Group

Protection Concepts [North America]

USA Canada
Basic Concept of
Type of Protection NEC® 500 NEC® 505 Existing New
Protection
Area Classification Code Area Classification Code
Increased Safety NA Zone 1, 2 AEx e NA Zone 1, 2 Ex e No arcs, sparks, or
Non-Incendive Division 2 Zone 2 AEx n Division 2 Zone 2 Ex n hot surfaces
Flameproof NA Zone 1, 2 AEx d NA Zone 1, 2 Ex d Contain the
Explosionproof Division 1,2 NA NA Division 1,2 NA NA explosion, prevent
Powder Filled NA Zone 1, 2 AEx q NA Zone 1, 2 Ex q flame propagation
Limit the spark
Division 1,2 Zone 0,1,2 AEx ia Division 1,2 Zone 0,1,2 Ex ia
Intrinsic Safety energy and
NA Zone 1, 2 AEx ib NA Zone 1, 2 Ex ib
temperatures
Pressurized (Purged) Division 1,2 Zone 1, 2 AEx p Division 1,2 Zone 1, 2 Ex p
Exclude gas from
Encapsulation NA Zone 1, 2 AEx m NA Zone 1, 2 Ex m
ignition sources
Oil Immersion Division 2 Zone 1, 2 AEx o Division 2 Zone 1, 2 Ex o
Note: NEC® Article 501.1 permits the use of zone-rated equipment in Class I Division 2 locations.

Gas Groups [North America]

Hazard Lower Upper
Substance: NEC 500: NEC 505:
Class: Exposure Limit: Exposure Limit:
Any Gas
Acetylene Group A IIC 2.3 % 100 %
Hydrogen Group B IIC 4% 77 %
Class I
Ethylene Group C IIB 2.3 % 36 %
Propane Group D IIA 1.7 % 11 %
Methane (mining) Group D 4.4 % 17 %
Combustible Metal Dusts Group E
Combustible Carbonaceous Dusts Group F
Class II
Combustible Dusts not in Group E or F
Group G
(Flour, Grain, Wood, Plastics, Chemicals)
Combustible Fibres and Flyings Class III

Intertek Guide to Explosive Atmosheres and Hazardous Locations 7

 International Protection IEC 60529
First Figure Protection against Solids Second Figure Protection against Liquids
IP Test Comment IP Test Comment
0 No Protection 0 No Protection
Protected against solid
bodies greater than Protected against
1 50
50mm diameter (e.g. 1 vertically falling drops
accidental contact with of water (condensation)
the hand)

Protected against solid

Protected against drops
bodies greater than
2 12.5
2 of water falling up to
12.5mm diameter (e.g.
15° from the vertical
finger) 15°

Protected against solid

2.5 bodies greater than
3 3
2.5mm diameter (e.g.
tools, wires)
Protected against water
sprayed up to 60° from
the vertical
30°

Protected against solid

Protected against
1.0 bodies greater than
4 4 splashing water from
1.0mm diameter (e.g.
all directions
thin tools and fine wire)

Protected against dust Protected against

5 (no harmful deposit) - 5 jets of water from all
Dust Proof directions

Completely protected Protected against

6 against dusts - Dust 6 powerful jets of water
Tight from all directions

IEC (International Electrotechnical Commission)

Publication 60529: Classification of Degrees of 150mm Protected against the
Protection Provided by Enclosures provides a system 7 1M
effects of temporary
for specifying the enclosures of equipment on immersion in water
the basis of the degree of protection provided by
the enclosure. IEC 60529 does not specify degrees Protected against the
of mechanical damage of equipment, risk of continuous effects of
explosions, or conditions such as moisture (produced 8 m
immersion in water
for example by condensation), corrosive vapours, having regard to
fungus, or vermin. specific conditions

8 Guide to Explosive Atmosheres and Hazardous Locations Intertek

NEMA Testing Approximate Cable Glands
Equivalent to IPXX
Cable glands used on explosion protected
NEMA 1  IP20 (Ex) equipment shall maintain the protection
NEMA 2  IP22 concept of the equipment. e.g.

NEMA 3  IP55 Ex d enclosures shall use Ex d cable glands

NEMA 3R  IP24 Ex e enclosures shall use Ex e cable glands
NEMA 3S  IP55 Ex nR enclosures shall use Ex nR cable glands
NEMA 4 & 4X  IP66 Ex nA or nC enclosures use Ex e cable glands
NEMA 5  IP53 Ex tD enclosures shall use Ex tD cable glands
NEMA 6 & 6P  IP67 & IP68
NB: Non-certified cable glands shall not be
NEMA 12 & 12K  IP54
used on Ex rated equipment. Intrinsically safe
NEMA 13  IP54 installations can use non-certified cable glands
Do not use to convert IP codes to NEMA ratings

Cable Gland Selection Chart

Start

Yes No
is area zoned?

The electrical concepts will be

one of the following types:
is No For Gases and Vapours
equipment EX d Increased safety (Ex e)
concept? Type n (Ex n)
For Combustible Dusts Glands must meet Use non-certified
Potection by enclosure (Ex t) the requirements compression cable
Yes of IEC 60079-0 glands

Note: All cable glands should maintain the protection concept

of the enclosure. e.g.
Ex d enclosures should use Ex d glands
Ex e enclosures should use Ex e glands
Ex nR enclosures should use Ex nR glands
To EX d cable For Ex nA, nC enclosures should use Ex e glands
selector chart Ex t enclosures should use Ex t glands

International (ingress) protection can be maintained by the

correct use of barrier glands, sealing washers or thread sealant

Intertek Guide to Explosive Atmosheres and Hazardous Locations 9

 EX d Selection Chart Flow chart in accordance
with IEC 60079-14:2008

From cable gland

Note 1: Cables used for fixed wiring in hazardous selector chart
areas shall be appropriate for the ambient
conditions in service. Cables shall be: Note 2: Internal sources of ignition include sparks
A) Sheathed with thermoplastic, thermo-setting or equipment temperatures occurring in normal
or elastomeric material. They shall be circular, Ensure cable type is in operation which can cause ignition. An enclosure
compact, have extruded bedding and fillers, if accordance with the containing terminals only or an indirect entry
any shall be non-hygroscopic requirements of IEC enclosure is not regarded as an internal source
B) Mineral insulated metal sheathed e.g. pyro’s 60079-14. Refer to note 1 of ignition
C) Special e.g. flat cable with appropriate cable
glands
Does this
Yes enclosure No
contain an internal
source of ignition?
See note 2 Use a suitable
flameproof cable
Does the gland with a
Yes hazardous No
sealing ring
gas require IIC
apparatus? (e.g. compression
glands)
Yes Is the area No
of installation of
zone 1?

Use a barrier Is the free

gland Yes volume of the No
enclosure greater
than 2 dm3?

Explosive Atmospheres Training Courses

Persons working in The latest editions of IEC 60079-14 and IEC

hazardous areas have 60079-17 identify the skill sets required for
to be competent Electro-Technical persons who may carry
out work in explosive atmospheres as:
Responsible Persons, Designers, Operatives

No No
Technical
Person?
e.g. Operators e.g. Management

DSEAR/ATEX Yes
Awareness course Foundation
for operators Course ExF
(Bespoke)
Area Classification
Courses Yes Responsible Yes Bespoke Courses
Gases and Vapours Person (Ask for details)
IEC 60079-10-1
Combustible Dusts
Either, No
IEC 60079-10-2
and/or

Either, Designers
and/or Courses Yes Project Engineer / Where the CompEx logo
Application
Available Maintenance is used, this indicates that
Designers course
Engineer the course is approved and
Ex12
licensed by CompEx
The designer can select No
Either, from up to three courses.
and/or They can do either or all
Practioners course of these courses as shown
Ex01-Ex04 Gases
and Vapours
Ex01R-Ex04R
Gases and Vapours Operatives Practitioners
Refresher Electrical / Instrumentation Technicians Mechanical course Ex11
Ex05 & Ex06 Mechanical
Combustible Dusts

10 Guide to Explosive Atmosheres and Hazardous Locations Intertek

Employer’s & End User’s Obligations [ATEX & DSEAR]
1. Prevent the formation of explosive atmosphere OR avoid the ignition of explosive atmospheres, and
control the effects of explosions.
2. Assess explosion risks:
• Likelihood of explosive atmospheres occurring and their persistence
• Likelihood that ignition sources are present
• Scale of the anticipated effects
3. Coordinate the implementation of all measures concerning workers’ health and safety.
4. Area classification
5. Mark explosive atmospheres with signs at point of entry
6. ‘Explosion Protection Document’ shall demonstrate:
• Explosion risks have been determined and assessed
• Adequate measures will be taken to comply with Directive 1999/92/EC
• Places have been classified into zones
• Places where minimum requirements in Annex II, Part A will apply
• Workplace and work equipment are designed, operated and maintained properly

ATEX Categories v Zones of Use

Equipment Category Zone of Use
ATEX 94/9/EC Gas, Vapours, & Mist Dust
Cat 1 Zone 0, 1 & 2 Zone 20, 21 & 22
Cat 2 Zone 1 & 2 Zone 21 & 22
Cat 3 Zone 2 Zone 22
Note: Unless the explosion protection risk assessment states otherwise.

Additional Market Access: IECEx Scheme

Manufacturers of Ex equipment can obtain certificates of conformity that will be
accepted at a national level in all countries that participate in the IECEx Scheme.
A certificate of conformity may be obtained from any certification body accepted into the Scheme.
The certificate will attest that (1) the equipment design conforms to relevant IEC Standards and (2) the
product is manufactured under a quality plan assessed by an ACB (Accepted Certification Body).
Manufacturers holding certificates of conformity may affix the IECEx Mark of Conformity to equipment
that they have verified complies with the certified design.
Intertek is an IECEx Testing Laboratory and has IECEx Accepted Certification Body status. For more
information on the IECEx Scheme, visit www.IECEx.com.

Intertek Guide to Explosive Atmosheres and Hazardous Locations 11

Related Services

Intertek has full EMC Test facilities, through one of the

largest network of global EMC laboratories, including
test cell and OATS sites. We also have significant
experience in solving EMC problems and EMC site/
assembly assessment.

Safety testing for LVD, IEC1010 and Electrical Safety of

Machines, as well as Machinery Directive and Pressure
Equipment (PED) Consultancy.

In addition to the ATEX and CE Certification of

equipment, Intertek can certify assemblies and
production lines against CE Directives or PUWER.

When products or assemblies are compliant, Intertek

can certify your Quality Systems to the necessary levels
(for example, ISO9001:2000, IECEx QAR and ATEX
Quality Modules) as well as offering the full range
of environmental product and management systems
services to meet the latest directives.

For more information please contact us:

Americas Europe
Intertek Intertek
Cortland United Kingdom
+1 607 753 6711 +44 1244 882590
icenter@intertek.com hazloc@intertek.com

Dallas
+1 972 202 8800
icenter@intertek.com

www.intertek-hazloc.com