ExplosionProtectionDocument GeneralPart

EXPLOSION PROTECION DOCUMENT
General part
Version 1.2, September 2011
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General part Explosion protection document
CONTENTS
ABOUT EXPLOSION PROTECTION ......................................................................................................1
EXPLOSIVE MIXTURES AND EXPLOSIVE ATMOSPHERES .................................................................2
General ............................................................................................................................................2
Flammable Gases and Liquids ........................................................................................................2
Combustible Dust, Fibres and Flyings ............................................................................................4
Hybrid Mixtures ...............................................................................................................................5
Inerting ...........................................................................................................................................6
Classification of Flammable Gases and Vapor ...............................................................................7
Classification of Combustible Dust .................................................................................................8
IGNITION SOURCES ............................................................................................................................8
Hot Surfaces ....................................................................................................................................9
Flames, Hot Gases and Hot Particles ...........................................................................................10
Mechanically Generated Sparks ..................................................................................................10
Electrical Equipment ....................................................................................................................10
Stray currents, cathodic protection ..............................................................................................10
Electrostatics .................................................................................................................................11
Lightning .......................................................................................................................................14
Radiofrequency Electromagnetic Waves - RF Field .....................................................................15
Optical Radiation (light) ................................................................................................................16
Ionizing Radiation ..........................................................................................................................16
Ultrazvok .......................................................................................................................................16
Adiabatic Compression ................................................................................................................16
Exothermic Reactions, Autoignition of Dust Layers ....................................................................16
CONSTRUCTIONAL EXPLOSION PROTECTION ...............................................................................17
General ..........................................................................................................................................17
Flammable Gases and Liquids ......................................................................................................18
Combustible Dust ..........................................................................................................................18
EQUIPMENT AND INSTALLATIONS .................................................................................................19
Equipment .....................................................................................................................................19
Electrical equipment .....................................................................................................................20
Non-electrical equipment .............................................................................................................21
Installations ...................................................................................................................................22
Maintenance ..................................................................................................................................26
TECHNOLOGICAL IGNITION SOURCES ............................................................................................29
RESPONSIBILITIES ...........................................................................................................................29
REFERENCES ....................................................................................................................................31
General part Explosion protection document
ABOUT EXPLOSION PROTECTION
Explosion hazard exists on workplaces where flammable gases, flammable liquids, combustible dust, fibres
or flyings are used, because these substances can form explosive mixture with air. If effective ignition source
occurs in the explosive mixtures, mixture ignites and explosion threatens personnel, property and possibly also
the environment. It is the obligation of the employer to prevent explosions that would pose the above mentioned
threat.
The Directive 1999/92/EC (user ATEX directive) requires certain preferential order of explosion protection
measures. First and foremost it is necessary to prevent the formation of explosive mixtures as far as reasonably
practicable. In seldom situations the prevention of formation of explosive mixtures can be reliable, so usually
also the prevention of occurrence of effective ignition sources is necessary. Combined these measures are
called measures of preventive explosion protection and in many cases these measures will suffice to achieve
appropriately low risk of explosion.
However, sometimes preventive measures do not suffice because residual risk of explosion is too high. Then
constructional explosion protection shall be implemented. With constructional explosion protection explosions
can occur, but explosions do not threaten personnel, property or environment.
Measures of explosion protection can also be divided to technical and organisational measures. As a rule
technical measures should be used to solve technical problems, while organisational measures are appropriate
to solve organisational issues.
Risk shall be assessed for all plants with explosion risk to assure that legal requirements are met. If the risk
of explosion does not meet the legal requirements, the situation shall be resolved without delay or production
should be temporarily (or permanently) stopped.
The residual risk, even if within legal requirements, can be unacceptable to the employer. The employer if free
(and encouraged) to take further steps and reduce the risk of explosion beyond minimum legal requirements. In
any case starting with situation better than bare minimum of legal requirements is a good practice, nevertheless,
due to expected degradation of equipment during the use. One should be aware that reasonable margin to
minimum legal requirements gives some necessary room for error to operating and maintenance staff.
Explosion protection document
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General part
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EXPLOSIVE MIXTURES AND EXPLOSIVE ATMOSPHERES
General
Flammable gases, vapour, sprayed droplets,
combustible dust, fibres and flyings can form
explosive mixtures with oxidants. If explosive mixture
forms in atmospheric condition with atmospheric
oxygen as oxidant, explosive atmosphere forms.
Atmospheric conditions require pressure between
0.8 bar and 1.1 bar and temperature between -20C
and 60C, where the air shall not be enriched with
additional oxygen or other oxidants. The concept
of explosive atmosphere is important because
equipment for hazardous areas is designed for
operation exclusively in atmospheric condition and
does not guarantee safety outside atmospheric
condition.
Explosive mixtures form only if the concentration
of flammable or combustible substance is between
Lower Explosive Limit (LEL) and Upper Explosive
Limit (UEL). If the concentration is below LEL,
relatively small amount of released heat at oxidation
does not suffice to heat unburned mixture to ignition
temperature, so flame can not propagate. On the
other hand, if the concentration is above UEL, burning is too incomplete. Again, the released heat is too small
to trigger spontaneous flame propagation.
Concentration of flammable and combustible materials at lower explosive limit is surprisingly low. The majority
of substances have lower explosive limit at order of magnitude few tens of grams per cubic meter.
All flammable and combustible substances need certain minimum oxygen content in a mixture to form explosive
mixture. If the oxygen content is too low, explosive mixture can not form and in this case the mixture is said to
be inert.
Flammable Gases and Liquids
The basic measures of explosion protection with
flammable gases and liquids are sealing of process
equipment and ventilation. With sealing the emissions
of flammable substances and consequential
formation of explosive mixtures outside process
equipment are prevented. Ventilation provides that
any flammable gases or vapour, that may occur
outside process equipment, are washed away or
diluted as soon as possible.
Flammable gases, that are usually kept in
pressurized equipment, shall not leak during normal
operation. The only acceptable normal emissions
are occasional outdoor releases through vents of
process equipment.
Also emissions of flammable liquids vapour and
leakage of flammable liquids shall be avoided as
much as reasonably practicable. However, the
requirements for flammable liquids are not as strict
as requirements for flammable gases, at least not for
Continuous source of vapour release
Evaporation of flammable vapour is continuous from
the surface of flammable liquid, e.g. in the drum.
Surface of continuously present flammable liquid is
always regarded as continuous source of release of
flammable vapour.
Primary sources of vapour and gas release
Primary sources of release emit flammable vapour
occasionally during normal operation. Doors of
process vessels, that are opened from time to time,
are typical example.
processes that take place at atmospheric pressure.
During some procedures emissions of flammable
vapour can not be avoided. Such procedures
include sampling from vessels, addition of various
substances into vessels, pumping of liquids with
portable pumps etc. Occasional small emissions
of flammable vapour are acceptable even during
normal operation.
Possible emissions of flammable substances and
grade of explosion hazard shall be assessed regarding
the characteristics of technological processes.
The assessment shall be performed according to
the requirements of the standard EN 60079-10-1:
Explosive atmospheres - Part 10-1: Classification of
areas - Explosive gas atmospheres. The assessment
shall include analysis of how often and in what way
can emissions of flammable substances occur and,
considering ventilation, to what extent do emissions
generate explosive mixtures.

SOURCES OF RELEASE
Grade of release Examples Notes
Continuous Liquid surface Continuous releases are permissible only inside
process equipment.
Primary Vents with releases during normal
operation, covers & doors of process
vessels that are occasionally opened,
etc.
Primary sources of release are acceptable at work-
places. However, the emissions shall be as limited
as possible regarding both, the amount of released
flammable substance and duration of release.
Process vessels with primary sources of release
should be more an exception than a rule.
Secondary Sealed joints of process equipment
that are not intended to be disman-
tled during normal operation, vents
of safety release valves, etc.
The target should be that process vessels are de-
signed with secondary sources of release, if any.
Technically dura-
bly leak-proof
Welded joints Technically durably leak-proof installations are not
deemed sources of release. Wherever possible the
joints should be designed as technically durably
leak-proof.
Ventilation of enclosed areas shall be at least as intense to prevent simultaneous formation of explosive mixture
in whole room even in the case of the most intense release of flammable substances. Good ventilation will make
the expected extent of explosive mixture at least two orders of magnitude smaller than the room volume.
Regarding the frequency, duration and mode of occurrence of explosive mixtures the areas are classified into
hazardous areas (zones).
Secondary sources of vapour and gas release
Secondary sources of release emit flammable sub-
stances only rarely (during faults) and even then only
for short periods. Typical example is sealed joint that
may leak during sealing fault. Sources of release that
can emit flammable substance for prolonged time in-
terval, even if only during fault (e.g. sealing fault likely
to be unnoticed), shall not be regarded as secondary
sources of release.
General part
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HAZARDOUS AREAS (ZONES)
Zone type Definition Notes
Zone 0 A place in which an explosive atmos-
phere consisting of a mixture with air of
flammable substances in the form of gas,
vapour or mist is present continuously or
for long periods or frequently.
Zone 0 is permitted only inside process equipment.
Zone 0 is not permitted in workplaces.
phere consisting of a mixture with air or
flammable substances in the form of gas,
vapour or mist is likely to occur in normal
operation occasionally.
Zone 1 usually extents throughout rooms with pri-
mary sources of release of flammable substances.
Exceptionally, when technically zone 1 area covers
only a small fraction of the room, non-uniform
classification with part of the room classified as
lower risk area makes sense.
phere consisting of a mixture with air
of flammable substances in the form of
gas, vapour or mist is not likely to occur
in normal operation but, if it does occur,
will persist for a short period only.
Zone 2 covers well ventilated rooms that contain
only secondary sources of release of flammable
substances. Only in rare circumstances can be
parts of the room that contains primary sources of
release, classified as zone 2.
Combustible Dust, Fibres and Flyings
Basic measures of explosion protection with combustible dust, fibres and flyings are avoidance of formation of
dust clouds outside process equipment and regular housekeeping. Formation of explosive dust atmospheres
outside process equipment is prevented with process design that does not emit dust clouds out of process
equipment. Regular cleaning and dust removal prevents formation of dust layers outside process equipment.
Processes with dust, where disturbance of dust is expected, should be performed inside dust sealed equipment.
This is especially important if dust contains substantial fraction of fine dust with granulation of the order
20 m or less. Fine dust settles only slowly and air
movement can carry it far from sources of release,
where it can form relatively thick layers even in the
areas that are hard to reach.
Possible emissions of dust and grade of explosion
hazard shall be assessed regarding the characteristics
of technological processes. The assessment shall
be performed according to the requirements of the
standard EN 60079-10-2: Explosive atmospheres -
Part 10-2: Classification of areas Combustible dust
atmospheres. The assessment shall include analysis
of how often and in what way can emissions of dust
occur, where dust layers can form and to what
extent do emissions and deposits generate explosive
mixtures.
Housekeeping shall assure that settled dust can
not fill the room with explosive dust atmosphere if
disturbance occurs. The thickness of dust deposits
shall always be kept well below 0.5 mm. It means
that dust shall not cover the surfaces.
Continuous source of dust release
Processes that continuously disturb dust, as dust ex-
traction system leading to cyclone filters, are continu-
ous sources of release that shall be contained within
enclosure.
SOURCES OF DUST RELEASE
Grade of release Examples Notes
Continuous Mills, continuous or frequent
disturbance of dust, bags in
filters, cyclone filters.
Continuous sources of release are permitted only inside
process equipment.
Primary Pouring of dust into vessels,
infrequent filling of silos.
Primary sources of dust release are acceptable at work-
places. However, the emissions shall be as limited as
possible regarding both, the amount of released dust and
duration of release. Process vessels with primary sources
of release should be more an exception than a rule.
Secondary Sealed joints of process equip-
ment designed for dust han-
dling.
The target should be that process vessels are designed with
secondary sources of dust release, if any.
Dust layers All areas where deposits of dust
can form.
With fine dust, these areas may be far from dust sources
Regarding the frequency, duration and mode of occurrence of explosive mixtures the areas are classified into
hazardous areas (zones).
DUST HAZARDOUS AREAS
Zone type Definition Notes
Zone 20 A place in which an explosive atmosphere
in the form of a cloud of combustible dust
in air is present continuously, or for long
periods or frequently.
Zone 20 is permitted only inside process equip-
ment. Zone 20 is not permitted in workplaces.
in air is likely to occur in normal operation
occasionally.
Zone 21 is usually classified inside process equip-
ment with occasional dust disturbance and near
open dust handling equipment.
in air is not likely to occur in normal opera-
tion but, if it does occur, will persist for a
short period only.
Zone 22 can be in rooms with regular housekeep-
ing, away from primary sources of dust release.
Where even for short periods dust layers can form
during normal operation, classification as zone 22
is not possible.
Hybrid Mixtures
Hybrid mixtures form when beside combustible dust
explosive mixture contains also such quantity of
flammable gas or vapour, that the sensitivity of mix-
ture to ignition is much higher than sensitivity of pure
dust explosive mixture. For this to happen even small
concentrations of flammable gases or vapour far be-
low LEL are sufficient.
Explosion protection with hybrid mixtures is diffi-
cult. The main problem is that dust processing often
causes weak electrostatic discharges too weak to
ignite pure dust mixtures but energetic enough to ig-
nite hybrid mixtures. Therefore with hybrid mixtures
the prevention of ignition sources often can not be
assured. In many cases dealing with hybrid mixtures
requires inerting or constructional explosion protec-
tion.
Primary sources of dust release
At primary sources of release dust is released occa-
sionally during normal operation. Pouring of dust into
process vessel is a typical example.
General part
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Inerting
Inerting is the process to replace the air in the
process vessel with inert gas, so that even with
flammable substances present the mixture is
not explosive. The system of inerting is designed
with consideration of choice of inert gas, choice of
appropriate procedure to replace air with inert gas
and choice of methods to maintain inert conditions.
Inerting technology is in detail described in the
document CEN/TR 15281:Guidance on Inerting for
the Prevention of Explosions.
Data on limiting oxygen concentration below which
explosions are not possible shall be obtained for
each combination of flammable and combustible
substances with particular inert gas, that is used for
inerting. Regarding the technical design of inerting
also appropriate safety margin on residual oxygen
concentration shall be considered.
When chosing the procedure to replace air with
inert gas the properties of vessel to be inerted
should be carefully considered. If the vessel is vacuum tight, the usual method of choice is vacuum swing: the
vessel is vacuumed and filled with inert gas. This method may be the most economical regarding the inert gas
consumption. Usually two cycles of vacuum are a good practice.
If the vessel isnt vacuum tight, flow through of inert gas is the usual choice due to the simplicity of the system.
However, this method has very limited use with branched systems. Additional difficulty is calibration of the
system, i.e. monitoring if enough air is displaced from the vessel.
Pressure resistant vessels can be inerted with pressure swing method. With this method inert gas is pumped
into the vessel to relatively high pressure, then the vessel is discharged into the atmosphere. At least two
cycles of high pressure are needed for appropriate inerting.
If the density of inert gas differs substantially from air density, inerting with displacement can be used. A heavy inert
gas is slowly introduced at the bottom of the vessel while air is displaced through the opening at the top of the vessel.
Monitoring of inert conditions can be direct with
measuring the oxygen content or inferred from
measurement of other parameters of inerting.
Direct oxygen content measurement is technically
superior to inference methods, however, oxygen
content measurement can be pricy due to
relatively high price of appropriate equipment.
Continuous inert conditions within the vessel are
usually maintained with slight overpressure in the
vessel. Technical problems with maintaining inert
conditions arise when substances (especially dust and
granulates) have to be added into the vessel, because
air is usually trapped between dust grains. Many times
addition of substances also requires opening of the
inert vessel with the risk of loosing inert conditions.
Secondary sources of dust release
Secondary sources of dust release are active only
rarely, usually during faults. A sealed joint of positive
pressure pneumatic conveying system may qualify as
secondary source of dust release.
Hybrid Mixtures
Explosion protection with hybrid mixtures is difficult.
Difficulties arise because dust handling causes statics
capable of igniting vapour explosive mixtures.
INERT GASES
Type of gas Properties
Nitrogen Nitrogen is most often used inert gas. It is useful for inerting of many substances, but can
chemically exothermally react with dust of light metals. The nitrogen gas density is approxi-
mately equal to air density. The advantage of nitrogen is ease of use, because nitrogen is not
poisonous. Its use is hazardous only if inerted vessel leaks so that air is displaced from vessel
surroundings causing a risk of suffocation near the vessel.
Carbon dioxide Carbon dioxide is useful for inerting of many substances, but can chemically exothermally
react with dust of light metals. It is more effective than nitrogen for inerting of organic sub-
stances. Carbon dioxide is heavier than air. The use of carbon dioxide is more hazardous than
the use of nitrogen, because it causes suffocation even in relatively small concentrations.
Steam As with nitrogen and carbon dioxide, steam is useful for inerting of many substances, but can
chemically exothermally react with dust of light metals. When used for inerting, steam shall
have pressure at least 3 bar (temperature approximately 135C). Steam is lighter than air.
The weakness of inerting with steam is that at cooling of the system steam will condense and
underpressure may occur in the vessel. Underpressure may cause ingress of air if vessel leaks
when in underpressure.
Flue gas Flue gases from combustion are used almost exclusively for coal mills inerting in plants that
use coal as a fuel. The oxygen content in flue gas can vary substantially and can occasionally
rise above the concentration that would allow inerting. Therefore a sufficient back-up inert gas
supply (usually carbon dioxide) shall be provided and oxygen concentration in inerted vessel
shall be continuously monitored.
Noble gases Noble gases, usually argon, do not chemically react with any chemical substance and are uni-
versally useful for inerting. Their only weakness is relatively high price.
Classification of Flammable Gases and Vapor
VFlammable gases and liquids are divided into gas groups and temperature classes. Gas groups tell the
sensitivity of substance to ignition with a spark and ability of flame to penetrate narrow gaps. The width of the
gap, that the flame just can not penetrate is called MESG (Maximum Experimental Safe Gap). Temperature class
tells the temperature interval where explosive atmosphere ignites spontaneously.
The most sensitive substances to ignition with a spark are classified into group IIC gases. The flame of this
substances can penetrate the narrowest gaps. The least sensitive substances are classified into group IIA where
also the flame has the weakest ability to penetrate narrow gaps. Groups IIA and IIB are further divided into
subgroups.
GAS GROUPS
Gas group Examples
IIA1
MESG > 1.14 mm
formic acid, acetic acid, acetonitrile, many
halogenated hydrocarbons
IIA
1.14 mm > MESG > 0.9 mm
gasoline, diesel fuel, benzene, n-pentane,
acetone, isopropanol, n-butanol
IIB1
0.9 mm > MESG > 0.85 mm
ethanol, diethylether, dibutylether, n-propa-
nol,
IIB2
0.85 mm > MESG > 0.75 mm
methyl ethyl ketone, dimethylether, carbon
monoxide
IIB3
0.75 mm > MESG > 0.65 mm
propylene oxide, furane, 1,4-dioxane
IIB
0.65 mm > MESG > 0. 5 mm
formaldehyde, paraformaldehyde, ethylene
oxide, tetrafluorethylene
IIC
MESG < 0. 5 mm
hydrogen, acetylene, carbon disulphide
General part
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TEMPERATURE CLASSES
Class
Autoignition temperature Ti
Examples
T1 T
i
> 450
O
C hydrogen, acetone, benzene, methane, ethane, formic acid, acetic acid
T2 450
O
C > T
i
> 300
O
C ethanol, methanol, n-butanol, isopropanol, ethylene, acetylene, propane,
formaldehyde
T3 300
O
C > T
i
> 200
O
C gasoline, diesel fuel, pentane, hexane, heptane, octane, cyclohexane
T4 200
O
C > T
i
> 135
O
C diethylether, trimethylamine, tetrahydrothiophene
T5 135
O
C > T
i
> 100
O
C no industrial chemicals in this class
T6 100
O
C > T
i
> 85
O
C carbon disulphide
Classification of Combustible Dust
Small solid combustible particles are divided into groups IIIA, IIIB and IIIC. Group IIIA includes fibres and flyings,
group IIIB electrically non-conductive dust and group IIIC electrically conductive dust.
The temperature classification of dust is two-fold: the necessary data are the temperature of autoignition of
dust cloud and the temperature of smouldering of (usually 5 mm thick) dust layer.
Also important is classification of dust into explosion classes that give criteria for the design of the measures
of constructional explosion protection. The explosion class of dust tells how fast is the pressure rise during
explosion, i.e. how violent the explosion can be. It is not solely a property of substance, because explosion class
of dust also depends on particle size distribution, humidity etc. The explosion classes are as follows:
EXPLOSION CLASSES OF DUST
Class
V
1/3
(dp/dt)
Examples
St1 < 200 bar m/s
flour, sugar coal, some wood dusts, most pharmaceutical
drugs
St2 200 bar m/s ... 300 bar m/s
some pharmaceutical drugs, some sorts of wood dust, corn
dust
St3 > 300 bar m/s aluminium, magnesium
The most hazardous is dust of the class St3, while the least hazardous is dust of the class St1.
IGNITION SOURCES
Occurrence of ignition sources in hazardous areas shall be prevented with reliability depending on area clas-
sification. The strictest requirements if course apply in zones 0 and 20, while the easiest to fulfil apply in zones
2 and 22.
PREVENTION OF IGNITION SOURCES
Zone Requirement
2 and 22 No ignition sources during normal operation and during normal course of procedures.
1 and 21
As for zones 2 and 22 plus no ignitions sources during expected malfunctions of equip-
ment and foreseeable deviations from normal course of procedures.
0 and 20
As for zones 1 and 21 plus no ignition sources even during rare malfunctions of equipment
and during unlikely deviations from normal course of procedures.
It shall be emphasized that normal operation also covers such faults that arise from intentional misuse of
equipment. For example, if fan is driven with speed above its nominal speed then in this sense fan malfunction
is a part of normal operation.
Sparking pairs of materials
Sparks are easily generated with impact between
sparking pairs of materials like steel and granite.
Even weak impacts with small energy release may
form ignition capable sparks.
Expected malfunctions usually arise from wear of properly used equipment. Even if fan is driven with nominal
speed, bearings will wear after some time. Such malfunction of bearings (that can be foreseen with certain level
of confidence) would qualify as expected malfunction. If fan bearings would have production fault (e.g. fault in
material) failure could occur much before nominal life span would pass. That would be a rare malfunction.
Hot Surfaces
If an explosive atmosphere comes into contact with a hot surface with ignition temperature and sufficient
exposed area, ignition occurs. Also smouldering of dust layers can be triggered by a hot surface if dust settles
on it. In the case of dust layers it should be noted, that dust layers act as thermal insulation so, keeping all other
conditions the same, dust covered surfaces can heat to higher temperature than clean surfaces.
Equipment or any other exposed parts in hazardous areas should never reach ignition temperature of explosive
atmosphere and smouldering temperature of dust layers. Regarding the maximum allowable temperature of
exposed surfaces a safety margin to ignition temperature according to SIST EN 1127-1 standard, depending on
zoning, shall be assured.
Similar as gases and vapour also equipment for potentially explosive gas atmospheres is classified in
temperature classes.
EQUIPMENT TEMPERATURE CLASS
Class Maximum surface temperature
T1 450
O
C
T2 300
O
C
T3 200
O
C
T4 135
O
C
T5 100
O
C
T6 85
O
C
Combustible dusts are not classified into temperature classes, but ignition temperature of dust cloud and
smouldering temperature of dust layers are given instead. The equipment for dust explosive atmospheres has
a temperature marking indicating the maximum surface temperature. This temperature shall not exceed 2/3 of
cloud ignition temperature in degrees Celsius and shall be at least 75 K lower than smouldering temperature
of dust layer.
Non-sparking pairs of materials
Sparks are not generated with impact of non-sparking
materials unless the velocity at impact is very high and
released energy is large. Hand held tools, designed for
impact or grinding during normal operation (e.g. ham-
mers, files), used in hazardous areas, shall be made of
non-sparking material like copper, brass or bronze.
General part
10/31 11/31
Flames, Hot Gases and Hot Particles
Flames, hot gases and hot (glowing) particles are effective ignition sources. Especially dangerous are flames
that are regarded as one of the most effective ignition sources.
These ignition sources, that as a rule arise from inadequate procedures by personnel (i.e. welding, smoking,
use of naked flames), are prevented with appropriate organisational measures.
Mechanically Generated Sparks
At impact between various objects sparks can be generated. Ignition capability depends on material pair,
relative velocity of objects and impact energy.
Regarding the ability to generate ignition capable mechanical sparks, material pairs are divided into three
classes.
MATERIAL PAIRS REGARDING MECHANICALLY GENERATED SPARKS
Material class Properties, examples
Sparking pairs Light metals combined with oxides of other metals (Al, Mg, Ti, Zr combined
with rust), pairs of hard metals (hardened steel with hardened steel, steel
with granite, ...)
Non sparking
pairs
Soft metals and alloys that are difficult to oxidize (Cu, bronze, brass, ... ),
combined with other materials, synthetic organic compounds combined with
other materials
Normal pairs Light metals, but not paired with oxides of other metals (Al-Al, Al with stain-
less steel), not too hard metals (ordinary steel with ordinary steel)
Impacts, friction and grinding between sparking pairs of materials are not allowed in hazardous areas.
Sparks, generated with single impacts between objects made of non sparking or normal pair of materials, are
not ignition sources if the impact velocity does not exceed 1 m/s and impact energy does not exceed 500 J. The
safe region can be generally extended to velocity 15 m/s (approximately 50 km/h), but the impact energy shall
be reduced to maximum 60 J for gaseous explosive atmospheres and 125 J for dust explosive atmospheres (with
non sparking pairs of materials) and 3 J for gaseous explosive atmospheres and
20 J for dust explosive atmospheres (with normal pairs of materials) respectively. Further information on
mechanically generated sparks, including safe limits
depending on gas groups and zoning, can be found in
the EN 13463-1 standard .
Electrical Equipment
All the electrical equipment has its own potential
ignition sources (most of it even during normal
operation), if it is not designed as explosion protected
equipment. Therefore all the electrical equipment
has to be explosion protected. Further consideration
on electrical equipment and on requirements in
different situations are described in a chapter on
equipment and installations.
Stray currents, cathodic protection
Inadequate electrical installations can cause that
stray currents flow outside electrical wiring. At points
of unreliable electrical contact incendive sparking
can occur. This ignition source is prevented with
proper design of electrical installations. Cathodic
What is 500 J impact at 1 m/s?
The kinetic energy of 500 J is released at impact veloc-
ity 1 m/s if a mass of 1000 kg falls from rest at height
5 cm and impacts on fixed object.
corrosion protection, if used, must be designed for
hazardous areas.
Electrostatics
Electrostatic discharges are one of the most frequent
actual ignition sources of explosive mixtures.
Physical processes, that generate static charging,
can not be avoided or prevented. Static charging is
generated with contact potential between different
materials, influence of external electrostatic field or
flow of electrical charges. Electrostatic charging is
thus generated whenever anything is going on - with
functioning of equipment, course of technological
processes and personnel activity in hazardous
areas. Preventive measures focus on avoidance of
substantial charge accumulation and prevention of
ignition capable discharges. Preventive measures are
described in detail in the document CLC/TR 50404:
Electrostatics - Code of practice for the avoidance of
hazards due to static electricity.
Charging
At contact of objects made of different materials
electrical potential develops between objects. This
potential causes flow of electrical charge from
object with higher potential to object with lower potential. When objects are separated charge flows back.
With conductive objects charge returns very fast, but if at least one of the object is non-conductive, the return
of charge can be very slow. The characteristic return time with conductors is so short, that in all practical
situations all charge returns and after separation conductive objects are electrically neutral. However, if one
of the objects is isolator, all charge can not return in due time and separated objects carry opposite charges.
Contact potentials between different materials are
low, of the order of few millivolts. High voltage,
characteristic for electrostatics, is generated during
separation when work is done against electrostatic
attraction between charges of different polarity.
Work done by the force needed to separate objects is
accumulated in the electrostatic field as electrostatic
energy of charged objects. Normally it is of the order
up to few tens of millijoules.
Electrostatic field, surrounding charged objects,
causes rearranging of charges in nearby conductors,
but keeps these conductors neutral as a whole.
However, if these conductors are divided into two
or more pieces (e.g. a person drops a conductive
item), separate parts carry net electrostatic charge.
The phenomenon is called charging by influence or
electrostatic induction.
Electrical charge can flow off high voltage sources
with corona current at sharp spikes and edges.
Charge can accumulate on nearby objects which
become charged.
Electrostatic discharges
Charged state of objects is not stable and objects
Separation of conductive materials
When two conductive materials are separated, no
charging occurs. As always, also in the case illustrated
above there is contact potential between different
materials (between metal sheet and metal wheels),
so during contact some amount of charge flows from
one item to another. However, the relaxation time for
charge return is only a tiny fraction of a second, so in
practice even fast rolling of metal sheet is far too slow
to prevent complete return of charge. Static charging
is not observed when separating metals or any other
good conductors. This holds even if conductors are not
earthed.
Separation with isolators
Electrostatic charging occurs when at least one of
materials, involved in separation process, is non-
conductive. Due to contact potential small amount
of charge flows from one item to another, even with
non-conductors. The relaxation time for the return of
charge is so long that substantial amount of charge
does not return during separation. If the other object
involved in separation process is conductive, the
accumulation of charge on conductor can be avoided
with earthing. However, if the conductive item is not
earthed, it will accumulate charge and this will give
rise to one of the most hazardous situations in the
presence of flammable and combustible substances:
electrostatically charged conductor.
General part
12/31 13/31
discharge if opportunity arises. The electrostatic
energy, that has been stored in electrostatic field, is
released during discharge. The amount of released
energy often exceeds the ignition energy of explosive
mixtures, so discharges can cause ignition.
Electrostatic sparks are characteristic for discharges of
conductors. If earthed conductive object is approached
to charged conductive object, the electrostatic field
between objects intensifies. The smaller the distance
between objects, stronger the electrostatic field.
When field strength reaches approximately 3 kV/mm,
field reaches electric breakdown strength of air and
discharge occurs. Because charges on conductor are mobile, all the charge can promptly flow to discharge point
and conductive object discharges practically completely. All the accumulated electrostatic energy is released in
a single spark that occupies a small volume. Therefore electrostatic spark has high ignition capability and can
ignite all types of explosive mixtures.
Similar situation arises if earthed conductor is approached to charged non-conductive object. Also in this
case electrostatic field intensifies and breakdown of air occurs at field strength of 3 kV/mm. However, there
is a difference with isolators. Static charges are not mobile, so charges cant flow along the surface of non-
conductor to the discharge point. The resulting discharge is mostly incomplete and includes only charges in
the vicinity of discharge point. Even there charges are teared off different parts of surface and form channels
only in air. The discharge geometry looks like a brush so this type of discharge is called brush discharge. At
brush discharges the energy released and amount of charge transferred are much smaller than with spark
discharges. Also, energy is released in larger volume. The ignition capability of brush discharges is smaller and
ignition of pure (not hybrid) dust explosive atmospheres has not yet been observed. In certain circumstances
also conductors can discharge with brush discharge.
If sharp earthed needle is approached to a charged object the field strength exceeds 3 kV/mm only in the
Charging by electrostatic induction
The content of blue plastic drum is electrostatically
charged. Far away the effect of drums
electrostatic charge (i.e. electrostatic field) is
negligible and induction is not observed (top left
figure). When person approaches the drum, it
enters stronger electrostatic field and the effects
of electrostatic field, i.e. electrostatic induction,
become evident. Positive charge in and on
plastic drum attracts negative charge and repels
positive charge. Human body and metal bucket
are conductive so that charges are mobile and
rearrange. However, the system is still neutral
because the total negative charge still balances out
positive charge (top right figure). If person drops the
bucket, it also drops some negative charge with it.
Now bucket carries net negative charge, while the
person carries opposite net positive charge (lower
figure). Without touching anything person and
bucket become electrostatically charged due to the
effect of external electrostatic field that surrounds
any charged item that is not enclosed by earthed
conductor (i.e. that is not in the Faraday cage).
This three step process is called charging with
electrostatic induction.
vicinity of spike. Neither spark, nor brush discharge
can occur. Between needle and charged object forms
a corona current, with which charge from charged
object flows slowly to earth. The electrical power is
so low that risk of ignition exists only with explosive
atmospheres of group IIC gases.
If a thin layer of isolator is oppositely charged at
opposite surfaces, electrical field stays confined to
interior of isolator. In this case the air with electric
breakdown strength of 3 kV/mm no longer acts as
voltage limitation. The role of voltage limitation is
taken over by isolator with possibly much higher
breakdown strength. Further, the thin layer of
isolator can have relatively large capacitance
so large amount of electrostatic energy can
accumulate. If the isolator breaks down or if the
charged surface is disturbed with earthed conductor,
a propagating brush discharge with extremely high
ignition capability occurs that can ignite any explosive
mixture. A precondition for propagating brush
discharge is extreme charging prior to breakdown,
that can be practically achieved with pneumatic
conveying of dust or flow of non-conductive liquids,
especially emulsions and suspensions. Most often
the opposite charge comes to the opposite side of isolator with electrostatic induction from earth, if the isolator
covers earthed surface.
If granulate or dust from extremely non-conductive material (specific resistance exceeding 10
10
m) is
transferred to silo, charge accumulation can trigger cone discharge. Ignition capability of cone discharges can
be inferred from empirical relation that tells the effective energy available for ignition if granulate with median
grain size d discharges in silo of diameter D:
E = E
0
_
0
]
3.36
_
J
J
0
]
1.46

with E
0
= 5.22 mJ, D
0
= 1 m, d
0
= 1 mm.
Prevention of hazardous discharges basic
requirements
Spark discharges are avoided with earthing of all
conductive items. The process equipment in hazardous
areas shall have earthing resistance maximum 1 M.
Personnel shall have earthing resistance maximum
100 M.
Corona current
In the vicinity of sharp edges and spikes of charged
objects the strength of electrostatic field can exceed
breakdown strength of air. Near the spike air ion-
izes and slowly carries charge away from the charged
object. Electrical power at corona discharge is very
low and can ignite only the most sensitive explosive
mixtures.
Spark discharge
Spark discharge occurs between conductors on differ-
ent electrical potential, most often between earthed
conductor and isolated conductor without earthing
connection.
General part
14/31 15/31
Non-conductive chargeable surfaces shall have limited exposed areas if explosion hazard is caused with
flammable gases or liquids, or, if hybrid mixtures can form. Limitations are as follows:
AREA LIMITATION FOR NON-CONDUCTIVE SURFACES [cm
2
]
IIA IIB IIC
Zone 0 50 25 4
Zone 1 100 100 20
Zone 2 no limit, if hazardous charging is unlikely during
normal operation
Exposed area can be four times larger if the area is within earthed frame.
The length of thin elongated items (e.g. tubes) is not limited, if the diameter is within the following limits:
DIAMETER LIMITATION OF ELONGATED ITEMS [cm]
IIA IIB IIC
Zone 0 0.3 0.3 0.1
Zone 1 3 3 2
Zone 2 no limit, if hazardous charging is unlikely during
normal operation
Dust and non-conductive liquids shall not be
transferred through non-conductive pipes and hoses
in hazardous areas, regardless of tube diameter.
Elongated items shall not form too large non-
elongated non-conductive surfaces (e.g. reels).
Non-conductive layers on earthed surfaces are
permitted if the thickness of layer does not exceed
2 mm for gas groups IIA and IIB, and 0.2 mm for gas
group IIC, if repeating charging does not occur and
if the possibility for propagating brush discharges
is excluded. These layers shall not be made of
fluorinated polymers.
Interior of process equipment with hazardous area
and pneumatic dust conveying or non-conductive
liquids transfer, shall have inner layer that prevents
incendive propagating brush discharges. The inner
layer shall be either electrostatically conductive, or
(for dust only) shall have breakdown strength less
than 4 kV , or (for dust only) shall have thickness
minimum 8 mm.
The maximum silo or vessels diameter, to which extremely non-conductive dust or granulates are transferred,
shall be inferred from formula for cone discharges regarding the minimum ignition energy of dust.
Lightning
If lightning strikes into explosive mixture it always ignites it. Besides direct strike of lightning also indirect
strikes can cause ignition sources, because lightning strikes cause short lived, but enormous local differences
in electrical potential.
The average frequency of lightning strikes in moderate climate zones (continental Europe) is approximately five
strikes per square kilometer per year. British Islands and Scandinavia are a bit less exposed with approximately
one strike per square kilometer per year. Lightning strikes in the vicinity of hazardous plant, that could cause
Brush discharge
Brush discharge usually occurs between charged non-
conductive item and grounded conductor.
ignition source, can be expected as rare incidents with a frequency of the order once per ten years or so.
Lightning by itself does not have voltage. High voltage arises only in conductor due to its impedance, especially
self inductance. In extreme cases lightning can impress current with slew rate up to 200 kA/s, that in a conductor
with self inductance 1 H (few meters of cable or metal structure) cause potential difference of 200 kV. Average
lightning impresses current with slew rate up to few 10 kA/s so that the expected potential differences are of
few tens of kilovolts.
The most hazardous are situations when lightning strikes into outer tank for flammable liquids that has installed
intrinsically safe circuits within its zone 0. Cables of intrinsically safe circuit and intrinsically safe apparatus
itself are galvanically separated from the tank. Usually the earthing connection of intrinsically safe circuits is
done in one point only in main electrical cabinet far from the tank. Due to impressed current the potential of
the tank rises to few 10 kV or more, while the intrinsically safe circuits, that do not carry any lightning current,
remain on the earth potential. Because the isolation between intrinsically safe circuit and tank usually can
withstand about 1 kV (isolation is tested with a voltage of 500 V) a breakdown occurs. If it happens in zone 0, the
explosion cant be avoided.
Protection measures against lightning focus on prevention of direct strikes into explosive mixture with appropriate
air terminals and prevention of too large potential differences. The necessary measures are adequate lightning
protection of hazardous plants and, for intrinsically safe circuits on structures exposed to lightning strikes, also
adequate surge protection, especially at passage of intrinsically safe circuit into zone 0.
Radiofrequency Electromagnetic Waves - RF Field
Radiofrequency electromagnetic waves can be ignition sources if waves are intercepted with conductors in
hazardous areas that can act as antennas. At spots of unreliable electrical connections of these conductors
sparking can occur. In extreme cases, where conductors are thin and RF field is strong, conductors can also
substantially heat.
The sources of the RF field, that shall be considered, can be stationed relatively far away from hazardous areas.
This especially holds for low frequency powerful broadcast transmitters.
GSM base stations are usually not problematic because they emit high frequency signal at relatively low power.
If GSM base station is located near the hazardous area, its position will be normally relatively high from the
ground. Because its signal is well directed horizontally usually hazardous power is not emitted into hazardous
area. More problematic than GSM base stations are GSM phones mainly because they can be carried into
hazardous areas. GSM phones are usually not explosion protected. The main hazard may not be due to emitted
RF field, but because at fault GSM phone can produce sparking, e.g. if internal circuits are interrupted.
Dust handling
Dust handling can generate high static charging.
All conductive items must be mutually galvanically
connected and earthed. If not, spark discharges are
expected.
Pumping flammable liquids
Safe pumping of flammable liquids with portable
pumps requires that all conductive items (drum,
pump, container and hose) are mutually galvani-
cally connected and earthed.
General part
16/31 17/31
Optical Radiation (light)
Optical electromagnetic waves can cause ignition source if power and flux density are sufficiently large. Usually
ignition source is indirectly caused with hot surface or hot particles due to absorption on solid surface or
airborne particles. Direct ignition with absorption in gas is hardly relevant because gases are transparent.
Exceptions could be in the case of radiation with very large flux density on the spectral range where particular
gas resonantly absorbs, i.e. if the radiation wavelength matches with absorption lines.
Safe limits of flux density and power of optical electromagnetic waves for gaseous explosive atmospheres are
set to 35 mW/mm
2
and 35 mW respectively, if optical electromagnetic waves are focused to cross section less
than 1 mm
2
.
For dust hazardous areas the safe limits are set to 10 mW/mm
2
and 35 mW for focused light.
Ionizing Radiation
The ionizing radiation that could cause ignition would be pretty powerful. No such sources are used in industrial
practice, so this ignition source is practically irrelevant.
Ultrasonic
Ultrazvok lahko povzroi vig, e sta mo in gostota toka dovolj veliki. Naprave, ki sevajo ultrazvok, so elektrine
naprave, pri katerih morajo biti izvedeni ukrepi protieksplozijske zaite. Pri izdelavi teh naprav je treba
upotevati tudi nevarnost viga z ultrazvokom.
Adiabatic Compression
Gases heat when compressed. If the gas is thermally isolated from the surroundings then the compression is
adiabatic and temperature rise is maximal for given compression ratio.
For adiabatic compression the temperature rise can be calculated from compression ratio and properties of
gas. The following relation can be used:
where
T final absolute temperature,
T
0
initial absolute temperature,
p final pressure,
p
0
initial pressure,
V final volume,
V
0
initial volume,
specific heat ratio: 2/3 for monoatomic (noble) gases, 5/3 for diatomic gases (air, hydrogen ...)
If the temperature of compressed explosive mixture reaches autoignition temperature, ignition occurs.
Exothermic Reactions, Autoignition of Dust Layers
The energy state of ingredients changes with chemical reactions, so with chemical reactions energy is either
released or binded. Reactions that release energy are exothermic.
Most often energy is mainly, and always at least partly, released as heat that heats the reaction mixture. With
temperature increase also the reaction rate increases, typically for a factor of two if the temperature is raised
for about 10 K to 20 K. Increased reaction rate further heats the reaction mixture and reaction rate increases
even more. A chain reaction establishes where a parameter, in this case temperature, grows exponentially
with time. During this so called thermal runaway the rising of temperature causes rising of pressure, that can
exceed pressure resistance of reaction vessel. If this happens explosion occurs, not due to ignition, but due to
released heat during chemical processes that causes pressure rise.
I = I
0
_
p
p
0
]
y-1
y
= I
0
_
I
I
0
]
1-y
Thermal runaway can be prevented with sufficient heat flow out of the reaction mixture that prevents
uncontrolled temperature rise. This is fairly simple with small amounts of reaction mixture, but can be difficult
with increased quantity of reaction mixture. This kind of behaviour occurs because with increasing the quantity
of reaction mixture the ratio of heat production to heat extraction is modified in favour of heat production. Heat
production is proportional to the quantity (volume) of reaction mixture, while the heat extraction is proportional
to outer surface area of reaction mixture. For example, if the size of reaction vessel is increased by a factor of
two the volume increases eight times, while the outer surface area increases only four times. Therefore the
cooling efficiency is reduced for a factor of two. The described dynamic characteristics of chemical reactions
shall be considered when chemical synthesis processes are scaled from laboratory to production conditions.
(Extreme case of a large body that is heated to glittering glow with small power is the Sun that has only 1 W of
heat power per 5 tonnes of its mass.)
Similar properties can be observed also with some dusts that at certain (sometimes quite low) temperature
begin to decompose exothermically. Real trouble in this case is low thermal conductivity of dust that prevents
effective cooling. Dust obstructs air flow so convective cooling can not establish within dust pile or dust layer.
Heat can only flow with conduction via dust grains that are not in a good thermal contact with each other and
via air between grains. Even slow exothermic reactions can therefore generate substantial temperature rise
that can cause difficulties, among others also autoignition of dust layers. (With liquids this kind of behaviour is
not observed because temperature differences in liquid generate convection that effectively carries heat from
interior of the reaction mixture to its outer surface). With dusts it is essential to know the temperature threshold
of exothermic decomposition and adjust the temperature of processes accordingly.
Nearly unsolvable difficulties arise if the substance can decompose autocatalytically. Autocatalytic decomposition
means that at least one of the decomposition products is catalyst of decomposition. With such substances
decreasing the temperature is mostly inefficient, because catalyst by itself can cause runaway reaction. With
decreasing the temperature runaway reactions are only delayed, but not prevented.
CONSTRUCTIONAL EXPLOSION PROTECTION
General
Measures of constructional explosion protection are implemented if preventive measures cant prevent ignition.
Measures of constructional explosion protection are of two kinds: prevention of propagation of hazardous
explosion effects out of the vessels where explosion can occur, and prevention of ingress of ignition sources
into vessels with explosive mixture.
Keeping the explosion in the vessel is not easy
because the explosion pressure can exceed 10 bar,
especially with dusts. The design of vessel to keep
explosion inside would be quite massive (comparable
to submarine designed for depth over 100 m), so
the usual solution is to provide explosion relief into
safe direction and therefore reducing the demands
for pressure resistance of the vessel. In any case it
is necessary to prevent propagation of flames and
shock wave to workplaces and to other vessels, e.g.
via connection piping.
Some vessels that contain explosive mixture are
connected to surroundings via pipes or breathing
valves, but in the surroundings the ignition sources
are not prevented according to demands of vessel
zoning (or perhaps the possible consequences
of explosion may be severe). In such cases it is
necessary to prevent ingress of ignition source from
surroundings into the vessel.
Flame arrester
Fine metal mesh in flame arrester prevents the
transmission of flame from outside of the vessel to its
interior.
General part
18/31 19/31
Equipment for explosion relief and for prevention
of flame propagation belongs to autonomous
protective systems. Autonomous protective systems
in European market must have EC declaration of
conformity that the manufacturer can issue on the
basis of EC type examination certificate and verified
quality system.
Flammable Gases and Liquids
With processes involving flammable gases and
liquids ignition sources from technology can usually
be avoided, if only dusts are not used (combustible or
not). Constructional explosion protection is used to
prevent ingress of flame into process vessels and to
prevent flame propagation along pipelines between
different vessels.
To prevent ingress of a flame from surroundings into
the vessel flame arresters are used, in many cases
on outdoor breathing valves to prevent ingress of flames into process vessels at eventual lightning strike or
other ignition source that may occur outdoors. Flame arresters operate with fine mesh through which gases
and gaseous mixtures can pass, but fine gaps in a mesh do not transmit flames. Because flames of different
flammable substances have different ability to
propagate through narrow gaps, flame arresters are
marked with gas group.
If the task is to prevent flame propagation along pipes
between process vessels flame arresters wont work
because in pipes ordinary flame propagation evolves
to detonation. With detonation explosive mixture is
pre-compressed so pressure rises violently and
flame front velocity reaches the speed of sound.
Such flames can be restrained only with specially
designed flame arresters so called detonation
arresters. These also have a marking of gas group.
Combustible Dust
Processes involving combustible dust often demand
application of measures of constructional explosion
protection, because at some procedures occurrence
of ignition sources is unavoidable. Typical example
are woodworking machines where sparks are
generated due to occasional presence of (metal)
foreign particles in the wood. In this case inerting is
not an option so constructional explosion protection
is the only practical solution.
Usually protected housings have built in devices for
explosion relief so that the requirements for pressure
resistance are reduced. With explosion relief the
expected pressure rise can be reduced from more
than 10 bar to less than 1 bar. The explosion relief
must be designed so that flames and shock wave
spread in non-hazardous direction.
Devices for explosion relief must be chosen
according to the requirements of the EN 14491 standard. Properties of dust (maximum explosion pressure
Detonation arrester
Detonation arrester can prevent propagation of deto-
nation wave in pipes.
Dust filter with explosion pressure relief
Dust filter is designed with constructional explosion
protection because ignition sources cant be reliably
avoided (e.g. sparks may enter the filter together with
the dust). The installed protective systems are:
explosion vents (metal membranes) that relief the
explosion (red arrows),
rotary valve that does not allow transmission of
explosion to silo(white arrow),
input hanging flap that closes if the direction of flow
is reversed (yellow arrow),
explosion diverter equipped with another explosion
vent (green arrow).
and explosion class) as well as pressure resistance,
volume and shape of the housing shall be considered
to determine the necessary area of relief openings.
Care shall be taken to ensure that relief openings
can not be obstructed in the case of explosion. For
example relief openings of dust filters shall be
positioned so that in the case of explosion filter bags
can not cover the openings.
Flames and shock wave of explosion from indoor
equipment are vented to the outdoor via venting
channels. Care shall be taken that the venting
channel does not have high resistance for fast flow of
gases. It means that it shall not be too long and shall
not have sharp bends or narrow sections.
The protected equipment shall be explosion
decoupled from other equipment and workplaces.
Flame and detonation arresters are not useful
because with dust these devices would stuff during
normal operation. With dust the devices for explosion
decoupling are fast acting valves, rotary valves, flaps,
decoupling chimneys etc.
EQUIPMENT AND
INSTALLATIONS
Equipment
The European requirements for the equipment are
drawn in the Directive 94/9/EC according to which the
equipment must bare a CE marking and must have an EC declaration of conformity. The requirements hold for
the equipment within the scope of the Directive - that is for the equipment with its own potential ignition source.
Equipments own potential ignition sources are the ones that are caused with the functioning of the equipment,
not with particular technological process.
Regarding the category of the equipment the manufacturer can issue an EC declaration of conformity if the
equipment fulfils the following conditions:
REQUIREMENTS ACCORDING TO CATEGORIES
Category Technical requirements Formal requirements
1G, 1D Equipment shall not have its
own ignition sources during
normal operation, expected and
even rare malfunctions.
A notified body shall confirm the conformity of the design and
manufacturing. Usually this means an EC type examination certifi-
cate and quality system notification.
normal operation and expected
malfunctions.
For electrical equipment and internal combustion engines a noti-
fied body shall confirm the conformity of the design and manufac-
turing. Usually this means an EC type examination certificate and
quality system notification.
normal operation.
The manufacturer confirms the compliance of the design and
manufacturing of the equipment. Revision and testing by notified
body are not required.
If equipment complies with the requirements of standards of the Directive, assumption of conformity applies.
Explosion pressure relief in action
In the case of explosion the installed protective systems
assure the following:
that the filter housing is not damaged with explosion
which is assured by explosion relief,
that flames of explosion and shock wave cant reach
the silo which is assured with rotay valve,
that flames of explosion and shock wave cant strike
back to production hall via dust extraction duct
which is assured by flap,
that shock wave cant strike back into the produc-
tion hall via duct for the return of clean air which is
assured by diverter.
General part
20/31 21/31
Electrical equipment
Regarding the type of equipment, different techniques are appropriate for protection. General requirements
are drawn in the EN 60079-0 standard while the particular requirements for different types of protection are
found in further standards of the series EN 60079 and EN 61241.
EXPLOSION PROTECTION OF ELECTRICAL EQUIPMENT
Flameproof en-
closure
Ex d,
EN/IEC 60079-1
Flameproof enclosures prevent transmission of flames of explosion that can occur inside
equipment to surrounding potentially explosive atmosphere. The protection is assured with
pressure resistant design of enclosure and good fitting of parts of enclosure. The fitting of
parts of enclosure is so tight that flames cant penetrate the gaps between them.
The protection is suitable for equipment for gaseous potentially explosive atmospheres.
Flameproof equipment has a marking of gas group IIA, IIB or IIC, because transmission ability
of flames depends on flammable substance. As usual, the strictest requirements are for the
gas group IIC, while the requirements for the gas group IIA are the least strict.
Flameproof enclosures are used for protection of equipment that contains ignition sources in
the enclosure (e.g. power equipment, electric motors, switches, etc.). Protection by flameproof
enclosure is one of the most widely used techniques of protection.
Pressurized
equipment
Ex p, Ex pD
EN/ IEC 60079-2
EN/ IEC 61241-4
Flow and over pressure of air prevent ingress into and accumulation of explosive atmosphere
within the enclosure. The enclosure may or may not contain internal source of flammable
substance.
Protection is suitable for equipment, intended for use with gaseous and dust potentially explo-
sive atmospheres, that contains ignition sources inside the enclosure.
Powder filling
Ex q,
EN/IEC 60079-5
Non-combustible powder that fills the enclosure prevents flame propagation.
The protection is suitable for equipment for gaseous potentially explosive atmospheres. The
protection is not suitable for equipment with moving parts or equipment with substantial power
dissipation.
Oil immersion
Ex o,
EN/IEC 60079-6
Oil prevents explosive atmosphere to reach ignition source.
The protection is suitable for equipment for gaseous potentially explosive atmospheres. Oil im-
mersion is rarely used, mostly in mining for protection of mining transformers.
Increased safety
Ex e,
EN/IEC 60079-7
Increased safety operates with prevention of ignition sources with improved construction and
conservative design of equipment. Reliable components, improved insulations, increased
separations between live parts etc. are used in the design. Electronic components without ad-
ditional protection are not permitted.
Protection is suitable for equipment, intended for use with gaseous potentially explosive
atmospheres. It is used for terminal boxes, electric motors etc. Increased safety is one of the
most widely used techniques of protection.
Intrinsic safety
Ex i, Ex iD
EN/IEC 60079-11
With this type of protection the electrical power and accumulated energy in the circuits are so
low that eventual spark, even in the case of specified faults, cant ignite explosive atmosphere.
Intrinsically safe systems usually consist of two parts: associated apparatus, installed outside
hazardous area, that assures appropriate electrical parameters, and intrinsically safe appara-
tus, that cant ignite explosive atmosphere when supplied with these electrical parameters.
The protection is suitable for electronic equipment for gaseous and dust potentially explosive
atmospheres, that does not require high voltage or current for operation. Intrinsically safe
equipment has a marking of gas group IIA, IIB or IIC, because sensitivity to ignition differs
between flammable substances.
Intrinsic safety is the most widely used technique for protection of electronic measuring sys-
tems, transmitters and process electronics.
n equipment
Ex n,
EN/IEC 60079-15
Type of protection n works as sort of simplified version of increased safety, intrinsic safety
and flameproof enclosure or as equipment with gas-tight enclosure that prevents the ingress
of explosive atmosphere into the enclosure.
The protection is suitable for all types of equipment if high level of protection is not required.
Depending on the principle of protection used, marking of gas group IIA, IIB or IIC may be
necessary.
Recently this type of protection gained on popularity.
EXPLOSION PROTECTION OF ELECTRICAL EQUIPMENT
Encapsulation
Ex m, Ex mD
EN/IEC 60079-18
Encapsulation compound prevents explosive atmosphere to reach ignition source. Encapsula-
tion compound prevents explosive atmosphere to reach ignition source.
The protection is suitable for equipment for gaseous and dust potentially explosive atmos-
pheres that neither contains movable parts, nor dissipates high power. It is mostly used for
protection of coils and electronics.
Protection of
equipment with
optical radiation
Ex op,
EN/IEC 60079-28
The protection works with limitation of optical power or optical flux density, by assuring that
equipment does not radiate into potentially explosive atmosphere or with switch off of radia-
tors in the case of optical system breaking. The equipment is suitable for protection of optical
communication systems.
Relatively new type of protection that has been introduced only recently.
Protection by
enclosure
Ex tD,
EN/IEC 60079-31
The protection operates with dust tight enclosure that prevents combustible dust to reach
ignition sources. The protection is suitable for equipment for dust potentially explosive atmos-
pheres. It is used for many types of equipment, including power equipment, switches, electric
motors, lamps, etc.
Protection by enclosure is most widely used technique for protection of electrical equipment
for use with combustible dust in the absence of flammable gases and liquids.
Non-electrical equipment
Characteristic ignition sources for the non-electrical equipment, when present, are hot surfaces, mechanically
generated sparks and electrostatic discharges. The mechanical equipment that has its own ignition source
usually has a motor drive (electrical, hydraulic, pneumatic or with internal combustion engine).
The essential difference between electrical and mechanical equipment is that for the compliance of the
mechanical equipment many times the use of general requirements standard EN 13463-1 suffices, while for the
compliance of the electrical equipment the use of at least one explosion protection technique is unavoidable.
If analysis according to the general standard reveals no ignition sources in view of category requirements, no
further measures for ignition protection of mechanical equipment are necessary.
When the use of the general standard identifies potential ignition source, appropriate explosion protection
measures shall be applied according to equipment and ignition source properties. Usually a standardized type
of protection according to series EN 13463 of standards is used.
EXPLOSION PROTECTION OF NON-ELECTRICAL EQUIPMENT
No additional
protection
EN 13463-1
Non-electrical equipment with no additional protection that complies with the requirements
of the Directive 94/9/EC either has no own potential ignition sources, or these ignition sources
cant become active in operating condition relevant to the category requirements. Many times
this equipment technically by itself fulfils the requirements for the protection with construc-
tional safety c, but is not marked as such.
Flow restriction
fr, EN 13463-2
Non-electrical equipment with flow restriction would fulfil the requirements for the category 3,
but the manufacturers do not find this type of protection useful. The standard EN 13463-2 will
most likely be withdrawn.
Flameproof en-
closure
d, EN 13463-3
The requirements are identical to the requirements for the same type of protection for the
electrical equipment.
Constructional
safety
c, EN 13463-5
Perhaps the most natural choice of protection for many kinds of non-electrical equipment that
seems like mechanical equivalent to electrical increased safety. It works with conservative
design that prevents faults that could give rise to ignition sources. Mechanical parts are chosen
with due redundancy and are preventively replaced before they wear out. This type of protection
is the most widely used type of protection for non-electrical equipment. Constructional safety
should not be misinterpreted as constructional explosion protection.
General part
22/31 23/31
EXPLOSION PROTECTION OF NON-ELECTRICAL EQUIPMENT
Control of ignition
sources
b, EN 13463-6
This type of protection uses the property of properly designed mechanical parts that faults do
not happen momentarily, but rather slowly. Faults of mechanical parts can be detected in their
initial phase before they can give rise to ignition source so that the machine can be shut down
in due time and necessary repairs can be made. Although the equipment is non-electrical, the
control systems are normally made of electrical (intrinsically safe) apparatus. The protection
works in a similar fashion as thermal protection of electric motors with thermistors.
Liquid immersion
k, EN 13463-8
With immersion of critical parts into the liquid the access of explosive mixture to ignition source
is prevented. This type of protection is mostly used with transmission gear.
Installations
The installation of equipment shall conform to the following criteria: it shall comply with the general safety
requirements that hold also in non-hazardous plants, it shall preserve the explosion protection of the equipment
and it shall not introduce new unacceptable risks. The basic guideline shall be to install the equipment outside
hazardous areas whenever reasonably practicable. If installation into hazardous areas cant be avoided, the
equipment shall be placed into the least hazardous area possible.
Electrical equipment shall be installed according to the requirements of the EN 60079-14 standard. Final as-built
documentation shall be prepared that shall contain also the documents on the compliance of the equipment and
on suitability of equipment for actual ambient conditions. No special international or European standard exists
for non-electrical installations in hazardous areas. Non-electrical installations shall be constructed according
to general safety requirements, manufacturers instructions and with due consideration of electrostatics and
mechanically generated sparks.
Equipment selection
Properties of flammable and combustible substances and zoning shall be the main criteria when equipment
is selected. With flammable gases and liquids consideration of gas group, temperature class and zoning will
suffice in most cases. With dusts the usually required data are dust group (normally obvious), smouldering
temperature of 5 mm thick dust layer and self-ignition temperature of dust cloud. Many times, especially when
selecting non-electrical equipment, also the data on minimum ignition energy, maximum explosion pressure
and explosion class are necessary.
The gas and dust group criteria are the following:
GROUP CRITERIA
Group Equipment marking
IIA IIA, IIB, IIC or II with no gas group marking
IIB IIB, IIC or II with no gas group marking
IIC IIC or II with no gas group marking
IIIA IIIA, IIIB, IIIC or II with no dust group marking
IIIB IIIB, IIIC or II with no dust group marking
IIIC IIIC or II with no dust group marking
GAS/VAPOUR TEMPERATURE CLASS CRITERIA
Substance Equipment marking
T1 T1, T2, T3, T4 ,T5 or T6
T2 T2, T3, T4 ,T5 or T6
T3 T3, T4 ,T5 or T6
T4 T4 ,T5 or T6
T5 T5 or T6
T6 T6
Some non-electrical equipment has a temperature marking TX. It means that the equipment does not have its
own heat sources but heats only with thermal contact with media and ambient.
With dusts safety margin regarding equipment heating shall be considered.
In zones 21 and 22: 75 K regarding the smouldering temperature of 5 mm thick dust layer. E.g., if smouldering
threshold is at 200C, equipment in zones 21 and 22 shall not heat above 125C.
In zone 20: the margin shall be inferred from method described in the installation standard regarding the
expected thickness of dust layers on the equipment or the equipment, tested with the expected thickness of
dust layer L [mm] shall be selected (temperature marking on the equipment TL). In the later case again the
safety margin of 75 K between smouldering temperature of L mm thick dust layer and temperature marking
of equipment shall be considered.
In all zones: 1/3 in degrees Celsius regarding the self ignition temperature of dust cloud. E.g. if the dust
cloud ignites at 240C, equipment shall not heat above 160C.
Equipment shall have appropriate marking of category according to the Directive 94/9/EC and IEC equipment
protection level (EPL) respectively. The following criteria apply:
ZONES, CATEGORIES AND EPL
Zone Category EPL
0 1G Ga
1 1G or 2G Ga or Gb
2 1G or 2G or 3G Ga or Gb or Gc
20 1D Da
21 1D or 2D Da or Db
22 1D or 2D or 3D Da or Db or Dc
Older equipment bares no marking of category and/or EPL. With this equipment the corresponding level of
protection of electrical equipment for gas explosive atmospheres is inferred from the following table:
EQUIPMENT FOR GAS/VAPOUR ATMOSPHERES
Type of protection Equivalent Category/EPL
ia 1G/Ga
ib, e, d, m, p, q, o 2G/Gb
nA, nL, nC, nR 3G/Gc
General part
24/31 25/31
The situation with older equipment for dust explosive atmospheres is a bit more complicated because the
technical requirements were essentially modified. However, many times the following table applies:
EQUIPMENT FOR DUST ATMOSPHERES
Type of protection Equivalent EPL
ia
IP6X
1D/Da
ib, e, d, m, p
IP6X
2D/Db
nA, nL, nC, nR
IP6X
3D/Dc
ia, ib, e, d, m, p, nA,
nL, nC, nR
IP 5X
3D/Dc
only for groups IIIA and IIIB
Similar correspondence for older non-electrical equipment is not possible because legal technical require-
ments for non-electrical equipment were first introduced with the Directive 94/9/EC. Conformity assessment
procedures for the older non-electrical equipment have not been performed yet and shall be done now (usually
under the users responsibility).
Electrical installations
The electrical installations shall comply to the requirements of the standard EN 60079-14 Explosive atmospheres
- Part 14: Electrical Installations design, selection and erection.
All installed equipment shall have appropriate potential equalization and appropriate electrical protection for
the case of overload or any other fault. The protection can function properly only if the protection is consistently
applied according to equipment ratings. This also holds for intrinsically safe circuits where the associated
apparatus need appropriate protection.
The choice of cables, cable glands and means of termination shall enable proper functioning of explosion
protection. The requirements for cables are described in detail in the installation standard with principle focus
on chemical and mechanical resistance. Cable glands shall be chosen according to the type of protection of
the equipment. For example increased safety equipment requires cable glands with a marking Ex e. Unused
openings shall be sealed according to type of protection requirements.
Special considerations deserve cable entries into flameproof enclosures. The problem is that cable entry tends
to be the weakest part of the enclosure due to elastomeric properties of sealing ring and cable sheath that flow
under stress. Even if the cable entry is compliant when assembled the cold flow of elastomerics can relax the
mechanical grip and can therefore jeopardize the entire protection of the apparatus. But there is also a durable
technically superior solution for cable entry with the use of cable bushings. This solution costs a bit more so
some users dont like it. However it seems reasonable to think it over if minor savings are worth increasing the
risk of explosion.
At the termination of conductors a few simple rules shall be followed:
only one conductor shall be terminated in a single terminal unless the terminal is designed for termination
of more than one conductor,
only as much isolation shall be removed from conductors that is absolutely necessary; the isolation shall
touch the conductive part of terminal,
fine-stranded conductors shall be protected against separation of strands, e.g.with the use of sleeves,
single conductors, connected with single screw saddle clamps, shall be connected with U turns,
unused conductors shall be appropriately terminated; the use of insulation tape alone is not sufficient.
Regarding the type of protection some additional requirements apply that are stated in detail in the installation
standard.
SOME BASIC INSTALLATION REQUIREMENTS
Type of protection Requirements
Ex e The principle of protection suggests that a careful design to prevent sparking or heating shall be
considered. The installation shall keep the IP protection of apparatus and shall not reduce separa-
tion distances between bare conductive parts under different voltages. Also the electrical protection
shall be designed with due care. The electric motors with this type of protection shall not be driven
with frequency converters or started with soft start unless drivers are certified together with mo-
tors.
Ex d The installation shall keep the pressure resistance and flameproof character of the enclosure. It is
wise to use cable bushings instead of cable glands. Electric motors that are driven with frequency
converters or started with soft start shall have appropriate thermal protection, normally with PTC
thermistors.
Ex i Ingress of foreign voltage or current into intrinsically safe circuits shall be prevented. Cables of
intrinsically safe circuits should be screened and run in separate shelves reserved for intrinsi-
cally safe cables only. The color of outer sheath shall be light blue. Connection of intrinsically safe
circuits in the same terminal box with non-intrinsically safe circuits should be avoided whenever
possible. When this is unavoidable at least 50 mm distance between bare parts of intrinsically safe
circuits to non-intrinsically safe circuits shall be assured. In multi-core cables with intrinsically
safe circuits non-intrinsically safe circuits are not permitted.
Ex m These devices are especially sensitive to proper electrical protection. Apparatus without internal
circuit breaker shall have appropriate protection installed in the main electrical cabinet. Normally
the rated current of circuit breaker shall not exceed three times the rated current of the apparatus.
Non-electrical installations
The standard for non-electrical installations has not been published yet, so there is no international reference
document on requirements for the installation of the non-electrical equipment. However, certain general rules
can be summarized from principles of protection of non-electrical equipment.
All non-electrical equipment shall operate according to manufacturers instructions and only within the
Fine stranded conductors
Fine stranded conductors shall be equipped with
sleeves. The blue conductor is prepared for con-
nection while the green conductor is not.
Single screw saddle clamps
Single conductors shall have U turns. Only as much
isolation as absolutely necessary shall be removed.
The isolation shall touch conductive part of the
terminal.
General part
26/31 27/31
limitations of intended use as defined by the manufacturer. It means among other things that power source
to which the equipment is connected shall not exceed the ratings of non-electrical apparatus (e.g. nominal
speed, power, pneumatic/hydraulic pressure, etc.). Also the ambinet and media temperatures shall be within
the range of manufacturers specifications.
All installed non-electrical equipment shall have appropriate potential equalization and shall be earthed. The
earthing resistance shall not exceed 1 M as required by electrostatics considerations.
Maintenance
The goal of maintenance is to keep equipment and installations in good repair regarding the explosion
protection. The maintenance activities consist of preventive and interventional actions. The basic preventive
activities are regular inspections and regular replacements of parts that can wear out or age. Interventional
activities are necessary when faults or other deficiencies occur. The requirements for the maintenance of
electrical installations in hazardous areas are drawn in the EN 60079-17 standard. Since there is no standard
for the maintenance of non-electrical installations, sensible use of the EN 60079-17 standard is recommended.
The frequency of necessary maintenance activities depends mainly on ambient conditions and general state
of equipment like the age. The core of successful maintenance are regular inspections of actual condition of
equipment and installations. The requirements for regular inspections are in detail described in the EN 60079-
17 standard.
For all equipment the following shall be regularly inspected:
equipment and installations shall be clearly marked;
equipment shall have appropriate group, temperature and category/EPL markings;
the documentation shall be in line with actual installations, e.g. inspections shall include checking if any
unauthorised (i.e. non-documented) modifications have been performed. If such a modification is found
either it shall be approved by responsible person and properly documented or matters returned to original
state;
electrical protection settings shall be as documented in the electrical scheme;
all cables shall be without any damage including potential equalization/earthing cables;
ambient conditions shall not degrade equipment or cables (e.g. rusty enclosures, degradation of synthetic
enclosures and cable insulations by sunlight or weather, etc.);
electrical installatons shall maintain integrity. Periodic measurements of electrical installations shall
confirm that.
power supply (motor drives, pneumatic/hydraulic supply) shall be according to equipment ratings;
BASIC INSPECTION REQUIREMENTS
Grade of inspection Activities
Visual The equipment can normally function during visual inspections, because at visual inspections
only those deficiencies are sought for that can be noticed without opening of equipment. Damag-
es to cable insulations, loosening of earthing connections, suspicious noise of machines, level of
lubricants, settings of electrical protection are typical examples of what should be inspected. A
good idea is that all personnel are qualified to perform visual inspections and that these inspec-
tions are carried out permanently. In such case there is no need to keep written records of visual
inspections.
Close At close inspections the equipment is dismantled to extent that does not require the use of spe-
cial tools or dismounting of the equipment. Of course, during the inspection the equipment shall
be separated from power source and due measures shall be taken to prevent accidental start-
up. Beside issues that are inspected during visual inspections also the parts that are prone to
wear-out and ageing shall be inspected, like sealings, drive belts, tightness of cable entries etc.
The close inspections include also replacement of parts that may wear-out in the near future. If
measuring equipment is used during the inspection it shall be adequately explosion protected or
formation of explosive mixtures shall be prevented during the inspection. Written records shall
be kept on close inspections.
BASIC INSPECTION REQUIREMENTS
Grade of inspection Activities
Detailed All the aspects of explosion protection that could degrade with time shall be inspected. Usually
this requires dismounting of the equipment and examination in appropriately equipped work-
shop (e.g. inspection of air gaps of flameproof enclosures). This should be done only by qualified
personnel with appropriate expertise. During detailed inspection all parts that are expected to
wear-out before the next scheduled inspection shall be replaced. This also holds for parts that
may be hard to reach (e.g. bearings). Detailed inspections also require the measurements of the
electrical installations that normally can't be safely performed if all(!) flammable substances are
not removed from the plant. Therefore detailed inspections are usually done during scheduled
refits of plants. Written records shall be kept on detailed inspections.
The basic requirements of maintenance for different types of electrical equipment protection are as follows:
MAINTENANCE OF ELECTRICAL EQUIPMENT - BASIC REQUIREMENTS
Protection type Tasks
Ex d if direct cable entries with glands with elastomeric sealings are used the inspection shall
focus on tightness of entry. Cables that plastically deform in the gland may not be appropriate
and should be replaced with appropriate ones;
enclosures shall be inspected for rust. If rust is observed detailed inspection of apparatus
shall be performed in appropriate workshop to check the air gaps;
apparatus with any deformation/damage on enclosure shall be replaced.
Ex p, Ex pD check the pressure settings of protective gas supply;
check the purging time;
check the operating pressure of the enclosure;
check the sealings of the enclosure.
Ex q check for any signs of powder leakage from the enclosure and replace the apparatus if leak-
age occurred;
do not open the enclosure.
Ex o check for signs of oil leakage and replace sealings if leakage occurred;
check oil level and refill if necessary. Use only oil type as specified by the manufacturer of the
equipment.
Ex e check grip of cable glands on cables. Tighten if necessary;
check the sealings of enclosure. Replace sealings if necessary;
check tightness of cable terminations. Tighten if necessary;
check cable terminations if installation requirements are met (U turns, sleeves on fine
stranded conductors, etc.),
check luminaries if appropriate bulbs are used.
Ex i, Ex iD check if associated/intrinsically safe apparatus are of correct type as in electrical scheme;
check grip of cable glands on cables. Tighten if necessary;
check tightness of cable terminations. Tighten if necessary;
check separations between Ex i bare parts and other circuits bare parts in electrical cabinet;
check separations between Ex i cables and other cables;
Ex n protection nA: do as for increased safety;
protection nC: do as for flameproof enclosures;
protection nL: do as for intrinsic safety;
protection nR:
check the sealings of enclosure. Replace sealings if necessary;
apparatus with any deformation/damage on enclosures shall be replaced;
Ex m, Ex mD apparatus with any deformation/damage on enclosures or encapsulation compound shall be
replaced.
General part
28/31 29/31
MAINTENANCE OF ELECTRICAL EQUIPMENT - BASIC REQUIREMENTS
Ex tD check the sealings of enclosure. Replace sealings if necessary;
check for any dust inside enclosure. Replace sealings if necessary;
apparatus with any deformation/damage on enclosures shall be replaced;
The basic requirements of maintenance for different types of non-electrical equipment protection are as follows:
MAINTENANCE OF NON-ELECTRICAL EQUIPMENT - BASIC REQUIREMENTS
d inspect according to Ex d electrical apparatus requirements with cable entries any other
non-metallic entries.
c check bearings for wear (e.g. operating hours, noise, vibration, heating) and replace if neces-
sary;
check belt drives for wear and replace if necessary. Use only antistatic belts;
check chain drives for wear and replace if necessary;
check lubrication/coolant liquid levels;
check moving/rotating parts for excessive friction;
check rotating parts for balance;
check rotating parts for deformations,
check the symmetry of clearance between rotating and fixed parts,
check ingress protection of enclosures. Replace sealings if necessary.
b simulate fault and check for protection functioning;
inspect (intrinsically safe) protection loop according to electrical apparatus requirements.
k check for signs of liquid (oil) leakage and replace sealings if leakage occurred;
check if (regular) oil change is necessary;
check oil level and refill if necessary. Use only oil type as specified by the manufacturer of the
equipment.
Maintenance of earthing connections
Earthing connections are a vital part of any explosion protection concept. Because electrostatic discharges are
one of the most frequent causes of ignition earthing connections shall be maintained rigorously so that users
can always rely on their integrity.
Clamped wire connections shall be regularly checked for any damages to cable or clamp. Visual inspections
shall be performed continuously, i.e. any time that clamp is used.
Fixed potential equalization wire connections shall be regularly visually inspected for loosening of contacts and
possible damage of wire.
Hoses with internal metal reinforcement shall be regularly checked for integrity of connection flange - metal
mesh - flange, i.e. flange to flange galvanic integrity. These inspections can not be done visually but only with
measurement of electrical resistance between flanges. These measurements shall be recorded. In any case of
suspicious resistance increase hose shall be repaired or discarded.
Protective systems
Protective systems, autonomous and integrated, shall be regularly visually inspected for obvious damage and
deformations. Detailed inspections of protective systems shall be done only by personnel, authorised by the
manufacturer.
TECHNOLOGICAL IGNITION SOURCES
Under the term technological ignition sources are understood the sources of ignition that are not own ignition
sources of the equipment, i.e. not caused solely by functioning of the equipment. These sources of ignition
can be caused by the equipment, but only in combination with substances and procedures being carried out.
Even equipment without any own potential ignition sources, that therefore doesnt need any ATEX markings or
explosion protection measures, can in combination with substances cause ignition (usually with electrostatics).
Distinguishing property of technological ignition sources is that usually they cant be adequately treated in
a routine fashion or by using simple recipes, because all specific properties of technological process and
substances involved shall be considered.
Equipment compliant to the requirements of the Directive 94/9/EC can in combination with substances cause
ignition because within the scope of the Directive are only potential ignition sources own to the equipment while
the ignition sources that could arise only in combination with substances are not. Therefore the measures to
prevent technological ignition sources are usually not determined by the manufacturer of the equipment and
also not assessed by notified bodies during certification. Explosion protection measures to prevent technological
ignition sources is sole responsibility of the user and shall be determined in the Explosion protection document
for specific situations. Their compliance should be assessed during the assessment of compliance of Explosion
protection document and installations of equipment.
The usually relevant technological sources of ignition are the following:
mechanically generated sparks
electrostatic discharges
exothermic reactions and autoignition of dust
Among these also ignition sources due to electrical installations could be added. However these are so tightly
connected to electrical equipment that they are considered separately.
Electrical installations and electrical equipment are in general less problematic than non-electrical equipment
regarding the technological ignition sources. The main reason for this is that practically all technological
procedures are carried out with mechanical or thermal processing of substances: the electrical equipment
has auxiliary function (e.g. providing power) while non-electrical parts of machinery are in direct contact with
hazardous substances. Here the combination of mechanical/thermal load and presence of hazardous substances
introduces new risks that are not possessed by equipment itself, nor by hazardous substance itself. Illustrative
example is milling where new risk is introduced due to possible mechanical sparking if foreign objects are in
the product. This risk is not caused by sole action of mill, nor can substance itself produce sparking. Similar
situations arise practically always when processes to modify the state of the substance are carried out.
Many complications can be avoided if the manufacturer is noticed in advance to some additional requirements
for the design of the equipment that we may have to enable safe operating procedures. If we dont do it in
due time, before order or purchase, we can be supplied with the machine that is not entirely safe for our
intended use. Many times redesigning of new machine is necessary, or even worse, the user is forced to
accept increased risk.
Therefore the Explosion protection document for the construction phase shall contain relevant requirements
for technological equipment that should be transposed into requirements when ordering the equipment. The
Explosion protection document for the construction phase shall also contain key requirements for carrying out
procedures as far as these requirements are connected with construction and ordering of equipment. However,
detailed requirements regarding the explosion protection shall be part of as built Explosion protection
document.
RESPONSIBILITIES
Everybody involved in design or execution of explosion protection measures have their share of responsibility.
General part
30/31 31/31
Employer
The responsibility of the employer is the largest because he (or she) decided to do business with hazardous
technologies that can lead to explosion. Objectively the employer is responsible for all that happens. Because
the employer usually isnt expert for explosion protection, the responsibility can effectively be managed only if
competent experts and personnel are employed to do the task. A lot can be done with proper choice of experts
to design the plant and choice of experts to supervise them.
Another obligation of the employer is to provide appropriate conditions for safe work in production phase where
one of the key tasks is to provide proper training of personnel and proper funds for maintenance.
Responsible persons
Appointed responsible persons for explosion protection shall have appropriate competence to do the job.
Among the responsibilities of these persons are managing and organising maintenance of equipment and
documentation, preparation of safe working procedures and supervision over the status of the explosion
protection in the plant. In spite of good expertise it should always be encouraged that responsible person seeks
independent advice on key decisions, modifications of procedures and/or technology and similar.
Personnel
Personnel that works in hazardous areas shall be trained to do their job. This applies to operators as well as to
maintenance personnel. In most cases there is no need that all the personnel should understand all the aspects
of applied explosion protection measures, but they shall be familiar with issues that concern their job. Regular
training at least once per two years shall be provided.
REFERENCES
Directives
Directive 94/9/EC
Directive 1999/92/EC
Standards
EN 1127-1:2007 Explosive atmospheres - Explosion prevention and protection - Part 1: Basic concepts and
methodology
EN 60079-10-1:2009 Explosive atmospheres -- Part 10-1: Classification of areas - Explosive gas atmospheres
EN 60079-10-2:2009 Explosive atmospheres -- Part 10-2: Classification of areas - Combustible dust
atmospheres
EN 60079-14:2008 Explosive atmospheres -- Part 14: Electrical installations design, selection and erection
EN 60079-17:2007 Explosive atmospheres -- Part 17: Electrical installations inspection and maintenance
CLC/TR 50404:2003 Electrostatics - Code of practice for the avoidance of hazards due to static electricity
CEN/TR 15281:2006 Guidance on Inerting for the Prevention of Explosions

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