TRBS2152 - 03 En121520

Subscribe to DeepL Pro to translate larger documents.
Visit www.DeepL.com/pro for more information.
TRBS 2152 Part 3

Dangerous explosive atmosphere
- Preventing the ignition of hazardous explosive atmospheres
GMBl. No. 77 of 20 November 2009, p. 1583

T EC HNIC AL REGELS FOR ECONOMICALPRODUC
TION
PUBLISHED BY KÜPPERS ENGINEERING
Technical rules Hazardous explosive atmosphere TRBS 2152 Part 3
for - Preventing the ignition of hazardous explosive GMBl. 20 Nov. 2009
operational safety atmospheres Page: 2 / 31
Preliminary remark
This Technical Rule for Operational Safety (TRBS) reflects the state of the
art in technology, occupational medicine and hygiene, as well as other
recognised ergonomic findings for the provision and use of work
equipment and for the operation of systems requiring monitoring.
It is determined by the Committee for Operational Safety and published by
the Federal Ministry of Labour and Social Affairs in the Joint Ministerial
Gazette.
The technical rule specifies the German Ordinance on Industrial Safety
and Health (BetrSichV) with regard to the identification and assessment of
hazards and the derivation of suitable measures. When applying the
exemplary measures mentioned, the employer can assert the presumption of
compliance with the provisions of the Ordinance on Industrial Safety and
Health. If the employer chooses a different solution, he must provide
written proof of equivalent fulfilment of the ordinance.
© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

Contents
1 Area of application 5.8 Lightning strike
2 Definitions 5.9 Electromagnetic fields in the frequency range from 9 x 103 Hz to 3 x 1011 Hz
2.1 Ignition source 5.10 Electromagnetic radiation in the range of frequencies from 3 x 1011 Hz
to 3 x 1015 Hz or wavelengths from 1000 µm to 0.1 µm (optical spectral
2.2 Effective ignition source range)
3 Identification and avoidance of effective ignition sources - General 5.11 Ionising radiation
4 Identification of ignition sources 5.12 Ultrasound
5 Prevention of ignition sources becoming effective 5.13 Adiabatic compression, shock waves, flowing gases
5.1 General information 5.14 Chemical reactions
5.2 Hot surfaces
Appendix
5.3 Flames and hot gases
5.4 Mechanically generated sparks
5.5 Electrical systems
5.6 Electrical equalising currents, cathodic corrosion protection
5.7 Static electricity

1 Area of application 3 Identification and avoidance of

Scope This technical rule specifies the requirements of the Ordinance on effective ignition sources - General
Industrial Safety and Health for preventing the ignition of hazardous explosive (1) To prevent the ignition of a hazardous explosive atmosphere, possible
atmospheres as a result of ignition sources becoming effective. It also applies ignition sources must be identified and measures taken to prevent ignition
to the determination of the relevant contents of the explosion protection sources from becoming effective. These measures include
document in accordance with § 6 BetrSichV. – Provision of suitable work equipment including system parts and
connecting devices
2 Definitions – Use of work equipment in such a way that ignition sources do not become
effective
2.1 Ignition source
– Assembly, installation and operation of the systems requiring
An ignition source is caused by a physical, chemical or technical process,
monitoring in such a way that ignition sources do not become
condition or work sequence that is capable of triggering the ignition of an
effective.
explosive atmosphere.
Note: Before measures are taken in accordance with sentence 1, it
should be checked whether the work equipment or processes with
2.2 Effective ignition source ignition sources can be relocated from the potentially explosive
An effective ignition source is a source of ignition that can trigger ignition atmosphere under consideration.
in the explosive atmosphere under consideration. (2) The effectiveness of ignition sources, i.e. the ability to ignite explosive
atmospheres, depends among other things on the energy of the ignition
source and the properties of the explosive atmosphere.
(3) If it is not possible to estimate the probability of an ignition source
becoming effective in accordance with the zoning of the area in which
it is located, the ignition source must be regarded as permanently
effective.
(4) For a number of ignition sources, limit values are specified which, if
complied with, can rule out an ignition hazard. However, this does not
mean that non-compliance with these values will always ignite an explosive

atmosphere. Rather, in these cases it must be determined whether and
to what extent other protective measures are required.

4 Identification of ignition sources 5 Prevention of ignition sources

(1) Possible ignition sources that can occur individually or in combination are becoming effective
– hot surfaces,
– Flames and hot gases, 5.1 General information
– mechanically generated sparks, (1) The measures to be taken should render ignition sources ineffective or
reduce the probability of them becoming effective. The scope of the
– electrical systems, protective measures depends on the probability of a hazardous explosive
– electrical equalising currents, cathodic corrosion protection, atmosphere occurring.
– static electricity,
(2) Avoid use in potentially explosive atmospheres:
– Lightning strike,
– in zones 2 and 22: ignition sources that can occur continuously or frequently,
– electromagnetic fields in the frequency range from 9 x 103 Hz to 3 x
1011
Hz, – in zones 1 and 21: in addition to the ignition sources specified for zones
2 and 22, ignition sources that may occur occasionally, e.g. in the event
– electromagnetic radiation in the range of frequencies from 3 x 1011 Hz of foreseeable faults in work equipment, and
to 3 x 1015 Hz or wavelengths from 1,000 µm to 0.1 µm (optical
spectral range), – in zones 0 and 20: in addition to the ignition sources specified for zones
1 and 21, also ignition sources that may occur infrequently.
– ionising radiation,
– Ultrasound, Note: The frequency of occurrence of ignition sources is measured by the
duration of the process or work step/procedure.
– adiabatic compression, shock waves, flowing gases,
– chemical reactions. (3) Unless otherwise specified in the explosion protection document based on
(2) Deposits of combustible dust are of particular importance when the results of the risk assessment, equipment and protective systems in
assessing possible ignition sources. The corresponding special measures potentially explosive atmospheres must be selected in accordance with
can be found in sections 5.2.6 to 5.2.8 and 5.14.2. the categories specified in the Explosion Protection Ordinance (11th
GPSGV) in conjunction with Directive 94/9/EC (see Table 1).

T table 1: Assignment of appliance category - zones in accordance with paragraph 2 (6) If several types of flammable gases, vapours, mists or dusts (e.g. also hybrid
mixtures) can occur simultaneously within a potentially explosive
in zone Category used designed for atmosphere, the protective measures to prevent ignition sources must be
Gas/air mixture or vapour/air adapted to the ignition sensitivity of the respective composition.
0 II 1 G
mixture or mist
Note: If nothing is known about the ignition sensitivity of this composition, it
Gas/air mixture or vapour/air is considered sufficiently safe to design the protective measures to avoid
1 II 1 G or 2 G
mixture or mist ignition sources on the most ignition-sensitive individual component.
Gas/air mixture or vapour/air
2 II 1 G or 2 G or 3 G Remark:
mixture or mist
Flammable gases and vapours are divided into explosion groups II A, II B
20 II 1 D Dust/air mixture and II C according to their flame transmission distance or their minimum
21 II 1 D or 2 D Dust/air mixture ignition energy. The explosion groups also characterise the ignition
sensitivity for electrical and electrostatic discharges and for mechanical
22 II 1 D or 2 D or 3 D Dust/air mixture
ignition sources.
G = Gases, vapours or mistD = Dust or dust layers
(7) To avoid some of the ignition hazards described below with gases and
vapours, the use of gas warning devices or suitable process control
(4) The area of application specified by the appliance manufacturer in the systems (PCS) is also possible. If the alarm and switching point are
operating instructions for the appliances (e.g. with regard to ambient selected accordingly, measures in accordance with the operating
temperature, pressure, temperature class, explosion group, etc.) must instructions may initially be sufficient before automatic switching. For
be observed. the use of gas warning devices, the measures described in section TRBS
(5) If it is necessary to use work equipment that could act as a source of 2152 Part 2 Number
ignition in potentially explosive atmospheres (e.g. motor vehicles, welding 2.5.1 (except paragraph 2 numbers 5 and 6) as well as test, operation
equipment, measuring devices), it must be ensured that explosive and maintenance conditions must be fulfilled.
atmospheres in hazardous quantities cannot occur during use. In the
case of gases and vapours, this can be monitored using measuring
equipment such as gas detectors.

Note: PCT devices are safety, monitoring and control devices within the Remark 2:
meaning of Directive 94/9/EC, provided they are used for the safe A higher wall temperature is required to ignite explosive atmospheres on
operation of equipment and protective systems with a view to hot convex bodies; it increases, for example, on spheres or straight pipes
preventing ignition hazards. with decreasing diameter. The standardised ignition temperature is a safe
limit temperature for ignition on convex bodies in most practical cases.
(8) Electrical products for personal use, e.g. wristwatches, hearing aids, long-
term ECG sensors, must also be considered with regard to their Remark 3:
ignition hazard. When an explosive atmosphere flows past heated surfaces, a higher wall
temperature may be required for ignition.
5.2 Hot surfaces
The aim of the protective measures is to prevent the ignition of explosive (3) In addition to operationally hot surfaces such as radiators, drying cabinets
atmospheres caused by a hot surface acting as an ignition source. and others, mechanical processes caused by friction or chip removal (e.g.
drilling) can also lead to dangerous temperatures in the area of the exposed
5.2.1 Notes for the risk assessment surfaces. Hot surfaces can therefore also occur on work equipment that
(1) If an explosive atmosphere comes into contact with hot surfaces (hot converts mechanical energy into heat loss, i.e. all types of friction
pipes, boilers, etc.), ignition may occur. clutches and mechanically acting brakes (e.g. on vehicles and centre joints).
Furthermore, rotating parts in bearings, shaft bushings, stuffing boxes, etc.
(2) The assessment is based on the standardised ignition temperature of the can therefore become sources of ignition if lubrication is inadequate. If parts
substances forming the explosive atmosphere. However, it must be taken rotate in narrow housings, friction processes can also occur due to the
into account that the ignitability of a hot surface depends, among other penetration of foreign bodies into the gap between the rotating part and
things, on the type and concentration of the respective substance in a the housing or due to axial misalignments, which may cause very high
mixture with air, on the size and shape of the hot body and on the wall surface temperatures within a short time.
material.
Remark 1: (4) Electromagnetic radiation can lead to a dangerous increase in temperature,
Explosive atmospheres can be ignited, for example, inside larger heated e.g. of a workpiece or reaction product (e.g. with radiation dryers) due
rooms by hot walls with a significantly lower temperature than the to absorption, see also sections 5.9 and 5.10.
standard ignition temperature of the fuel.

5.2.2 General protective measures for all zones The maximum surface temperature is already taken into account, so that
(1) Depending on the zone in question, the maximum surface temperature they may be used in the corresponding potentially explosive atmospheres
of system parts that are in contact with an explosive atmosphere must without further safety distances. In contrast, devices in categories 1D to
not fall below a certain specified safety distance (see 5.2.3 to 5.2.8) from 3D are labelled with the maximum surface temperature without taking a
the limit temperature (or ignition temperature) associated with the safety distance into account. For compliance with the safety distance in
temperature class. this case, see sections 5.2.6 to 5.2.8.
(2) The temperature limits specified in 5.2.3 to 5.2.8 may be exceeded in
(5) Flammable gases and vapours are divided into temperature classes
special cases (e.g. in the case of very small hot surfaces) if there is reliable
according to their ignition temperature. For explosive atmospheres
evidence that no ignition is to be expected.
consisting of substances of one temperature class, the lower value of the
(3) If the risk assessment shows that ignition of the atmosphere cannot be ignition temperature of their temperature class is generally the basis for
ruled out below the standardised ignition temperature (e.g. in large determining the maximum permissible surface temperatures (see Table
concave structures such as containers with a uniform surface 2).
temperature), the permissible temperatures of the surfaces that may
come into contact with an explosive atmosphere must be specified on a
case-by-case basis. Table 2: Relationship between temperature class and ignition temperature
(4) For devices and, where applicable, components and protective Temperature class Ignition temperature (TZ) in °C
systems in accordance with the Explosion Protection Ordinance
T1 > 450
(11th GPSGV) in conjunction with Directive 94/9/EC, the maximum TC
surface temperature is determined by the manufacturer in his ignition T2 300 < TZ ≤ 450
risk assessment. If devices, components or protective systems of T3 200 < TZ ≤ 300
categories 1G to 3G according to the Explosion Protection Ordinance (11th
GPSGV) are labelled with the temperature class, the lowest permissible T4 135 < TZ ≤ 200
ignition temperature of an explosive atmosphere or the explosive T5 100 < TZ ≤ 135
atmospheres for which they are suitable, safety precautions must be taken.
T6 85 < TZ ≤ 100

5.2.3 Protective measures for zone 0 5.2.6 Protective measures for zone 20
(1) In Zone 0, surfaces must not become dangerously hot - even in the (1) In zone 20, the temperature of all surfaces that may come into contact with
event of rare operating faults. For this purpose, effective monitoring and dust clouds must be sufficiently low. This is fulfilled if 2/3 of the minimum
limitation must ensure and verify by checking the effectiveness that the ignition temperature of the dust cloud in question is not exceeded, even in
temperatures of surfaces that may come into contact with an explosive the event of infrequent operating faults.
atmosphere do not exceed 80 % of the ignition temperature or the lower (2) In addition, the temperature of surfaces on which dust can be deposited
value of the ignition temperature associated with the temperature class. must be lower by a safety margin than the minimum ignition temperature
(2) Paragraph 1 sentence 1 is deemed to be fulfilled, for example, if the of the thickest layer that can form from the dust in question; this must
permissible temperature is safely maintained by the saturated vapour also be ensured in the event of infrequently occurring malfunctions. If
pressure of a liquid (steam heating). the layer thickness is unknown, the thickest foreseeable layer must be
assumed. Unless otherwise specified in the risk assessment, a safety
5.2.4 Protective measures for zone 1
distance of 75 K between the minimum ignition temperature of a dust
(1) In zone 1, surface temperatures must be limited so that they can only
layer and the surface temperature of the work equipment is sufficient.
rarely exceed 80 % of the ignition temperature.
Note 1: With thicker layers of dust, a greater insulating effect occurs,
(2) A permanent exceeding of the surface temperature according to paragraph
which leads to higher surface temperatures of the work equipment.
1 up to the ignition temperature is permissible if the surface temperature
remains safely limited under the operating conditions. Note 2: The distance of 75 K only applies to dust thicknesses of max. 5 mm.
5.2.5 Protective measures for zone 2

(1) In zone 2, the temperature of surfaces must not exceed the ignition 5.2.7 Protective measures for zone 21
temperature during normal operation. (1) In zone 21, the temperature of all surfaces that may come into contact with
(2) Work equipment with surface temperatures above the ignition temperature dust clouds must be sufficiently low. This is fulfilled if 2/3 of the minimum
is permitted in special cases, particularly in outdoor installations, if ignition temperature in °C of the dust cloud in question is not exceeded,
adequate safety is ensured by the operating conditions (e.g. increased even in the event of malfunctions.
flow of the explosive atmosphere due to wind movement) (see section (2) In addition, the temperature of surfaces on which dust can be
5.2.1 (2)). deposited must be lower by a safety margin than the minimum ignition
temperature of the thickest layer resulting from the dust in question.

dust can form; this must also be ensured in the event of malfunctions. 5.3 Flames and hot gases
Unless otherwise specified in the risk assessment, a safety distance of 75 Avoid hot gases, which can be an effective source of ignition, and flames.
K between the minimum ignition temperature of a dust layer and the 5.3.1 Notes for the risk assessment
surface temperature of the work equipment is sufficient. (1) Flames are the result of exothermic chemical reactions that take place
Note 1: With thicker layers of dust, a greater insulating effect occurs, which rapidly at temperatures of around 1000 °C and above. Both the flames
leads to higher surface temperatures of the work equipment. themselves and the hot reaction products can ignite explosive
Note 2: The distance of 75 K only applies to dust thicknesses of max. 5 atmospheres.
mm. (2) If there is an explosive atmosphere both inside and outside a piece of
equipment or in neighbouring parts of the system, the flame can be
5.2.8 Protective measures for zone 22 ignited in one of the areas through openings, such as a vent.
(1) In zone 22, the temperature of surfaces that may come into contact with B. vent lines can be transferred to the other area. Preventing a flame
dust clouds must be sufficiently low during normal operation. This is transmission requires special constructive protective measures (see
fulfilled if 2/3 of the minimum ignition temperature is not exceeded. TRBS 2152 Part 4).
(2) In addition, the temperature of surfaces on which dust can be Note: Particular care must be taken in the presence of sublimable substances,
deposited must be a safety distance lower than the minimum ignition e.g. sulphur (sublimation can cause re-ignition, e . g . behind a flame
temperature of the thickest layer that can form from the dust in question. arrester).
Unless otherwise specified in the risk assessment, a safety distance of 75 5.3.2 Protective measures for zones 0 and 20
K between the minimum ignition temperature of a dust layer and the (1) Equipment with flames must not be used in zones 0 and 20. Gases from
surface temperature of the work equipment is sufficient. flame reactions, e.g. exhaust gases for the purpose of inertisation and
Note 1: Thick layers of dust can lead to an increase in surface other heated gases, may only be discharged into zones 0 and 20 if
temperature due to their thermal insulation effect. special protective measures to be specified for the individual case are
Note 2: The distance of 75 K only applies to dust thicknesses of max. 5 applied.
mm. Note: In addition to limiting the temperature, these special protective
measures also relate to the separation of ignitable particles and the
prevention of gas backflow and flame propagation.

5.3.3 Protective measures for zones 1 and 2 as well as 21 and and with regard to flame transmission to TRBS 2152 Part 4.
22
(1) In zones 1 and 2 as well as 21 and 22, devices with flames are only
permitted if the flames are safely contained and the safety measures
specified in number
5.2 must not be exceeded on the outer surfaces of the system components.
In the case of work equipment with enclosed flames (e.g. flame ionisation
detectors or special heating systems), it must also be ensured that the
enclosure is sufficiently resistant to the effects of flames and reliably
prevents the penetration of flames into the danger zone.
The air required for combustion processes may only be extracted from
zone 1 or 2 or 21 or 22 if the hazards caused by the extraction of an
explosive atmosphere (e.g. a flashback into the potentially explosive
atmosphere) are avoided by appropriate protective measures (see TRBS
2152 Part 4).
(2) Hot gases may be introduced into zones 1 and 2 as well as 21 and 22 if
they cannot ignite the explosive atmosphere at the point of entry. This is
ensured, for example, if the temperature of the hot gases does not exceed
the ignition temperature of the explosive atmosphere. Deposited dusts
must also not be ignited. The minimum ignition temperatures or the
glow temperatures of the dusts can serve as a criterion for this
requirement.
Note: With regard to protective measures for glowing solid particles (flying
sparks), reference is made to section 5.4 (mechanically generated sparks)

5.4 Mechanically generated sparks
Mechanically generated sparks, which can form an effective ignition
source, must be avoided.
5.4.1 Notes for the risk assessment
(1) Friction, impact and removal processes, e.g. during grinding, can
separate particles from solid materials, which take on an increased
temperature due to the energy applied during the separation process. If
the particles are made of oxidisable materials, such as iron or steel,
they can undergo an oxidation process during which they can heat
up further. These particles (sparks) can ignite combustible gases and
vapours as well as dust/air mixtures (especially metal dust/air
mixtures). Furthermore, sparks in deposited dust can create glowing
pockets, which can then become a source of ignition for an
explosive atmosphere.
(2) The penetration of foreign materials, e.g. stones or pieces of metal, into
system components must be taken into account as a cause of
sparks.
(3) Friction, even between similar ferrous metals and between certain
ceramic materials, can cause localised heating and sparks similar to
grinding sparks. This can ignite an explosive atmosphere.
(4) A single spark generated by simple tools (e.g. spanners, pliers,
screwdrivers) and simple devices (e.g. conductors) only rarely leads to
the ignition of an explosive atmosphere. However, the possibility of
ignition must always be assumed in explosive atmospheres
consisting of one or more of the gases of explosion group IIC
(acetylene, carbon disulphide, hydrogen) as well as hydrogen sulphide,
carbon monoxide and ethylene oxide.

(5) Friction, impact and abrasion processes involving rust and light metals 5.4.2 Protective measures for all zones
(e.g. aluminium and magnesium) and their alloys can trigger highly (1) If the limit values specified in 5.4.1 (9) may be exceeded or the exact
exothermic, spark-forming reactions that can ignite explosive composition of the aluminium coating is not known, care must be taken to
atmospheres. ensure that an explosive atmosphere in hazardous quantities is not
(6) Ignitable sparks can also be produced when striking or rubbing titanium present or cannot arise during work processes with steel objects.
or zirconium against sufficiently hard materials, even in the absence of (2) Examples of the use of tools in potentially explosive atmospheres are
rust. listed in the appendix.
(7) Welding sparks produced during welding and cutting are sparks with a very
large surface area and are particularly effective ignition sources. Similar 5.4.3 Protective measures for zones 0 and 20
sparks are also produced during grinding or cutting. It should be noted
(1) In zones 0 and 20, no ignitable friction, impact or grinding sparks may
that these ignitable sparks can also be carried over long distances into
occur, even in the event of rare operating faults.
potentially explosive atmospheres.
(2) In zones 0 and 20, frictional processes between aluminium, magnesium,
(8) There is an increased risk of ignition in all zones if an aluminothermic
zirconium and titanium (except alloys with less than a total of 10 % by mass
reaction (thermite reaction) is to be expected. If one strikes
of the metals mentioned and no more than a total of 7.5 % by mass of Mg,
z. For example, sparks with a high ignition effect are easily formed on a
Zr, Ti) and iron or steel (except stainless steel, if the presence of rust
rusty steel surface covered with aluminium foil, painted with aluminium
particles can be excluded) must be excluded. Friction and impact
paint or covered with aluminium abrasion or aluminium chips. Sparks
processes between titanium or zirconium and any hard material must
are also produced when rusty parts strike aluminium components or rust
be avoided.
film lies on such components and impacts are directed at these
points.
(9) If aluminium paints or aluminium coatings are used to improve the 5.4.4 Protective measures for zones 1 and 21
electrostatic discharge capacity of floors, the formation of ignitable sparks In zones 1 and 21, the requirements for zones 0 and 20 must be met
is not to be assumed, provided that the aluminium content of the paints wherever possible. Materials must not contain more than 7.5 %
and coatings in an aged, dry state is less than 25 % by mass. Depending on magnesium by mass. However, if work processes are required in which
the various binders and fillers, this limit can also be extended up to a ignitable friction, impact or grinding sparks may occur, sparks must be
proportion of 45% by mass. avoided or shielded by suitable measures.

This is deemed to be fulfilled, for example, if the following measures are 5.5.1 Notes for the risk assessment
complied with: In electrical installations - even at low voltages - electrical sparks (e.g. when
– Water cooling at the grinding point, opening and closing electrical circuits and in the event of equalising
– Separation of ignitable particles in exhaust gases, e.g. in water systems. currents (see section 5.6)) and hot surfaces (see section 5.2) can occur as
effective ignition sources.
Note: The occurrence of ignitable friction and impact sparks can be limited by
Note: The use of safety extra-low voltage (e.g. 42 volts) is not an explosion
selecting favourable material combinations. For work equipment with moving
protection measure, as ignition of an explosive atmosphere is possible even
parts, the material combination of light metal and steel (except stainless
at lower voltages.
steel) should always be avoided at possible friction, impact or grinding
points.
5.5.2 General protective measures
5.4.5 Protective measures for zones 2 and 22 5.5.2.1 General requirements

In Zones 2 and 22, it is generally sufficient to implement the protective Section 5.5.2.1 does not apply to conduit systems; requirements for the
measures described for Zones 1 and 21 only against ignitable sparks that are assembly, installation and operation of these systems must be specified on
constantly or frequently expected. a case-by-case basis.
Note: Portable equipment and test equipment are also work equipment or
systems requiring monitoring within the meaning of the BetrSichV. This also
5.5 Electrical systems includes plug connections and couplings.
Ignition sources from electrical systems must be avoided.
Note: Electrical installations within the meaning of this TRBS are (1) Electrical installations in potentially explosive atmospheres must also
individually installed or interconnected devices, safety, control and fulfil the requirements for electrical installations in non-hazardous areas.
regulation equipment and their connection devices that generate, (2) Electrical equipment and cable connections in potentially explosive
convert, store, transmit, distribute, measure, control or consume electrical atmospheres and equipment used for their safe operation must be
energy. This may also include process control and information technology selected, assembled and installed in accordance with sections 5.5.2.2
equipment. The following requirements assume that the basic to 5.5.2.6 and the additional requirements for the respective type of
electrotechnical and safety requirements for such systems and equipment protection (sections 5.5.3 to 5.5.6).
are met.
(3) Cable and wire entries must be suitable for the respective type of 5.5.2.3.2 Danger from bodies of electrical equipment and other
protection. conductive parts
(4) Electrical systems must be designed and electrical equipment must be (1) Operational and external currents must be prevented on structural
assembled and installed in such a way that easy access for testing and parts and enclosures by taking suitable measures to avoid potential
maintenance is guaranteed. increases. This is deemed to be fulfilled if, for example
– if a TN system is available, this is only used as a TN-S system,
(5) Electrical cables and lines must be laid separately from pipework, with
– if a TT system is present in zone 1 or 21, it is protected by a residual
the exception of electrical trace heating systems.
current device,
5.5.2.2 Selection of electrical equipment – if an IT system is present, its isolation is monitored.
Electrical equipment must be selected and installed in such a way that it is (2) When using protective separation, only one piece of electrical equipment
protected against external influences that could adversely affect its required may be connected to an isolating transformer.
freedom from ignition sources (e.g. chemical, mechanical, thermal and 5.5.2.3.3 Potential equalisation protective measure
electrical/electromagnetic effects, vibration or moisture, accumulation of All conductive system components must be included in the potential
electrically conductive dusts). equalisation if a dangerous potential shift or carry-over is to be expected.
Note: To prevent sparks and overloads, precautions must be taken to Ensure that the equipotential bonding equipment is sufficiently
prevent foreign objects from falling into the ventilation openings of dimensioned with regard to electrical and mechanical properties. As a rule,
rotating electrical machines in a vertical arrangement. conductive bodies of electrical equipment must be included in the
equipotential bonding. Connections for potential equalisation must be
secured against automatic loosening.
5.5.2.3 Protection against the occurrence of dangerous
5.5.2.3.4 Electromagnetic fields
(ignitable) sparks
When designing electrical systems, the effects of electromagnetic fields must
5.5.2.3.1 Hazard due to active parts be limited to a safe level.
In order to avoid the formation of sparks that could ignite an explosive 5.5.2.3.5 Accumulation of electrically conductive dusts
atmosphere, the possible unintentional touching of bare active parts - with Dangerous accumulations of electrically conductive dust in or on electrical
the exception of parts of intrinsically safe circuits - must be prevented. equipment must be avoided, e.g. by increasing the dust-tightness of the
- be prevented. equipment.

5.5.2.4 Electrical protective measures 5.5.2.6 Cables and wires

(1) Electrical equipment, cables and lines as well as their connections must
be selected and installed in such a way that electrical, mechanical, 5.5.2.6.1 General information
thermal and chemical stresses do not lead to an ignition hazard. Suitable measures must be taken to prevent ignition sources from entering
potentially explosive atmospheres via cable and pipe fires.
(2) Rotating electrical machines must be protected against overload even if an
outer conductor fails, with the exception of motors that can carry the 5.5.2.6.2 Aluminium ladder
starting current at the rated voltage and rated frequency, or generators When using aluminium conductors, suitable clamps must be used.
that can carry the short-circuit current continuously without heating up
inadmissibly. 5.5.2.6.3 Conductors
Conductors may only be used as live conductors in control panels or
(3) Transformers must be protected against overload if they cannot -enclosures. This also applies to cables in intrinsically safe circuits.
continuously carry the secondary short-circuit current at the primary rated
voltage and rated frequency without inadmissible heating or if no 5.5.2.6.4 Connections
overload is to be expected from the connected loads. The connection of cables and lines must fulfil the requirements of the
respective type of protection. The cold flow properties of the cables must be
(4) Overcurrent and earth fault protection devices must be designed in
taken into account.
such a way that automatic restarting is prevented before the fault that
caused the switch-off has been eliminated. 5.5.2.6.5 Unused openings
Unused openings for cable and wire entries must be sealed with closing
5.5.2.5 Unlock elements that are suitable for the type of protection in question.
(1) Suitable disconnection devices must be provided for each circuit or 5.5.2.6.6 Connection points
circuit group, which cover all active conductors including neutral Cables and lines in potentially explosive areas must be laid without
conductors. interruption. If this is not possible, the connections must be arranged in
(2) An identification mark must be affixed directly to or next to each enclosures with a type of protection corresponding to the zone or they must be
disconnecting device to allow clear assignment of the associated circuit or secured with suitable sleeves.
circuit group.

5.5.2.6.7 Sockets in potentially explosive dust atmospheres 5.5.3 Additional requirements when using type of
(1) In order to minimise the ingress of dust in the event that a dust protection "d" - flameproof enclosure
protection cap is inadvertently left off, sockets must be arranged so 5.5.3.1 Protection of flameproof gaps
that the opening faces downwards.
With type of protection "flameproof enclosure", gaps must be protected
(2) In the case of socket outlets, an ignition spark must be prevented against corrosion and the ingress of water.
during the closing or disconnection of the plug connection, e.g. by
5.5.3.2 Motors that are operated with variable voltage
mechanical or electrical interlocks.
and frequency
5.5.2.6.8 Protection of multi-wire conductor ends If motors in the "flameproof enclosure" type of protection are operated with
Multi-stranded or finely stranded conductor ends must be protected against variable frequency and voltage, the relevant surfaces must be monitored, e.g.
splicing. Soldering the conductor ends for direct connection is not with temperature sensors, so that a protective device switches off the motor
permitted. before the critical surface temperature is reached.
5.5.2.6.9 Unused core conductors Alternatively, the motor with the intended protective devices may also have
Each unused core conductor in multi-core cables in potentially explosive been subjected to a conformity assessment procedure as a whole in accordance
areas must either be connected to earth at the end or adequately insulated with the Explosion Protection Ordinance (11th GPSGV) in conjunction with
using suitable terminating agents. Directive 94/9/EC.
5.5.2.6.10 Surface temperature of cables and wires Note: Possible overvoltage peaks - triggered by the inverter
For cables and lines, the maximum permissible surface temperature of the - must be observed.
system in accordance with 5.2 must be observed. 5.5.4 Additional requirements when using type of
protection "e" - increased safety - and "tD" - dustproof
5.5.2.6.11 Connection of the armouring and shielding of cables and
enclosure
lines
Motors with "increased safety" and "dustproof enclosure" types of
Reinforcements and shields must be integrated into the potential
protection must be protected against overload in such a way that the
equalisation.
specified temperature class is not exceeded even in the event of hard
5.5.2.6.12 Cables and wires in Zone 0 braking. For motors in delta connection, the failure of an outer conductor
Cables and lines must not be routed through zone 0. If this is not possible, must also be controlled. If a soft start is used, the necessary measures
measures must be defined on a case-by-case basis. must be determined on a case-by-case basis.

Note: For motors with ignition protection type "increased safety" or "dust-proof".

safe enclosure" with variable frequency and voltage, the absence of 5.5.5.2 Cables and wires
ignition sources for the motor with the intended protective devices must be 5.5.5.2.1 General information
considered as a whole, usually by means of a conformity assessment (1) Only insulated cables and lines with a test voltage of at least AC 500 V or
procedure in accordance with the Explosion Protection Ordinance (11th DC 750 V between conductor to earth, conductor to shield and shield to
GPSGV) in conjunction with Directive 94/9/EC. earth may be used in intrinsically safe circuits.
(2) The diameter of individual conductors in the potentially explosive
5.5.5 Additional requirements when using type of
atmosphere must not be less than 0.1 mm. This also applies to the
protection "i" - intrinsic safety - in systems for zones 1,
individual wires of fine-stranded conductors.
21, 2 and 22
(3) Intrinsically safe circuits must be set up in such a way that safe isolation
Note: Installation requirements for zones 1 and 2 can also be applied to
from other circuits is ensured even under assumed fault conditions.
zones 21 and 22 without further ado when using devices with protection
type "iD". 5.5.5.2.2 Installation of cables and lines
5.5.5.1 Operating resources (1) Systems with intrinsically safe circuits must be installed in such a way that
(1) For associated operating equipment, cables and lines connected to an their intrinsic safety is not impaired by external electric or magnetic
intrinsically safe circuit that are installed outside potentially explosive fields.
atmospheres, the same requirements apply with regard to safe (2) In deviation from 5.5.2.6.9, each unused core of a multi-core cable
electrical installation as for the potentially explosive atmosphere. must be
(2) The operation of simple electrical equipment is permitted if it fulfils – be sufficiently insulated at both ends either to earth or from the
the requirements of ignition protection types "intrinsic safety i" or other cores by the use of suitable terminations or
"intrinsic safety iD". – if other circuits in the multi-core cable have an earth connection (e.g.
(3) Electrical equipment that is connected to non-intrinsically safe via associated equipment), be connected to the earth point used for
connection terminals of an associated piece of equipment must not be earthing all intrinsically safe circuits in the same cable. They must be
supplied with a supply voltage that is greater than the voltage Um adequately insulated from earth and from each other at the other end
specified on the rating plate of the associated piece of equipment. The by suitable terminations.
maximum expected (prospective) short-circuit current of the supply must
not exceed 1,500 A at max. AC 250 V.

(3) Conductors of intrinsically safe and non-intrinsically safe circuits must 5.5.5.3 Connection of intrinsically safe circuits
not be routed in the same cable. In electrical systems with intrinsically safe circuits, the terminal points must
be reliably separated from the non-intrinsically safe circuits (e.g. by a
5.5.5.2.3 Earthing of conductive shields separating plate with a minimum thread size of 50 mm or a distance of at
If shielding is required in the cable or line, the shield must be earthed in least 50 mm). The terminals of intrinsically safe circuits must be labelled as
such a way that no ignition source can arise. Particular care must be taken such. For intrinsically safe terminal points, the minimum distance between
to ensure that the current carrying capacity of the shielding cannot be the bare conductive parts of the external conductors connected to the
exceeded. terminals and earthed or other non-voltage-carrying conductive parts must
5.5.5.2.4 Labelling of cables and wires be 3 mm. The distances between bare conductive parts of connection
Cables and wires for intrinsically safe circuits must be clearly labelled. If sheaths terminals of separate intrinsically safe circuits must be at least 6 mm
or sheathing are identified by a colour, the colour used must be light blue. between the bare conductive parts of connected external conductors.
5.5.5.2.5 Multi-core cables and lines with more than one Connectors for connecting external intrinsically safe circuits must be separate
intrinsically safe circuit from and indistinguishable from those used for non-intrinsically safe circuits.
Several intrinsically safe circuits may be laid together in multi-core cables if
mutual harmful interference is prevented in such a way that intrinsic safety 5.5.5.4 Earthing intrinsically safe circuits
is maintained in all intrinsically safe circuits. In addition to 5.5.5.2.1, multi- If intrinsically safe circuits are to be earthed, they must be connected
core cables and lines without conductive shields for the individual circuits must to an equipotential bonding system that extends over the entire range of
be of a type that can withstand an insulation test of at least AC 1,000 V the intrinsically safe circuit. Multiple earthing of an intrinsically safe circuit
(effective value) or DC 1,500 V, applied between a bundle containing one half is only permitted under special conditions.
of the interconnected cable cores and another bundle containing the other half
of the interconnected cable cores.
5.5.5.5 Proof of intrinsic safety
5.5.5.2.6 Fault considerations for multi-core cables and lines Multi-core
cables must be assessed with regard to the possibility of faulty (1) If there is no system certificate stating the parameters for the complete
interconnections depending on the design of the cables or the intrinsically safe intrinsically safe circuit, the interconnection of the devices, including
circuits they contain.

Cables and lines must be assessed to determine whether the (4) The cable or line between the intrinsically safe electrical equipment in
requirements of the "intrinsic safety" type of protection are met. Zone 0 and the surge protective device must be installed in such a way that
Proceed accordingly for two or more interconnected, intrinsically safe it is protected against the effects of lightning.
circuits. Note: The above measures for Zone 0 can also be applied to Zone 20
Note: The maximum permissible surface temperature according to 5.2 must under certain conditions.
not be exceeded.
5.6 Electrical equalising currents, cathodic corrosion
(2) Proof of intrinsic safety must be documented. protection
Ignitable electrical sparks and ignitable heating of current paths due to
electrical equalising currents or cathodic corrosion protection must be avoided
5.5.5.6 Cable and wire entries
in accordance with the following requirements.
Terminal boxes for ignition protection type "i" must comply with
protection class IP 54, in dry and clean rooms with protection class IP 20. 5.6.1 Notes for the risk assessment
(1) Equalising currents (also known as stray or leakage currents) can flow
temporarily or continuously in electrical systems or other conductive
5.5.6 Additional requirements when using type of system components:
protection "i" - intrinsic safety - in systems for zones 0 – as return currents to power generation systems (especially in the area
and 20 of electric railways, large welding systems and systems with cathodic
(1) Intrinsically safe circuits must be installed in accordance with 5.5.5; the corrosion protection), if, for example, electrically conductive system
following special requirements apply as an exception or supplement. components laid in the ground such as rails, pipes and cable sheaths
reduce the resistance of this return current path,
(2) If earthing of the circuit is required for functional reasons, the earth
connection must be connected outside Zone 0, but as close as possible to – as a result of body or earth faults in electrical installations,
the Zone 0 equipment. Multiple earthing of the circuit is not permitted. – as a result of induction (e.g. in the vicinity of electrical installations
(3) If overvoltages are to be expected in Zone 0, suitable protective with high currents or high frequencies) (see section 5.9) and
measures must be taken. – as a result of lightning (see section 5.8).

(2) If such system parts are disconnected, connected or bridged, explosive 5.6.2.2 Protective measures for zones 2 and 22
atmospheres can be ignited by electrical sparks, even with small potential In zones 2 and 22, additional equipotential bonding can generally be
differences. Furthermore, ignition is possible due to heating of these dispensed with unless arcs or sparks caused by equalising currents occur
current paths (see section 5.2). during normal operation.
5.6.3 Protective measures for cathodically protected systems

5.6.2 Protective measures for equalising currents
Cathodically protected metal parts located in potentially explosive
5.6.2.1 Protective measures for all zones
atmospheres are active external conductive parts that cannot normally be
(1) All conductive system components must be included in the potential included in the potential equalisation (exception: local cathodic corrosion
equalisation if a dangerous potential shift is to be expected. This also protection systems LKS). They must be permanently insulated against
includes mobile system components. accidental bridging. Insulating couplings and insulating flanges must be
(2) The potential equalisation conductor must have a sufficient cross- arranged outside the potentially explosive area wherever possible. If this is
section and be laid so that it is protected against mechanical loads. not possible, they must be protected against arcing and flashover by
(3) Before opening and closing the connections of conductive system parts, e.g. explosion-protected spark gaps with a suitable response voltage, except in
when removing fittings and pipe parts, bridging with connecting lines with a zones 2 and 22, if dangerous overvoltages are to be expected.
sufficient cross-section is required.
5.6.3.1 Protective measures for zones 0, 20, 1and 21
(4) Connections to portable system components must either be
(1) If electrical equipment inside cathodically protected containers (tanks,
– in a non-hazardous area or
pipelines, etc.) with external anodes (CP) is provided with connecting cables
– with a connection that meets the zoning requirements of the place of from the outside, unearthed equipotential bonding must be carried out
use between all cables and against the cathodically protected wall via
or lightning current-carrying surge protective devices in the immediate
– according to a documented procedure that reduces the risk of vicinity of the zone, but if possible outside it.
sparking to an acceptable level, The overvoltage protection must be matched to the insulation strength of
can be produced. the cable and the devices in the potentially explosive area. The installation
(5) Potential equalisation connections must be secured against self- site must be protected against direct lightning strikes.
loosening.

The unearthed potential equalisation conductor must have a sufficient 5.7 Static electricity
cross-section and be laid so that it is protected against damage. Discharges of static electricity must be avoided if they can be effective
The dangerous coupling of electric, magnetic or electromagnetic fields ignition sources. TRBS 2153 "Avoidance of ignition hazards due to
must be prevented. electrostatic charges" applies to the assessment and avoidance of ignition
(2) If conductive system components are brought into the zones, e.g. hazards due to electrostatic charges in potentially explosive atmospheres and
ventilation and suction pipes in tanks, they must be included in the to the selection and implementation of protective measures to avoid these
potential equalisation beforehand. hazards.
(3) In zones 0 and 20, no internal cathodic protection (ICP) may be provided
for metal parts. By way of derogation from sentence 1, ICS is permissible
if measures are taken to ensure that
5.8 Lightning strike
– the anodes are kept permanently under liquid during protection
A lightning strike can ignite an explosive atmosphere both through a
system operation or
direct strike and through the effects of a strike at a greater distance.
– If the liquid level falls below a minimum level, the ICS system is
switched off and the potential between the anodes and the
protected object is equalised. 5.8.1 Notes for the risk assessment
Note: Depending on the electrolyte, water may be released. (1) If a lightning strike occurs in an explosive atmosphere, the atmosphere
is directly ignited by the lightning. There is also a risk of ignition due to
Remark: strong heating of the lightning discharge paths.
IKS is used to protect internal surfaces (e.g. containers) and consists of a (2) Strong currents flow from lightning strikes, which can trigger ignitable
suitable current source and an anode that is insulated in the electrolyte sparks and spray fires even at a greater distance from the point of
inside. The cathode is formed by the surface to be protected. strike. The effects of lightning strikes can also occur at a greater
distance from the point of strike as a result of overvoltages.
5.6.3.2 Protective measures for zones 2 and 22
In zones 2 and 22, additional protective measures of section (3) If lightning strikes outside the zones, repercussions can occur in the areas
5.6.3.1 can be waived. at risk of explosion.

5.8.2 Protective measures for all zones The risk of explosion is minimised if surge arresters are installed in
(1) Lightning strikes in potentially explosive atmospheres must be suitable locations, i.e. outside potentially explosive atmospheres.
prevented, otherwise the potentially explosive atmosphere will ignite. (2) Connections and joints with pipelines must be designed in such a way that
(2) In addition, the discharge paths of the flash must be designed in no sparks or impermissibly high temperatures are generated when
such a way that heating or ignitable sparks or spray sparks cannot lightning current passes through. Suitable connections to pipelines are
become a source of ignition of the potentially explosive atmosphere. welded lugs or bolts or threaded holes in the flanges to accommodate
screws. These connection points must be dimensioned so that they are
(3) The damaging effects on potentially explosive atmospheres, even from
capable of carrying lightning currents.
lightning strikes that occur at a greater distance, must be avoided.
(4) Systems must be protected by suitable lightning protection measures if
dangers from lightning strikes are to be expected. The measures must
5.8.4 Protective measures for zones 1 and 21
be taken at least in such a way that a lightning sphere with a radius of 30
metres can be controlled. Equipotential bonding as well as connections and joints with metal system
components must be designed in such a way that no sparks or impermissibly
(5) The effect or configuration of lightning protection measures must not
high temperatures are generated when lightning current passes through.
impair other protective measures, e.g. cathodic corrosion protection.
Suitable connections to pipework are welded lugs or bolts or threaded
(6) In addition to electrical cables, connecting cables between metal parts and holes in the flanges to accommodate screws.
earth electrodes also include system parts made of metal that are safely
connected in an electrically conductive manner.
5.8.5 Protective measures for zones 2 and 22
5.8.3 Protective measures for zones 0 and 20 Lightning protection systems as measures for zones 2 and 22 are not
(1) Harmful effects on zones 0 and 20 from lightning striking outside zones 0 required, as the probability of a lightning strike coinciding with the
and 20 must be prevented. This applies, for example, to occurrence of a hazardous explosive atmosphere can be regarded as
extremely low. If necessary, organisational measures (e.g. during
maintenance work) can be applied.

5.9 Electromagnetic fields in the frequency range from 9 x 103 (2) If the radiation-generating source (transmitter/antenna) is located
Hz to 3 x 1011 Hz outside the potentially explosive area, the formation of effective
ignition sources must be avoided by maintaining a sufficient safety
5.9.1 Notes for the risk assessment distance.
(1) Electromagnetic fields are emitted by all systems that generate and use (3) As a general protective measure against the ignition effect of
high-frequency electrical energy (high-frequency systems). This includes, unintentional exposure to electromagnetic fields, a safety distance
for example, radio transmitters (e.g. for mobile or CB radio) or medical, must be maintained in all directions between the transmitting antenna
scientific and industrial high-frequency generators for heating, drying, and a receiving structure located in a potentially explosive atmosphere.
hardening and for welding or cutting. In the case of transmitting antennas with directional characteristics, it
(2) All conductive parts in the radiation field act as a receiving antenna (so- should be noted that the safety distance may depend on the direction.
called receiving structure). An explosive atmosphere can be ignited if the The safety distance can be determined by calculation or measurement. If a
field is strong enough and the receiving structure is large enough. This can sufficient safety distance cannot be maintained, suitable protective
happen, for example, if the received high-frequency power causes thin measures must be defined on the transmitter or receiver side.
wires to glow or if sparks are generated when conductive parts come into (4) The time it takes for the flame to spread independently is the ignition
contact or are interrupted. In the case of particularly strong induction time. It is different for different substances.
electromagnetic fields, such as in the immediate vicinity of high-power high-
Remark:
frequency generators, even non-conductive materials can heat up
In the most ignitable composition with air, the ignition induction time
considerably and become a source of ignition. The energy absorbed by the
for hydrogen is about 20 µs, for propane and ethylene about 100 µs.
receiving structure, which can lead to ignition, is primarily dependent on
The energy supplied during the ignition induction time can practically be
the distance between the radiator and the receiving structure and the
regarded as fully effective for ignition. A later supply of energy can no
dimensions of the receiving structure for a given frequency and
longer be fully effective for ignition, as the energy available for ignition
transmitting power.
is already reduced by heat losses to the surrounding gas.
5.9.2 Protective measures for all zones With a continuous supply of energy, a state is finally reached in which
(1) By limiting the transmission power/radiation power used, sparks must the energy supply and losses to the environment are in balance. In this
be avoided within the potentially explosive area in accordance with the case, the electrical power supplied to the spark is decisive for ignition.
following requirements for the relevant zones. With a single energy supply in

form of a short-duration pulse, where the pulse duration is shorter than (7) For pulsed electromagnetic fields with a frequency range of 9 x 103 Hz to 3
the ignition induction time of the mixture, the energy contained in the x 1010 Hz (e.g. radar), in which the pulse duration is shorter than half the
pulse is to be regarded as the decisive factor for ignition. ignition induction time, but the time span between two successive pulses is
longer than three times the ignition induction time, the energy that can be
(5) For direct exposure of a potentially explosive atmosphere of zones 1 and extracted from the individual pulse is a more suitable ignition criterion.
2 to the radiation field of a continuous high-frequency source with a Under these conditions, ignition by a pulsed high-frequency discharge is
frequency range of 9 x 103 Hz to 3 x 1010 Hz, the following applies, depending not to be expected if the maximum energy of the single pulse that can be
on the explosion group, for an irradiated peak power of not more extracted from the receiving structure does not exceed the ignition limits
than specified in Table 3.
– 2 W for explosion group IIC, averaged over 20 µs The averaging must extend over the time spans of the specified ignition
– 3.5 W for explosion group IIB, averaged over 80 µs and induction times.
– 6 W for explosion group IIA, averaged over 100 µs
an ignition hazard is not to be expected. In zone 0, 80 % of this power Table 3: Maximum extractable energy and ignition limits
must not be exceeded. If continuous electromagnetic radiation in the Ignition limit values of the energy of
frequency range from 3 x 1010 Hz to 3 x 1011 Hz cannot be avoided, the Explosion group
the single pulse
ignition hazard must be assessed on a case-by-case basis.
IIA 950 µJ
(6) In the case of explosive dust/air mixtures in zones 21 and 22, a IIB 250 µJ
maximum power of 6 W may be radiated if the minimum ignition IIC 50 µJ
energy of the explosive dust/air mixture is greater than or equal to 1 mJ. In
zone 20, 80 % of this power must not be exceeded. When selecting and applying protective measures, dusts with a
Note: The general operating licence, the VDE radio protection mark, the minimum ignition energy of less than 3 mJ are generally equated with
indication of the radio interference suppression level or the CE marking in gas/air mixtures in terms of their ignition behaviour.
accordance with the EMC Directive do not contain any information as to If pulsed electromagnetic radiation in the frequency range of 3 x 1010 Hz
whether the device or its radiation field poses an ignition hazard. to 3 x 1011 Hz cannot be avoided, the ignition hazard must be assessed
on a case-by-case basis.

5.10 Electromagnetic radiation in the frequency range from 3 x 1011 5.10.2 Protective measures for all zones
Hz to 3 x 1015 Hz or wavelengths from 1000 µm to 0.1 µm ( optical (1) Devices that can cause ignition through resonance absorption are not
spectral range) Radiation in the optical spectral range, which can be an permitted.
effective ignition source, must be avoided in accordance with the following
(2) The energy of a radiation pulse or the power or irradiance of continuous
requirements for the corresponding zones.
radiation must be limited in such a way that it cannot ignite the
5.10.1 Notes for the risk assessment explosive atmosphere.
(1) Radiation in the optical spectral range can - especially when focussed -
(3) For example, the following radiation powers are not to be regarded as
become a source of ignition through absorption in an explosive
ignition sources if it is assumed that the radiation is completely absorbed
atmosphere or on solid surfaces.
by a solid and converted into heating, thus producing a hot surface. The
(2) Sunlight can trigger ignition if objects cause the radiation to be focussed
values given in Table 4 are rough simplifications with a large safety
(e.g. filled spray bottle, concave mirror, etc.).
margin. With lower absorption or good heat dissipation to the
(3) The radiation from flash light sources may be so strongly absorbed by environment, or even in the absence of an absorber, higher outputs are
dust particles that these particles become a source of ignition for also possible without ignition.
explosive atmospheres or dust deposits.
(4) With laser radiation, the energy or power density of even the
Table 4: Examples of safe radiation outputs for continuous radiation
unfocussed beam can be so high that ignition is possible, even at
great distances. Explosion group I IIA IIA IIB IIC IIC
Here too, heating mainly occurs when the laser beam strikes a solid Temperature class - T1-T3 T4 T1-T4 T1-T4 T5-T6
surface or is absorbed by dust particles in the atmosphere or by
contaminated translucent parts; in addition, the coincidence of absorption Power in mW 150 150 35 35 35 15
bands of the gas with the laser wavelength can be the cause of Irradiance inmW/mm2
ignition. (for surfaces < 400 mm2) 20 *) 20 *) 5 5 5 5

(5) It should be noted that the radiation-generating work equipment itself
(e.g. lamps, arcs, lasers, etc.) can also be sources of ignition within the *) For surfaces > 30 mm2 , the 5mW/mm2 limit value applies if there may be burning
meaning of 5.2 or 5.5. material (e.g. coal dust) in the beam.

(4) Alternatively, the radiation must be contained in such a way that – Accelerator or
– any escape of radiation that could ignite an explosive atmosphere from – Nuclear reactors
the enclosure into the hazardous area is safely prevented and there generated radiation can ignite explosive atmospheres (especially
are no surfaces heated by the radiation that could ignite an explosive atmospheres with dust particles) as a result of energy
explosive atmosphere outside the enclosure, and absorption.
– the explosive atmosphere cannot penetrate into the enclosure or an
(2) In addition, a radioactive source itself can also heat up to such an extent
explosion occurring inside the enclosure cannot spread into the
through its own absorption of radiant energy that the ignition temperature
hazardous area.
of the surrounding explosive atmosphere is exceeded.
(5) In zones 2 and 22, the conditions specified in paragraphs 2 to 4 must be
ensured during normal operation, in zones 1 and 21 even in rare (3) Under the influence of ionising radiation, explosive substances and
situations (e.g. malfunctions) and in zones 0 and 20 even in very rare mixtures can be produced by radiolysis and chemical decomposition or
situations (e.g. rare malfunctions). transformation, especially when highly reactive radicals are formed,
thus creating further explosion hazards.
5.11 Ionising radiation (4) Limit values below which no protective measures are required:
Ionising radiation, which can be an effective source of ignition, must be Gas-tight sealed radioactive substances with activities of up to 4 x 1010 Bq are
avoided to a sufficient extent. permitted in all zones. If sufficient heat dissipation is ensured, these values
5.11.1 Notes for the risk assessment may also be exceeded. In cases of doubt, the permissible activity limit
must be specified. The ion dose rate for irradiation facilities must not
(1) A hazard due to ionising radiation exists if the
exceed 3 mA/kg (approx. 400 Gy/h).
z. e.g. through
The permissible quantities of radioactive substances and the
– short-wave UV lamps,
permissible irradiation intensity (dose rate) must be specified in detail if
– X-ray tubes, the specified values can be exceeded. In non-destructive material
– short-wave lasers, testing with the widely used iridium-192 and selenium-75 sources,
– radioactive substances, activities up to the order of 1012 Bq can be regarded as harmless without
special consideration of the heat dissipation conditions.

5.11.2 Protective measures for all zones 5.12 Ultrasound

(1) Work equipment that emits ionising radiation is permitted in all zones, Ultrasound, which can be an effective source of ignition, must be avoided in
generate UV radiation or laser radiation when accordance with the following requirements for the relevant zones.
a) the energy of a radiation pulse or the energy flow (power) of

continuous radiation is so low that it cannot ignite the explosive
atmosphere, or When ultrasound is used, a large proportion of the energy emitted by the
transducer is absorbed by solid or liquid substances. As a result of internal
b) the radiation is enclosed in such a way that friction, heating occurs in the sonicated material, which in extreme cases
– any leakage of radiation that could ignite an explosive atmosphere can lead to temperatures above the ignition temperature.
from the enclosure into the hazardous area is safely prevented and
that there are no surfaces heated by the radiation that could ignite 5.12.2 Protective measures for all zones
an explosive atmosphere outside the enclosure, and (1) Ultrasonic waves with a frequency above 10 MHz are not permitted in all
zones, unless it can be proven that there is no risk of ignition in the given
– the explosive atmosphere cannot penetrate into the enclosure or an case because there is no absorption by molecular resonance.
explosion occurring inside the enclosure cannot spread into the
hazardous area. (2) The following applies to ultrasonic waves with a frequency of up to 10 MHz:
– Ultrasonic waves are only permitted in all zones if the safety of
Note: In zones 2 and 22, the above conditions must be guaranteed during the work process is guaranteed.
normal operation, in zones 1 and 21 even in rare situations (e.g. – The power density of the generated sound field must not exceed 1
malfunctions) and in zones 0 and 20 even in very rare situations (e.g. rare mW/mm2 unless it can be demonstrated that there
is no risk of ignition in the given case.
malfunctions).

5.13 Adiabatic compression, shock waves, flowing gases (4) An additional source of ignition occurs when handling flowing oxygen
Adiabatic compression, shock waves and flowing gases, which can be an under pressure; entrained particles, such as rust, grind off iron particles
effective source of ignition, must be avoided in accordance with the following from the pipe wall at sufficiently high speed, which then burn at high
requirements for the relevant zones. temperature in the compressed oxygen and can transfer the fire to the pipe
or valve. Oxygen gate valves and valves are particularly at risk due to the
high flow velocities that occur when they open and close.
(1) In shock waves and adiabatic compression, temperatures can be so high
5.13.2 Protective measures for all zones
that explosive atmospheres (including deposited dust) can be ignited. The
temperature increase essentially depends on the pressure ratio, but not (1) Work processes that could trigger ignitable compressions or shock waves
on the pressure difference. must be avoided. Dangerous compressions and shock waves can
generally be ruled out if, for example, gate valves and valves between
(2) Shock waves form, for example, when high-pressure gases in pipelines
sections of the system with high pressure ratios can only be opened
suddenly relax. They penetrate into areas of lower pressure at supersonic
slowly.
speed. Particularly high temperatures occur when they are diffracted or
reflected by pipe bends, constrictions, end flanges, closed valves or (2) When using work equipment that contains highly oxidising gases, special
similar. Explosions can occur in outlet lines of air compressors and in protective measures must be taken, if necessary according to the risk
downstream and intermediate tanks due to compression ignition of assessment, to prevent the materials and auxiliary substances from
lubricating oil mists. igniting.
(3) When fluorescent lamps break, for example, an explosive hydrogen/air Note: In zones 2 and 22, the above conditions must be guaranteed during
or acetylene/air mixture flowing into the evacuated tube can heat up so normal operation, in zones 1 and 21 even in rare situations (e.g.
high through compression that ignition is possible. malfunctions) and in zones 0 and 20 even in very rare situations (e.g. rare
malfunctions).

5.14 Chemical reactions Substances (e.g. gases or vapours) can themselves form explosive
The ignition of hazardous explosive atmospheres due to chemical atmospheres with the surrounding air and thus considerably increase the
reactions must be avoided. danger of such systems as a source of ignition. Reactions leading to self-
heating can occur in both multi-component and single-component systems
5.14.1 Notes for the risk assessment involving all states of matter.
(1) Chemical reactions that generate heat (exothermic reactions) can (5) A combination of several effects can occur, e.g. when self-igniting dusts
cause substances or material systems to heat up and thus become a are deposited, if the smouldering nests initially formed by self-ignition
source of ignition. This self-heating is possible if the rate of heat become ignition sources for explosive atmospheres.
production is greater than the rate of heat loss to the environment. (6) Chemical ignition sources can also be activated by impact or friction.
(2) The chemical reactions on which self-heating is based can take place at (7) Under certain conditions, pyrophoric substances can be produced, e.g.
room temperature or below. They then usually proceed so slowly that the during the storage of sulphur-containing petroleum products or during
heat released is generally released into the environment so quickly the grinding of light metals in an inert atmosphere.
that the system is not heated up dangerously. However, by hindering (8) An explosive atmosphere can be ignited, for example, by
the dissipation of heat and by increasing the ambient temperature (e.g.
– Oxidation (e.g. auto-oxidation of oil-contaminated cleaning wool),
during storage), the reaction rate can increase to such an extent that the
conditions necessary for ignition are reached. – Decomposition (e.g. of organic peroxides, biological processes),
– Polymerisation,
(3) Among other parameters, the following are decisive
– Spontaneous exothermic reaction when strong oxidising agents or
– the amount of substance,
other particularly reactive substances (e.g. nitric acid, chlorates,
– the volume/surface ratio of the reaction system, fluorine) come into contact with flammable substances,
– the ambient temperature and – Reaction of pyrophoric substances with air (e.g. some
– the dwell time. organometallic compounds),
(4) The resulting high temperature can lead to the ignition of an explosive – Alkali metals with water,
atmosphere as well as to the formation of smouldering pockets and – Copper with acetylene,
fires. Flammable substances that may be produced during the reaction

– Heavy metals with hydrogen peroxide, 5.14.2 Protective measures for all zones
– slow self-heating with subsequent self-ignition (e.g. (1) In all zones, substances and substance systems that
B. polybutadiene, alcoholates, iron-II-oxide), a) have a tendency to spontaneous combustion or
– Glowing in the air (sulphur iron, various metals in finely divided form, b) can lead to a dangerous increase in temperature due to chemical
Raneynickel), reactions under selected or unavoidable process conditions.
– spontaneous reaction on contact with catalytic surfaces (e.g. (2) If such substances and substance systems are handled, the necessary
hydrogen/air mixture with platinum), protective measures must be tailored to the individual case. Suitable
– unstable substances, even if they have been preserved with protective measures may include
stabilisers, which react spontaneously and with the release of – Inertisation,
considerable energy due to catalytic impurities,
– Stabilisation,
– Impact or friction, e.g. with finely distributed material combinations
– Improve heat dissipation, e.g. by dividing the fabric mixtures into
such as aluminium/rust.
smaller units, storage techniques with gaps,
– Temperature and pressure control,
– Quantity and ratio control,
– Storage at lowered temperature,
– Limitation of dwell times,
– Separate storage of reaction components,
– Use of inhibitors and chain breakers.

must be shielded from the rest of zones 21 and 22 and one of the following
Appendix measures must also be implemented:
– Dust deposits must be removed from the workplace or
Re No. 5.4 Protective measures when using tools – The work area must be kept moist so that dust cannot be stirred up
and smouldering nests cannot form.
(1) When using tools, a distinction must be made between those that can
(6) When working with flying sparks, e.g. when grinding or cutting, in zones 21
generally only produce a single spark,
and 22 or their surroundings, the wider area around the workplace
z. e.g. screwdrivers or spanners, and those where a large number of
must also be included in the protective measures mentioned with
sparks are generated when working on the workpiece, e.g. during
regard to the formation of smouldering nests.
chiselling work, or even spark sheaves, e.g. when using cutting and
grinding equipment.
(2) In potentially explosive areas of zone 0 or 20, no work equipment may
be used where the occurrence of even individual sparks must be
expected.
(3) Steel tools may be used in potentially explosive atmospheres in Zones 1 and
2, provided that neither sparking sparks nor hot surfaces (e.g. when
drilling) are produced during use.
(4) However, a ban on use in Zone 1 applies to all types of mechanical
tools if there is a risk of explosion from substances in explosion group IIC
(acetylene, carbon disulphide, hydrogen) as well as hydrogen sulphide,
carbon monoxide and ethylene oxide, unless special measures are taken to
prevent the occurrence of ignitable mechanical sparks.
(5) Steel tools can be used in potentially explosive atmospheres in zones 21
and 22, provided that neither sparking sheaves nor hot surfaces (e.g.
when drilling) are created. Otherwise, the workplace

Disclaimer and copyright
This edition has been compiled conscientiously and carefully. Nevertheless, no guarantee can be given that the information corresponds
exactly to the adopted text and is necessarily complete, accurate and up-to-date. No responsibility is accepted for the content provided.
The user is responsible for the correct selection and the consequences of using or not using the information provided, as well as the
intended or achieved results. In particular, no liability is accepted for any consequential damage arising from the use of the information
(including, without limitation, direct and indirect damage due to personal injury, loss of profit, business interruption or any financial
loss). The official versions of the official announcements are legally binding.
Imprint:
KÜPPERS Engineering
Dipl.-Ing. Andreas
Küppers An der
Flachsroth 32 52525
Waldfeucht

TRBS2152 - 03 En121520

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

TRBS2152 - 03 En121520

Uploaded by

Copyright:

Available Formats

Subscribe to DeepL Pro to translate larger documents.

Visit www.DeepL.com/pro for more information.

TRBS 2152 Part 3

GMBl. No. 77 of 20 November 2009, p. 1583

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

1 Area of application 5.8 Lightning strike

5.4 Mechanically generated sparks

5.5 Electrical systems

5.6 Electrical equalising currents, cathodic corrosion protection

5.7 Static electricity

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

1 Area of application 3 Identification and avoidance of

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

4 Identification of ignition sources 5 Prevention of ignition sources

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

5.2.5 Protective measures for zone 2

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

5.4.5 Protective measures for zones 2 and 22 5.5.2.1 General requirements

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

5.5.2.4 Electrical protective measures 5.5.2.6 Cables and wires

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

5.6.3 Protective measures for cathodically protected systems

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

ignition. (for surfaces < 400 mm2) 20 *) 20 *) 5 5 5 5

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

5.11.2 Protective measures for all zones 5.12 Ultrasound

a) the energy of a radiation pulse or the energy flow (power) of

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

© KÜPPERS Engineering Published by KÜPPERS Engineering www.druckgeraete-online.de

You might also like

ignition. (for surfaces < 400 mm2) 20 ) 20 ) 5 5 5 5