Exd Flameproof Enclosures Page 1 of 3

Exd FLAMEPROOF ENCLOSURES- A Brief Guide

REFERENCE STANDARDS

IEC 79-0, IEC 79-1, BS 5501.1, BS 5501.5, EN 50 018, AS 2380.1, AS 2380.2

DEFINITIONS

Flameproof Enclosure: Type of protection for electrical equipment in which the enclosure will withstand an internal explosion of a
flammable mixture which has penetrated into the interior without suffering damage and without causing ignition, through and joints
of structural openings in the enclosure, of an external explosive atmosphere consisting of one or more of the gases or vapours for
which it is designed.

Flameproof Joint: Place where corresponding surfaces of the different parts of a flameproof enclosure come together. Where the
flame or products of combustion may be transmitted from the inside to the outside of the enclosure.

Length of Flamepath: The shortest path through a joint from the inside to the outside of an enclosure.

Gap: The distance between the corresponding surfaces of a flameproof joint when the electrical equipment has been assembled.

Pressure Piling: A condition resulting from ignition of precompressed gases in compartments or subdivisions other than those in
which ignition was initiated.

CONSTRUCTION REQUIREMENTS

Some of the other details that are covered by the standards are:-

z Minimum Surface Roughness, (machined surfaces).

z Inspection Access to measure the gap between flanged joints - usually with feeler gauges.
z Holes in joint surfaces. See drawing and table defining 'L' and 'I'.
z Joints, including, Class of Fit, Pitch, Minimum number of threads engaged.
z Gaskets and 'O' Rings.
z Operating Rods and Spindles.
z Shafts and Bearings.
z Breathing and Draining Devices.
z Fasteners. Especially the requirement that all holes must be blind holes, so that if a bolt is removed there will not be direct
access into the flameproof enclosure. Minimum wall thickness-3mm or 1/3 the diameter of the hole-whichever is the greater.
Minimum length of thread engaged, and the depth of the hole to ensure the bolt does not 'bottom out' before it is fully
engaged.
z Mechanical Strength. Pressure piling.
z Cable glands and cable connection techniques.

MINIMUM WIDTH OF JOINT AND MAXIMUM GAP FOR I, IIA, IIB

ENCLOSURES. A.S. 2380.2 TABLE 1.1
Maximum Gap for Volume, V (cm3), (mm)
Width of Joint L, (mm) V <100 100 V > 2000
I IIA IIB I IIA IIB I IIA IIB
Flanged and spigot Joints
6 9.5 12.5 25 .30 .30 .20 - - - - - -
.30 .30 .20 - - - - - -

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.40 .30 .20 .40 .30 .20 .40 .20 .15
.50 .50 .20 .50 .40 .20 .50 .40 .20
Operating Rods and Spindles
6 12.5 25 .30 .30 .20 - - - - - -
.40 .30 .20 .40 .30 .20 .40 .20 .15
.50 .40 .20 .50 .40 .20 .50 .40 .20
Shafts with Rolling Brgs
6 12.5 25 40 .45 .45 .30 - - - - - -
.60 .50 .40 .60 .45 .30 .60 .30 .20
.75 .60 .45 .75 .60 .40 .75 .60 .30
.75 .75 .60 .75 .75 .45 .75 .75 .40

For Rods, Spindles, and shafts the gap is the maximum diametral clearance. Usually if equipment is to be used for Groups I, IIA and
IIB, it will be designed and built to meet with requirements of a IIB enclosure, which exceeds the requirements of IIA and I. Separate
tables apply for Group IIC with much tighter tolerances and gaps. As IIC requirements are not common, standard equipment is not
usually produced to IIC to cover the requirements of the other groups. IIC is usually produced specially when required.

FLAMEPROOF THEORY

It is not possible or desirable to produce equipment with no gaps between the different parts, especially with an electric motor with a
revolving shaft. The allowable gap between the different parts is accepted, but strictly defined. The 'gaps' help to relieve the pressure
inside the enclosure caused by an explosion. Experimental testing is used to establish the 'maximum experimental safe gap' for
different gases and gas mixtures. This data has been used to establish A.S. 2380.2 TABLE 1.1. It can be seen that the wider the joint
the larger the allowable gap, and that gases that explode more violently require a smaller gap. The standard that covers the testing to
establish the 'maximum experimental safe gap' is IEC79-1A (Appendix D).

FLAMEPATH DIMENSIONS FOR JOINT SURFACES INTERRUPTED BY HOLES

Width of Joint “L”mm Dimension “1”mm <12.5> 12.5 <25> 25 689

OTHER GENERAL REQUIREMENTS FOR EXPLOSIVE ATMOSPHERES

z Fasteners can only be undone by the use of a special tool, if the parts they are securing are necessary to achieve a type of
protection, (Ex d, Ex e, etc.). For Ex d equipment this is usually achieved by using socket head cap screws with a counterbore,
or hexagon head bolts with a counterbore or shroud.
z Limits on the amount of aluminium of magnesium in external alloys, especially for Group 1 applications. This is because Coal
dust and aluminium under ideal conditions can create spontaneous combustion at temperatures as low as 180 deg. C. For
group 1 equipment it is usual for all external parts to be Cast Iron or Steel.
z External temperatures during normal operation - “T” ratings.
z IP ratings.
z Usual Electric tests including a High voltage test at 2 X the Operating Voltage plus 1500 volts. (2330 volts for 415 colt
equipment)
z Impact tests.
z Marking, including information required on nameplates.

TESTING

Type tests are carried out on all Ex d equipment before it can be approved. these tests are performed in 2 stages.
1. Tests of the ability of the enclosure to withstand pressure, and the rate of rise of pressure, developed inside the enclosure during an
explosion - the “Reference Pressure”. The enclosure is then overpressure tested to 1.5 times the “Reference Pressure” usually with
compressed air or water, to ensure a factor of safety. During manufacture all equipment that is of a steel fabricated construction must
be Routine tested at a static pressure of 1.5 times the “Reference Pressure” to ensure the integrity of the welding. If equipment is of
cast or moulded construction it can be exempted from the requirement for Routine Pressure Testing if the sample passes a 4 times
overpressure test.

2. Tests to ensure that the enclosure is flameproof, i.e. that an internal explosion does not create an external explosion.

The equipment is modified by drilling and tapping suitable holes to install spark plugs, pressure transducers, and gas pipes. to
determine the explosion “Reference Pressure” at least 3 explosions are performed inside the enclosure using the appropriate mix of
gas to suit the Gas Group the enclosure is designed for. For electric motors these tests are performed while the motor is running and

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while it is stationary.

The equipment is placed in a test chamber which is filled with the same explosive gas mixture as is used in the equipment under test.
the gas inside the equipment is exploded at least 5 times to prove that the external gas is not ignited by the internal explosions.

The equipment is considered to have passed the tests if no flame transmission has occurred, and the enclosure has not suffered any
damage or permanent deformation that may affect its flameproof properties.

Before any explosion testing is performed copies of the Approval drawings which are carefully checked to ensure that the design
details meet the requirements of the relevant standards. After explosion testing is completed the samples, (prototypes), are
disassembles and all the component parts are carefully measured to ensure that they have been manufactured to the dimensions and
tolerances specified on the Approval drawings.

SUMMARY

To design, test and manufacture Flameproof equipment requires a great deal of attention to detail and a high level of safety which is
understandable as failure will put peoples lives a risk. The information above is a brief summary of some of the detail that has to be
complied with to meet the requirements of the standards. While we believe this information to be correct we can accept no
responsibility for any inaccuracies.

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