Guide To The Ex World CORTEM Group

Guide to the EX world
How to use electrical equipment in areas with risk of

explosion
Index
1. Introduction pag. 5
2. Hazardous areas classification pag. 13
3. Equipment choice pag. 20

3.1. Groups, categories and EPL (Equipment Protection Level) pag. 20
3.2. Protection methods pag. 22
3.3. Electrical equipment pag. 22
3.3.1. Gases pag. 22
3.3.2. Dusts pag. 23
3.4. Non-electrical equipment pag. 23
3.5. “Ex” Abecedarium
pag. 25
3.6. Cortem Group equipment pag. 25
3.6.1. Product classes pag. 25
3.6.2. Our protection methods pag. 28
3.6.2.1. “Ex d” explosion-proof junction boxes pag. 30
(literally flame-proof)
3.6.2.2. “Ex e” increased safety equipment pag. 34
3.6.2.3. “Ex n” equipment pag. 35
3.6.2.4. “Ex t” equipment pag. 36
3.6.2.4.1. Enclosure protection degrees (IP code) pag. 36
3.6.2.5. “Ex de” combined protection method pag. 39
3.6.3. Marking of explosion-proof equipment pag. 40
3.6.4. The ambient temperature of our equipment pag. 45
3.6.5. Our temperature classes pag. 45
3.6.6. Materials used in our equipment pag. 46
3.6.6.1. Aluminium alloy pag. 47
3.6.6.2. Stainless steel pag. 48
3.6.6.3. Polyester reinforced with glass fibers pag. 49
3.6.6.4. Borosilicate glass pag. 49
3.6.6.5. Polycarbonate pag. 50
3.6.6.6. Nickel-plated brass pag. 50
3.6.6.7. Galvanized steel pag. 50
3.6.6.8. Polyamide 6 pag. 50
3.6.6.9. Neoprene pag. 51
3.6.6.10. Silicone pag. 51
3.6.7. Our certifications (PART I) pag. 51
3.6.7.1. The 94/ 9/CE “ATEX 95” Directive pag. 51
3.6.7.2. IEC-EX pag. 52
3.6.7.3. Russia pag. 53
3.7. Our certifications (PART II) pag. 54
3.7.1. The “CE conformity statement” pag. 55
3.7.2. “User instructions” pag. 55
4. Installation pag. 56
Guide to the EX world – How to use electrical equipment in areas with risk of explosion 3
Index
5. Inspection pag. 59
6. Maintenance and repairs pag. 61
6.1. Maintenance pag. 61
6.2. Repairs pag. 62
7. End-of-life equipment pag. 63

7.1. Disposal pag. 63
7.2. Recyclability pag. 64
8. Application examples for different types of plants pag. 65

8.1. Pharmaceutical industries pag. 65
8.1.1. Reference standards pag. 66
8.1.2. Plant emission sources pag. 66
8.1.3. Classification for gas pag. 67
8.1.4. Classification for dusts pag. 67
8.2. Deposit of cereals pag. 67
8.2.1. Risk of explosion by clouds of dust pag. 68
8.2.2. Areas classification pag. 68
8.2.3. Areas inside containment system pag. 68
8.2.4. Areas outside containment system pag. 68
8.2.5. Electrical installations pag. 69
8.3. Coating booths pag. 69
8.3.1. Coating booths with liquid coatings pag. 69
8.3.2. Coating booths with dust coatings pag. 70
8.4. Biogas plants pag. 71
8.4.1. Plant type pag. 71
8.4.2. Risk of explosion pag. 72
8.4.3. Regulations pag. 72
9. Appendix pag. 73
9.1. Brief description of protection methods for electrical equipment pag. 73
addressed to areas with risk of explosion for presence of gas
9.2. Brief description of protection methods for electrical equipment pag. 74
addressed to areas with risk of explosion for presence of dusts
9.3. Brief description of protection methods for non-electrical equipment pag. 74
addressed to areas with risk of explosion due to presence of gas and dusts
9.4. Structural requirements for explosion-proof electrical equipment pag. 75
for potentially explosive atmospheres due to presence of gas
Marking of electrical equipment in areas with risk of explosion pag. 77
4 Guide to the EX world – How to use electrical equipment in areas with risk of explosion
1. Introduction
D
uring production, transformation, delivery and sto-
cking of flammable substances in the chemical and
petrochemical plants, so as during the production of
oil and natural gas, inside the mines and in many other fields
(such as the food field), gases, vapors and mists are produced. In
contact with the oxygen in the air, they can create an explosive at-
mosphere. If this atmosphere is triggered, the deriving explosion
can provoke serious damages to people and environment.
The aim of this Guide is to follow the Ex path (Image 1, following
page), providing experts and non with an overview on the world
of the explosion-proof electrical protection.
It is worth remembering that inside the European Community,
there are the technical standards (to be applied to reduce risks),
and the Community guidelines which are prevalent on technical
standards.
The European law has intervened to discipline different fields;
for our memo we will consider two blocks:
• the Product Directives;
• the Social Directives.
1.Introduction
Image 1 Ex path
hazardous areas classification marking of equipment

GASES: EN 60079-10-1 : 2009-03 and of assembly
DUSTS: EN 60079-10-2 : 2009-08
equipment choice
EN 60079-14: 2008-10
disposal
of equipment
equipment installation
EN 60079-14: 2008-10
repairing the equipment plants’ inspection and maintenance

EN 60079-19: 2011-01 EN 60079-17: 2007-09
ASL o ARPA, DPR 462/2001
The Product Directives were born in the first half of the 80s in or-
der to eliminate national laws and unify the technical references
on the various products. With an unique European reference and
the passage from national to European harmonized standards,
national barriers were eliminated and the goods could freely cir-
culate within the Community, as stated in the article No. 100
(now article No. 95) of the Treaty signed in Rome in March 1957,
where the Economic European Community was founded. This
path, composed of the first legislative documents (Directives,
Decisions, Resolutions) became complete in the first half of the
90s, with the decision that the products fulfilling the Safety and
Health Essential Requirements defined in the related Directive,
1.Introduction
had to bear a graphic mark Image 2 CE Graphic symbol

to circulate freely within
the European Community.
This graphic mark is the CE
(Image 2) that has to comply
with certain proportions.
Over the years, the first le-
gislative documents have
been emended, integrated
and modified till the last re-
Tab. 1 83/189/CEE “Framework Directive”: enactment, amendments and implementation in Italy

http://ec.europa.eu/enterprise/policies
83/189/CEE Directive by the Commission of Law 21st June 1986, n° 317, concerning the
28th March 1983 concerning the “information “application of the directive n° 83/189/CEE
“Framework Directive”
procedure in the field of technical standards and about the information procedure in the field of
regulations” technical and standards and regulations”
(G.U.C.E., L series, n° 109 of 26 April 1983) (G.U.R.I., General series, n° 151 of 2 July1986)
modified by:
decision n° 768/2008/CE of the European
Parliament and the Council of 9 July 2008
concerning a common frame for the product
trading and that repeals 93/465/CEE decision.
(G.U.C.E., L series, n° 218 of 13 August 2008)
vision, dated 2008 (Table 1).

In this block, along with many other Product Directives (low voltage,
electromagnetic compatibility, equipment, etc.) there is the Directi-
ve 94/9/CE, known as “ATEX 95” (by virtue of the number of the
article of the Treaty) or more simply as the first “ATEX” Directive.
It is addressed to manufacturers of equipment that will be used
in potentially explosive atmosphere. These manufacturers, after
the conformity assessment procedure foreseen for the equipment
group and category, will put, in addition to the CE mark, also the
graphic symbol of the “ATEX” Directive (Table 2).
1.Introduction
Tab. 2 “ATEX 95” Directive: enactment, amendments and implementation in Italy

http://ec.europa.eu/enterprise/sectors/mechanical/
Directive 94/9/EC of the European Parliament D.P.R. 23 March 1998, n° 126 “regulation laying
and the Council of 23 March 1994 on the down rules for the implementation of Directive
“approximation of the laws of the Member 94/9/EC concerning equipment and protective
States concerning equipment and protective systems intended for use in potentially explosive
systems intended for use in potentially explosive atmospheres”
atex/index_en.htm
atmospheres”
“ATEX 95”
(G.U.C.E., L series, n° 100 of 19 April 1994) (G.U.R.I. General series, n° 101 of 4 May1998)
Corrigendum to Directive 94/9/EC of the European

Parliament and of the Council of 23 March 1994
on the “approximation of the laws of the Member
States concerning equipment and protective
systems intended for use in potentially explosive
atmospheres.”
(G.U.C.E., L series, n° 21 of 26 January 2000)
Its official name is “distinctive community mark”. The hexagon in-

scribed with the epsilon-x must have these proportions (Image 3).
The Social Directives were born in the second half of the 80s to
implement measures to improve the workers’ health and safety
at work by the achievement of an harmonization of the workers’
protection levels in the EU, and by defining the minimum requi-
rements to improve working environment, such as to protect the
workers’ safety, as it was stated, in the article 118 (now article
137) of the Treaty signed in Rome in March 1957, in which the
Economic European Community was founded (Tables 3 and 4).
Image 3 European Community mark Over the years, the “framework” Directive
has been integrated with “specific” Directives
that took into consideration the various risks
existing in the working environment (con-
struction sites, extracting industries, physi-
cal agents, etc.) and, consequently, there
have been the various national transpositions
among those the last one, at Italian level, is
the one that generated the “Consolidated law
1.Introduction
Tab. 3 89/391/CEE “Framework Directive”: promulgation and implementation in Italy
“Framework Directory” Council Directive 89/391/EEC of 12 June 1989 Leg. September 19, 1994, No. 626, concerning
http://ec.europa.eu/social
on the introduction of measures to encourage the “implementation of Directives 89/391/EEC,
improvements in the safety and health of 89/654 / EEC, 89/655/EEC, 89/656/EEC, 90/269/
workers at work EEC, 90 / 270/CEE, 90/394/EEC, 90/679/EEC,
93/88 / EEC, 95/63/EC, 97/42/EC, 98/24/EC,
99/38/EC, 99/92 / EC, 2001/45/EC, 2003/10/
EC, 2003/18/EC and 2004/40/EC concerning the
improvement of safety and health of workers at
work “
(G.U.C.E., L series, n° 183 of 29 June1989) (G.U.R.I., General series, n° 265 of 12 November
1994)
on health and safety at work - TUS”: the legislative Decree of 9th

April 2008, No. 81 “Implementation of article 1 of the law of 3rd
August 2007, ne. 123, for the protection of health and safety in
the working environment” (G.U.R.I General series, No. 101 of
30th April 2008) and the legislative Decree of 3rd August 2009,
No. 106 “Supplementary and corrective measures of the legislati-
ve Decree of 9th April 2008, No. 81, for the protection of health
and safety in the working environment” (G.U.R.I General series,
No. 180 of 5th August 2009).
In this block, there is the 99/92/CE Directive, known as “ATEX
137” (by virtue of the article number in the Treaty) or more sim-
ply as the second “ATEX” Directive.
It is addressed to the employers of the workers who can be expo-
Tab. 4 “ATEX 137” Directive: promulgation and implementation in Italy

http://ec.europa.eu/social
Directive 1999/92/EC of the European Leg. June 12, 2003, No. 233 “Implementation of
Parliament and of the Council of 16 December Directive 1999/92/EC on minimum requirements
“ATEX 137”
1999 “minimum requirements for improving for improving the safety and health protection
the safety and health protection of workers of workers potentially at risk from explosive
potentially at risk from explosive atmospheres” atmospheres”
(XV individual Directive within the meaning of
Article 16, paragraph 1 of Directive 89/391/EEC)
(G.U.C.E., L series, n° 23 of 28 January 2000) (G.U.R.I., General series, n° 197 of 26 August
2003)
1.Introduction
Graph 1 Number of non-fatal accidents at workplace for diversion and contact during 2005
inside EU_V
against stationary object (victim
hit by a moving object, collision

contact with electrical voltage
contact with sharp, pointed,

drowned, buried, wrapped
horizontal / vertical impact
physical or mental stress

temperature, hazardous
bite, kick, etc. (animal or

rough agent or coarse
all contacts – mode
trapped, crushed, etc.
other contacts
of damage
substances
in motion)
material
human)
with ...
explosion 2.366 1.422 8 38 359 98 15 377 : 49
1% trapped, crushed, etc. 16% physical 0% bite, kick, etc. (animal or human)
or mental stress 2% other contacts
4% contact with sharp, pointed,

rough agent or coarse material
15% hit by a moving object, 60% contact with electrical voltage
collision with... temperature, hazardous substances
2% horizontal / vertical impact

against stationary object (victim in motion)
0% drowned, buried, wrapped
source: eurostat -
ESAW (European Statistics on Accidents at Work)
sed to the risk of explosive atmospheres.

Now, the collection of these two blocks of Directives, the
equipment or, more generally, the “products” put on the market
regardless of their use (domestic or industrial) from one side, and
the health and safety at work from the other, make that, each of
them, with its own role, contributes to a general improvement of
working conditions.
Even though we keep on giving ourselves news rules increasing
the “state of the art” and we turn to the best and the most inde-
Notes: EU_V indi-

pendent of the Notified Bodies for our product certification, there
cates that, for this will always be some risks.
analysis, 20 Mem-
ber States (out of But what is the risk?
27) have provided
the information. It is difficult to gather information but, to have an idea, we can have
Two points reported
in Graphs 1 and a look at the graphs 1, 2 and 3, taken from the document “Causes
2 indicate that the
information is not
and circumstances of accidents at work in the EU” published by the
available or that it
“Directorate-General for Employment, Social Affairs and Equal
comprises less than
4 elements. Opportunities” of the European Commission in November 2008.
1.Introduction
Graph 2 Number of fatal accidents at work for diversion and contact in the period 2003-2005
inside European Union EU_V
hit by object in motion, collision

contact with electrical voltage
contact with sharp, pointed,

drowned, buried, wrapped
horizontal / vertical impact
physical or mental stress

rough agent, and coarse
against a stationary object
temperature, hazardous
all contacts- mode of
trapped, crushed, etc.
bite, kick, etc. (animal

damage / accident
(victim in motion)
other contacts
substances
or human)
material
with ...
explosion 98 56 4 4 23 : 6 : : :
0% contact with sharp, pointed, rough agent, 7% trapped,

coarse material crushed, etc.. 0% physical or mental stress
0% bite, kick, etc. (animal or human)

25% hit by object in motion, 0% other contacts
collision with..
60% contact with electrical voltage,
4% horizontal / vertical impact temperature, hazardous substances
against a stationary object (victim in motion)
4% drowned, buried, wrapped

source: eurostat -
Considering that some information covers the period 2003-2005

(fatal accidents) and other the year 2005 (non-fatal accidents),
and that both the “ATEX” Directives were almost at the begin-
ning, we can reasonably hope that in the coming future the acci-
dents will be reduced.
This will happen by reason of the familiarity we will achieve with
the “risk analysis” tool, that will consider whether the potential
ignition sources are present or not and, if present, what they are
worth and what effects they can produce in case of contact with
a potentially explosive mixture inside its explosive ranges. The
sources to take into consideration are:
• hot surfaces;
• flames and hot gases (hot particles included);
• mechanically generated sparks;
• electrical equipment;
• stray electrical currents, cathodic corrosion protection;
• static electricity;
1.Introduction
Graph 3 Number of accidents at work for diversion, number of days lost, and average age of
victims during 2005 inside European Union EU_V
Permanent incapacity in 2005
Mortal accidents from 2003

number of mortal accidents
more than 3 days lost
21 days - 1 month lost
Permanent incapacity
from 2003 to 2005

1 - 3 months lost
3 - 6 months lost
7 - 13 days lost
14 - 20 days lost
4 -6 days lost
to 2005
explosion
2.406 316 492 339 384 572 155 148 102 39,3 40,5
600
500
400
300
200
100
0
4-6 days 7-13 days 14-20 days 21 days 1- 3 months 3-6 months permanent
lost lost lost 1 month lost lost lost incapacity
source: eurostat -
• lightning;
• electromagnetic waves;
• ionizing radiations;
• ultrasound;
• adiabatic compression and shock waves;
• exothermic relations, self-ignition of dust included.
To have an explosion it is not sufficient that fuel, oxidizer and igni-
tion meet (Image 4), but, in addition to this, there must be the
confinement in which the combustion occurs (Image 5).
Image 4 The fire triangle Image 5 The pentagon of the explosion

ignition cause ignition cause
confinement concentration
combustible combustion combustible combustion

material agent material agent
2. Hazardous
areas classification
I n facing the chapter on the classifi-

cation, the first thing that came to
our minds is: what is classification?
The answers could be various: it is a docu-
It has to be pointed out that the references of
the “state of the art”(technical standards) in
this field (currently IEC 60079-10-1 for gases
and IEC 60079-10-2 for combustible dusts) do
ment, it is the drawing with the “clouds”, it not refer either to the areas with presence of fi-
is a number identifying the area, it is the pro- redamp gas (group I), or to the areas where the
bability that the explosive atmosphere is pre- explosives are processed and produced, etc.
sent in a certain area. The classification is a teamwork! The area
The answers are correct, but only if conside- classification should be made by people who
red all together. understand the importance and meaning of
We could therefore define the areas classifica- the properties of flammable substances, as
tion as a method of analysis and classification of well as by people who are familiar with the
the environment where explosive atmospheres process and the equipment, together with qua-
may occur because of the presence of gases and/ lified personnel in the field of safety, electrical
or combustible dusts, in order to facilitate the and mechanical installations, and more; it
correct choice and installation of the equipment is necessary, moreover, a tight cooperation
to be used safely in that environment. among experts in safety and equipment.
What are these areas? Some of these hazardous areas will be
More than we can imagine! The combustible ga- analyzed in chapter 8.
ses classified in the regulation IEC 60079-20-1 What do we have to do?
are 328, while the combustible dusts listed in the First of all we have to build the team!
BIA report 13/97 are more than 4.300, sawdust, After that, step by step, work must be faced.
flour and breadcrumbs included! And, since a) Identifying the hazardous sub-
1997, many others have been classified! stances – with the help of the informa-
Reasoning by macro areas, the classification tion contained in the safety form, in the
could be required for the following areas: IEC 60079-20-1 standard “Explosive atmo-
spheres – part 20-1: classification of gases
and vapors – test methods and information”
in the BIA report 13/97 “Combustion and ex-
refineries recycling plosion – characteristics of dusts” and in the
bibliographical references. But sometimes,
especially for combustible dusts, the infor-
mation we find in literature does not coincide
metallurgical
chemical
industries
and plastics with the characteristics of our sample (type
industry
of substance and grain size) or we are not in
presence of a single dust. In these cases, it is
recommended to refer to specialized centers
landfills,
energy
production
waste treatment in order to have the specimen characteriza-
and waste water
tion made; in Italy, a reference is the “Fuel
Experimental Station” (http://www.ssc.it)
based in San Donato Milanese (MI).
food
and feed wood industries Some information about gas is interesting.
industry
In Table 5, we have gathered the gases
that, for some reason, are representative
of something:
gas treatment
coating and supply • those highlighted in bold (No. 18, 20,
plants
21, 27 and 288) are representative of the
gas subgroups;
• No. 55 and 7 for the lower explosive li-
pharmaceutical
industry
mit (L.E.L), the lowest and the highest,
respectively;
• No. 181 and 21, 37, 170, 293 for the
2. Hazardous areas classification
Tab. 5 Some of the most representative gases
n° GAS Name Formula L.E.L. U.E.L. M.I.T. M.I.E.* GROUP

[vol %] [°C] [μJ]
7 64-18-6 Formic acid HCOOH 18,00 57,00 525 IIA
methane CH4 4,40 17,00 600 IIA

18 74-82-8 280
firedamp gas 4,40 17,00 595 I
20 74-85-1 ethylene CH2=CH2 2,30 36,00 440 82 IIB
21 74-86-2 ethyne (acetylene) CH=CH 2,30 100,00 305 19 IIC
27 74-98-6 propane CH3CH2CH3 1,70 10,90 450 250 IIA
35 75-15-0 Carbon disulphide CS2 0,60 60,00 90 9 IIC
37 75-21-8 ethylene oxide CH2CH2O 2,60 100,00 429 IIB
55 78-10-4 tetraethoxysilane (C2H5)4Si 0,45 7,20 174

(silicic acid tetraethyl ester)
170 110-05-4 bis (1.1-dimethylethyl) peroxide (CH3)3COOC(CH3)3 0,74 100,00 170 IIB
181 110-96-3 2-methyl-N-(2-methylpropyl)-1- ((CH3)2CHCH2)2NH 0,80 3,60 256 IIA

propanammina (diisobutilammina)
206 123-42-2 4- hydroxy -4-methylpentane-2-one CH3COCH2C(CH3)2OH 1,80 6,90 680 IIA

(diacetonalcol)
288 1333-74-0 hydrogen H2 4,00 77,00 560 16 IIC
293 1712-64-7 nitric acid 1-methylethyl ester (CH3)2CHONO 2,00 100,00 175 IIB
Legenda: L.E.L.: (Lower Explosive Limit; U.E.L.: Upper Explosive Limit;

M.I.T.: Minimum Ignition Temperature; M.I.E.: minimum Ignition Energy;
upper explosive limit (U.E.L.), the lo- tively;

west and the highest, respectively; • No. 35 and 206 for the ignition tempe-
• No. 181 and 170 for the explosive limit, rature, the minimum and the maximum,
the least and the most extended, respec- respectively.
Graph 4 Graph 5
Subdivision of gas in groups Number of gas for temperature class
28 indeterminate 1I
140
5 IIC
120
66 IIB
100
[n°]
80
60
40
20
0
227 IIA T6 T5 T4 T3 T2 T1 ind.ti
temperature classes
Tab. 6 Some of the most representative dusts
Combustible Grain Explosive level M.I.T. [°C ] M.I.E. Kst

materials [µm] L.E.L. [mJ ] [°C]
[g/m3]
in cloud in 5 mm
Tcl layer
T5mm
wood 70 40 440 325 20 128
wheat flour 57 60 430 450 50 87

lactose 23 125 450 melts 10 81
rice 45 60 490 ˝ 80 101
sugar 35 200 350 490 30 138
polyethylene < 10 25 450 ˝ 80 156
phenol < 10 25 460 melts 10 129
aluminium 29 40 700 320 50 415
magnesium 28 30 600 490 120 508
zinc < 10 480 680 460 650 176
coke 15 80 ˝ ˝ 80 47
urea hydrolysed 13 70 450 ˝ 80 136
cellulose 112 30 350 465 ˝ 112
Legenda: L.E.L.: (Lower Explosive Limit; U.E.L.: Upper Explosive Limit;
M.I.T.: Minimum Ignition Temperature; M.I.E.: minimum Ignition Energy;
source: BIA-Report 13/97
In the Graph 4, the great prevalence of Table 6 depends on that in the first two co-
subgroup IIA is evident, while the Graph 5 lumns. Here we have something different if
shows the gas distribution in the tempera- compared to how we were used to treat ga-
ture class identification with a Gaussian di- ses: the dust ignition temperatures are cha-
stribution. racterized by two different state conditions:
As far as the dusts are concerned, being they may be triggered when, because of the
them almost unknown, the information is convection, they move in the air forming
more complex to extract. Once identified the “clouds” (Tcl), or when they are deposited on
nature of dust, the second fundamental in- the surfaces forming increasingly thicker la-
formation for its identification is the average yers; conventionally we take as reference a
particle size. Let’s have a look at some exam- layer of 5 mm (T5mm).
ples of dusts in Table 6 at the previous page. Moreover, we have to add that recently, as a
The information in the second column of technical standard, dusts have been classi-
Image 6 Hazardous areas classification based on presence and concentration of gas (Zone 0, 1 and 2)
and dusts (Zone 20, 21 and 22)
Zone 0 Zone 1 Zone 2
Zone 20 Zone 21 Zone 22
Note: the graphic images in the boxes are those normalized at international level
fied into three subcategories, similarly way c) Defining the emission rate of the
to what was done years ago for gases. The sources – (speed, geometry, concentra-
subgroups are: tion, volatility, temperature).
• IIIA: flammable particles, such as “solid d) Establishing the ventilation degree.
particles, fibers included, with nominal e) Defining the hazardous areas (Image 6).
sizes > 500 μm”; f) Defining the hazardous areas extension.
• IIIB: non-conductive dust, such as “fi- The areas division reported in Image 6 in
nely divided solid particles, with nominal the previous page is a widely spread sy-
sizes ≤ 500 μm, with electrical resistivity stem, in fact it is the one adopted both by
> 103 Ωm”; Europe and by the international IEC stan-
• IIIC: conductive dust, such as “finely di- dards. In case this division is not enough,
vided solid particles, with nominal sizes UNECE, an UNO Agency, has reinforced
≤ 500 μm, with electrical resistivity ≤ this concept, and also in its latest report of 2011
103 Ωm”. (http://www.enece.org/) it refers to the inter-
b) Identifying the emission sources – national IEC standards as reference to adopt.
(continuous, first degree, second degree). It can happen, however, that some documents
Tab. 7 Comparison between hazardous areas classification for presence of gas based on international standards
(IEC Zone System) and according to North American standards
GAS
Area in which during normal

Area in which an explosive Area in which during normal activities the formation of
atmosphere, consisting in a activities the formation of an explosive atmosphere
mixture of air and flammable an explosive atmosphere consisting in a mixture of air
Zone 0 substances in the shape of Zone 1 consisting in a mixture of air Zone 2 and flammable substances
gas, vapor or mist, is present and flammable substances in the shape of gas, vapor or
permanently or for long in the shape of gas, vapor or mist, is not possible, and in
periods or often. mist, is possible. case it happens, it lasts very
shortly.
Class I, Division 1 Class I, Division 2
> 1.000 h/year 10 ÷ 1.000 h/year 0,1 ÷ 10 h/year
Tab. 8 Comparison between hazardous areas classification for presence of dusts based on international
standards (IEC Zone System) and according to North-American standards
DUSTS
Area in which during

normal activities the
Area in which an explosive Area in which occasionally
formation of an explosive
atmosphere is present during normal activities the
atmosphere in the shape
permanently or for long formation of an explosive
Zone 20 Zone 21 atmosphere in the shape of
Zone 22 of cloud of combustible
periods or often, in the
dust is not possible, and
shape of clouds of dusts. cloud of combustible dust in
in case it happens, it lasts
the air, is possible.
very shortly.
Class II, Division 1 Class II, Division 2
> 1.000 h/year 10 ÷ 1.000 h/year 0,1 ÷ 10 h/year
written according to the North-American will be traced, that is to say of the extension
standards (USA and Canada) refer to their na- of each classified area. This document, as
tional standards and that, therefore, also the it will be understood, is very important for
nomenclature is different from that adopted the employer, who, on the basis of which,
internationally. Tables 7 and 8 highlight the will have to make some choices and take
correlation between the two systems. some measures. Some information, neces-
Regardless of the normative reference sary for the production process, has to be
used, the hazardous areas classification will found in this document:
be composed of: a descriptive document, • installation area or category / EPL of the
in which the factory, the processes taken equipment that will have to be installed;
into account, the list of the hazardous sub- • gas subgroup or specific gas/es and/or
stances present, etc., will be identified; a dust subgroup or specific dust/s;
plan drawing and a perspective drawing in • max permissible temperature class of the
which, by means of the proper conventional equipment that will have to be installed;
graphic symbols, the limits of the “clouds” • ambient temperature.
3. Equipment choice
3.1. Groups, categories and EPL (Equipment • category M2: equipment which guaran-
Protection Level) tees a very high protection level; it must
T
he 94/9/CE Directive foresees be possible to cut the power off in presen-
the following division: ce of explosive atmosphere.
• Group I: products addressed Group II
to mines and in their surface systems, where • category 1: equipment which guarantees a
firedamp gas can be present. very high protection level; it is intended to be
• Group II: products addressed to surface used in areas in which there is, always or for
sites with the presence of explosive atmo- long periods, the presence of explosive atmo-
sphere. sphere.
The products are then divided inside the • category 2: equipment which guarantees
Groups as follows: a very high protection level; it is intended to
Group I be used in areas in which the development
• category M1: equipment which guaran- of explosive atmosphere is most likely.
tees a very high protection level; it has to • category 3: equipment which guarante-
be kept powered in presence of explosive es a very high protection level; it is inten-
atmosphere. ded to be used in areas in which the deve-
Tab. 9 Correlation between equipment category and Tab. 10 Correlation between equipment category and the
installation area for Group II protection level
1 2 3 1G 2G 3G
M1 M2
1D 2D 3D
G Zone 0 Zone 1 Zone 2
Ga Gb Gc
D Zone 20 Zone 21 Zone 22 Ma Mb
Da Db Dc
lopment of explosive atmosphere is slightly blished and highlighted in Table 9, between

possible. equipment category and installation area.
The category numbers of group II (1, 2, 3) are What we have described above is valid for
followed by a capital letter: the EU.
• G, for gases; Outside EU, until 2007, the equipment was
• D, for combustible dusts. marked only with the protection method.
For example: II 2G. Therefore, inspired by the European system,
On the basis of group II definitions and by com- the EPL Equipment Protection Level (Table
paring them to those provided by the 99/92/CE 10) has been created, replacing the letters
“ATEX 137” Directive, a two-way link is esta- “a”, “b”, “c” to the numbers “1”, “2” and “3”.
Tab. 11 Standardization bodies subdivided according to technical competence and territoriality
Field
Electrotechnical International International
and electronic
Electrotechnical Commission International International Organization
International Commission Electrotechnique Telecommunication Union for Standardization
International Organisation internationale
de normalisation
Geneve, Switzerland Geneve, Switzerland Geneve, Switzerland
http://www.iec.ch http://www.itu.int http://www.iso.org/iso/home.htm
European European Committee for European Telecommunications European Committee
Electrotechnical Standardization Standards Institute for Standardization
Comité Européen de Comité européen
Normalisation Electrotechnique de normalisation
Brussels, Belgium Sophia Antipolis, France Brussels, Belgium
http://www.cenelec.eu http://www.etsi.org http://www.cen.eu
Italy Italian Electrotechnical Committee CONCIT Italian National body
National Coordinating of unification
Committee for Informatics
and telecommunications
Milan, Italy
http://www.ceiweb.it Rome, Italy Milan, Italy
http://www.isticom.it http://www.uni.com
3. Equipment choice
For the Group III, related only to dusts, please (flame-proof junction boxes), the purpose
refer to what described in the previous pages. is achieved.
Regularly, the European Commission publi-
3.2. PROTECTION METHODS shes in the Official Journal of the European
The protection methods are techniques avai- Union the list of the harmonized technical
lable thanks to the harmonized standards, ai- standards which tend to comply with the re-
ming to meet the Safety and Health Essential quirements of the “ATEX 95” Directive.
Requirements. The standardization bodies are divided accor-
These techniques “play” on the fact that, remo- ding to their technical competence and territo-
ving also only one of the elements which form riality, as it is represented in Table 11 in the pre-
the explosion Pentagon, the explosion itself vious page.
cannot take place. So, by limiting the energy In the Graphs 6, 7 and 8 we quote the main
(intrinsic safety) and the heat (increased protection methods for electrical and non-
safety, structural safety), by removing the electrical equipment. For a deep analysis of
fuel (pressurization, liquid immersion, the protection methods that Cortem uses, re-
encapsulation), by containing the explosion fer to paragraph 3.6.2.
3.3. ELECTRICAL EQUIPMENT

3.3.1. GASES
Graph 6 Main protection modes for electrical equipment in presence of gas
Main electrical
protection
modes
Prevention Prevention
Absence Absence Segregation Explosion-proof

of the ignition of explosive of the ignition db
source atmosphere source
Intrinsic Pressurization Encapsulation

safety pxb ma
ia pyb mb
ib pzc mc Legend: those in
ic red background are
Protection mode Immersion in
“n” oil “suitable” for category
nRc ob 1 and/or M1; those in
Increased
safety orange background
eb Filling are “suitable” for
qb category 2 and/or
Protection mode M2; those in pink
“n” Protection mode background are
nAc “n” “suitable” for
nLc nCc category 3.
3.3.2. DUSTS
Graph 7 Main protection modes for electrical equipment in presence of dusts
Main electrical
protection modes
for dusts
Prevention
Absence Absence Segregation

of the ignition of explosive of the ignition
source atmosphere source
Intrinsic Pressurization Encapsulation

safety pD ma
ia pD mb
ib mc
ic
Through Legend: those in red background are

junction boxes “suitable” for category 1 and/or M1; those
ta in orange background are “suitable”
tb for category 2 and/or M2; those in pink
tc
background are “suitable” for category 3.
3.4. NON-ELECTRICAL EQUIPMENT

Graph 8 - Main protection modes for non-electrical equipment in presence of gas or dusts
Main electrical
protection modes
for gas and dusts
Prevention Protection
Absence Control Absence Segregation

of the ignition of ignition of explosive of the ignition
source source atmosphere source
Inherent Control Pressurization Immersion Explosion-proof

safety of ignition p in liquid
g source k d
b Limited k
Constructive b respiration k
safety enclosure
c fr
c
Legend: those in red background are “suitable” for
category 1 and/or M1; those in orange background
are “suitable” for category 2 and/or M2; those in pink
background are “suitable” for category 3.
3. Equipment choice
Tab. 12 List and explanation of the letters used in the marking
Capital Small Comment

A • it appears in gas subgroups of group II: IIA
• it appears associated to protection mode “n”, nA
a • it appears associated to other letters, i.e. ia, ma
• it appears in the EPL associated to letter G or D
B • it appears in gas subgroups of groups II: IIB
b • it appears associated to other letters, i.e.: ib, mb
• protection mode by source control
C • it appears in gas subgroups of group II: IIC
• it appears associated to protection mode “n”, nC
c • it appears associated to other letters, i.e..: ic
• protection mode by constructive safety
D • it appears associated to other letters, i.e.: iD, mD, pD
• it identifies combustible dusts category
• it identifies the EPL with combustible dusts
d • flame-proof protection mode (both electrical and non-electrical)
e • increased safety protection mode
f • combined to letter “r”, it represents the limited respiration protection mode “fr”
G • it identifies gas category
• it identifies gas EPL
g • protection mode by inherent safety
i • protection mode by intrinsic safety, for gas combined to letters “a”, “b” or “c”
• protection mode by intrinsic safety, for dusts combined to letter “D”
J • combined to letter “m”, it represents protection mode for electrostatic spraying “.. mJ”
k • protection mode by immersion in a liquid
L • it appears associated to protection mode “n”, nL
M • it identifies equipment for the mines
• it could be associated to protection mode “v”
m • protection mode by encapsulation, for gas combined to letters “a” or “b”
• protection mode by encapsulation, for dusts combined to letter “D”
• combined to letter “J”, it represents protection mode for electrostatic spraying “.. mJ”
n • protection mode “n” combined to different letters: “A”, “C”, “L”, “R”
o • protection mode by immersion in oil
• combined to letter “p”, optical transmission protection mode “op”
p • protection mode by pressurization (electrical) for gas combined to letters “x”, “y” or “z”
• protection mode by pressurization (non-electrical)
• protection mode by pressurization for dusts combined to letter “D”
• combined to letter “o”, optical transmission protection mode “op”
q • protection mode by pulverulent material
R • it appears associated to protection mode “n”, nR
r • combined to letter “f”, it represents limited respiration protection mode “fr”
s • special protection mode
t • protection mode by enclosure
v • transportable ventilated cabins protection mode, combined to numbers “1”, “2”, “3”, “4”, or “M2”
x • it appears associated to protection mode “p”, px
y • it appears associated to protection mode “p”, py
z • it appears associated to protection mode “p”, pz
3.5. “EX” ABECEDARIUM Image 8 Image 7 Aluminium
alloy enclosure
Looking at the letters used in the previous “Ex d” EJB series
graphs, it seems that few letters have remai- Image 8 Stainless
steel control
ned at the “standard-makers’ ” disposal! We station, “Ex ed”
I series
have checked it in the Table 12.
3.6. CORTEM GROUP EQUIPMENT

3.6.1. PRODUCT CLASSES
Since 1968, our company has been designing
and manufacturing electrical equipment
meant to be used in potentially explosive
atmospheres, acquiring competence, year
after year, in the regulations of industrial
products and becoming specialized in those Cortem Group is a multi-product company
“Ex”. In general, our equipment is used in en- and, to help the reader find what he is looking
vironments different from the domestic one, for, we have divided the products in “macro
and follow certain binding requirements as areas”. Most of our equipment is “Ex”, but
well as a lot of technical requirements, and there are some meant to be also used in non-
both are kept constantly updated. classified, or safe, areas.
1. “Junction boxes” macro area
Image 7
The term “junction boxes” itself, for some years
part of the common speech of the Ex operators,
does not identify anything but a generic enclo-
sure, that generally has the “Ex d” protection
method, where it has to be specified the function
it will have to perform according to its content.
Industrial nomenclature gives us a hand and so
our “junction boxes” are:
•“empty involucres low-voltage switchgear and
control gear assemblies”, in other words all tho-
se empty “junction boxes”, certified as a compo-
nent (Image 7);
•“command and control devices”, (Image
8) such as automatic switches, command
switches, disconnectors, control devices – di-
3. Equipment choice
Image 9 Image 10
Image 9 Enclosure with terminal strip in aluminium

alloy, series SA in “Ex e” execution
Image 10 Electronic grounding system in aluminium
alloy, series GRD4200 in “Ex d” execution
Image 11 Plug and socket in aluminium alloy, series
PY and SPY in “Ex d” execution
sconnectors and combined unities with fuses, •“equipment for tests, measures or monito-
electromechanical devices for control circu- ring of protection methods”, such as systems
its, switching equipment, etc.; for the grounding measure (Image 10).
•“low-voltage switchgear and control gear 2. “Plugs and sockets” macro area
assemblies”, such as the switchboards, diffe- Our plugs and sockets, with cylindrical cells,
rent sizes, where several “control devices and with interlocking device, allow the connec-
control gear” can be present, signaling lights, tion also with plugs and sockets of other ma-
measuring devices, etc.; nufacturers who comply with the product in-
•“junction boxes”, such as those that are dustrial standards (Image 11).
usually called “terminal strips” (Image 9); 3. “Lighting equipment” macro area
•“electrical equipment of the machinery”,
such as the electrical equipment with a con- Image 11
trol action on a machine;

•“electrical measuring instruments, analog
gauges for direct actions and related acces-
sories”, such as ammeters and voltage testers,
wattmeters and varmeters, frequency meters,
power factor meters, (cos φ) and synchroni-
zers, ohmmeters, (impedance meters) and
conductance meters, multitasking tools;
Image 12 Image 16
Image 12 EWL series lighting fixture with LED in Image 16 Floodlight for discharge lamps in aluminium
aluminium alloy in “Ex de” execution alloy SLFE series in “Ex de” execution
Image 13 Fluorescent or LED tubes lighting fixture in
aluminium alloy and borosilicate glass series FLF and The “lighting equipment” macro area, together
FLFE in “Ex d” or “Ex de” execution with the “junction boxes” one, is an important
Image 14 Fluorescent tubes hand lighting fixture in type of equipment we put on the market and it
aluminium alloy FHL series in “Ex d” execution
is divided as follows:
Image 15 Lighting fixture for emergency in aluminium
alloy EVF-18EX series in “Ex d” execution • “fixed equipment for general use” (Ima-
ges 12-13);
Image 13
• “portable equipment” (Image 14);
• “emergency” (Image 15);
• “floodlights” (Image 16);
• “street lighting”.
Our lighting equipment uses different lu-
minous lamps and is codified in accordance
Image 14
with the “International Lamp Coding System
-ILCOS”, that became international standard
(IEC 61231:2010-01) in 2010;
• “filament lamps”, such as traditional in-
candescent lamps and halogen incandescent
lamps;
Image 15
• “discharge lamps”, such as fluorescent
(tubular and compact), mercury-vapor
(high pressure), sodium-vapor (high pres-
sure), metal-halide, mixed light;
• “LED”.
1: For the European Union, availability is regulated by Regulation n° 244/2009/EC of March 18, 2009 implementing Directive 2005/32/EC of the European Parliament and
of the Council with regard to ecodesign requirements for non-directional household lamps.
3. Equipment choice
Image 17 • “accessories”, such as fittings, curves, re-

Image 17
Electromagnetic horns in ductions, plugs, nipples, etc.
aluminium alloy C series
in “Ex de” execution
3.6.2. OUR PROTECTION METHODS
As it is evident in the previous chapters, the
number of the protection methods currently
available is definitely increased (about 26) if
compared to the first 6 adopted by the Eco-
nomic European Community quoted in the
79/196/CEE Directive of 6th February 1979.
At the beginning, the use of electrical
4. “Signaling devices” macro area. equipment in potentially explosive atmo-
• “audible warning devices” (Image 17 and 18); spheres was prevalent in the mining, while its
• “visual signaling devices”, that are the devi- surface use is more recent, dating back to end
ces to signal aerial obstacles, the traffic lights of IInd World War. Safety used to be quite
(Images 19 and 20). rudimentary. In late 1800, the coal was the
5. “Cable glands, systems of pipes and main source for the heating and for the gene-
accessories for electrical installations” ration of electrical energy. The main danger
macro area. in the coal mine was and still is represented
• “cable glands” for armored and unarmored by the possible presence of firedamp, a com-
cables (Images 21 and 22); bustible odorless, colorless gas, mainly com-
• rigid and flexible “tubes”; posed of a mixture of methane (from 77% to
Image 18
Image 18 Image 19 Image 20 Electromechanical
sirens in aluminium
alloy SCL series in
“Ex de” execution
Image 19 LED
obstruction lighting
fixture complying with
ICAO standard
XLFE-4 series in
“Ex de” execution
Image 20 LED traffic
lights in aluminium
alloy CCA-02E/SLD
series in “Ex d”
execution
Image 21 Image 22
Image 21 and 22 Cable glands for non-armored and armored cables REV, REVD in “Ex d”, “Ex e” and “Ex tb”
execution
99%) or of other similar hydrocarbons and be used was the lighting one as well as the one
of varying amounts of carbonic anhydride, generating driving force. Both equipment
oxygen and nitrogen. sets had to be controlled. The problem was
The mining history reminds us of the re- analyzed and possible solutions came out.
levant number of workplace fatalities: the In Germany the mostly involved organiza-
most serious mining accidents in the USA tion was the Berggewerkschaftlichen Ver-
(Monongah, West Virginia, December 6th suchsstrecke (BVS) that, together with the
1907: 362 victims) and in Europe (Courri- mining engineer Carl Beyling, introduced a
ères, France, March 10th 1907: 1099 victims; technique, around 1905, according to which
Marcinelle, Belgium, August 8th 1956: 262 electrical equipment (lamps and electric
victims). Therefore, over the years the mi- motors) was contained in an enclosure
ners have looked for solutions that could strong enough to keep inside the possible
warn them of dangers. Methane is lighter explosion which could be triggered by the
than the air and, consequently, tends to go electrical equipment. In 1908 Carl Beyling
upwards. So, “canaries in cage” were one of wrote a document describing the applica-
the first safety and warning methods; being tion of what was later called “druckfeste
very sensitive to gases, when these birds kapselung”, that are explosion-proof jun-
died by suffocation, they were a warning for ction boxes, at that time called “closed en-
the miners who immediately run out of the capsulation” or “explosion-proof encapsu-
mine. Before Sir Humphry Davy developed lation”, from where the letter “d” derives,
the lamp, some oil lamps were used in order and stands for the present identification of
to burn the possibly present mixture. I let the protection method. Immediately after
you guess the consequences! that, a second signaling system technique
The introduction of electricity at the end of for the mines was introduced, based on the
XIXth Cen. brought some benefits, but also use of low energy values: the intrinsic safe-
some risks. The first electrical equipment to ty was created.
3. Equipment choice
Today, the term “electrical construction Ex” 3.6.2.1. “Ex d” EXPLOSION-PROOF JUNCTION
refers to an electrical equipment for explo- BOXES (LITERALLY FLAME-PROOF)
sive atmospheres that complies with the As described above, the “Ex d” protection
IEC and CENELEC standards of the series method is highly probably the oldest protec-
60000 and 61000. tion method and its applicability to multiple
We have decided to focus on the protection types of industrial products has allowed its
methods we have been designed and manu- great spread (Image 23).
factured for 45 years. Concerning the pro- Comparing a normal equipment to an “Ex d”
tection methods suitable to be installed in one, the first evident characteristic is the
presence of explosive atmospheres for gas strength of the latter, since it has to resist
presence, we will analyze: mechanically, without being deformed pla-
• the “Ex d” explosion-proof junction boxes stically, to the internal pressure generated
(literally flame-proof); by the explosion. The pressure ranges nor-
• the “Ex e” increased-safety equipment; mally from 5 to 12 bar (Image 24). Therefore,
• the “Ex n” equipment. in this method, which is the only one based
Concerning the protection methods suitable to be on the explosion containment (held at pres-
installed in presence of explosive atmospheres for sure), the protection is given by the junction
combustible dust presence, we will analyze: box.
• the “Ex t” equipment. The sparking electrical components are enclo-
For a brief description of the other protection sed inside the junction box, that allows the ex-
methods for gases and dusts, please refer to plosive atmosphere to enter but, in case of con-
Tables 27, 28 and 29 in the Appendix. tact between this and the ignition source (arc or
Image 23 Small control panels in “Ex d” execution. EJB enclosure in aluminium

Image 23
alloy and control devices mounted on lid
Image 24 Explosion-proof “Ex d” protection mode
Image 24
interstice
joint
length
Image 25 Image 26
mounting screw

lid “Ex d” explosion-proof
chamber
flame-path
body
Three-piece union
Sealing
Image 25 Flame-path fitting
Image 26 Conduit installation. Entry in an “Ex d” Tube
enclosure through a sealing fitting
spark) the consequent explosion remains confi- ter the insertion of the gasket;
ned inside the junction box. • if the thread is conical, the connection
Through the flame-paths (Image 25), the fla- must be fully tightened;
me cools down and the combustion product is • if an adapter is required, it must com-
not able to trigger the mixture present outside ply with the “Ex d” (IEC 60079-1) pro-
(held at flame). There are no normative limita- tection method;
tions concerning the sizes or the electrical cha- • the unused cable entries must be sealed
racteristics but, beyond certain dimensional with elements that comply with “Ex d”
limits building with this technique is expensive. (IEC 60079-1) protection method.
When choosing the “Ex d” protection me- The cable entry into enclosure can be made
thod, the following indications have to be by means of three systems:
considered: A. conduit installation;
• do not make further holes in the jun- B. cable installation with direct entry;
ction boxes than those allowed in the C. cable installation with indirect entry.
certificate; A. Conduit installation
• if the cable entry has a parallel thread, The electric cables run in a system of rigid
the coupling must have at least 5 full th- conduits and enter explosion-proof boxes by
reads; means of sealed fittings. This allows possible
• if the use of gasket is foreseen, the num- explosions to expand and spread inside the
ber of threads must be still sufficient af- housings (Image 26). The outlet of every “Ex d”
3. Equipment choice
Image 27
Conductor
CRV Filling plug

Sealing
mixture
Plug
FV Glass fiber
Conduit tubes
Image 27 Example conduit
installation. Between
the enclusures, sealing fittings
are visible
box features a sealed fitting (Image 27) which the conduit installation from a possible part
prevents explosions from spreading to other made with external cables.
sections, delimits the volume of the “Ex d” The wires pass inside a threaded conduit
electrical construction to a value close to that and through a sealed fitting; these sealed fit-
for which it has been proven, and separates tings must be filled with the right mixture of
Image 28 Cable installation with direct entry Image 29 Cable installation with indirect entry
Image 28 Image 29
“Ex d”
explosion-proof
chamber
“Ex d”
explosion-proof
chamber
Camera a prova
di esplosione “Ex d”
“Ex d”
Sealing bushings
“Ex e” enclosure

Cable gland
Pressacavo

CableCavo “Ex e”
Cable glands
Image 30
“Ex d” enclosure
“Ex d” sealing bushings
“Ex e” enclosure
Image 30
Example of cable
“Ex e” cable glands installation with
indirect entry
bi-component resin. This method effectively C. Cable installation with indirect entry
protects cables against mechanical and che- In this system, cables enter and exit a jun-
mical damage. One disadvantage is that it is ction box through terminals. By means of
difficult to modify the wiring later on. sealed bushings, this box is connected to
B. Cable installation with direct entry the explosion-proof box which contains
This type of system is mainly used in the UK houses electrical equipment that may cau-
and in countries under British influence. se sparks.
The cable enters directly the explosion-pro- The box containing terminals and the termi-
of box through a cable gland with a gasket nals with terminal fittings are both “Ex e” and
that prevents possible explosions inside the “increased safety” types (Image 29). This sy-
box from spreading elsewhere (Image 28). stem uses non-armored cables and, therefo-
Every cable gland must have standard safety re, fittings with the right cable glands. This
specifications and the same internal diame- type of installation is therefore used when
ter as the cable used. The gasket must also there is a low risk of mechanical damage and
be explosion-proof. Armored cables with when earth continuity is not essential.
braid, wire and tape are used in this instal- This system is quick to install, flexible and
lation along with cable glands for armored economical. However, it does not effecti-
cables. The advantage of this method is that vely protect against the risk of mechanical
armored cables guarantee both mechanical damage, so it is better to use an armored
protection and electrical continuity. One cable or anti-static cable trunking trays
disadvantage is that the cable clamp instal- wherever this risk is present. Image 30 of-
lation requires special maintenance to gua- fers an example of cable installation with
rantee earth continuity. indirect entry.
3. Equipment choice
3.6.2.2. “Ex e” INCREASED SAFETY EQUIPMENT conductive parts excluded), installed in

Increased safety equipment is very similar to clean environments and regularly che-
the industrial one and the term “increased” cked by qualified personnel, must have
refers to the safety level which is increased if enclosures with protection degree ≥
compared to the one given by the industrial IP20. The installation limitations must
equipment (Images 31 and 32). This protec- be specified on the machine. While in-
tion method imposes some limitations: stalling “Ex e” equipment, extreme at-
• it can be applied to equipment that, whi- tention must be paid to those operations
le operating, in normal and/or irregular that can affect the protection degree,
operating conditions, does not produce starting with the equipment cable entri-
arcs, sparks or excessive temperatures; es. In case solids and/or water enter the
• nominal supply voltage cannot exceed 10 kV. equipment, the conductive path between
While installing the equipment, extreme at- the two live parts of the equipment can
tention must be paid in particular to the four be shortened until the break of the die-
following critical aspects: lectric, and consequently an electric arc
• Protection degree of the equipment. can be formed.
Enclosures containing active nude parts • Way in which the equipment is
must have protection degree ≥ IP54, connected to the power supply cir-
while enclosures containing only isola- cuit. In general, the fuel system of “Ex e”
ted parts must have protection degree equipment is made with “Ex e” cable
≥ IP44. By contrast, rotary electrical gland and certified by a Notified Body,
equipment, (terminal strips and nude and made with internal sealing ring and
Image 31 “Ex e” increased safety protection mode

Image 32
Image 32 “Ex e” increased safety enclosure SA...SS
series in stainless steel with control devices
Image 33 Example of conformity marking
Image 31
external “o-ring”, in order to maintain Image 33
IP54 degree. The connection between ca-
bles and terminals must be carefully ta-
ken care of not to reduce the terminals
isolation construction characteristics. It
means: to follow manufacturer’s specifi-
cations about the cable cross-section to
connect to terminals and about the ma-
ximum number of wires connectable to
each terminal (or power dissipation of
the enclosure); to guarantee, in screw
terminals, the tightening of the conduc-
tor in the terminal (or of more conduc- of the temperature class, considering the
tors when the instructions allow it), ap- resistance of the terminal (declared by
plying the indicated tightening and being the manufacturer) and of the cable, and
careful not to affect the air insulation di- of the circuit current.
stances. • Choice of protection. Every single
• Thermal dissipation. “Ex e” protec- protection method must be always gua-
tion method allows the gas to enter the ranteed. The conformity marking com-
enclosure. For this reason the equipment plying with the 60079 standards of the
manufacturer measures the maximum “Ex” equipment, provides the informa-
temperature developed by the structure tion required to make the right choice
also in the internal components. As the and install the equipment correctly, as
cable inside the enclosure also increa- well as to use it and maintain it properly
ses the heat, it is necessary to avoid that according to the method of protection it
temperature exceeds the temperature guarantees (Image 33).
class declared by the manufacturer. The
installer must strictly follow the manu- 3.6.2.3. “Ex n” EQUIPMENT
facturer’s indications about the allowed For some aspects, it is similar to the increased
number of terminals, min and max con- safety protection method and has different
ductor section, max current and possible characteristics depending on the equipment:
indications about the conductors inside if it produces arcs or sparks (“Ex nA”), if it is
the enclosure. Alternatively, it is neces- breaking or non-injecting (“Ex nC”), if it is re-
sary to calculate the power dissipated by spiration limited (“Ex nR”). In any case, the
the enclosure that guarantees the respect nominal supply voltage cannot exceed 15 kV.
3. Equipment choice
3.6.2.4. “Ex t” EQUIPMENT electrical resistivity ≤ 103 Ωm.

This protection method, introduced as such Our equipment has a mechanical protection de-
after the “ATEX 95” Directive 94/9/CE, is gree provided by the use of elastomeric material.
about preventing combustible dusts from en- Such protection degree (IP 6x) has been verified
tering the enclosures where there is the elec- after impact tests and heat and cold tests.
trical equipment that could cause ignition.
Currently, technical standards classify this 3.6.2.4.1. ENCLOSURES PROTECTION DEGREES
equipment under Group III, that has been di- (IP CODE)
vided into three subgroups: In the history of the use of electricity, a lot
• IIIA: flammable particles; solid particles, of designers have made efforts to make that
fibers included, with nominal sizes > 500 plants and electrical equipment could be
μm; used safely. Among the various technical so-
• IIIB: non-conductive dust; finely divided solutions adopted to prevent accidents related
lid particles, with nominal sizes ≤ 500 μm, with to electrical systems, there is also the IP code.
electrical resistivity > 103 Ωm; The IP code (International Protection) sum-
• IIIC: conductive dust; finely divided solid marizes the protection level of an electrical
particles, with nominal sizes ≤ 500 μm, with equipment against the accidental or intentio-
Tab. 13 IP protection degree: meaning of the first digit
First characteristic digit
Code Graphic symbol Meaning for equipment Meaning for people

protection protection
IP 0X No protection
IP 1X Protected against solid bodies greater Protected against access with the back of
than 50 [mm] the hand
IP 2X Protected against solid bodies greater Protected against access with a finger
than 12 [mm]
IP 3X Protected against solid bodies greater Protected against access with a tool
than 2,5 [mm]
IP 4X Protected against solid bodies greater Protected against access with a thread
than 1 [mm]
IP 5X Protected against dust Protected against access with a thread
IP 6X Totally protected against dust Protected against access with a thread
Tab. 14 IP protection degree: meaning of the second digit
Second characteristic digit
Code Graphic symbol Meaning for equipment protection
IP XO No protection
IP X1 Protected against vertically falling water drops
IP X2 Protected against falling water drops with maximum inclination 15°
IP X3 Protected against rain
IP X4 Protected against sprinkles
IP X5 Protected against water splashes
IP X6 Protected against strong water splashes (waves)
IP X7 Protected against temporal immersion
IP X8 Protected against continuous immersion
nal contact with the human body, objects and • additional letter: to be used when
water. the protection of the people against
Besides the “IP” letters, the code is compo- dangerous parts is higher than the pro-
sed of two significant digits and of the addi- tection against solids, required by the
tional letters as indicated in the IEC 60529 first digit;
standard: • supplementary letter: to be used to
• first digit (0 ÷ 6): protection of the peo- provide information about the material.
ple from the contact with dangerous parts Explanations concerning the first significant
and protection of the materials from so- digit are contained in Table 13. The protec-
lids; tion level provided is progressive, from the
• second digit (0 ÷ 6; 7 ÷ 8): protection lowest (IP 0X) to the highest (IP 6X).
of the materials against harmful effects Explanations concerning the second signifi-
of water; cant digit are contained in Table 14. The pro-
3. Equipment choice
Tab. 15 Meaning of additional letters about protection Talking about the second digit, two aspects
against human access
must be considered:
Additional Description 1. between digits 6 and 7, it is as if there
letters
was a border between splashes section
A Protected against access with the and immersion section; it is misleading
back of the hand
and makes people think that a IP X7
B Protected against access with a code is higher than a IP X6 code;
finger
2. IEC 60529 Standard does not give any
C Protected against access with a tool information about the test of IP X8,
but that it cannot have lower condi-
D Protected against access with a tions than the test for IP X7; it means
thread
that defining IP X8 without defining the
immersion depth and/or the residence
tection level provided is progressive: time makes no sense.
• about the protection against water, from Table 15 contains explanations about the
the lowest (IP X0) to the highest (IP 6X); supplementary letters related to protection
• about the effects of the immersion, from against human access, while Table 16 con-
the lowest (IP X7) to the highest (IP X8). tains those concerning the supplementary
Tab. 16 Meaning of additional letters about Tab. 17 Comparison between NEMA code and IP code
protection against materials
Additional Description NEMA IP

letters 1 10
2 11
H High-voltage equipment 3R 14
3 54
3S 54
M Tested against harmful effects due 4 56
to water ingress with equipment in
motion 4X 56
5 52
S Tested against harmful effects due
to water ingress with switched-off 6 67
equipment 6P 67
12 52
W Suitable to be used in specified
atmospheric conditions 12K 52
13 54
letters related to protection of material. 3.6.2.5. “Ex de” COMBINED PROTECTION
Some marking examples: METHOD
• IP65: equipment that is totally protected It is an equipment, typically a power panel or
from dust and splashes of water; a lighting equipment, with a part made with
• IP67: equipment that is totally protected the “Ex d” explosion-proof protection method
both from dust and splashes of water and (usually the main part, for example: a power
from temporary immersion; panel or a lighting equipment, Image 34 and
• IP65W: equipment that is totally pro- 35) and another part made with the “Ex e” in-
tected from dust, from splashes of water creased safety protection method (usually the
in specified weather conditions (i.e. with connection box to the external circuits).
ambient temperature -60 ÷ + 55°C). From the union of the two protection me-
Sometimes it is required that the protection thods we have different solutions:
against solids and/or liquids must comply • “Ex d”: a sufficiently strong equipment
with the NEMA code instead of the IP code. providing a good safety level and allowing
Table 17 compares NEMA to IP. NEMA code the manufacture of a lot of devices, thanks
considers also other elements, such as pro- to its ductility;
tection against corrosion, while IP code do- • “Ex e”: a connection between equipment
esn’t. and plant providing a good safety level, as
Image 34
Image 34 Image 35 Example of
control panel
“Ex d” enclosure in “Ex de”
• Flame-paths protection execution
• Standard internal components Image 35 Series
• Attention to entry into enclosure EJBE “Ex de”
system composed
of a “Ex d”
EJB series
“Ex e” terminal strips junction box
• IP66 enclosure in aluminium
• Gaskets
• Attention to entry alloy and of a
into enclosure “Ex e” CTB series
• “Ex e” non-sparking junction box
components
“Ex d” sealed passages are the interface between the two enclosures
• It must not affect “d” protection mode
• It must guarantee “e” protection mode’s protection degree
3. Equipment choice
Image 36 Example of identification plate
Image 36
well as simple installation and maintenance • data of the Ex aspects, such as the
at affordable costs. marking, the number of certificate,
etc. 8 ;
3.6.3. MARKING OF EXPLOSION-PROOF • notice.
EQUIPMENT Some data are required by the European
As required by IEC 60079-0 standard, each Community directives, others are the conse-
product put on the market has its own iden- quence of the application of technical stan-
tification sign with the following informa- dards, specific for every equipment.
tion (Image 36): Let’s explain the Ex marking. The EN
• the name or place of the manufacturer, 60079-0:2009 standard, that has repla-
the subject responsible for putting the ced both EN 60079-0:2006 and EN 61241-
product on the market; 0:2006, and that became effective on 1st
• the year of manufacture 1 , the serial June 2012, has brought some changes such
number 2 , the equipment identification as the “Equipment protection levels” (EPL)
by defining the product code 3 ; and the way of marking the products.
• the equipment data: the temperature According to the new regulations, the sign is
class 4 , the maximum surface tempera- composed of five different sections (Image 37):
ture 5 , the ambient temperature 6 , the • the first is the marking related to the ap-
electrical data as stated in the certificate plication of at least one European Com-
7 etc; munity Directive: it is highlighted with
the graphic sign CE; a four-digit number perature class 8 , the protection method
can be placed nearby to indicate the No- for dusts 10 , the max temperature that
tified Body that has to supervise the the equipment can reach while operating
production (in our case = CESI) 1 in the pertinent ambient temperature 11
and 2 ; • the fourth is the marking related to EPL. It
• the second is the marking related to the indicates the level of protection provided by
application of “ATEX” 94/9/CE directi- the equipment and it is similar to the cate-
ve, and it is composed of the European gories 9 and 12 ;
Community mark epsilon-x 3 , of the • finally, the protection degree IP 13 .
equipment group (“I” or “II”) and of 4 Some examples of markings on our equipment
its category (for groups “II”: “1”, “2” or are contained in Table 18 (following page).
“3” 5 followed by letter “G” for gases or
“D” for combustible dusts) 6 ; IECEx System (International Elec-
• the third is the marking related to the trotechnical Commission System for
protection method and consequent to the Certification to Standards Relating to
application of the harmonized standards, Equipment for use in Explosive Atmo-
for example the standards of the 60079 spheres)
series: the protection method for gases In the European Union countries, the com-
and for the group of gases 7 , the tem- pliance with ATEX Directive is a necessary
and sufficient condition for the explosion-
Image 37 Example of Ex marking proof electrical equipment installation in
hazardous areas.
Image 37
Outside the European Union but IEC
countries, the explosion-proof electrical
equipment conformity to IEC standards
must be evaluated by a third part for both
general parties and types of protection.
Also here the marking must include: manu-
facturer name, serial number, identification
code, Ex symbol followed by:
• type of protection (d, ia, E, P, Na, etc.);
• group (II, IIA, IIB, IIIA …);
• temperature class or maximum surface
temperature (T1, T2, T6, …);
• equipment protection levels (GA, GB or GC).
3. Equipment choice
Tab. 18 Ex marking examples
CE marking ATEX marking Protection mode EPL

0 1 2 3 4 5 6 7 8 9 10
2(1)G Ex d [ia Ga] IIB+H2 T6..T5 Gb

0722 II
2(1)D Ex tb [ia Da] IIIC T85..100°C IP66/IP67 Db
0 graphic symbol indicating that at least one European Directive has been applied; it is placed
CE marking
only on the equipment, not on the components
1 nnn number identifying the Notified Body responsible for the inspection on production; placed on
M2 and 2 category equipment
2 “Epsilon-x” European Community mark, specific of the protection against explosions, defined
for the first time in the 76/117/CE Directive of 18th December 1975
3 n Equipment group
I = equipment addressed to underground work in mines and in their surface plants exposed
to risk of release of firedamp gas and/or combustible dusts
II = equipment not addressed to underground work in mines or their surface plants which
could exposed to risk of explosive atmospheres
4 xx Equipment category
M2 = equipment addressed to underground work in mines and in their surface plants exposed
to risk of release of firedamp gas and/or combustible dusts – in presence of potentially
explosive atmosphere, it should be possible to interrupt the power supply
2G = equipment suitable for areas where, during normal activities, explosive atmospheres due
to gas, vapors or mists (zone 1) may occur; suitable to be installed in Zone 1 and 2
ATEX marking
2(1)G = equipment suitable for areas where, during normal activities, explosive atmospheres
due to gas, vapors or mists (zone 1) may occur, and that has inside a bonded device that will
be connected to a category 1 equipment; suitable to be installed in Zone 1 and 2
2(2)G = equipment suitable for areas where, during normal activities, explosive atmospheres
due to gas, vapors or mists (zone 1) may occur, and that has inside a bonded device that will
be connected to a category 2 equipment; suitable to be installed in Zone 1 and 2
3G = equipment suitable for areas where, during normal activities, explosive atmospheres
consisting of an air and flammable substances mixture in the shape of gas, vapors or mist
may occur and, if it occurs, it is really for a short time (zone 2); suitable to be installed in
zone 2
2D = equipment suitable for areas where, during normal activities, explosive atmospheres
due to a mixture of air and flammable dusts (zone 21) and that has inside a bonded device
that will be connected to a category 1 equipment; suitable to be installed in zone 21 and 22
2(1)D = equipment suitable for areas where, during normal activities, explosive
atmospheres due to a mixture of air and flammable dusts (zone 21) and that has
inside a bonded device that will be connected to a category 1 equipment; suitable to be
installed in zone 21 and 22
3D = equipment suitable for areas where, during normal activities, explosive atmospheres in
the shape of cloud of flammable dust and, if it occurs, it is really for a short time. (Zone 22);
suitable to be installed in zone 22
5 Ex It identifies that a protection mode against explosions has been adopted
6 α Letter indicating the protection mode adopted
d = equipment protected by a “d” explosion-proof enclosure
e = “e” increased safety equipment
i = “i” intrinsic safety equipment
de = equipment with a part protected by a “d” explosion-proof enclosure and an “e” increased
safety part
ed = equipment with an “e” increased safety part and a part protected by a “d” explosion-
proof enclosure
d (ia Ga) = equipment protected by a “d” explosion-proof enclosure with inside an “ia”
intrinsic safety associated device (usually a barrier)
d (ib Gb) = equipment protected by a “d” explosion-proof enclosure with inside an “ib”
intrinsic safety associated device (usually a barrier)
nA = equipment created to reduce to minimum the risk of arcs or sparks able to originate an
ignition danger during normal working
nR = equipment designed to limit gas, vapors and mists ingress
tb = equipment with an enclosure that prevents dust ingress and with devices to limit surface
temperatures; protection level “b”
tD = equipment protected by an enclosure to prevent a cloud or a layer-of-dust ignition
tb (ia Da) = equipment with an enclosure that prevents dust ingress and devices to limit
surface temperatures with “b” protection level, with inside an “ia” intrinsic safety associated
Protection mode
device (usually a barrier)
7 xxx I = equipment addressed to underground work in mines and in their surface plants exposed
to risk of release of firedamp gas and/or combustible dusts
IIB = equipment not addressed to underground work in mines or their surface plants which
could exposed to risk of explosive atmospheres – subgroup of B gas; suitable to be installed in
presence of gases of subgroup A and B
IIB+H2 = equipment not addressed to underground work in mines or their surface plants
which could exposed to risk of explosive atmospheres – subgroup of B gas; suitable to be
installed in presence of gases of subgroup A, B and hydrogen
IIC = equipment not addressed to underground work in mines or their surface plants which
could exposed to risk of explosive atmospheres – subgroup of C gas; suitable to be installed in
presence of any gas (subgroups A, B and C)
IIIC = equipment not addressed to underground work in mines or their surface plants which
could exposed to risk of explosive atmospheres – subgroup of C dusts; suitable to be installed
in presence of any dust (subgroups A, B and C)
A21 = equipment not addressed to underground work in mines or their surface plants which
could exposed to risk of explosive atmospheres – method A; suitable to be installed in zone 21
and 22
A22 = equipment not addressed to underground work in mines or their surface plants which
could exposed to risk of explosive atmospheres – method A; suitable to be installed in zone 22
8 xx Definition of temperatures generated by equipment

T6 = equipment that can reach, but not exceed 85°C of absolute temperature (depending
on the protection mode, it can be either maximum temperature or surface maximum
temperature)
T5 = equipment that can reach, but not exceed 100°C of absolute temperature
T...°C = equipment that can reach, but not exceed in surface …°C of absolute temperature
9 IPnn Identifies equipment; for further info, refer to previous paragraph 3.6.2.4.1. “Enclosures pro-
tection degrees (IP code)”
10 αα Mb = equivalent to M2 category
Gb = equivalent to 2G category
Gc = equivalent to 3G category
EPL
Db = equivalent to 2D category
Dc = equivalent to 3D category
3. Equipment choice
Tab. 19 Differences between European/IECEx practice and North-American practice
STANDARD NORMAL OPERATION DANGER IN UNSUAL CONDITION
Continuous
Occasional danger
danger
IEC/EUROPE Zone 0 Zone 1 Zone 2
U.S.A./CANADA Class 1 Division 1 Class 1 Division 2
North America nes 0 and 1” correspond with the American

American classification and marking follow “Class I Division 2”. We can conclude that
the method of Classes and Divisions, while the equipment specifically designed for use
both the ATEX European and the IEC inter- in “Zone 1” in Europe cannot always be used
national standards follow the method of Are- in American “Class I Division 2”.
as. Hazardous areas are, therefore, subdivi- Compared to IEC zone system:
ded into 3 classes depending on the type of - Class I only (stated by article 500 in NEC
explosive atmosphere: standards) is divided into three zones depen-
- Class I (gases, vapors, combustible mists); ding on IEC standard: Zone 0, Zone 1 and
- Class II (dusts); Zone 2;
- Class III (combustible fibers). - temperature classes T1-T6 are the same;
Each class is divided into two types of are- - gases groups IIA, IIB, IIC are the same.
as at risk of explosion depending on the Article 505 allows to choose how to classify,
frequency or duration of the explosive at- with the aim of giving a global recognition to
mosphere formation. IEC system, promoting the free movement of
- Division 1: areas with constantly or occa- equipment suitable for areas classified accor-
sionally dangerous concentrations of gases, ding to IEC system.
vapors or combustible mists during normal Therefore, products can be approved both by:
operations. • Classes, Divisions and Groups of sub-
- Division 2: areas without dangerous con- stances
centrations of gases, vapors or combustible For example: Class 1, Division 2, A, B, C, D T3;
mist during normal operations but only in and by:
case of failure. • Classes, Divisions and Groups of gases
It is clear that “Zone 2” of the European For example: Class 1, Area 2, IIA, IIB, IIC, T3.
classification is the same as the American The Table 19 highlights the differences
“Class I Division 2”, while European “Zo- between North-American and IEC/ Euro-
pean classification. methods. The marking must contain:
Explosion-proof equipment must be tested • the protection level;
and certified by American Notified Bodies • the Ex symbol;
(such as, for example, the Underwriters La- • the symbol of the type of protection ap-
boratories (UL) or Factory Mutual) and by plied;
Canadian ones (such as the Canadian Stan- • the equipment group (I, II or IIA, IIB, IIB);
dards Association). • the temperature class;
The Image 38 describes the geographical • and the symbol X, if certain use condi-
distribution of the NEC and IEC standards, tions must be followed or if the product
highlighting the countries in which both are is an Ex component.
applicable and valid.
3.6.4. THE AMBIENT TEMPERATURE OF OUR
EQUIPMENT
Image 38 The ambient temperature is the air tempera-
ture or the temperature of another material
very close to the equipment. Usually, for Ex
NEC-Standard IEC-Standard Both standards
equipment, the interval considered is -20 ÷
+40 (°C). For the Cortem Group equipment
the interval is wider: -60 ÷ +60 (°C) to
meet the needs of extreme areas where our
equipment is installed. To do so, we have lo-
oked for materials suitable to this tempera-
ture range.
3.6.5. OUR TEMPERATURE CLASSES

The temperature class is the maximum sur-
face or absolute temperature, depending on
Image 38 Geographical distribution of the NEC the protection method, that the equipment
and IEC standards
can reach while operating.
The less the equipment heats up, the fewer
Russia are the chances that they cause an explosion.
The marking of the explosion-proof The average ignition temperature of the
equipment must comply with the GOST R classified gases is about 360°C (T2) – see
51330.0-99 standards and with the stan- Graph 5, chapter 2.
dards concerning the single protection Find comparison between European/Inter-
3. Equipment choice
Tab. 20 Comparison between European/international When choosing the best materials to be

and North-American temperature classes
transformed into finished products, it is im-
[°C] [°F] portant to consider the limiting factors of
nature.
450 842
T1 All materials, including the ones we use,
300 572 have three enemies:
T2
• environment;
280 536 T2A
• temperature;
260 500 T2B • time.
Temperature and time are familiar factors,
230 446 T2C
while the environment, where our products
215 419 T2D are used, is not easy to control.
200 392 We are not talking about familiar potential

T3
hazards caused by an explosive atmosphere
180 356 T3A
(which can be controlled by laboratory tests
165 329 T3B and guaranteed by certification), but rather
deterioration caused by highly aggressive
160 320 T3C
environments like chemical and petroche-
135 275
T4
mical plants.
Corrosion resistance is a relative factor, as it
120 248 T4A
depends on the actual environmental condi-
100 212 tions that significantly influence the nature
T5
85 185 of the attack.

T6
This is why Cortem Group constan-
tly tests its materials in accordance
with ASTM standards (American So-
national and North-American temperature ciety for Testing and Materials) – for
classes in Table 20. example B117 in salt fog, G31 in hydro-
gen sulphide and hydrochloric acid,
3.6.6. MATERIALS USED IN OUR EQUIPMENT etc. - and carries out in-depth rese-
Today, we use many different materials for arch into their resistance in outdoor
producing equipment and components de- environments. It is therefore able to
signed for areas with a potentially explosive choose the right material based on
atmosphere. They can be basically classified objective experience and to guarantee
in Table 21. long-term product safety.
3.6.6.1. ALUMINIUM ALLOY stainless steel. The mechanical properties
Aluminium alloy is one of the world’s most of aluminium alloy castings are more than
widely used materials in the production of adequate for ensuring explosion-proof elec-
explosion-proof enclosures. trical protection.
It is highly corrosion-resistant and, there- In the past, either aluminum-copper alloys
fore, universally known as the most effec- were used, but they were not at all corro-
tive and versatile material for most appli- sion-resistant, or aluminium-magnesium.
cations. Although being corrosion-resistant, magne-
It is much lighter than cast iron, so it ma- sium, when mechanically hit, can generate
kes the equipment much easier to install sparks with energy values able to trigger an
and maintain; moreover, it is highly corro- explosion (technical standards limit the ma-
sion-resistant and does not require surface gnesium presence at 7,5% in mass). Today
protection, unlike cast iron which has to be we use the aluminum-silicon alloys, where
galvanized or coated. copper is present as impurity. Its main fea-
Nevertheless, Cortem Group protects its tures can be summarized as follows:
products with a surface coating, RAL 7035, • fairly high mechanical resistance;
that contains stainless steel particles, a • adequate ductility;
protection against mechanical impact, and • good denseness;
characterizes our production avoiding imi- • corrosion resistance.
tations and fake products. The aluminium- silicon alloys we use mostly
Aluminium is also much cheaper than are the AlSi10Mg(a) (EN AB 43000) and the
Tab. 21 Materials used by Cortem Group for the production of explosion-proof equipment
Metallic Plastic Transparent

material materials parts
Equipment • aluminium alloys • reinforced polyester • borosilicate glass
• stainless steel with glass fiber • polycarbonate
external part
Gaskets • neoprene, silicone
Ex entry • nickel-plated brass • polyamide 6

• aluminium alloy
• stainless steel
• galvanized steel
3. Equipment choice
Tab. 22 Chemical composition of aluminum-silicon alloys
Fe Si Mn Ni Ti Cu Pb Mg Zn Sn other
AlSi10Mg(a) max 9 ÷ 11 max max max max max 0,2 ÷ 0,45 max max each 0,05;
0,55 0,45 0,05 0,15 0,05 0,05 0,1 0,05 total 0,15
AlSi12(b) max 10,5 ÷ 13,5 max max max max max max 0,1 max // each 0,05;
0,65 0,55 0,1 0,2 0,15 0,1 0,15 total 0,15
AlSi12(b) (EN AB 44100), and their chemical tion layer”. It is formed when the materials of
compositions, in accordance with EN 1706 the alloy come into contact with the air or wa-
standard, are contained in Table 22. ter oxygen.
The stainless steels are traditionally divided
3.6.6.2. STAINLESS STEEL into three big families, depending on their
The stainless steels, because of highly aggres- metallographic structure:
sive environments or for technical/legislative • martensitic;
reasons (for example in the food and phar- • ferritic;
maceutical sectors), have been so much re- • austenitic.
quested in the last years, that almost all our In order to meet the market needs, such as
equipment is being made also of this mate- providing highly resistant materials to chlo-
rial, regardless of the protection method. ride corrosion, we have chosen the AISI 316
The stainless steels are iron-, coal- and chro- (X5CrNiMo17-12-2) stainless steel, belonging
me-based alloys that combine the mechanical to the austenitic family.
properties typical of carbon steels with the In general this family has the following pro-
corrosion resistance properties, due to a thin perties:
and transparent surface layer called “passiva- • high corrosion resistance;
Tab. 23 Chemical composition of stainless steel AISI 316
C Si Mn Ni Cr Mo N other
X5CrNiMo17-12-2 ≤ 0,07 ≤ 1,00 ≤ 2,00 10,0 ÷ 13,0 16,5 ÷ 18,5 2, ÷ 2,5 ≤ 0,11 each ≤ 0,03;
total ≤ 0,045
• ease of cleaning and excellent hygienic typical dark grey color.
coefficient. Fibers are highly traction-resistant and re-
But stainless steel presents also some di- present, therefore, the resistant elements of
sadvantages: the fiber-reinforced material.
• in low temperatures the corrosion resi- In fact, when a fiber-reinforced material un-
stance decreases dramatically. Acids bre- dergoes an axial traction, the real efforts are
ak the oxide film creating generic corro- absorbed by the fibers, while the polymer ma-
sion in these steels; trix has only to distribute them to the fibers,
• in the interstices and in the protected are- leveling the stress.
as, oxygen quantity may not be sufficient Moreover, the resin protects the fibers from
to preserve the oxide film, and may there- the wear and ensures a good fiber alignment.
fore provoke interstitial corrosion; Thanks to flame retardants present in the
• halide ions, especially the (Cl-) anion, chemical formulation, our material complies
break the passivation film on the au- also with Vo degree according to UL94 stan-
stenitic stainless steels and provoke dard.
the so-called corrosion to alveoli (cal- The main properties are:
led also “pitting corrosion”); another • high lightness;
chlorine’s effect is the SSC (Stress Cor- • high mechanical resistance;
rosion Cracking). • high thermal insulation;
Chemical composition, in accordance with • high dielectric and magnetic properties.
EN 10088 standard, is contained in the
Table 23. 3.6.6.4. BOROSILICATE GLASS
Borosilicate glass is a strong material, known
3.6.6.3. POLYESTER REINFORCED WITH GLASS for its resistance to thermal shocks and for its
FIBERS low expansion; it is resistant to chemical agents
This material appeared in Italy in the Ex sec- and has excellent features of transparency.
tor in the second half of the 80s, and was ap- For our equipment we use the one in class
plied mostly in the increased safety deriva- 3.3, in accordance with ISO 3385 standard,
tion boxes. that has the following characteristics:
The material we use is an unsaturated polye- • smooth, non-porous surface, easy to clean;
ster resin, reinforced with glass fibers to im- • excellent and wide chemical compatibili-
prove its mechanical characteristics, and ty; it is moreover highly resistant to wa-
graphite, to make the surface “conductive” in ter, salt solution, organic substances, ha-
order to reduce the risk of accumulation of logens and acids;
electrostatic charges; graphite provides the • no catalytic effect in chemical processes;
3. Equipment choice
Tab. 24 Chemical composition of borosilicate glass 3.3 bon, petrol, greases, oils, alcohols (except
methyl alcohol) and water under 70°C;
SiO2 B2O3 Na2O Al2O3 other
• good electrical properties.
Borosilicate 80,6 % 12,5 % 4,2 % 2,2 % 0,5 %
glass, 3.6.6.6. NICKEL-PLATED BRASS
class 3.3. We use this material (leaded brass with Cu
58%, Zn 40% and Pb 2%) exclusively for the
construction of Ex cable entry (Cable glands).
• no harmful physiological characteristic in Besides the traditional copper (Cu) and zinc
biochemical process; (Zn) alloy, our material has also a low lead
• transparency; (Pb) percentage on the external part of the
• good stability and thermal resistance; bar, which simplifies the turning since it does
• low thermal expansion. not create a solution with the alloy Cu-Zn, and
The chemical composition, adherent to ISO since it has a lower solidification temperature
3585 standard, is contained in the Table 24. than the other two elements. Subsequently, it
undergoes a surface treatment of electrolytic
3.6.6.5. POLYCARBONATE nickel plating, to provide the product, more
Polycarbonate (PC) is a generic polyester of than with an aesthetic aspect, with a higher
carbonic acid. Notwithstanding Du Pont has corrosion-protection level by external agents.
studied it as a possible cotton fiber replacer
since the end of the 20s, it is the most recent 3.6.6.7. GALVANIZED STEEL
among the materials above described since We use even this type of material, an iron (Fe)
Bayer (Makrolon®) and General Electric (Le- carbon (C) alloy, as well as nickel-plated brass,
xan®) started its commercial use in the 60s. for connection elements of Ex entries. It is a
The polycarbonate we use is of bisphenol-A, a stainless steel, sweet, for general use, with small
polymer composed of many (“poly”) identical amounts of lead, bismuth, tellurium or sulfur.
units of bisphenol A connected to carbonate To protect the component from corrosion, at
in the main chain. Main features of this ther- the end of machining it undergoes a galvani-
moplastic material are: zing process.
• transparency: high refractive index due
to its aromatic feature; transparency and 3.6.6.8. POLYAMIDE 6
absence of color allow a light permeability We use also this material, as well as the pre-
of 89% in the visible spectrum; vious ones, exclusively for the construction of
• thermal and mechanical resistance; Ex cable entries. The polyamides (Pa) are linear
• resistance to mineral acids, hydrocar- polymers characterized by the presence of the
amide group -NH-CO-. In the range of polya- (R) linked to the silicon atoms. Typically, the
mides, commonly known as “nylon”, different silicone rubbers (VMQ) are remarkably resi-
types may be distinguished. The single types stant to temperature, chemical attack and oxi-
of polyamide do not differ much: relatively low dation, and are excellent electrical insulators.
specific weight, resistance to impact and wear, They are excellent non-stick, flexible, resistant
discreet electrical insulation, resistance to sol- to aging and to high temperatures.
vents, oils, greases and fuels. We use the polya-
mide 6 (Pa6) or polycaprolactam, that belongs 3.6.7. OUR CERTIFICATIONS (PART I)
to the family of aliphatic polyamides. 3.6.7.1. THE 94/ 9/CE “ATEX 95”
DIRECTIVE
3.6.6.9. NEOPRENE Most of the equipment we produce belongs to
Neoprene is one of the main materials we use group II, category 2G and 2D. On the basis of this
for our seals. The neoprene (originally called and considering that it is electrical equipment,
duprene) was the first residue of the synthe- our conformity assessment procedures were
tic rubber produced in a large scale with more aimed to obtain the various CE type-examina-
than 75 years of proven performance in a wide tion certificates for the design aspects of the Ex
spectrum of areas. It was originally developed equipment and the notification of product war-
as oil-resistant replacer for natural rubber. ranty (Image 39) to cover the manufacturing
The basic chemical composition of the Neopre- aspects of the equipment itself.
ne synthetic rubber is polychloroprene (CR).
It belongs to the family of elastomers synthe- Image 39 ATEX Certification of production quality
sis (i.e. synthetic rubber) and it looks like a Image 39

porous rubber, whose mass is made up of gas
cells uniformly distributed. The main features
are: the elasticity, shear strength and crushing,
resistance to aging, air pollution and heat, and,
moreover, it appears to be inert towards many
chemical agents, oils and solvents.
3.6.6.10. SILICONE
The silicone, as well as the neoprene, is one of
main materials we use for our seals. Silicones
or polysiloxanes (methylvinyl polysiloxane)
are inorganic polymers based on a silicon-
oxygen chain and organic functional groups
3. Equipment choice
Even if it is not required by the conformity Image 40

assessment procedures of the directive, for
greater transparency to our customers, our
equipment belonging to categories 3G
and 3D underwent the design asses-
sment obtaining the type-examination
certificate.
To satisfy essential safety and health re-
quirements we use the harmonized stan-
dards. Representing the state of the art,
they are in continuous evolution (a stan-
dard is valid for about 5 years). The Offi-
cial Journal of the European Union (OJ)
publishes periodically, on C series, the
list of standards satisfying the essential
requirements of each Directive issued by
the Union and defines the end date of the
presumption of conformity with the requi-
rements themselves.
Therefore, our certificates are always upda-
ted so that our equipment projects meet the Image 40 Example of certificate IECEx
state of the art present when we put the pro-
ducts on the market.
Moreover, we have chosen the Notified Body 3.6.7.2. IEC-EX
as our partner on the product certification. Since the beginning of 2000, outside EU a
At the beginnings there were about 15; now voluntary certification scheme has been ap-
there are 64, among those more than 10 in plied internationally. We talked about it in
Italy. We have chosen a Body whose com- chapter 3.6.3.: IECEx (http://www.iecex.
petence, impartiality and toughness were com/) scheme.
recognized not only at a national but also This scheme is very similar to that of the 94/
at an international level. So we have chosen 9/CE Directive and foresees both the design
CESI - Italian Experimental Electrotechni- control (Ex-TR) and the manufacturing con-
cal Centre “Giacinto Motta” based in Milan; trol (QAR) by a Certification Body accredited
its first test report on an explosion-proof by this scheme. With these two documents it
equipment took place in 1969. is possible to require the conformity certifi-
Image 41 • an international database;
• maintenance of a confidence level towards
the equipment and the services expressed
in the IECEx certification.
This scheme and its certificates are recognized
internationally by more and more countries.
Certificates by IECEx system are issued as
“electronic certificates” and are available on
IECEx website (Image 40). This allows public
access in order to view and print.
3.6.7.3. RUSSIA
Standards in Russia are very different from
the European contest, where we can move ea-
sily. In the EU we find the principle of mutual
recognition, and the mandatory certification
(CE mark) is required only for certain hazar-
dous product families or products associated
to serious risks; by contrast, in Russia, ac-
cording to the law No. 508 of 22/07/92 on
Image 41 GOST R certification the defense of consumer rights, most of the
products meant to be marketed within the
confederation, must be certified to verify the
cate (CoC). The reference standards are those product conformity to the Russian national
of the IEC 60079 and IEC 61241 series. standards.
The IECEx system aims to facilitate the inter- Since the safety and quality control of the
national marketing of equipment meant to be imported products does not depend on the
issued in the environment with explosive at- custom bodies, they verify only presence
mospheres, maintaining the necessary safety and authenticity of documents certifying
level: the imported product properties.
• reduction of trial and certification costs In the Customs control of goods, the main do-
for the producer; cument is the certificate of conformity issued
• reduction of the time to market; within the compulsory product certification
• international confidence in the product system GOST R (Image 41); another impor-
assessment process; tant document is the permission to use, is-
3. Equipment choice
sued by Rostechnadzor (RTN). other liquids at high pressure/high tempe-

GOST is the short form for “Gosudarstven- rature belong to this category, since they
nyj Standart” (“State standard” in Rus- are considered hazardous liquids used in
sian). This national certification system hazardous operations. The permission is
has been introduced to protect public he- necessary to use the equipment and start
alth and to guarantee the safety and quali- the plant. Without permission the plant
ty of imported products that have invaded cannot be authorized. In general, they un-
the national markets in the former-USSR dergo all the necessary controls (revision
countries. of the maintenance and repair procedures,
The products labelled with “GOST R” com- of systems, hydraulic tests, non-destructi-
ply with the applicable standards and have ve tests, etc.). A revision of possible effects
received a GOST R certificate by an accre- on the environment, such as drains, sewa-
dited certification office. Therefore, they can ge spills, etc.
be custom cleared only if they have this cer- According to the Russian law, the permis-
tification issued by a Russian official body sion is valid for 5 years. Technical passes
accredited by Goststandart; the certificate of and user manual in Russian are required to
conformity must be shown together with the obtain the permission to use.
cargo customs declaration and is fundamen-
tal to import the products into the Russian 3.7. OUR CERTIFICATIONS (PART II)
Federation. On each product put on the market, the
Deliveries with official copy of the certificate subject applying the mark must:
will be custom cleared and will be accepted • prepare the “CE conformity statement”
by the Russian customer. for devices, or the “conformity certifica-
An extra permission is required for many te” with the embedding conditions for
products meant to be used in industrial components;
and potentially hazardous areas based • provide the user instructions.
in Russia, among which we find the Ex From a legal point of view, the EU considers
equipment. Among these we find also the “producer”:
Rostechnadzor (RTN), issued by the Ser- i) the manufacturer of the product defined
vice for ecology, technology and Nuclear in the European Community and every other
monitoring. This permission is necessa- person who introduces him/herself as ma-
ry to state that the potentially hazardous nufacturer by applying on the product his/
equipment satisfies Russian safety pa- her name, label, or still who makes the pro-
rameters and can be used without risks. duct new;
All the goods handling oil, natural gas or ii) manufacturer’s representative, if the
manufacturer is not defined in the Europe- last two digits of the year in which the CE
an Community, or the importer of the pro- mark was applied;
duct itself; • the “machinery” Directive requires the
iii) the other professional operators if their description and the identification of the
activity affects the product safety features. machinery, with generic denomination,
Let’s have a further look at these two docu- function, model, type, serial number,
ments. commercial denomination;
• “ATEX 95” Directive requires, if it is gi-
3.7.1. THE “CE CONFORMITY STATEMENT” ven, name, identification No. and ad-
The “CE conformity statement” is the formal dress of the Notified Body that issued the
and final act in which the producer declares CE type-examination certificate and the
to the single market of the European Union, certificate No.
that he has followed the Essential Safety and
Health Requirements of all the community 3.7.2. “USER INSTRUCTIONS”
Directives. Instructions provide information about the
correct use of the product in safety condi-
The “CE conformity statements” are prepa- tions; for this reason they are written not
red considering the following legislative and only in the language of the producer, but
normative references: also in English. Instructions are part of the
• “CE conformity statement” annex III product supply.
of the European Parliament and Board Also in this case, instructions are prepared
Decision No. 768/2008/CE of 9th July considering the following legislative and
2008 concerning a common scheme for normative references:
marketing of products and that repeals • IEC 62079 Technical standard “Prepara-
the Decision 93/465/CEE (G.U.U.E. , L tion of instructions – structure, content
series, No. 218 of 2008-08-13); and presentation”;
• ISO/IEC 17050-1 and 17050-2 technical Depending on the applied Directives, spe-
standards “Evaluation of conformity - cific requirements can be found, such as:
conformity statement issued by the sup- • the “machinery” Directive requires at
plier”. least a series of information defined in
chapter 1.7.4. and/or in chapter 3.6.3
Depending on the applied Directives, par- and/or in chapter 4.4, etc. of annex I;
ticular extra requirements can be made, • “ATEX 95” Directive requires at least a
such as: series of information defined in chapter
• the “Low tension” Directive requires the 1.0.6 of annex II.
4. Installation
S afety in the potentially explosive

areas can be guaranteed only with
a tight and effective collaboration
among all the parts involved (Image 42).
maintenance activity.
Installation design, equipment choi-
ce and assembly must be carried out
by competent personnel trained in the
The employer is responsible for the safety of different protection and installation
his plants. He must verify where there is a methods, as well as in the rules and le-
risk of explosion and subdivide the zones into gislative standards about areas classi-
Areas. He must guarantee that equipment is fication.
installed in accordance with the standards Producers of explosion-proof electrical
and that it is checked before its use. Moreo- equipment are responsible for routine tests,
ver, he must verify that equipment is properly product certification and documentation.
used, and carry out periodical inspection and They have to guarantee that each device com-
plies with the approved design. sheath. Each sealing ring is suitable for
After that, the installer will have to consi- single cable diameters.
der both normative standards (such as the Cable glands must be chosen considering
EN 60079-14) and what is reported on the the cable diameter. The tightness is ensu-
user instructions provided by the manu- red by the compression of a rubber gasket
facturer, in particular if there are “special that tightens on the external diameter and
conditions for safe use – (X)”. prevents the flame from spreading elsewhe-
Our choice of cable glands for “Ex d” re. Usually the sealing ring is as long as the
equipment is relevant. Cable glands fol- lamination joint; some cable glands with a
lowing “Ex d” protection method can be of shorter sealing ring can be used in enclosu-
different types, depending on the their use. res whose internal volumes are limited by
Generally, they are divided into two catego- the certificate. Min and max diameters of
ries: the use of the cable are reported on the sea-
• for armored cable: used for the armo- ling rings. It is forbidden to insert more ca-
red cable direct entry into explosion-proof bles into the same cable gland, as well as to
enclosures, they can be built for different increase the sealing ring diameter with in-
types of armors; sulating tape or similar, in order to make it
• for normal cable: used for the non-armo- match with the sealing ring diameter. Cable
red cable entry into explosion-proof en- glands for armored cables have two sealing
closures. The sealing is carried out with a rings: the front one tightens on the inter-
sealing ring directly on the external cable nal diameter and guarantees the explosion-
Image 42 Cooperation among all parts involved
Image 42
Certification
Employer authority
Installator
Authority
Manufacturer Standards
4. Installation
Graph 9 Flowchart to choose the right cable gland
Does equipment have a

potential ignition source
inside?
yes
no
Does hazardous gas require
a IIC construction?
yes no
Is installation area
zone 1?
yes no
Is equipment free
volume higher
than 2 dm2?
Use as an alternative:
A. an Ex d sealing device,
containing a sealant (EYS, yes no Use Ex d entry cable
EYD or EZS sealing joint) devices with sealing
B. an Ex d cable gland, that ring (REV or REVD
incorporates the joints filled type cable gland)
with sealant (FB or FGAB type
barrier cable gland)
proof protection; the rear one tightens on mes, either “barrier” or normal cable glands
the external diameter and prevents liquids with sealing rings can be used. Graph 9 helps
from penetrating into the cable gland, whe- you choose the right cable gland. This flux
re the armor is sealed by two conic rings diagram considers whether the equipment is
guaranteeing the electronic continuity of marked “IIC” and if its volume is > 2 dm3.
grounding. Since we understand that the production of
There are also “barrier” cable glands. In this “AD-PE” = explosion-proof safety” plants
case the cable is sealed with a resin in a slee- and its maintenance – above all if sealant has
ve. It is inserted in the cable gland and forms been used in the Ex entry - is tough work, we
a lamination joint with its internal part of the have chosen to help plant operators by provi-
object. ding them with high-safety level equipment,
The use of different types of cable glands must that is more simple to manage. This is “Ex de”
follow EN 60079-14 standards. Depending protection method equipment, above men-
on the plant type and on the enclosure volu- tioned (chapter 3.6.2.5.).
5. Inspection
W
hat is the aim of inspection? nel trained in the different protection and
To verify with an inspec- installation methods, as well as in the na-
tion that the installation has tional rules about plants and about hazar-
been properly made, and that it main- dous areas classification.
tains its safety characteristics. We remind The normative standard concerning in-
you once more that plant inspection and spection and maintenance activities is
maintenance have to be made by person- IEC/EN 60079-17.
Graph 10 Types of inspections depending on frequency, quantity and quality parameters
Inspection
Inspections
frequency
Initial Periodical
quantity
Total Random Total

quality (degree)
Detailed At sight Close Detailed
The inspections consider three aspects • qualitative: able to detect defects visi-
(Graph 10): ble to the naked eye without any extra
• temporal: carried out before the tool (visual; also able to identify defects
equipment is used (initial) or periodi- detected only with means of access (clo-
cally; se); and finally able to detect defects by
• quantitative: made on all equipment opening the equipment and/or by using
(total) or on part of it (random); tools (detailed).
6. Maintenance
and repairs
6.1. MAINTENANCE the “preventive” one, such as “maintenance
T
he maintenance is “the combi- carried out at scheduled intervals or accor-
nation of all the administrative ding to defined criteria and aimed at redu-
techniques, including the super- cing the probability of failure or the degra-
visory actions, aimed at maintaining or at dation of the operation of an entity”, to the
bringing an entity into a state where it can “accidental” one, such as as “maintenance
perform the required function.” after the detection of failure and aimed at
Over the years, the approach to maintenan- bringing an entity in the state where it can
ce has changed dramatically, passing from perform the function required.”
The time interval between two maintenance that high-quality objects can be repaired, this
operations depends on different aspects, such action can be made by specialized centers or
as the design choices, the environment where by the equipment manufacturer.
it is installed, the care for the equipment. Repairing our equipment
Since we handle equipment aiming at re- We design and make our equipment long-
ducing the risk of explosion, maintenance lasting and able to maintain the safety level
should be made punctually, following the in- requested in the hazardous environment
structions carefully. where it is installed. Our equipment can be
repaired.
6.2. REPAIRS In our Italian factory based in Villesse (GO)
Repairs in general and in the authorized Cortem centers, our
Repairing is aimed at bringing failed equipment is repaired and restored in ac-
equipment in its suitable operating condition cordance with the design documents ap-
to service in accordance with the appropria- proved by the Notified Bodies. It can gua-
te standard. Even though we have forgotten rantee again the initial safety level.
7. End-of-life
equipment
7.1. DISPOSAL electronic equipment: 2012/19/EU directive
E
nd-of-life electrical equipment of 4th July 2012, according to which some
must be disposed of equipment (like some of ours)
properly. Starting from has to be disposed of in a cer-
the title XX “environment” of the tain way. This is why we apply on
Treaty on the Functioning of the Eu- them the symbol here represen-
ropean Union, EU has issued a new ted (left below).
Directive about waste electrical and Cortem Group, as well as other
companies, in ac- our products we
cordance with use generally:
ISO 14001 stan- - cardboard boxes;
dard, has adopted - wooden boxes.
an environmental • the second la-
management sy- yer is related to
stem with speci- the material of the
fic ways to dispo- equipment enclo-
se of end-of-life sure; our choice is
equipment, which based on both fun-
is a waste. Each ctional and envi-
country can have ronmental aspects
established spe- of the product, and
cific environmen- we have created
tal management the certification of
system concer- our environmen-
ning waste collec- tal management
tion and disposal. system (DNV
Have a look at it Certification No.
for further infor- 78704-2010-AE-
mation. ITA-SINCERT).
Therefore, most of the materials, descri-
7.2. RECYCLABILITY bed in chapter 3, are recyclable:
Recyclability is strictly connected to di- - aluminium;
sposal. Because of non-endless material - steel;
availability and of production costs, for - polyester, polycarbonate, polyamide;
several years we have been accustomed to - glass.
choose materials that can be recycled. • The third layer is related to the mate-
In almost all cases, equipment has three rial of the equipment installed inside
layers: the equipment enclosure. Even thou-
• the first is related to the packaging, and gh it is electric equipment, the com-
for its correct disposal EU has issued a ponents are various: wires, terminals,
Community Directive: 94/64/CE of 20th transformers, switches, lamps (fila-
December 1994 on the packaging and ment and discharge, led), electronic
packaging waste. For the packaging of circuits, batteries, etc.
8. Application
examples for different
types of plants
8.1. PHARMACEUTICAL INDUSTRIES tures able to emit flammable vapors, or they
P
roduction processes in compa- can reach temperatures even higher than the
nies producing drugs for mixing, flashpoint.
emulsion and chemical reaction Besides industrial plants, where a product
of organic compounds, can generate envi- process takes place, there are research and
ronmental conditions able to create poten- development chemical laboratories, in which
tially explosive atmospheres. In the produc- liquids, gases or combustible dusts could be
tion process, liquid substances are very often present in such quantities that they can beco-
used; they can be brought to such tempera- me a risk of explosion.
Substances are usually contained in sealed list and to map the areas where the substan-
enclosures and kept in storage areas, before ces are used or stored. Only highly qualified
being produced. staff should carry out this activity. Each ha-
If we quantify the explosion risk, we have to zardous substance must have a form indica-
consider the following possibilities: ting all the chemical and physical properties
1. potentially explosive atmosphere due to required for the classification (flashpoint,
the production process for the presence of: ignition temperature, U.E.L, L.E.L., etc.)
gases, vapors of flammable liquids processed
at temperatures higher than the flashpoint, 8.1.1. REFERENCE STANDARDS
combustible dusts; Hazardous areas classification must be car-
2. potentially explosive atmosphere due to ried out in compliance with EN 60079-10-1
plants serving the production process, such standard for the plant sections with gases,
as power plants of gas; vapors or mists, and in compliance with
3. potentially explosive atmosphere in che- EN 60079-10-2 standard for the zones with
mical plants where studies and researches combustible dust. The latter allows the clas-
with flammable substances are carried out sification considering all the hazards due to
(substances such as gases, vapors or mists the presence of dusts in a cloud and/or of
and combustible dusts), in presence of po- layers of dusts, taking into account the in-
tential ignition sources. formation about the processing.
For areas classification, the first step is to ve-
rify the characteristics of all the substances 8.1.2. PLANT EMISSION SOURCES
present in the production process, to make a Let’s analyze the plant emission sources of an
8. Application examples for different types of plants
industrial pharmaceutical plant. of points of discontinuity of the plant.

The emission sources of continuous grade Hazardous areas extension may be determi-
are: ned by “dz” distance, starting from the emis-
• open enclosures containing the substan- sion source in direction dependent on the
ces in processing; type of gas.
• enclosures in open air used for the prepa-
ration of compounds for hand or automa- 8.1.4. CLASSIFICATION FOR DUSTS
tic mixing and/or in which additions to In presence of dust in the process, we could
the processing liquid solution are made. have:
Depending on the operation procedures, first- • Zone 20, inside containment systems, loa-
degree emission sources are the following: ding hoppers, etc.;
• loading and unloading in open air; • Zone 21, originated by the emission
• pickup points for sampling. sources due to loading and unloading
Second-degree emission sources are flanges, operations, etc.;
unions, valves and, in general, points of di- • Zone 22, originated by points of disconti-
scontinuity of the production plant, of con- nuity of containment systems, by the se-
tainment or conveying. aled inlets and possibly around Zone 21.
In presence of combustible dusts in the pro-
cess (such as lactose, used as adjuvant), the 8.2. DEPOSIT OF CEREALS
probability that layers are formed as well as Cereal storage silos are deposits, inside or
the risk that layers rise in clouds becoming outside a building, where food industry pro-
emission sources must be verified. ducts (such as wheat, grain, rice, or similar
– Tab. 26) are stored. Loading operations
8.1.3. CLASSIFICATION FOR GAS are performed by means of mechanical devi-
The result of classification depends on ope- ces such as tubes, conveyor belts, augers etc.,
rating conditions, plant parameters, volume through inlets placed on the top of the tower
of environment, ventilation and coefficient of silo. Once disconnected, products are picked
performance f. up by unloading doors place on the lower
In general, for gases, vapors and mists we part, or transported through pneumatic con-
could have: veying systems or manually.
• Zone 0, inside containment systems and All food products are made of coal, hydrogen,
inside open enclosures; nitrogen, sulfur, oxygen, etc. Therefore, they
• Zone 1, around mixing operations, pickup are combustible and may provoke fires and
points, loading, unloading, etc.; explosions. If cereals are ground before being
• Zone 2, originated by the emission sources stored, they can have an extra-thin consi-
the layers, due to air circulation, generate a
continuous cloud.
Airborne combustible dusts form clouds of
explosive atmosphere. Clouds, if triggered,
can oxidize so rapidly that they can genera-
te an explosion. The greater the reactivity of
dust is, the smaller its particles are.
Cloud is explosive when the concentration of
dust inside substance explosion ground ran-
ges between L.E.L (Lower Explosive Limit)
and U.E.L. (Upper Explosive Limit), expres-
sed in dust grams per air volume, g/m3.
8.2.2. AREAS CLASSIFICATION

Hazardous areas classification in a silo can be
made according to EN 60079-10-2 standard,
that allows classification considering the ha-
zards due to the presence of dusts in a cloud
or of layers of dust.
8.2.3. AREAS INSIDE CONTAINMENT SYSTEM

stency and, if particle size is lower than 500 Inside silo volume, the layer of stored cere-
μmm, particles themselves can originate an als is continuous-degree emission source and
explosive atmosphere if mixed with air. may generate a Zone 20 extended to all the
In any case, even if cereals have higher sizes, internal silo volume.
we have to consider that solid parts usually If loading and unloading operations are car-
generate dusts. The rule says that dusts gene- ried out through automatic conveying sy-
rate thinner and thinner dusts. stems, a dust/air mixture is formed and it
Presence of combustible dust always genera- may generate a risk of explosion. In this case,
tes risk of explosion, if triggered. the interior of the transport system is classi-
fied as Zone 20.
8.2.1. RISK OF EXPLOSION BY CLOUDS OF DUST
Air is always present inside the silos, and 8.2.4. AREAS OUTSIDE CONTAINMENT SYSTEM
stored cereals form deposited layers of dust. During loading and unloading operations, a
During loading and unloading operations, certain quantity of dust is emitted through
the inlets connected with the outside. In case Tab. 25 ATEX markings that must be present in each
Zone
of frequent or continuous operations, inlets
and outfalls are to be considered first-degree ZONE MARKING
emission sources, they may originate a Zone ZONE 20 CE EX II 1D
21 and, possibly, a Zone 22 all around.
ZONE 21 CE EX II 2D
Open systems of automatic transport, such
ZONE 22 CE EX II 3D
as conveyor belts, open bucket elevators, can
be considered first-degree emission sources,
and they may generate a Zone 21 and, possi-
bly, a Zone 22 all around. 8.3. COATING BOOTHS
The coating booths where spray coating is
8.2.5. ELECTRICAL INSTALLATIONS used, are areas with risk of explosion. Spray
Possible electrical installations controlling coating is based on the forced passage of
loading / unloading equipment, must be ma- flammable liquid or of dust coatings through
nufactured and certified in order to be used in the gun nozzle.
areas with presence of explosive atmosphere.
As far as electrical equipment classification is 8.3.1. COATING BOOTHS WITH LIQUID
concerned, please refer to Tab. 25 indicating COATINGS
the ATEX markings that must be present in The protection methods to use in order to
each Zone. prevent risks of explosion in the coating bo-
Tab. 26 Some examples of dusts and their characteristics
Substance Particles L.E.L [g/m2] Cloud Layer ignition Dust

medium ignition temperature conductivity
dimensions temperature 5mm T5mm (C/NC)
[μm] Tcl [°C]
Wheat flour 57 40 440 325 NC
Grain 80 60 370 370 NC
Soybean flour 59 125 430 430 NC
oths with liquid coatings are contained in the L.E.L is reached. The internal volume of bo-
UNI EN 12215 standard “Coating booths for oth (ducts for air recirculation included) is
the application of liquid coating products – classified as Zone 1, while the external one,
Safety requirements”. up to 1m from the permanent openings, is
According to this standard, the concentration classified as Zone 2.
of flammable substances must be kept below
L.E.L. (Lower Explosive Limit) by means of 8.3.2. COATING BOOTHS WITH DUST COATINGS
forced ventilation. In particular, the standard Protection against risks of explosion in coa-
contemplates two possibilities: ting booths with dust coatings is regulated by
1. Concentration within 25% of L.E.L. (bo- the UNI EN 12981 standard “Coating booths
oths with the presence of an operator). In this for the application of dust coating products
case, the internal volume of the booth (ducts – Safety requirements”.
for air recirculation included) as well as the According to this standard, the concentration
external one, up to 1m from the permanent of flammable substances must be kept below
openings, are classified as Zone 2. 50% of the dust L.E.L., by means of forced
2. Concentration within 50% of L.E.L. (bo- ventilation; if L.E.L. value is not reliable, me-
oths without the presence of an operator). In dium concentration must not exceed 10 g/m3.
this case, the booth must be provided with a The following classification is foreseen:
control system of the L.E.L. able to stop the • Zone 22: internal volume of booth (ducts for
influx of flammable substances when 50% of air recirculation as well as the open dust col-
lection systems included); nic compounds in fermentation. Such biogas

• Zone 22: external volume of booth, up to 1m is used for the production of electrical energy
from the permanent openings; and heat.
• Zone 20: sealed dust collection systems.
Dust characteristics vary and depend on the 8.4.1. PLANT TYPE
product used. Usually, L.E.L. ranges betwe- These biogas plants (Image 43) are composed
en 10÷100g/m3, while ignition temperatu- of a primary mixing tank, possibly of a sanita-
res vary between 350÷400°C (cloud) and tion tank, of a main heated fermenter, a final
200÷250°C (layer). Information stated in the storage tank and, sometimes, of a secondary
product safety form must be verified. fermenter.
Once the biogas is produced, it must be pro-
8.4. BIOGAS PLANTS cessed and stored before being reused.
In the modern biogas plants, biodegradable The co-generator is composed of a gas engi-
organic substrates such as grass, straw, ma- ne with heat exchanger and generator. On the
nure, biodegradable waste, residues of food basis of the energy content of biogas, this pro-
production, leftovers and greases are fermen- duces electrical energy with a 30% efficiency
ted. For this purpose fermenters, that are se- and heat with a 60% efficiency. The electri-
aled containers, are filled with organic ma- cal energy is fed into the network. The heat is
terials. In this environment without oxygen, used for the fermenters, and the excess heat
bacteria produce biogas starting from orga- for houses, agricultural structures or similar.
Image 43 Biogas plant scheme

Image 43
Thermal energy
Biogas
Electrical energy Cogeneration unit
Process
heat
Process heat
Pump
Organic substrates Main fermenter Thermal decay Second fermenter
Fertilizer
Pump Depot
Sewage sludge
8.4.2. RISK OF ESPLOSION 8.4.3. REGULATIONS
Since in a biogas plant there is always the The employer must survey and evaluate
presence of explosive atmosphere, especial- all risk factors for the areas with risk of
ly in the gas tank area and in the fermenters, explosion. Environments with explosive
these plants are to be considered at risk of ex- atmosphere must be subdivided into are-
plosion. as, following the EN 60079-10-1 standard
Currently ATEX 94/9/CE and ATEX 99/92/CE for gases and EN 60079-10-2 standard for
are the reference directives for equipment and dusts.
protection systems meant to be used in explosi- Depending on the results of risk asses-
ve atmosphere. sment, the areas with risk of explosion must
Their reference standard is EN UNI 1127-1 be defined and described in a document for
“Explosive atmospheres – Explosion preven- the protection against the risk of explosion.
tion and protection – Part 1: Main concepts In case of protection against lightning, the
and methods”, where 13 different ignition series CEI EN 62305 standards must be fol-
sources are listed. lowed.
It is a general protection standard that con- All the electrical equipment placed in classi-
siders each possible ignition source and, in fied areas must comply with safety require-
particular, protection from lightning. All of ments and belong to the protection degree
these plants are isolated in the countryside suitable to the type of classified area, accor-
and, therefore, are exposed to lightning risks. ding to the ATEX 94/9/CE standard.
9. Appendix
9.1. BRIEF DESCRIPTION OF PROTECTION METHODS FOR ELECTRICAL EQUIPMENT ADDRESSED
TO AREAS WITH RISK OF EXPLOSION FOR PRESENCE OF GAS (TAB. 27)
Tab. 27 Gas protection modes
Protection IEC/EN Base Main characteristics Applications
mode standard principle
“d” explosion-proof IEC 60079-1 Containment Gas may enter. If triggered, the atmosphere explodes. Enclosure Control panels, lighting fixtu-
enclosures EN 60079-1 contains explosion and joints are designed so that flame cools res, switches, control unit. All the
while going out, and only the combustion product, unable to equipment that, in normal operating
trigger the surrounding atmosphere, arrives outside. conditions, can provoke sparks or
over temperatures.
“e” increased safety IEC 60079-7 Prevention Building requirements preventing arcs, sparks or high tempera- Non-sparkling equipment such
EN 60079-7 tures, such as isolation distances in air and enlarged surfaces. as: enclosures, terminals, lighting
equipment, revolving machines.
“i” intrinsic safety IEC 60079-11 Prevention Electrical equipment installed in hazardous area is part of a sy- Electrical parameter limitations
EN 60079-11 stem of circuits and electronic barrier limiting its performance exclude the application to power
at such energies that the ignition of explosive atmosphere is pre- equipment. It is applied to measure
vented by the control of electrical parameters (power, current, and control machinery as well as to
inductances and cable grounding capacity, etc.). Intrinsic safety regulate the production processes.
protection mode is achieved with an equipment inside the area,
a connection circuit and a barrier, generally installed outside
hazardous area.
“n” protection mode IEC 60079-15 Prevention Protection mode made according to building prescriptions Lighting equipment, control panels,
EN 60079-15 and less strict values in order to prevent the ignition of ex- control stations for Zone 2.
plosive atmosphere only in normal equipment functioning.
Ex nA= sparkling equipment
Ex nC= protected contacts
Ex nR= limited respiration
Ex nP= simplified pressurization
“p” internal IEC 60079-2 Segregation Live equipment and circuits enclosed in an enclosure, in which It is suitable to carry out complete
overpressure EN 60079-2 pressure is kept higher than the outer one by the insertion of an controls because of the lack of a
inert gas or air. In this way, the ingress of explosive atmosphere construction dimensional limit as
is prevented. It requires sophisticated control and alarm systems. well as of electrical measurements
of the equipment it contains.
immersion in oil “o” IEC 60079-6 Segregation Electrical equipment is fully immersed in oil so that explosive It is applied above all to devices not
EN 60079-6 atmosphere, that is outside or above the liquid, cannot be trig- provided with moving parts.
gered.
“q” powdery filling IEC 60079-5 Segregation Enclosure containing electrical equipment is filled with dust It is applied to small components
EN 60079-5 (for example, quartz powder) that prevents the ignition of exter- such as capacitors, transformers, or
nal explosive atmosphere. electronic devices such as starters
for tubular lamps.
Encapsulation “m” IEC 60079-18 Segregation Components which may cause sparks or over temperatures are Small sized equipment such as ca-
EN 60079-18 fully covered with a compound (usually resin), in order to separate pacitors, reactors, transformers, level
them from explosive atmosphere. Compound resists to ambient and proximity sensors and electronic
conditions in which the equipment operates and it is tested to equipment in general.
guarantee the maintenance of its properties in the time (aging).
9.2. BRIEF DESCRIPTION OF PROTECTION METHODS FOR ELECTRICAL EQUIPMENT ADDRESSED
TO AREAS WITH RISK OF EXPLOSION FOR PRESENCE OF DUSTS (TAB. 28)
Tab. 28 Protection methods – Dusts
Protection IEC/EN Main characteristics Applications

mode standard
Absence of ignition IEC 60079-31 Enclosure sealing prevents the ingress of dust or reduces it Control panels, lighting fixtures, engines, con-
source. Protection EN 60079-31 to a minimum non dangerous quantity. nection enclosures and terminal strips.
with “t” enclosures In this way equipment can be mounted inside the enclo-
(ta, tb, tc) sure. Enclosure surface temperature must not trigger the
surrounding atmosphere.
Absence of ignition IEC 60079-11 Equipment used in a potentially explosive area con- Sensors, actuators, measure and control techno-
source. “i” intrinsic EN 60079-11 taining only intrinsic safety electrical circuits. Each logy.
safety protection electrical circuit is intrinsically safe when any spark or
(ia, ib, ic) thermal effect produced in conditions such as normal
functioning and specific failure conditions are not able
to cause a combustion of an explosive atmosphere.
Absence of explosive IEC 60079-11 The “Ex p” internal overpressure protection mode con- MT/BT transformers, big electrical machinery,
atmosphere. EN 60079-11 sists in injecting protection gas in the enclosure to keep (alternative to “Ex e” protection), automation
“p” pressurization it in overpressure comparing to external atmosphere, and instrumentation panels, industrial pro-
preventing the creation of explosive atmosphere inside cesses control systems (gas chromatographs,
the enclosure. analyzers), analysis cabin and pressurized ca-
Protection gas can consist in air or inert gas, such as bins.
nitrogen.
Ignition source IEC 60079-18 Components that may produce sparks or overpressures Small-sized equipment such as capacitors, reac-
segregation. “m” EN 60079-18 are fully covered with a compound (generally resin), tors, transformers, level and proximity sensors
encapsulation in order to separate them from explosive atmosphere. and electronic equipment in general.
(ma, mb, mc). Compound resists to ambient conditions in which the
equipment operates and it is tested to guarantee the
maintenance of its properties in the time (aging).
9.3. BRIEF DESCRIPTION OF PROTECTION METHODS FOR NON-ELECTRICAL EQUIPMENT ADDRESSED

TO AREAS WITH RISK OF EXPLOSION FOR PRESENCE OF GAS AND DUSTS (TAB. 29)
Tab. 29 Protection methods for non-electrical equipment in presence of gas and dusts
Protection ISO/EN Main characteristics Applications

mode standard
Absence of ignition EN 13463-5 Technical principles tested on equipment with no ignition source in normal opera- Joints, pumps, gears,
source. “c” constructive ISO 80079-37* tions are applied. The risk of mechanical breaks, that can cause flammable tempe- transmission chains, con-
safety ratures and sparks, is therefore reduced to minimum. veyor belts.
Protection. “d” EN 13463-3 Gas may enter. If triggered, the atmosphere explodes. Enclosure contains explosion Brakes, joints.
explosion-proof and joints are designed so that flame cools while going out, and only the combu-
stion product, unable to trigger the surrounding atmosphere, arrives outside.
Absence of explosive EN 13463-2 An effective sealing can reduce the entry of explosive atmosphere so that no poten- Equipment only for Zone
atmosphere. “fr” limited tially explosive atmosphere may occur inside. Pressure differences between the inside 2 or 22.
respiration enclosure. of the enclosure and the outside environment, due to temperature changes, must be
considered. Application only to category 3 equipment.
“b” ignition source EN 13463-6 Sensors inside the equipment survey possible risks of explosion in the initial phase, Pumps, conveyor belts.
control ISO 80079-37* so that countermeasures can be applied before potential ignition sources become
effective. The measures applied can be started automatically by a direct connection
between sensors and ignition protection system, or manually by sending an infor-
mation message to the operator.
Ignition source segmenta- EN 13463-8 Ignition sources become inactive by being immersed in a protective liquid or by Submergible pumps, gears,
tion. Immersion in liquid ISO 80079-37* being constantly kept humidified with a liquid film. immersion in liquid.
“k”
* standards about to be published by ISO
9. Appendix
9.4. STRUCTURAL REQUIREMENTS FOR EXPLOSION-PROOF ELECTRICAL EQUIPMENT FOR POTENTIALLY
EXPLOSIVE ATMOSPHERES FOR PRESENCE OF GAS (TAB. 30 AND 31)
Tab. 30 Structural requirements in Europe, USA, Canada and international comparison
Protection Abbreviation Region Installation Standards

method Zone
General US Class I, Division 1 e 2 FM 3600
requirements AEx US Class I, Zone 0, 1 e 2 ISA 60079-0
Ex CA Class I, Zone 0, 1 e 2 CSA E60079-0
Ex EU Zone 0, 1 e 2 EN 60079-0
Ex IEC Zone 0, 1 e 2 IEC 60079-0
Increased safety AEx e US Class I, Zone 1 ISA 60079-7

Ex e CA Class I, Zone 1 CSA E60079-7
Ex e EU Zone 1 EN 60079-7
Ex e IEC Zone 1 IEC 60079-7
Ignition-proof (NI) US Class I, Division 2 FM 3611

(NI) CA Class I, Division 2 C22.2 No. 213
Non sparkling AEx nA US Class I, Zone 2 ISA 60079-15

equipment Ex nA CA Class I, Zone 2 CAS E60079-15
Ex nA EU Zone 2 EN 60079-15
Ex nA IEC Zone 2 IEC 60079-15
Explosion (XP) US Class I, Division 1 FM 3615

Prevention (XP) CA Class I, Division 1 C22.2 No. 30
Flame-proof AEx d US Class I, Zone 1 ISA 60079-1

enclosures Ex d CA Class I, Zone 1 CSA E60079-1
Ex d EU Zone 1 EN 60079-1
Ex d IEC Zone 1 IEC 60079-1
Filling with dust AEx q US Class 1, Zone 1 ISA 60079-5

Ex q CA Class I, Zone 1 CSA E79-5
Ex q EU Zone 1 EN 50017
Ex q IEC Zone 1 IEC 60079-5
Protected structures AEx nC US Class I, Zone 2 ISA 60079-15

and components Ex nC CA Class I, Zone 2 CSA E60079-15
Ex nC EU Zone 2 EN 60079-15
Ex nC IEC Zone 2 IEC 60079-15
Intrinsic safety (IS) US Class I, Division 1 FM 3610

(IS) CA Class I, Division 1 C22.2 No. 157
AEx ia US Class I, Zone 0 FM 3610
AEx ib US Class I, Zone 1 FM 3610
Ex ia CA Class I, Zone 0 CSA E60079-11
Ex ib CA Class I, Zone 1 CSA E60079-11
Ex ia EU Zone 0 EN 50020
Ex ib EU Zone 1 EN 50020
Ex ia IEC Zone 0 IEC 60079-11
Ex ib IEC Zone 1 IEC 60079-11
Tab. 31 Structural requirements in Europe, USA, Canada and international comparison
Protection Abbreviation Region Installation Standards

method Zone
Limited-energy AEx nC US Class I, Zone 2, ISA 60079-15
equipment Ex nL CA Class I, Zone 2 CSA E60079-15
Ex nL EU Zone 2 EN 60079-15
En nL IEC Zone 2 IEC 60079-15
Pressurized Type X US Class I, Division 1 FM 3620

enclosures Type X CA Class 1, Division 1 NFPA 496
Type Y US Class I, Division 1 FM 3620
Type Y CA Class I, Division 1 NFPA 496
Type Z US Class 1, Division 2 FM 3620
Type Z CA Class 1, Division 2 NFPA 496
AEx px US Class I, Zone 1 ISA 60079-2
CA Class I, Zone 1 CSA E60079-2
EU Zone 1 EN 60079-2
IEC Zone 1 IEC 60079-2
US Class I, Zone 1 ISA 60079-2
US Class I, Zone 2 ISA 60079-2
Pressurized AEx nR US Class I, Zone 2 ISA 60079-15

Ex nR CA Class I, Zone 2 CSA E60079-15
Ex nR EU Zone 2 EN 60079-15
Ex nR IEC Zone 2 IEC 60079-15
Encapsulation Ex ma EU Zone 0 EN 60079-18

Ex ma IEC Zone 0 IEC 60079-18
AEx m US Class I, Zone 1 ISA 60079-18
Ex m CA Class I, Zone 1 CSS E60079-18
Ex mb EU Zone 1 EN 60079-18
Ex mb IEC Zone 1 IEC 60079-18
Immersion in oil AEx o US Class I, Zone 1 ISA 60079-6

Ex o CA Class I, Zone 1 CSA E79-6
Ex o EU Zone 1 EN 50015
Ex o IEC Zone 1 IEC 60079-6
Marking
of electrical equipment in areas
at risk of explosion
Marking of electrical equipment in areas at risk of explosion
78
Equipment category
M2 = equipment addressed to underground work in mines and in their surface plants
exposed to risk of release of firedamp gas and/or combustible dusts – in presence of
potentially explosive atmosphere, it should be possible to interrupt the power supply;
2G = equipment suitable for areas where, during normal activities, explosive
atmospheres due to gas, vapors or mists (zone 1) may occur; suitable to be installed
in Zone 1 and 2
2(1)G = equipment suitable for areas where, during normal activities, explosive
atmospheres due to gas, vapors or mists (zone 1) may occur, and that has inside
a bonded device that will be connected to a category 1 equipment; suitable to be
Graphic symbol identifying that at least one European Directive has been installed in Zone 1 and 2
applied; it is placed only on the “equipment”, not on the “components” 2(2)G = equipment suitable for areas where, during normal activities, explosive
atmospheres due to gas, vapors or mists (zone 1) may occur, and that has inside a
bonded device that will be connected to a category 2 equipment; suitable to be installed
in Zone 1 and 2
3G = equipment suitable for areas where, during normal activities, explosive
0722 = dentification number of Notified Body responsible for production control; atmospheres consisting of an air and flammable substances mixture in the shape of
placed on the category M2 and 2 equipment. In our case it is the CESI - (Italian gas, vapors or mist may occur and, if it occurs, it is really for a short time (zone 2);
Experimental Electrotechnical Centre) suitable to be installed in zone 2
2D = equipment suitable for areas where, during normal activities, explosive
atmospheres due to a mixture of air and flammable dusts (zone 21); suitable to be
European Community mark “Epsilon-x” specific for protection against installed in zone 21 and 22
explosions, defined for the first time in the Directive 76/117/CEE of 18 2(1)D = equipment suitable for areas where, during normal activities, explosive
December 1975 atmospheres due to a mixture of air and flammable dusts (zone 21) and that has
inside a bonded device that will be connected to a category 1 equipment; suitable
to be installed in zone 21 and 22
3D = equipment suitable for areas where, during normal activities, explosive
Equipment Group atmospheres in the shape of cloud of flammable dust and, if it occurs, it is really for a
I = equipment addressed to underground work in mines and in their surface plants short time. (Zone 22); suitable to be installed in zone 22
exposed to risk of release of firedamp gas and/or combustible dusts
Marking of electrical equipment in areas at risk of explosion
II = equipment addressed to different than underground work in mines and their

surface plants which could exposed to risk of explosive atmospheres
Guide to the EX world – How to use electrical equipment in areas with risk of explosion
CE Marking ATEX Marking Protection mode EPL
2(1)G Ex d [ia Ga] IIB+H2 T6..T5 Gb
0722 II
2(1)D Ex tb [ia Da] IIIC T85..100°C IP66/IP67 Db
Ex = indicates that protection mode against explosions has been applied
I = equipment addressed to underground work in mines and in their surface plants

exposed to risk of release of firedamp gas and/or combustible dusts
IIB = equipment not addressed to underground work in mines or their surface plants
Letter indicating the protection mode adopted which could exposed to risk of explosive atmospheres – subgroup of B gas; suitable to be
d = equipment protected by means of a “d” explosion-proof enclosure installed in presence of gases of subgroup A and B
e = “e” increased safety equipment IIB+H2 = equipment not addressed to underground work in mines or their surface
i = “i” intrinsic safety equipment plants which could exposed to risk of explosive atmospheres – subgroup of B gas;
de = equipment with a part protected by means of a “d” explosion-proof enclosure and an suitable to be installed in presence of gases of subgroup A, B and hydrogen
“e” increased safety part IIC = equipment not addressed to underground work in mines or their surface plants
ed = equipment with an “e” increased safety part and a part protected by means of a “d” which could exposed to risk of explosive atmospheres – subgroup of C gas; suitable to be
explosion-proof enclosure installed in presence of any gas (subgroups A, B and C)
d [ia Ga] = equipment protected through a “d” explosion-proof enclosure with inside an “ia” IIIC = equipment not addressed to underground work in mines and their surface plants
which could exposed to risk of explosive atmospheres – subgroup of C dusts; suitable to
intrinsic safety associated device (usually a barrier) be installed in presence of any dust (subgroups A, B and C)
d [ib Gb] = equipment protected by means of a “d” explosion-proof enclosure with inside an A21 = equipment not addressed to underground work in mines or their surface plants
“ib” intrinsic safety associated device (usually a barrier) which could exposed to risk of explosive atmospheres – method A; suitable to be
nA = equipment created to reduce to minimum the risk of arcs or sparks able to originate an installed in zone 21 and 22
ignition danger during normal working A22 = equipment not addressed to underground work in mines and their surface
nR = equipment designed to limit gas, vapors and mists ingress plants which could exposed to risk of explosive atmospheres – method A; suitable to be
tb = equipment with an enclosure that prevents dust ingress and with devices to limit surface installed in zone 22
temperatures; protection level 2b”
tD = equipment protected by an enclosure to prevent a cloud or a layer-of-dust ignition
tb [ia Da] = equipment with an enclosure that prevents dust ingress and devices to limit
surface temperatures with “b” protection level, with inside an “ia” intrinsic safety associated
device (usually a barrier)
Definition of temperatures generated by equipment
T6 = equipment that can reach, but not exceed 85°C of absolute temperature (depending on
protection mode it can be either maximum temperature or surface maximum temperature)
T..°C = equipment that can reach, but not exceed in surface …°C of absolute temperature
Identifies equipment; for further info, refer to previous paragraph 3.6.2.4.1. “Enclosu-
Guide to the EX world – How to use electrical equipment in areas with risk of explosion
res protection degrees (IP code)”
Equipment Protection Level

Mb = equivalent to M2 category Db = equivalent to 2D category
Gb = equivalent to 2G category Dc = equivalent to 3D category
Gc = equivalent to 3G category
79
CORTEM GROUP
To be sure to be safe
Since 1968, Cortem S.p.A. has been designing and manufacturing explosion-
protected electrical equipment addressed to hazardous areas (with risk of
explosion and fire).
Thanks to a continuous effort in technical innovation and improvement, it is today
a leader in this field, able to provide a whole range of products, meeting on-shore
and off-shore applications.
The peculiarity of Cortem Group, formed by the brands Cortem, Elfit and
Fondisonzo, is the experience gained in more than 40 years of activity in the field
which results not only in the supply of simple Ex-products, but also in customized
solutions.
All our products are internally designed and manufactured following different
protection methods, such as “Ex d” explosion-proof, “Ex e” increased safety, “Ex
d” mixed, “Ex n” non-sparkling, and using aluminium alloys, titled steels and
first-quality plastic materials that assure resistance and duration. Aluminium alloy
used by Cortem has passed all tests required by EN 60068-2-30 Standard (hot/
humid cycles) and EN 60068-2-11 Standard (salt spray test). All our products in
aluminium alloy are protected by an epoxy coating RAL 7035. This treatment,
only provided by Cortem Group, guarantees a durable protection.
Cortem production range can be summarized as follows:
- Lighting fixtures, obstruction lighting fixtures, floodlights and hand lamps.
- Junction and pulling boxes, control stations.
- Signaling and control equipment, plugs and sockets.
- Cable glands and electrical fittings.
- Special executions: switchgears and panel boards tailor made upon customers
specifications.
90% of our production are located in the Oil & Gas sector both off-shore and on-
shore, but also in chemical, pharmaceutical plants and in all those manufacturing
areas where the presence of explosive atmospheres may occur such as grain
silos, woodworks and paper mills. We invest every year some of our resources to
develop innovative products that meet the market needs and, for this reason, our
R&D department studies the best solution valuating normative and market price
issues, plant and security aspects.
With more than 30 agencies, 90 distributors, 7 partners and 3 production
centers displaced, Cortem provides a local and qualified presence around the
world. For Cortem “displacing” does not means transferring facilities, resources
and know-how in low cost Countries, but replicating a successful model of
industrial organization in which environment safety, product quality, compliance
with standards, technical and after-sales services are the fundamentals of our
corporate mission.
The pay-off “to be sure to be safe” represents our pride and passion for what we
design and manufacture.
2
Guide to the EX world
How to use the electrical equipment in areas with risk of explosion
Issued October 2013
Copyright
In accordance with copyright laws, the Italian Civil Code and other regulations in effect in the markets where the Cortem Group operates, all
the information, images, photographs, drawings, tables and anything else contained in the Cortem Group promotional material are the exclusive
property of the Cortem Group, which has all the moral rights to the aforesaid material as well as the right to use it for commercial and economic
purposes. It is therefore forbidden to reproduce all or part of the Cortem Group promotional material in any way, unless otherwise authorized
by the Cortem Group in writing. Any violation of the above is against the law. © by Cortem - Villesse - Italy. All rights reserved.
Sales Offices
Piazzale Dateo 2
20129 Milan (ITALY)
Ph. +39 02 76 1103 29 a.m.
Fax +39 02 73 83 402
infomilano@cortemgroup.com
Export
Ph. +39 02 76 1105 01 a.m.
Fax +39 02 70 00 54 71
export@cortemgroup.com
saleseurope@cortemgroup.com
Headquarters and Factory
Design and layout

GUIDAEX10/2013 - K....
Raffaella Sesia
Via Aquileia 10
34070 Villesse (GO), Italy
Ph. +39 481 964911 a.m.
Fax +39 0481 964999
info@cortemgroup.com

Via Aquileia 10
Ph. +39 481 964911 a.m.
Fax +39 0481 964999
info@elfit.com
vendite@elfit.com
www.elfit.com
Sales Offices
Piazzale Dateo 2
20129 Milan (ITALY)
Ph. +39 02 76 1103 29 a.m.
Fax +39 02 73 83 402
infomilano@cortemgroup.com
Export
Ph. +39 02 76 1105 01 a.m.
Fax +39 02 70 00 54 71
export@cortemgroup.com
saleseurope@cortemgroup.com

Via Aquileia 10
Ph. +39 481 964911 a.m.
Fax +39 0481 964999
info@cortemgroup.com
www.cortemgroup.com

Guide To The Ex World CORTEM Group

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Guide to the EX world

How to use electrical equipment in areas with risk of

2. Hazardous areas classification pag. 13

3. Equipment choice pag. 20

7. End-of-life equipment pag. 63

8. Application examples for different types of plants pag. 65

Marking of electrical equipment in areas with risk of explosion pag. 77

hazardous areas classification marking of equipment

repairing the equipment plants’ inspection and maintenance

ASL o ARPA, DPR 462/2001

had to bear a graphic mark Image 2 CE Graphic symbol

Tab. 1 83/189/CEE “Framework Directive”: enactment, amendments and implementation in Italy

vision, dated 2008 (Table 1).

Tab. 2 “ATEX 95” Directive: enactment, amendments and implementation in Italy

Corrigendum to Directive 94/9/EC of the European

Its official name is “distinctive community mark”. The hexagon in-

Tab. 3 89/391/CEE “Framework Directive”: promulgation and implementation in Italy

on health and safety at work - TUS”: the legislative Decree of 9th

Tab. 4 “ATEX 137” Directive: promulgation and implementation in Italy

against stationary object (victim

hit by a moving object, collision

contact with sharp, pointed,

horizontal / vertical impact

physical or mental stress

bite, kick, etc. (animal or

trapped, crushed, etc.

4% contact with sharp, pointed,

2% horizontal / vertical impact

sed to the risk of explosive atmospheres.

Notes: EU_V indi-

hit by object in motion, collision

contact with sharp, pointed,

horizontal / vertical impact

physical or mental stress

trapped, crushed, etc.

bite, kick, etc. (animal

0% contact with sharp, pointed, rough agent, 7% trapped,

0% bite, kick, etc. (animal or human)

4% drowned, buried, wrapped

Considering that some information covers the period 2003-2005

Permanent incapacity in 2005

Mortal accidents from 2003

21 days - 1 month lost

from 2003 to 2005

Image 4 The fire triangle Image 5 The pentagon of the explosion

combustible combustion combustible combustion

I n facing the chapter on the classifi-

Tab. 5 Some of the most representative gases

n° GAS Name Formula L.E.L. U.E.L. M.I.T. M.I.E.* GROUP

methane CH4 4,40 17,00 600 IIA

20 74-85-1 ethylene CH2=CH2 2,30 36,00 440 82 IIB

21 74-86-2 ethyne (acetylene) CH=CH 2,30 100,00 305 19 IIC

27 74-98-6 propane CH3CH2CH3 1,70 10,90 450 250 IIA

35 75-15-0 Carbon disulphide CS2 0,60 60,00 90 9 IIC

37 75-21-8 ethylene oxide CH2CH2O 2,60 100,00 429 IIB

55 78-10-4 tetraethoxysilane (C2H5)4Si 0,45 7,20 174

181 110-96-3 2-methyl-N-(2-methylpropyl)-1- ((CH3)2CHCH2)2NH 0,80 3,60 256 IIA

206 123-42-2 4- hydroxy -4-methylpentane-2-one CH3COCH2C(CH3)2OH 1,80 6,90 680 IIA

288 1333-74-0 hydrogen H2 4,00 77,00 560 16 IIC

Legenda: L.E.L.: (Lower Explosive Limit; U.E.L.: Upper Explosive Limit;

upper explosive limit (U.E.L.), the lo- tively;

Tab. 6 Some of the most representative dusts

Combustible Grain Explosive level M.I.T. [°C ] M.I.E. Kst