Government T0104
Presented by
CCO
ONNSSUULLTTIINNG
G
– Testing and Certification – Certification Mark for Explosion Protected (Ex) Equipment –
– Area Classification / Explosion Risk Assessment – Inspection of New or In-service Ex Equipment &
Installations – Management System for Ex Installations – Consultation – Presentations & Workshops –
– Training Courses –
INSPECTION OF IN-SERVICE EXPLOSION PROTECTED EQUIPMENT
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INDEX
TOPICS Page
1. Introduction ........................................................................................................................... 3
2. Questions to be answered ................................................................................................... 3
3. Definition of “Inspection” ...................................................................................................... 3
4. Standards / Info Basis .......................................................................................................... 3
5. GRADES of inspection ......................................................................................................... 4
6. TYPES of inspection ............................................................................................................ 5
7. Generic Inspection Sheets ................................................................................................... 6
8. Conclusions ........................................................................................................................ 25
Annex A Equipment selection.............................................................................................. 26
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1. Introduction
The inspection of Explosion Protected (Ex) Equipment, together with appropriate
maintenance and repair, is critical for safety. This paper highlights the differences
between electrical and Ex inspections and presents some solutions based on
standards covering the subject and best practice from experience.
2. Questions to be answered
1. Q: What is the PURPOSE of an Ex inspection ?
3. Definition of “Inspection”
Action comprising careful scrutiny of an item carried out either without dismantling, or
with the addition of partial dismantling as required, supplemented by means such as
measurement, in order to arrive at a reliable conclusion as to the (suitability and)
condition of an item.
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NOTE that information taken from SANS 60079-17 Edition 4 (IEC 60079-17 Edition 4)
is used on the next pages (updated versions of the examples listed in
SANS 10086-1).
NOTE that this presentation is based on the above national standards. Individual
companies may have stricter requirements.
5. GRADES of inspection
SANS 60079-17 defines visual, close, and detailed inspections.
visual inspection (V): An inspection that identifies, without the use of access
equipment or tools, those defects, for example, missing bolts, which will be apparent
to the unaided eye. Visual inspections do not require the enclosure to be opened, or
the equipment to be de-energized.
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6. TYPES of inspection
TYPES of inspection are as follows.
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Using the preceding definitions, generic inspection sheets from SANS 60079-17
Edition 4 (IEC 60079-17 Edition 4) may be used for practical inspection.
(Reminder: These are updated versions of the examples listed in SANS 10086-1).
Depending on the sophistication of the inspection staff, these can be used, or specific
checklists (suitable for specific equipment, e.g. fluorescent luminaries of a particular
make and model, or Ex nA motors) can be compiled.
The inspections sheets address three areas of compliance, i.e. the equipment, its
installation and its environment. Equipment inspection requires the explosion
protection rating and suitability to be first evaluated, then its condition.
The inspection sheets make provision for the three grades of inspection, i.e. Visual
(V), Close (C), Detailed (D).
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1A EQUIPMENT
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Ex e and Type “n” equipment Enclosure must provide IP54 rating if containing
bare live parts.
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9* Bolts, cable entry devices (direct and indirect entry) and blanking elements are
of the correct type and are complete and tight
- physical check
- visual check
Cable glands, adaptors and plugs must have the same explosion protection as
the enclosure to which connected. The check-tightening of cable glands under
close inspection can be effected by hand without the need to remove weather-
proofing tape or shrouds. Detailed inspections may necessitate that the cable
glands are dismantled only where the integrity of the glands cannot be
ascertained by close Inspection.
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10 Ex d Flange faces are clean and undamaged and gaskets, if any, are
satisfactory
Faces must be rust-free and without deep pits, scratches or marks, e.g. caused
by screwdriver to remove lid. A thin layer of grease (not silicone rubber) after
removing loose rust is ideal protection.
Generally speaking, the biggest flange gap that will be permitted is 0,4mm. A
feeler gauge can be carried along. It should be possible to confirm a
completely tight fit visually on smaller enclosures.
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Lamps with higher power ratings or other types of lamps may get hotter than
the approved lamp type. Some lamps will have a specific condition of use in
terms of position/orientation, for example the lens of a highbay light fitting
normally pointing downwards will get hotter if the light is pointed up.
Restricted breathing devices are part of Ex nC equipment and must only allow
a low exchange rate between internal and external atmosphere.
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Ex e and Type “n” equipment B&D devices must provide IP54 rating if
enclosure contains bare live parts.
1B INSTALLATION
Cables used for fixed wiring in hazardous areas shall be appropriate for the
ambient conditions in service. Cables shall be:
a) sheathed with thermoplastic, thermosetting, or elastomeric material.
They shall be circular, compact, have extruded bedding and fillers, if
any, shall be non hygroscopic, or
b) mineral insulated metal sheathed, or
c) special, e.g. flat cables with appropriate cable glands.
Such cables must be flame retardant.
Openings in walls for cables and conduits between different hazardous areas
and between hazardous and non-hazardous areas shall be adequately sealed,
for example by means of sand seals or mortar sealing to maintain the area
classification where relevant. Trunking, ducts or pipes connecting differently
zoned areas must be sealed, for example by a sealing compound or sealing
devices. For trenches, adequate venting or sand-filling may be used.
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Bonding connections must prevent self loosening and corrosion which may
reduce the effectiveness of connection.
Metallic enclosures of intrinsically safe or energy-limited apparatus generally
need not be connected to the equipotential bonding system.
Wiring Protection against overload and from the harmful effects of short-circuits
and earth faults.
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If unused cable are not removed, the cores of the hazardous area end of such
unused cables shall either be connected to earth or be adequately insulated by
means of terminations suitable for the type of protection, for example isolating
and capping both ends. Insulation by tape alone is not permitted.
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Gas Minimum
group distance
(mm)
IIA 10
IIB 30
IIC 40
1C ENVIRONMENT
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1 2 3 4
Grade of inspection
Check that:
Detailed Close Visual
2A EQUIPMENT
1 Circuit or equipment (or both) documentation is appropriate to area classification X X X
2 Equipment installed is that specified in the documentation - Fixed equipment only X X
3 Circuit or equipment (or both) category and group are correct ...................... X X
4 Equipment temperature class is correct .......................................................... X X
5 Installation is clearly labelled ............................................................................ X X
6 Enclosures, glass parts and glass-to-metal sealing gaskets and/or compounds are X
satisfactory
7 There are no unauthorized modifications ........................................................ X
8 There are no visible unauthorized modifications ............................................ X X X
9 Safety barrier units, relays and other energy limiting devices are of the approved type, X X X
installed in accordance with the certification requirements and securely earthed, where
required
10 Electrical connections are tight ........................................................................ X
11 Visible printed circuit boards are clean and undamaged ............................... X
2B INSTALLATION
1 Cables are installed in accordance with the documentation .......................... X
2 Cable screens are earthed in accordance with the documentation ............... X
3 There is no obvious damage to cables ............................................................ X X X
4 Sealing of trunking, ducts, pipes or conduits (or both) is satisfactory ........... X X X
5 Point-to-point connections are all correct ........................................................ X
6 Earth continuity is satisfactory (for example, connections are tight and conductors are of X
sufficient cross-sectional area) .........................................................................
2C ENVIRONMENT
1 Equipment is adequately protected against corrosion, weather, vibration and other adverse X X X
factors ................................................................................................................
2 There is no undue accumulation of dust and dirt ............................................ X X X
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2A EQUIPMENT
The essential documents are the ATL-certified installation (loop) drawing and
the ATL certificates for individual equipment used in the loop.
Levels of protection (EPLs) available for intrinsic safety equipment are ia, ib
and ic. EPL/Zone is provided from the area classification process. EPLs are
determined by risk and are mostly directly related to the allocated zones.
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This includes exchanging one type of device with a similar (but not identical)
unit, e.g. a new series.
9 Safety barrier units, relays and other energy limiting devices are of the
approved type, installed in accordance with the certification requirements and
securely earthed, where required
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2B INSTALLATION
Generally, screens are earthed at one point i.e. in the safe area. They must
however not be cut off.
Openings in walls for cables and conduits between different hazardous areas
and between hazardous and non-hazardous areas shall be adequately sealed,
for example by means of sand seals or mortar sealing to maintain the area
classification where relevant. Trunking, ducts or pipes connecting differently
zoned areas must be sealed, for example by a sealing compound (e.g.
expansion foam) or sealing devices. For trenches, adequate venting or sand-
filling may be used.
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8* The intrinsically safe circuit is isolated from earth or earthed at one point (see
the documentation)
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2C ENVIRONMENT
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8. Conclusions
1. Q: What is the PURPOSE of an Ex inspection ?
A: To preserve the explosion protection features (and certification).
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In order to select the appropriate electrical equipment for hazardous area caused by
gases, vapours or dusts, the following information is required:
pe = pg x pi
Where
- pe is the probability of a fire or explosion occurring;
- pg is the probability that an explosive atmosphere will be present in a particular
place at a particular time (given by the zone); and
- pi is the probability that the above explosive atmosphere can be ignited.
Risk-based approach
The equipment selection standard now also allows for a risk-based approach. In a
risk-based approach, the consequence of an explosion is also taken into account,
together with the probability of an explosion. This means quite simply that under
certain circumstances, the occurrence of an explosion is more tolerable (or less
tolerable) than normal.
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Example: A typical example is of two neighbouring plants of similar design, but due to
differences in the materials being handled, the one is Zone 1 and the other Zone 2.
Some engineers will decree that Zone 1 equipment is used even in the Zone 2 plant,
because the danger exists that the wrong replacement equipment will be selected
from stores during a breakdown.
The table below shows the relationship between types of protection and EPLs.
Protection EPL Type of protection Code According to Conditions of
afforded standard operation
Group Group Group
I II III
Very High „Ma‟ Same as „Ga‟ Equipment remains
functioning when
explosive
atmosphere present
Very High „Ga‟ Intrinsically safe „ia‟ SANS 60079-11 Equipment remains
Encapsulation „ma‟ SANS 60079-18 functioning in Zones
0, 1 and 2
Two independent type SANS 60079-26
of protection each
meeting EPL „Gb‟
Protection of SANS 60079-28
equipment and
transmission systems
using optical radiation
Very High „Da‟ Intrinsically safe „iD‟ SANS 60079-11 Equipment remains
functioning in Zones
Encapsulation „mD‟ SANS 60079-18
20, 21 and 22
Protection by „tD‟ SANS 60079-31
enclosure
High „Mb” Same as „Gb‟ Equipment de-
energised when
explosive
atmosphere present
High „Gb‟ Flameproof enclosures „d‟ SANS 60079-1 Equipment remains
functioning in Zones
Increased safety „e‟ SANS 60079-7
1 and 2
Intrinsically safe „ib‟ SANS 60079-11
Encapsulation „m‟ SANS 60079-18
„mb‟
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Selection
If risk is normal, which is mostly the case, the probability of an explosion is the only
controlling factor and a direct relationship between EPL and Zone exists that is used
to select equipment:
Table A.1 – Equipment protection level (EPLs) where only zones are assigned
Where in exceptional circumstances, the risk is not normal, a higher or lower EPL
than that defined in the table may be required.
It is recommended that the required explosion protection levels (EPLs) are recorded
on the area classification drawing, even if the risk-based approach has not been
followed.
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The electrical equipment shall be so selected that its maximum surface temperature will not
reach the ignition temperature of any gas or vapour which may be present.