Cortem Group - Guide To The Ex World

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

explosion
Index
1. Introduction
pag.
2. Hazardous areas classification
pag. 13
3. Equipment choice
pag. 20
3.1. Groups, categories and EPL (Equipment Protection Level)
pag. 20
3.2. Protection methods
pag. 22
3.3. Electrical equipment
pag. 22
3.3.1. Gases
pag. 22
3.3.2. Dusts
pag. 23
3.4. Non-electrical equipment
pag. 23
3.5. Ex Abecedarium
pag. 25
3.6. Cortem Group equipment
pag. 25
3.6.1. Product classes
pag. 25
3.6.2. Our protection methods
pag. 28
3.6.2.1. Ex d explosion-proof junction boxes
pag. 30
(literally flame-proof)
3.6.2.2. Ex e increased safety equipment
pag. 34
3.6.2.3. Ex n equipment
pag. 35
3.6.2.4. Ex t equipment
pag. 36
3.6.2.4.1. Enclosure protection degrees (IP code)
pag. 36
3.6.2.5. Ex de combined protection method
pag. 39
3.6.3. Marking of explosion-proof equipment
pag. 40
3.6.4. The ambient temperature of our equipment
pag. 45
3.6.5. Our temperature classes
pag. 45
3.6.6. Materials used in our equipment
pag. 46
3.6.6.1. Aluminium alloy
pag. 47
3.6.6.2. Stainless steel
pag. 48
3.6.6.3. Polyester reinforced with glass fibers
pag. 49
3.6.6.4. Borosilicate glass
pag. 49
3.6.6.5. Polycarbonate
pag. 50
3.6.6.6. Nickel-plated brass
pag. 50
3.6.6.7. Galvanized steel
pag. 50
3.6.6.8. Polyamide 6
pag. 50
3.6.6.9. Neoprene
pag. 51
3.6.6.10. Silicone
pag. 51
3.6.7. Our certifications (PART I)
pag. 51
3.6.7.1. The 94/ 9/CE ATEX 95 Directive
pag. 51
3.6.7.2. IEC-EX
pag. 52
3.6.7.3. Russia
pag. 53
3.7. Our certifications (PART II)
pag. 54
3.7.1. The CE conformity statement
pag. 55
3.7.2. User instructions
pag. 55
4. Installation
Guide to the EX world How to use electrical equipment in areas with risk of explosion
pag. 56
Index
5. Inspection
6. Maintenance and repairs
6.1. Maintenance
6.2. Repairs
7. End-of-life equipment
7.1. Disposal
7.2. Recyclability
8. Application examples for different types of plants

8.1. Pharmaceutical industries
8.1.1. Reference standards
8.1.2. Plant emission sources
8.1.3. Classification for gas
8.1.4. Classification for dusts
8.2. Deposit of cereals
8.2.1. Risk of explosion by clouds of dust
8.2.2. Areas classification
8.2.3. Areas inside containment system
8.2.4. Areas outside containment system
8.2.5. Electrical installations
8.3. Coating booths
8.3.1. Coating booths with liquid coatings
8.3.2. Coating booths with dust coatings
8.4. Biogas plants

8.4.1. Plant type
8.4.2. Risk of explosion
8.4.3. Regulations
9. Appendix
9.1. Brief description of protection methods for electrical equipment
addressed to areas with risk of explosion for presence of gas
9.2. Brief description of protection methods for electrical equipment
addressed to areas with risk of explosion for presence of dusts
9.3. Brief description of protection methods for non-electrical equipment
addressed to areas with risk of explosion due to presence of gas and dusts
9.4. Structural requirements for explosion-proof electrical equipment
for potentially explosive atmospheres due to presence of gas
Marking of electrical equipment in areas with risk of explosion
pag. 59
pag. 61
pag. 61
pag. 62
pag. 63
pag. 63
pag. 64
pag. 65
pag. 65
pag. 66
pag. 66
pag. 67
pag. 67
pag. 67
pag. 68
pag. 68
pag. 68
pag. 68
pag. 69
pag. 69
pag. 69
pag. 70
pag. 71
pag. 71
pag. 72
pag. 72
pag. 73
pag. 73
pag. 74
pag. 74
pag. 75
pag. 77
1. Introduction
uring production, transformation, delivery and stocking of flammable substances in the chemical and
petrochemical plants, so as during the production of
oil and natural gas, inside the mines and in many other fields
(such as the food field), gases, vapors and mists are produced. In
contact with the oxygen in the air, they can create an explosive atmosphere. If this atmosphere is triggered, the deriving explosion
can provoke serious damages to people and environment.
The aim of this Guide is to follow the Ex path (Image 1, following
page), providing experts and non with an overview on the world
of the explosion-proof electrical protection.
It is worth remembering that inside the European Community,
there are the technical standards (to be applied to reduce risks),
and the Community guidelines which are prevalent on technical
standards.
The European law has intervened to discipline different fields;
for our memo we will consider two blocks:
the Product Directives;
the Social Directives.
1.Introduction
Image 1 Ex path
hazardous areas classification
GASES: EN 60079-10-1 : 2009-03
DUSTS: EN 60079-10-2 : 2009-08
marking of equipment
and of assembly
equipment choice
EN 60079-14: 2008-10
disposal
of equipment
equipment installation
EN 60079-14: 2008-10
repairing the equipment

EN 60079-19: 2011-01
plants inspection and maintenance

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

the European Community.
This graphic mark is the CE
(Image 2) that has to comply
with certain proportions.
Over the years, the first legislative
documents
have
been emended, integrated

and modified till the last re-
http://ec.europa.eu/enterprise/policies
Framework Directive
Tab. 1 83/189/CEE Framework Directive: enactment, amendments and implementation in Italy
83/189/CEE Directive by the Commission of

28th March 1983 concerning the information
procedure in the field of technical standards and
regulations
Law 21st June 1986, n 317, concerning the

application of the directive n 83/189/CEE
about the information procedure in the field of
technical and standards and regulations
(G.U.C.E., L series, n 109 of 26 April 1983)
(G.U.R.I., General series, n 151 of 2 July1986)
modified by:
decision n 768/2008/CE of the European
Parliament and the Council of 9 July 2008
concerning a common frame for the product
trading and that repeals 93/465/CEE decision.
(G.U.C.E., L series, n 218 of 13 August 2008)
vision, dated 2008 (Table 1).

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

and the Council of 23 March 1994 on the
approximation of the laws of the Member
States concerning equipment and protective
systems intended for use in potentially explosive
atmospheres
D.P.R. 23 March 1998, n 126 regulation laying

down rules for the implementation of Directive
94/9/EC concerning equipment and protective
atmospheres
(G.U.C.E., L series, n 100 of 19 April 1994)
(G.U.R.I. General series, n 101 of 4 May1998)
Corrigendum to Directive 94/9/EC of the European

Parliament and of the Council of 23 March 1994
on the approximation of the laws of the Member
States concerning equipment and protective
atmospheres.
(G.U.C.E., L series, n 21 of 26 January 2000)
Its official name is distinctive community mark. The hexagon inscribed with the epsilon-x must have these proportions (Image 3).
The Social Directives were born in the second half of the 80s to
implement measures to improve the workers health and safety
at work by the achievement of an harmonization of the workers
protection levels in the EU, and by defining the minimum requirements to improve working environment, such as to protect the
workers safety, as it was stated, in the article 118 (now article
137) of the Treaty signed in Rome in March 1957, in which the
Economic European Community was founded (Tables 3 and 4).
Image 3 European Community mark
Over the years, the framework Directive

has been integrated with specific Directives
that took into consideration the various risks
existing in the working environment (construction sites, extracting industries, physical agents, etc.) and, consequently, there
have been the various national transpositions
among those the last one, at Italian level, is
the one that generated the Consolidated law
1.Introduction
http://ec.europa.eu/social
Framework Directory
Tab. 3 89/391/CEE Framework Directive: promulgation and implementation in Italy
Council Directive 89/391/EEC of 12 June 1989

on the introduction of measures to encourage
improvements in the safety and health of
workers at work
Leg. September 19, 1994, No. 626, concerning

the implementation of Directives 89/391/EEC,
89/654 / EEC, 89/655/EEC, 89/656/EEC, 90/269/
EEC, 90 / 270/CEE, 90/394/EEC, 90/679/EEC,
93/88 / EEC, 95/63/EC, 97/42/EC, 98/24/EC,
99/38/EC, 99/92 / EC, 2001/45/EC, 2003/10/
EC, 2003/18/EC and 2004/40/EC concerning the
improvement of safety and health of workers at
work
(G.U.C.E., L series, n 183 of 29 June1989)
(G.U.R.I., General series, n 265 of 12 November

1994)
on health and safety at work - TUS: the legislative Decree of 9th

April 2008, No. 81 Implementation of article 1 of the law of 3rd
August 2007, ne. 123, for the protection of health and safety in
the working environment (G.U.R.I General series, No. 101 of
30th April 2008) and the legislative Decree of 3rd August 2009,
No. 106 Supplementary and corrective measures of the legislative Decree of 9th April 2008, No. 81, for the protection of health
and safety in the working environment (G.U.R.I General series,
No. 180 of 5th August 2009).
In this block, there is the 99/92/CE Directive, known as ATEX
137 (by virtue of the article number in the Treaty) or more simply as the second ATEX Directive.
It is addressed to the employers of the workers who can be expo-
http://ec.europa.eu/social
ATEX 137
Tab. 4 ATEX 137 Directive: promulgation and implementation in Italy
Directive 1999/92/EC of the European

Parliament and of the Council of 16 December
1999 minimum requirements for improving
the safety and health protection of workers
potentially at risk from explosive atmospheres
(XV individual Directive within the meaning of
Article 16, paragraph 1 of Directive 89/391/EEC)
Leg. June 12, 2003, No. 233 Implementation of

Directive 1999/92/EC on minimum requirements
for improving the safety and health protection
of workers potentially at risk from explosive
atmospheres
(G.U.C.E., L series, n 23 of 28 January 2000)
(G.U.R.I., General series, n 197 of 26 August

2003)
1.Introduction
explosion 2.366 1.422
1% trapped, crushed, etc.
38
16% physical
or mental stress
359
98
15
377
other contacts
bite, kick, etc. (animal or

human)
physical or mental stress
trapped, crushed, etc.
contact with sharp, pointed,

rough agent or coarse
material
hit by a moving object, collision

with ...
horizontal / vertical impact

against stationary object (victim
in motion)
drowned, buried, wrapped
contact with electrical voltage

temperature, hazardous
substances
all contacts mode

of damage
Graph 1 Number of non-fatal accidents at workplace for diversion and contact during 2005
inside EU_V
49
0% bite, kick, etc. (animal or human)

2% other contacts
4% contact with sharp, pointed,

rough agent or coarse material
15% hit by a moving object,
collision with...
60% contact with electrical voltage

temperature, hazardous substances
2% horizontal / vertical impact

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

Now, the collection of these two blocks of Directives, the
equipment or, more generally, the products put on the market
regardless of their use (domestic or industrial) from one side, and
the health and safety at work from the other, make that, each of
them, with its own role, contributes to a general improvement of
working conditions.
Even though we keep on giving ourselves news rules increasing
the state of the art and we turn to the best and the most indeNotes: EU_V indicates that, for this
analysis, 20 Member States (out of
27) have provided
the information.
Two points reported
in Graphs 1 and
2 indicate that the
information is not
available or that it
comprises less than
4 elements.
10
pendent of the Notified Bodies for our product certification, there

will always be some risks.
But what is the risk?
It is difficult to gather information but, to have an idea, we can have
a look at the graphs 1, 2 and 3, taken from the document Causes
and circumstances of accidents at work in the EU published by the
Directorate-General for Employment, Social Affairs and Equal
Opportunities of the European Commission in November 2008.
1.Introduction
explosion 98 56
0% contact with sharp, pointed, rough agent,

coarse material
23
7% trapped,
crushed, etc..
other contacts
bite, kick, etc. (animal

or human)
physical or mental stress

6
0% physical or mental stress

0% bite, kick, etc. (animal or human)
0% other contacts
25% hit by object in motion,

collision with..
60% contact with electrical voltage,

temperature, hazardous substances
4% horizontal / vertical impact

against a stationary object (victim in motion)
4% drowned, buried, wrapped
trapped, crushed, etc.
contact with sharp, pointed,

rough agent, and coarse
material
hit by object in motion, collision

with ...
horizontal / vertical impact

against a stationary object
(victim in motion)
drowned, buried, wrapped
contact with electrical voltage

temperature, hazardous
substances
all contacts- mode of

damage / accident
Graph 2 Number of fatal accidents at work for diversion and contact in the period 2003-2005
inside European Union EU_V
Considering that some information covers the period 2003-2005

(fatal accidents) and other the year 2005 (non-fatal accidents),
and that both the ATEX Directives were almost at the beginning, we can reasonably hope that in the coming future the accidents will be reduced.
This will happen by reason of the familiarity we will achieve with
the risk analysis tool, that will consider whether the potential
ignition sources are present or not and, if present, what they are
worth and what effects they can produce in case of contact with
a potentially explosive mixture inside its explosive ranges. The
sources to take into consideration are:
hot surfaces;
flames and hot gases (hot particles included);
mechanically generated sparks;
electrical equipment;
stray electrical currents, cathodic corrosion protection;
static electricity;
11
1.Introduction
Mortal accidents from 2003

to 2005
Permanent incapacity in 2005
number of mortal accidents

from 2003 to 2005
Permanent incapacity
3 - 6 months lost
1 - 3 months lost
21 days - 1 month lost
14 - 20 days lost
7 - 13 days lost
4 -6 days lost
more than 3 days lost
Graph 3 Number of accidents at work for diversion, number of days lost, and average age of
victims during 2005 inside European Union EU_V
explosion
2.406
316 492 339 384
572 155 148 102
39,3 40,5
600
500
400
300
200
100
4-6 days
lost
7-13 days 14-20 days 21 days 1- 3 months 3-6 months permanent

lost
lost 1 month lost
lost
lost
incapacity
lightning;
electromagnetic waves;
ionizing radiations;
ultrasound;
adiabatic compression and shock waves;
exothermic relations, self-ignition of dust included.
To have an explosion it is not sufficient that fuel, oxidizer and ignition meet (Image 4), but, in addition to this, there must be the
confinement in which the combustion occurs (Image 5).
Image 4 The fire triangle
Image 5 The pentagon of the explosion
ignition cause
ignition cause
confinement
combustible
material
12
combustion
agent
combustible
material
concentration
combustion
agent
2. Hazardous
areas classification
n facing the chapter on the classifi-
It has to be pointed out that the references of
cation, the first thing that came to
the state of the art(technical standards) in
our minds is: what is classification?
this field (currently IEC 60079-10-1 for gases
The answers could be various: it is a docu-
and IEC 60079-10-2 for combustible dusts) do
ment, it is the drawing with the clouds, it
not refer either to the areas with presence of fi-
is a number identifying the area, it is the pro-
redamp gas (group I), or to the areas where the
bability that the explosive atmosphere is pre-
explosives are processed and produced, etc.
sent in a certain area.
The classification is a teamwork! The area
The answers are correct, but only if conside-
classification should be made by people who
red all together.
understand the importance and meaning of
We could therefore define the areas classifica-
the properties of flammable substances, as
tion as a method of analysis and classification of
well as by people who are familiar with the
the environment where explosive atmospheres
process and the equipment, together with qua-
may occur because of the presence of gases and/
lified personnel in the field of safety, electrical
or combustible dusts, in order to facilitate the
and mechanical installations, and more; it
correct choice and installation of the equipment
is necessary, moreover, a tight cooperation
to be used safely in that environment.
among experts in safety and equipment.
13
What are these areas?
Some of these hazardous areas will be
More than we can imagine! The combustible ga-
analyzed in chapter 8.
ses classified in the regulation IEC 60079-20-1
What do we have to do?
are 328, while the combustible dusts listed in the
First of all we have to build the team!
BIA report 13/97 are more than 4.300, sawdust,
After that, step by step, work must be faced.
flour and breadcrumbs included! And, since
a) Identifying the hazardous sub-
1997, many others have been classified!
stances with the help of the informa-
Reasoning by macro areas, the classification
tion contained in the safety form, in the
could be required for the following areas:
IEC 60079-20-1 standard Explosive atmospheres part 20-1: classification of gases

and vapors test methods and information
in the BIA report 13/97 Combustion and ex-
refineries
recycling
plosion characteristics of dusts and in the

bibliographical references. But sometimes,
especially for combustible dusts, the information we find in literature does not coincide
chemical
industries
metallurgical
and plastics
industry
with the characteristics of our sample (type

of substance and grain size) or we are not in
presence of a single dust. In these cases, it is
recommended to refer to specialized centers
energy
production
landfills,
waste treatment
and waste water
in order to have the specimen characterization made; in Italy, a reference is the Fuel
Experimental Station (http://www.ssc.it)
based in San Donato Milanese (MI).
food
and feed
industry
wood industries
Some information about gas is interesting.

In Table 5, we have gathered the gases
that, for some reason, are representative
of something:
gas treatment
and supply
plants
coating
those highlighted in bold (No. 18, 20,

21, 27 and 288) are representative of the
gas subgroups;
No. 55 and 7 for the lower explosive li-
pharmaceutical
industry
mit (L.E.L), the lowest and the highest,

respectively;
No. 181 and 21, 37, 170, 293 for the
14

Tab. 5 Some of the most representative gases
n GAS
7
18
64-18-6
Name
Formula
Formic acid
HCOOH
methane
CH4
L.E.L.
U.E.L. M.I.T. M.I.E.* GROUP
[vol %]
[C] [J]
18,00
57,00
525
IIA
4,40
17,00
600
IIA
4,40
17,00
595
74-82-8
280
firedamp gas
20
74-85-1
ethylene
CH2=CH2
2,30
36,00
440
82
IIB
21
74-86-2
ethyne (acetylene)
CH=CH
2,30
100,00
305
19
IIC
27
74-98-6
propane
CH3CH2CH3
1,70
10,90
450
250
IIA
35
75-15-0
Carbon disulphide
CS2
0,60
60,00
90
IIC
37
75-21-8
ethylene oxide
CH2CH2O
2,60
100,00
429
55
78-10-4
tetraethoxysilane
(silicic acid tetraethyl ester)
(C2H5)4Si
0,45
7,20
174
170 110-05-4
bis (1.1-dimethylethyl) peroxide
(CH3)3COOC(CH3)3
0,74
100,00
170
IIB
181 110-96-3
2-methyl-N-(2-methylpropyl)-1propanammina (diisobutilammina)
((CH3)2CHCH2)2NH
0,80
3,60
256
IIA
206 123-42-2
4- hydroxy -4-methylpentane-2-one
(diacetonalcol)
CH3COCH2C(CH3)2OH
1,80
6,90
680
IIA
288 1333-74-0 hydrogen
H2
4,00
77,00
560
293 1712-64-7
(CH3)2CHONO
2,00
100,00
175
nitric acid 1-methylethyl ester
IIB
16
IIC
IIB
Legenda: L.E.L.: (Lower Explosive Limit; U.E.L.: Upper Explosive Limit;

M.I.T.: Minimum Ignition Temperature; M.I.E.: minimum Ignition Energy;
upper explosive limit (U.E.L.), the lowest and the highest, respectively;
No. 181 and 170 for the explosive limit,
the least and the most extended, respec-
tively;
No. 35 and 206 for the ignition temperature, the minimum and the maximum,
respectively.
15
Graph 4
Subdivision of gas in groups
28 indeterminate
Graph 5
Number of gas for temperature class
1I
140
5 IIC
120
66 IIB
[n]
100
80
60
40
20
0
227 IIA
T6
T5 T4 T3 T2 T1 ind.ti
temperature classes
Tab. 6 Some of the most representative dusts
Combustible
materials
Grain
[m]
Explosive level
L.E.L.
[g/m3]
M.I.E.
[mJ ]
M.I.T. [C ]
in cloud
Tcl
Kst
[C]
in 5 mm
layer
T5mm
wood
70
40
440
325
20
128
wheat flour
57
60
430
450
50
87
lactose
23
125
450
melts
10
81
rice
45
60
490
80
101
sugar
35
200
350
490
30
138
polyethylene
< 10
25
450
80
156
phenol
< 10
25
460
melts
10
129
aluminium
29
40
700
320
50
415
magnesium
28
30
600
490
120
508
zinc
< 10
480
680
460
650
176
coke
15
80
80
47
urea hydrolysed
13
70
450
80
136
112
30
350
465
112
cellulose
Legenda: L.E.L.: (Lower Explosive Limit; U.E.L.: Upper Explosive Limit;

M.I.T.: Minimum Ignition Temperature; M.I.E.: minimum Ignition Energy;
source: BIA-Report 13/97
16

In the Graph 4, the great prevalence of
Table 6 depends on that in the first two co-
subgroup IIA is evident, while the Graph 5
lumns. Here we have something different if
shows the gas distribution in the tempera-
compared to how we were used to treat ga-
ture class identification with a Gaussian di-
ses: the dust ignition temperatures are cha-
stribution.
racterized by two different state conditions:
As far as the dusts are concerned, being
they may be triggered when, because of the
them almost unknown, the information is
convection, they move in the air forming
more complex to extract. Once identified the
clouds (Tcl), or when they are deposited on
nature of dust, the second fundamental in-
the surfaces forming increasingly thicker la-
formation for its identification is the average
yers; conventionally we take as reference a
particle size. Lets have a look at some exam-
layer of 5 mm (T5mm).
ples of dusts in Table 6 at the previous page.
Moreover, we have to add that recently, as a
The information in the second column of
technical standard, dusts have been classi-
Image 6 Hazardous areas classification based on presence and concentration of gas (Zone 0, 1 and 2)
and dusts (Zone 20, 21 and 22)
Zone 0
Zone 20
Zone 1
Zone 2
Zone 21
Zone 22
Note: the graphic images in the boxes are those normalized at international level
17
fied into three subcategories, similarly way
c) Defining the emission rate of the
to what was done years ago for gases. The
sources (speed, geometry, concentra-
subgroups are:
tion, volatility, temperature).
IIIA: flammable particles, such as solid
d) Establishing the ventilation degree.
particles, fibers included, with nominal
e) Defining the hazardous areas (Image 6).
sizes > 500 m;
f) Defining the hazardous areas extension.
IIIB: non-conductive dust, such as fi-
The areas division reported in Image 6 in
nely divided solid particles, with nominal
the previous page is a widely spread sy-
sizes 500 m, with electrical resistivity
stem, in fact it is the one adopted both by
> 103 m;
Europe and by the international IEC stan-
IIIC: conductive dust, such as finely di-
dards. In case this division is not enough,
vided solid particles, with nominal sizes
UNECE, an UNO Agency, has reinforced
500 m, with electrical resistivity
this concept, and also in its latest report of 2011
103 m.
(http://www.enece.org/) it refers to the inter-
b) Identifying the emission sources
national IEC standards as reference to adopt.
(continuous, first degree, second degree).
It can happen, however, that some documents
Tab. 7 Comparison between hazardous areas classification for presence of gas based on international standards
(IEC Zone System) and according to North American standards
GAS
Zone 0
Area in which an explosive

atmosphere, consisting in a
mixture of air and flammable
substances in the shape of
gas, vapor or mist, is present
permanently or for long
periods or often.
Zone 1
Area in which during normal

activities the formation of
an explosive atmosphere
consisting in a mixture of air
and flammable substances
in the shape of gas, vapor or
mist, is possible.
Class I, Division 2
Class I, Division 1
> 1.000 h/year
18
Zone 2
Area in which during normal

activities the formation of
an explosive atmosphere
consisting in a mixture of air
and flammable substances
in the shape of gas, vapor or
mist, is not possible, and in
case it happens, it lasts very
shortly.
10 1.000 h/year
0,1 10 h/year

Tab. 8 Comparison between hazardous areas classification for presence of dusts based on international
standards (IEC Zone System) and according to North-American standards
DUSTS
Zone 20
Area in which an explosive

atmosphere is present
permanently or for long
periods or often, in the
shape of clouds of dusts.
Zone 21
Area in which occasionally

during normal activities the
formation of an explosive
atmosphere in the shape of
cloud of combustible dust in
the air, is possible.
Zone 22
Class II, Division 2
Class II, Division 1

> 1.000 h/year
Area in which during

normal activities the
formation of an explosive
atmosphere in the shape
of cloud of combustible
dust is not possible, and
in case it happens, it lasts
very shortly.
10 1.000 h/year
0,1 10 h/year
written according to the North-American
will be traced, that is to say of the extension
standards (USA and Canada) refer to their na-
of each classified area. This document, as
tional standards and that, therefore, also the
it will be understood, is very important for
nomenclature is different from that adopted
the employer, who, on the basis of which,
internationally. Tables 7 and 8 highlight the
will have to make some choices and take
correlation between the two systems.
some measures. Some information, neces-
Regardless of the normative reference
sary for the production process, has to be
used, the hazardous areas classification will
found in this document:
be composed of: a descriptive document,
installation area or category / EPL of the
in which the factory, the processes taken
equipment that will have to be installed;
into account, the list of the hazardous sub-
gas subgroup or specific gas/es and/or
stances present, etc., will be identified; a

plan drawing and a perspective drawing in
which, by means of the proper conventional
graphic symbols, the limits of the clouds
dust subgroup or specific dust/s;

max permissible temperature class of the
equipment that will have to be installed;
ambient temperature.
19
3. Equipment choice
3.1. Groups, categories and EPL (Equipment

Protection Level)
category M2: equipment which guarantees a very high protection level; it must
he 94/9/CE Directive foresees
be possible to cut the power off in presen-
the following division:
ce of explosive atmosphere.
Group I: products addressed
to mines and in their surface systems, where
Group II
category 1: equipment which guarantees a
firedamp gas can be present.
very high protection level; it is intended to be
Group II: products addressed to surface
used in areas in which there is, always or for
sites with the presence of explosive atmo-
long periods, the presence of explosive atmo-
sphere.
sphere.
The products are then divided inside the
category 2: equipment which guarantees
Groups as follows:
a very high protection level; it is intended to
Group I
be used in areas in which the development
category M1: equipment which guaran-
of explosive atmosphere is most likely.
20
tees a very high protection level; it has to
category 3: equipment which guarante-
be kept powered in presence of explosive
es a very high protection level; it is inten-
atmosphere.
ded to be used in areas in which the deve-
Tab. 10 Correlation between equipment category and the

protection level
Tab. 9 Correlation between equipment category and

installation area for Group II
1
G
Zone 0
Zone 20
2
Zone 1
Zone 21
1G
M1
M2
1D
Zone 2
Ma
Zone 22
Mb
2G
Ga
3G
2D
Gb
Da
3D
Gc
Db
Dc
lopment of explosive atmosphere is slightly
blished and highlighted in Table 9, between
possible.
equipment category and installation area.
The category numbers of group II (1, 2, 3) are
What we have described above is valid for
followed by a capital letter:
the EU.
G, for gases;
Outside EU, until 2007, the equipment was
D, for combustible dusts.
marked only with the protection method.
For example: II 2G.
Therefore, inspired by the European system,
On the basis of group II definitions and by com-
the EPL Equipment Protection Level (Table
paring them to those provided by the 99/92/CE
10) has been created, replacing the letters
ATEX 137 Directive, a two-way link is esta-
a, b, c to the numbers 1, 2 and 3.
Tab. 11 Standardization bodies subdivided according to technical competence and territoriality
Field
International
European
Italy
Electrotechnical
and electronic
International
International
Electrotechnical Commission
Commission Electrotechnique
International
International
Telecommunication Union
Geneve, Switzerland
http://www.iec.ch
Geneve, Switzerland
http://www.itu.int
International Organization
for Standardization
Organisation internationale
de normalisation
Geneve, Switzerland
http://www.iso.org/iso/home.htm
European Committee for

Electrotechnical Standardization
Comit Europen de
Normalisation Electrotechnique
Brussels, Belgium
http://www.cenelec.eu
European Telecommunications
Standards Institute
Italian Electrotechnical Committee
CONCIT
National Coordinating
Committee for Informatics
and telecommunications
Rome, Italy
http://www.isticom.it
Milan, Italy
http://www.ceiweb.it
Sophia Antipolis, France

http://www.etsi.org
European Committee
for Standardization
Comit europen
de normalisation
Brussels, Belgium
http://www.cen.eu
Italian National body
of unification
Milan, Italy
http://www.uni.com
21
3. Equipment choice
For the Group III, related only to dusts, please
(flame-proof junction boxes), the purpose
refer to what described in the previous pages.
is achieved.
Regularly, the European Commission publi-
3.2. PROTECTION METHODS
shes in the Official Journal of the European
The protection methods are techniques avai-
Union the list of the harmonized technical
lable thanks to the harmonized standards, ai-
standards which tend to comply with the re-
ming to meet the Safety and Health Essential
quirements of the ATEX 95 Directive.
Requirements.
The standardization bodies are divided accor-
These techniques play on the fact that, remo-
ding to their technical competence and territo-
ving also only one of the elements which form
riality, as it is represented in Table 11 in the pre-
the explosion Pentagon, the explosion itself
vious page.
cannot take place. So, by limiting the energy
In the Graphs 6, 7 and 8 we quote the main
(intrinsic safety) and the heat (increased
protection methods for electrical and non-
safety, structural safety), by removing the
electrical equipment. For a deep analysis of
fuel (pressurization, liquid immersion,
the protection methods that Cortem uses, re-
encapsulation), by containing the explosion
fer to paragraph 3.6.2.
3.3. ELECTRICAL EQUIPMENT

3.3.1. GASES
Graph 6 Main protection modes for electrical equipment in presence of gas
Main electrical
protection
modes
Prevention
Prevention
Absence
of the ignition
source
Absence
of explosive
atmosphere
Segregation
of the ignition
source
Intrinsic
safety
Pressurization
Encapsulation
pxb
pyb
pzc
ma
mb
mc
Protection mode
n
Immersion in
oil
nRc
ob
ia
ib
ic
Increased
safety
eb
qb
Protection mode
n
nAc
nLc
22
Filling
Protection mode
n
nCc
Explosion-proof
db
Legend: those in
red background are
suitable for category
1 and/or M1; those in
orange background
are suitable for
category 2 and/or
M2; those in pink
background are
suitable for
category 3.
3.3.2. DUSTS
Graph 7 Main protection modes for electrical equipment in presence of dusts
Main electrical
protection modes
for dusts
Prevention
Absence
of the ignition
source
Absence
of explosive
atmosphere
Segregation
of the ignition
source
Intrinsic
safety
Pressurization
Encapsulation
pD
pD
ma
mb
mc
ia
ib
ic
Legend: those in red background are

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

Graph 8 - Main protection modes for non-electrical equipment in presence of gas or dusts
Main electrical
protection modes
for gas and dusts
Prevention
Protection
Absence
of the ignition
source
Control
of ignition
source
Absence
of explosive
atmosphere
Segregation
of the ignition
source
Inherent
safety
Control
of ignition
source
Pressurization
Immersion
in liquid
Explosion-proof
b
b
k
k
k
Limited
respiration
enclosure
Constructive
safety
c
c
fr
Legend: those in red background are suitable for

category 1 and/or M1; those in orange background
are suitable for category 2 and/or M2; those in pink
background are suitable for category 3.
23
3. Equipment choice
Tab. 12 List and explanation of the letters used in the marking
Capital
Small
it appears in gas subgroups of group II: IIA

it appears associated to protection mode n, nA
it appears associated to other letters, i.e. ia, ma
it appears in the EPL associated to letter G or D
it appears in gas subgroups of groups II: IIB
it appears associated to other letters, i.e.: ib, mb
protection mode by source control
it appears in gas subgroups of group II: IIC
it appears associated to protection mode n, nC
it appears associated to other letters, i.e..: ic
protection mode by constructive safety
it appears associated to other letters, i.e.: iD, mD, pD
it identifies combustible dusts category
it identifies the EPL with combustible dusts
flame-proof protection mode (both electrical and non-electrical)
increased safety protection mode
combined to letter r, it represents the limited respiration protection mode fr
it identifies gas category
it identifies gas EPL
protection mode by inherent safety
protection mode by intrinsic safety, for gas combined to letters a, b or c
protection mode by intrinsic safety, for dusts combined to letter D
combined to letter m, it represents protection mode for electrostatic spraying .. mJ
protection mode by immersion in a liquid
it appears associated to protection mode n, nL

it identifies equipment for the mines
it could be associated to protection mode v
protection mode by encapsulation, for gas combined to letters a or b
protection mode by encapsulation, for dusts combined to letter D
combined to letter J, it represents protection mode for electrostatic spraying .. mJ
protection mode n combined to different letters: A, C, L, R
protection mode by immersion in oil
combined to letter p, optical transmission protection mode op
r
s
t
v
x
protection mode by pressurization (electrical) for gas combined to letters x, y or z

protection mode by pressurization (non-electrical)
protection mode by pressurization for dusts combined to letter D
combined to letter o, optical transmission protection mode op
protection mode by pulverulent material
it appears associated to protection mode n, nR
combined to letter f, it represents limited respiration protection mode fr
special protection mode
protection mode by enclosure
transportable ventilated cabins protection mode, combined to numbers 1, 2, 3, 4, or M2
it appears associated to protection mode p, px
y
z
it appears associated to protection mode p, py

it appears associated to protection mode p, pz
a
B
b
C
c
D
d
e
f
G
g
i
J
k
L
M
m
n
o
p
q
R
24
Comment
3.5. EX ABECEDARIUM
Image 8
Looking at the letters used in the previous

graphs, it seems that few letters have remained at the standard-makers disposal! We
have checked it in the Table 12.
Image 7 Aluminium
alloy enclosure
Ex d EJB series
Image 8 Stainless
steel control
station, Ex ed
I series
3.6. CORTEM GROUP EQUIPMENT

3.6.1. PRODUCT CLASSES
Since 1968, our company has been designing
and manufacturing electrical equipment
meant to be used in potentially explosive
atmospheres, acquiring competence, year
after year, in the regulations of industrial
products and becoming specialized in those
Cortem Group is a multi-product company
Ex. In general, our equipment is used in en-
and, to help the reader find what he is looking
vironments different from the domestic one,
for, we have divided the products in macro
and follow certain binding requirements as
areas. Most of our equipment is Ex, but
well as a lot of technical requirements, and
there are some meant to be also used in non-
both are kept constantly updated.
classified, or safe, areas.

1. Junction boxes macro area
Image 7
The term junction boxes itself, for some years

part of the common speech of the Ex operators,
does not identify anything but a generic enclosure, that generally has the Ex d protection
method, where it has to be specified the function
it will have to perform according to its content.
Industrial nomenclature gives us a hand and so
our junction boxes are:
empty involucres low-voltage switchgear and
control gear assemblies, in other words all those empty junction boxes, certified as a component (Image 7);
command and control devices, (Image
8) such as automatic switches, command
switches, disconnectors, control devices di-
25
3. Equipment choice
Image 9
Image 10
Image 9 Enclosure with terminal strip in aluminium

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

such as the electrical equipment with a con-
Image 11
trol action on a machine;

electrical measuring instruments, analog
gauges for direct actions and related accessories, such as ammeters and voltage testers,
wattmeters and varmeters, frequency meters,
power factor meters, (cos ) and synchronizers, ohmmeters, (impedance meters) and
conductance meters, multitasking tools;
26
Image 12
Image 16
Image 12 EWL series lighting fixture with LED in
Image 16 Floodlight for discharge lamps in aluminium
aluminium alloy in Ex de execution
alloy SLFE series in Ex de execution
Image 13 Fluorescent or LED tubes lighting fixture in

aluminium alloy and borosilicate glass series FLF and
The lighting equipment macro area, together
FLFE in Ex d or Ex de execution
with the junction boxes one, is an important
Image 14 Fluorescent tubes hand lighting fixture in
type of equipment we put on the market and it
aluminium alloy FHL series in Ex d execution

Image 15 Lighting fixture for emergency in aluminium
alloy EVF-18EX series in Ex d execution
Image 13
is divided as follows:
fixed equipment for general use (Images 12-13);
portable equipment (Image 14);
emergency (Image 15);
floodlights (Image 16);
street lighting.
Our lighting equipment uses different lu-
Image 14
minous lamps and is codified in accordance

with the International Lamp Coding System
-ILCOS, that became international standard
(IEC 61231:2010-01) in 2010;
filament lamps, such as traditional incandescent lamps and halogen incandescent
Image 15
lamps;
discharge lamps, such as fluorescent
(tubular and compact), mercury-vapor
(high pressure), sodium-vapor (high pressure), metal-halide, mixed light;
LED.
1: For the European Union, availability is regulated by Regulation n 244/2009/EC of March 18, 2009 implementing Directive 2005/32/EC of the European Parliament and
of the Council with regard to ecodesign requirements for non-directional household lamps.
27
3. Equipment choice
Image 17
Image 17
accessories, such as fittings, curves, re-
Electromagnetic horns in
ductions, plugs, nipples, etc.
aluminium alloy C series

in Ex de execution
3.6.2. OUR PROTECTION METHODS

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

alloy and control devices mounted on lid
Image 24 Explosion-proof Ex d protection mode
Image 24
interstice
joint
length
30
Image 25
Image 26
mounting screw

Ex d explosion-proof
chamber
lid
flame-path
body

Image 25 Flame-path
Image 26 Conduit installation. Entry in an Ex d
enclosure through a sealing fitting
spark) the consequent explosion remains confined inside the junction box.
Through the flame-paths (Image 25), the fla-
Three-piece union
Sealing
fitting
Tube
ter the insertion of the gasket;

if the thread is conical, the connection
must be fully tightened;
me cools down and the combustion product is
if an adapter is required, it must com-
not able to trigger the mixture present outside
ply with the Ex d (IEC 60079-1) pro-
(held at flame). There are no normative limita-
tection method;
tions concerning the sizes or the electrical cha-
the unused cable entries must be sealed
racteristics but, beyond certain dimensional
with elements that comply with Ex d
limits building with this technique is expensive.
(IEC 60079-1) protection method.
When choosing the Ex d protection me-
The cable entry into enclosure can be made
thod, the following indications have to be
by means of three systems:
considered:
A. conduit installation;
do not make further holes in the jun-
B. cable installation with direct entry;
ction boxes than those allowed in the
C. cable installation with indirect entry.
certificate;
A. Conduit installation
if the cable entry has a parallel thread,
The electric cables run in a system of rigid
the coupling must have at least 5 full th-
conduits and enter explosion-proof boxes by
reads;
means of sealed fittings. This allows possible
if the use of gasket is foreseen, the num-
explosions to expand and spread inside the
ber of threads must be still sufficient af-
housings (Image 26). The outlet of every Ex d
31
3. Equipment choice
Image 27
Conductor
CRV
Sealing
mixture
Filling plug
Plug
FV Glass fiber
Conduit tubes
Image 27 Example conduit

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

Ex d
Sealing bushings
Ex e enclosure

Cable gland
Pressacavo

CableCavo
32
Ex e
Cable glands
Image 30
Ex d enclosure
Ex d sealing bushings
Ex e enclosure
Ex e cable glands
Image 30
Example of cable
installation with
indirect entry
bi-component resin. This method effectively
C. Cable installation with indirect entry
protects cables against mechanical and che-
In this system, cables enter and exit a jun-
mical damage. One disadvantage is that it is
ction box through terminals. By means of
difficult to modify the wiring later on.
sealed bushings, this box is connected to
B. Cable installation with direct entry
the explosion-proof box which contains
This type of system is mainly used in the UK
houses electrical equipment that may cau-
and in countries under British influence.
se sparks.
The cable enters directly the explosion-pro-
The box containing terminals and the termi-
of box through a cable gland with a gasket
nals with terminal fittings are both Ex e and
that prevents possible explosions inside the
increased safety types (Image 29). This sy-
box from spreading elsewhere (Image 28).
stem uses non-armored cables and, therefo-
Every cable gland must have standard safety
re, fittings with the right cable glands. This
specifications and the same internal diame-
type of installation is therefore used when
ter as the cable used. The gasket must also
there is a low risk of mechanical damage and
be explosion-proof. Armored cables with
when earth continuity is not essential.
braid, wire and tape are used in this instal-
This system is quick to install, flexible and
lation along with cable glands for armored
economical. However, it does not effecti-
cables. The advantage of this method is that
vely protect against the risk of mechanical
armored cables guarantee both mechanical
damage, so it is better to use an armored
protection and electrical continuity. One
cable or anti-static cable trunking trays
disadvantage is that the cable clamp instal-
wherever this risk is present. Image 30 of-
lation requires special maintenance to gua-
fers an example of cable installation with
rantee earth continuity.
indirect entry.
33
3. Equipment choice
3.6.2.2. Ex e INCREASED SAFETY EQUIPMENT
conductive parts excluded), installed in
Increased safety equipment is very similar to
clean environments and regularly che-
the industrial one and the term increased
cked by qualified personnel, must have
refers to the safety level which is increased if
enclosures with protection degree
compared to the one given by the industrial
IP20. The installation limitations must
equipment (Images 31 and 32). This protec-
be specified on the machine. While in-
tion method imposes some limitations:
stalling Ex e equipment, extreme at-
it can be applied to equipment that, whi-
tention must be paid to those operations
le operating, in normal and/or irregular
that can affect the protection degree,
operating conditions, does not produce
starting with the equipment cable entri-
arcs, sparks or excessive temperatures;
es. In case solids and/or water enter the
nominal supply voltage cannot exceed 10 kV.
equipment, the conductive path between
While installing the equipment, extreme at-
the two live parts of the equipment can
tention must be paid in particular to the four
be shortened until the break of the die-
following critical aspects:
lectric, and consequently an electric arc
Protection degree of the equipment.
can be formed.
Enclosures containing active nude parts
Way in which the equipment is
must have protection degree IP54,
connected to the power supply cir-
while enclosures containing only isola-
cuit. In general, the fuel system of Ex e
ted parts must have protection degree
equipment is made with Ex e cable
IP44. By contrast, rotary electrical
gland and certified by a Notified Body,
equipment, (terminal strips and nude
and made with internal sealing ring and
Image 31 Ex e increased safety protection mode

Image 32 Ex e increased safety enclosure SA...SS
series in stainless steel with control devices
Image 33 Example of conformity marking
Image 32
Image 31
34
external o-ring, in order to maintain
Image 33
IP54 degree. The connection between cables and terminals must be carefully taken care of not to reduce the terminals
isolation construction characteristics. It
means: to follow manufacturers specifications about the cable cross-section to
connect to terminals and about the maximum number of wires connectable to
each terminal (or power dissipation of
the enclosure); to guarantee, in screw
terminals, the tightening of the conductor in the terminal (or of more conduc-
of the temperature class, considering the
tors when the instructions allow it), ap-
resistance of the terminal (declared by
plying the indicated tightening and being
the manufacturer) and of the cable, and
careful not to affect the air insulation di-
of the circuit current.

Choice of protection. Every single
stances.
Thermal dissipation. Ex e protec-
protection method must be always gua-
tion method allows the gas to enter the
ranteed. The conformity marking com-
enclosure. For this reason the equipment
plying with the 60079 standards of the
manufacturer measures the maximum
Ex equipment, provides the informa-
temperature developed by the structure
tion required to make the right choice
also in the internal components. As the
and install the equipment correctly, as
cable inside the enclosure also increa-
well as to use it and maintain it properly
ses the heat, it is necessary to avoid that
according to the method of protection it
temperature exceeds the temperature
guarantees (Image 33).
class declared by the manufacturer. The

installer must strictly follow the manu-
3.6.2.3. Ex n EQUIPMENT
facturers indications about the allowed
For some aspects, it is similar to the increased
number of terminals, min and max con-
safety protection method and has different
ductor section, max current and possible
characteristics depending on the equipment:
indications about the conductors inside
if it produces arcs or sparks (Ex nA), if it is
the enclosure. Alternatively, it is neces-
breaking or non-injecting (Ex nC), if it is re-
sary to calculate the power dissipated by
spiration limited (Ex nR). In any case, the
the enclosure that guarantees the respect
nominal supply voltage cannot exceed 15 kV.
35
3. Equipment choice
3.6.2.4. Ex t EQUIPMENT
electrical resistivity 103 m.
This protection method, introduced as such
Our equipment has a mechanical protection de-
after the ATEX 95 Directive 94/9/CE, is
gree provided by the use of elastomeric material.
about preventing combustible dusts from en-
Such protection degree (IP 6x) has been verified
tering the enclosures where there is the elec-
after impact tests and heat and cold tests.
trical equipment that could cause ignition.

Currently, technical standards classify this
3.6.2.4.1. ENCLOSURES PROTECTION DEGREES
equipment under Group III, that has been di-
(IP CODE)
vided into three subgroups:
In the history of the use of electricity, a lot
IIIA: flammable particles; solid particles,
of designers have made efforts to make that
fibers included, with nominal sizes > 500
plants and electrical equipment could be
m;
used safely. Among the various technical so-
IIIB: non-conductive dust; finely divided so-
lutions adopted to prevent accidents related
lid particles, with nominal sizes 500 m, with
to electrical systems, there is also the IP code.
electrical resistivity > 103 m;
The IP code (International Protection) sum-
IIIC: conductive dust; finely divided solid
marizes the protection level of an electrical
particles, with nominal sizes 500 m, with
equipment against the accidental or intentio-
Tab. 13 IP protection degree: meaning of the first digit
First characteristic digit

Code
36
Graphic symbol
Meaning for equipment

protection
Meaning for people

protection
IP 0X
No protection
IP 1X
Protected against solid bodies greater

than 50 [mm]
Protected against access with the back of

the hand
IP 2X

than 12 [mm]
Protected against access with a finger
IP 3X

than 2,5 [mm]
Protected against access with a tool
IP 4X

than 1 [mm]
Protected against access with a thread
IP 5X
Protected against dust
IP 6X
Totally protected against dust
Tab. 14 IP protection degree: meaning of the second digit
Second characteristic digit

Code
Graphic symbol
Meaning for equipment protection
IP XO
No protection
IP X1
Protected against vertically falling water drops
IP X2
Protected against falling water drops with maximum inclination 15
IP X3
Protected against rain
IP X4
Protected against sprinkles
IP X5
Protected against water splashes
IP X6
Protected against strong water splashes (waves)
IP X7
Protected against temporal immersion
IP X8
Protected against continuous immersion
nal contact with the human body, objects and
additional letter: to be used when
water.
the protection of the people against
Besides the IP letters, the code is compo-
dangerous parts is higher than the pro-
sed of two significant digits and of the addi-
tection against solids, required by the
tional letters as indicated in the IEC 60529
first digit;
supplementary letter: to be used to
standard:
first digit (0 6): protection of the peo-
provide information about the material.
ple from the contact with dangerous parts
Explanations concerning the first significant
and protection of the materials from so-
digit are contained in Table 13. The protec-
lids;
tion level provided is progressive, from the
second digit (0 6; 7 8): protection
lowest (IP 0X) to the highest (IP 6X).
of the materials against harmful effects
Explanations concerning the second signifi-
of water;
cant digit are contained in Table 14. The pro-
37
3. Equipment choice
Tab. 15 Meaning of additional letters about protection
against human access
Talking about the second digit, two aspects

must be considered:
Additional
letters
Description
Protected against access with the

back of the hand
and immersion section; it is misleading
Protected against access with a

finger
code is higher than a IP X6 code;
B
C
D
1. between digits 6 and 7, it is as if there

was a border between splashes section
Protected against access with a tool
and makes people think that a IP X7

2. IEC 60529 Standard does not give any
information about the test of IP X8,
but that it cannot have lower condi-
Protected against access with a

thread
tions than the test for IP X7; it means

that defining IP X8 without defining the
immersion depth and/or the residence
tection level provided is progressive:
time makes no sense.
about the protection against water, from
Table 15 contains explanations about the
the lowest (IP X0) to the highest (IP 6X);
supplementary letters related to protection
about the effects of the immersion, from
against human access, while Table 16 con-
the lowest (IP X7) to the highest (IP X8).
tains those concerning the supplementary
Tab. 16 Meaning of additional letters about

protection against materials
Tab. 17 Comparison between NEMA code and IP code
Additional
letters
H
38
Description
High-voltage equipment
Tested against harmful effects due

to water ingress with equipment in
motion
Tested against harmful effects due
to water ingress with switched-off
equipment
Suitable to be used in specified
atmospheric conditions
NEMA
IP
10
11
3R
14
54
3S
54
56
4X
56
52
67
6P
67
12
52
12K
52
13
54
letters related to protection of material.
3.6.2.5. Ex de COMBINED PROTECTION
Some marking examples:
METHOD
IP65: equipment that is totally protected
It is an equipment, typically a power panel or
from dust and splashes of water;
a lighting equipment, with a part made with
IP67: equipment that is totally protected
the Ex d explosion-proof protection method
both from dust and splashes of water and
(usually the main part, for example: a power
from temporary immersion;
panel or a lighting equipment, Image 34 and
IP65W: equipment that is totally pro-
35) and another part made with the Ex e in-
tected from dust, from splashes of water
creased safety protection method (usually the
in specified weather conditions (i.e. with
connection box to the external circuits).
ambient temperature -60 + 55C).
From the union of the two protection me-
Sometimes it is required that the protection
thods we have different solutions:
against solids and/or liquids must comply
Ex d: a sufficiently strong equipment
with the NEMA code instead of the IP code.
providing a good safety level and allowing
Table 17 compares NEMA to IP. NEMA code
the manufacture of a lot of devices, thanks
considers also other elements, such as pro-
to its ductility;
tection against corrosion, while IP code do-
Ex e: a connection between equipment
esnt.
and plant providing a good safety level, as
Image 35
Image 34
Ex d enclosure
Flame-paths protection
Standard internal components
Attention to entry into enclosure
Ex e terminal strips
IP66 enclosure
Gaskets
Attention to entry
into enclosure
Ex e non-sparking
components
Image 34
Example of
control panel
in Ex de
execution
Image 35 Series
EJBE Ex de
system composed
of a Ex d
EJB series
junction box
in aluminium
alloy and of a
Ex e CTB series
junction box
Ex d sealed passages are the interface between the two enclosures

It must not affect d protection mode
It must guarantee e protection modes protection degree
39
3. Equipment choice
Image 36 Example of identification plate
Image 36
well as simple installation and maintenance

at affordable costs.
data of the Ex aspects, such as the

marking, the number of certificate,
etc. 8 ;
3.6.3. MARKING OF EXPLOSION-PROOF
notice.
EQUIPMENT
Some data are required by the European
As required by IEC 60079-0 standard, each
Community directives, others are the conse-
product put on the market has its own iden-
quence of the application of technical stan-
tification sign with the following informa-
dards, specific for every equipment.
tion (Image 36):
Lets explain the Ex marking. The EN
the name or place of the manufacturer,
60079-0:2009 standard, that has repla-
the subject responsible for putting the
ced both EN 60079-0:2006 and EN 61241-
product on the market;
0:2006, and that became effective on 1st
the year of manufacture 1 , the serial
June 2012, has brought some changes such
number 2 , the equipment identification
as the Equipment protection levels (EPL)
by defining the product code 3 ;
and the way of marking the products.
the equipment data: the temperature
According to the new regulations, the sign is
class 4 , the maximum surface tempera-
composed of five different sections (Image 37):
ture 5 , the ambient temperature 6 , the
the first is the marking related to the ap-
electrical data as stated in the certificate
plication of at least one European Com-
40
etc;
munity Directive: it is highlighted with
the graphic sign CE; a four-digit number
perature class 8 , the protection method
can be placed nearby to indicate the No-
for dusts 10 , the max temperature that
tified Body that has to supervise the
the equipment can reach while operating
production (in our case = CESI) 1
in the pertinent ambient temperature 11
and 2 ;
the fourth is the marking related to EPL. It
the second is the marking related to the
indicates the level of protection provided by
application of ATEX 94/9/CE directi-
the equipment and it is similar to the cate-
ve, and it is composed of the European
gories 9 and 12 ;
Community mark epsilon-x 3 , of the
finally, the protection degree IP 13 .
equipment group (I or II) and of 4
Some examples of markings on our equipment
its category (for groups II: 1, 2 or
are contained in Table 18 (following page).
3 5 followed by letter G for gases or

D for combustible dusts) 6 ;
IECEx
System
(International
Elec-
the third is the marking related to the
trotechnical Commission System for
protection method and consequent to the
Certification to Standards Relating to
application of the harmonized standards,
Equipment for use in Explosive Atmo-
for example the standards of the 60079
spheres)
series: the protection method for gases
In the European Union countries, the com-
and for the group of gases 7 , the tem-
pliance with ATEX Directive is a necessary

and sufficient condition for the explosion-
Image 37 Example of Ex marking

Image 37
proof electrical equipment installation in

hazardous areas.
Outside the European Union but IEC
countries, the explosion-proof electrical
equipment conformity to IEC standards
must be evaluated by a third part for both
general parties and types of protection.
Also here the marking must include: manufacturer name, serial number, identification
code, Ex symbol followed by:
type of protection (d, ia, E, P, Na, etc.);
group (II, IIA, IIB, IIIA );
temperature class or maximum surface
temperature (T1, T2, T6, );
equipment protection levels (GA, GB or GC).
41
3. Equipment choice
Tab. 18 Ex marking examples
CE marking
0
ATEX marking
CE marking
0722
II
nnn
2(1)G
Ex
d [ia Ga]
IIB+H2
T6..T5
2(1)D
Ex
tb [ia Da]
IIIC
T85..100C
10
Gb
IP66/IP67
Db
number identifying the Notified Body responsible for the inspection on production; placed on
M2 and 2 category equipment
Epsilon-x European Community mark, specific of the protection against explosions, defined
for the first time in the 76/117/CE Directive of 18th December 1975
2
3
Equipment group
I = equipment addressed to underground work in mines and in their surface plants exposed
to risk of release of firedamp gas and/or combustible dusts
II = equipment not addressed to underground work in mines or their surface plants which
could exposed to risk of explosive atmospheres
xx
Equipment category
M2 = equipment addressed to underground work in mines and in their surface plants exposed
to risk of release of firedamp gas and/or combustible dusts in presence of potentially
explosive atmosphere, it should be possible to interrupt the power supply
2G = equipment suitable for areas where, during normal activities, explosive atmospheres due
to gas, vapors or mists (zone 1) may occur; suitable to be installed in Zone 1 and 2
2(1)G = equipment suitable for areas where, during normal activities, explosive atmospheres
due to gas, vapors or mists (zone 1) may occur, and that has inside a bonded device that will
be connected to a category 1 equipment; suitable to be installed in Zone 1 and 2
2(2)G = equipment suitable for areas where, during normal activities, explosive atmospheres
due to gas, vapors or mists (zone 1) may occur, and that has inside a bonded device that will
be connected to a category 2 equipment; suitable to be installed in Zone 1 and 2
3G = equipment suitable for areas where, during normal activities, explosive atmospheres
consisting of an air and flammable substances mixture in the shape of gas, vapors or mist
may occur and, if it occurs, it is really for a short time (zone 2); suitable to be installed in
zone 2
2D = equipment suitable for areas where, during normal activities, explosive atmospheres
due to a mixture of air and flammable dusts (zone 21) and that has inside a bonded device
that will be connected to a category 1 equipment; suitable to be installed in zone 21 and 22
2(1)D = equipment suitable for areas where, during normal activities, explosive
atmospheres due to a mixture of air and flammable dusts (zone 21) and that has
inside a bonded device that will be connected to a category 1 equipment; suitable to be
installed in zone 21 and 22
3D = equipment suitable for areas where, during normal activities, explosive atmospheres in
the shape of cloud of flammable dust and, if it occurs, it is really for a short time. (Zone 22);
suitable to be installed in zone 22
Ex
It identifies that a protection mode against explosions has been adopted
ATEX marking
42
EPL
graphic symbol indicating that at least one European Directive has been applied; it is placed
only on the equipment, not on the components
Protection mode
Protection mode
EPL
Letter indicating the protection mode adopted

d = equipment protected by a d explosion-proof enclosure
e = e increased safety equipment
i = i intrinsic safety equipment
de = equipment with a part protected by a d explosion-proof enclosure and an e increased
safety part
ed = equipment with an e increased safety part and a part protected by a d explosionproof enclosure
d (ia Ga) = equipment protected by a d explosion-proof enclosure with inside an ia
intrinsic safety associated device (usually a barrier)
d (ib Gb) = equipment protected by a d explosion-proof enclosure with inside an ib
nA = equipment created to reduce to minimum the risk of arcs or sparks able to originate an
ignition danger during normal working
nR = equipment designed to limit gas, vapors and mists ingress
tb = equipment with an enclosure that prevents dust ingress and with devices to limit surface
temperatures; protection level b
tD = equipment protected by an enclosure to prevent a cloud or a layer-of-dust ignition
tb (ia Da) = equipment with an enclosure that prevents dust ingress and devices to limit
surface temperatures with b protection level, with inside an ia intrinsic safety associated
device (usually a barrier)
xxx
I = equipment addressed to underground work in mines and in their surface plants exposed
to risk of release of firedamp gas and/or combustible dusts
IIB = equipment not addressed to underground work in mines or their surface plants which
could exposed to risk of explosive atmospheres subgroup of B gas; suitable to be installed in
presence of gases of subgroup A and B
IIB+H2 = equipment not addressed to underground work in mines or their surface plants
which could exposed to risk of explosive atmospheres subgroup of B gas; suitable to be
installed in presence of gases of subgroup A, B and hydrogen
IIC = equipment not addressed to underground work in mines or their surface plants which
could exposed to risk of explosive atmospheres subgroup of C gas; suitable to be installed in
presence of any gas (subgroups A, B and C)
IIIC = equipment not addressed to underground work in mines or their surface plants which
could exposed to risk of explosive atmospheres subgroup of C dusts; suitable to be installed
in presence of any dust (subgroups A, B and C)
A21 = equipment not addressed to underground work in mines or their surface plants which
could exposed to risk of explosive atmospheres method A; suitable to be installed in zone 21
and 22
A22 = equipment not addressed to underground work in mines or their surface plants which
could exposed to risk of explosive atmospheres method A; suitable to be installed in zone 22
xx
Definition of temperatures generated by equipment

T6 = equipment that can reach, but not exceed 85C of absolute temperature (depending
on the protection mode, it can be either maximum temperature or surface maximum
temperature)
T5 = equipment that can reach, but not exceed 100C of absolute temperature
T...C = equipment that can reach, but not exceed in surface C of absolute temperature
IPnn
Identifies equipment; for further info, refer to previous paragraph 3.6.2.4.1. Enclosures protection degrees (IP code)
10
Mb = equivalent to M2 category
Gb = equivalent to 2G category
Gc = equivalent to 3G category
Db = equivalent to 2D category
Dc = equivalent to 3D category
43
3. Equipment choice
Tab. 19 Differences between European/IECEx practice and North-American practice
STANDARD
NORMAL OPERATION
IEC/EUROPE
DANGER IN UNSUAL CONDITION
Continuous
danger
Occasional danger
Zone 0
Zone 1
U.S.A./CANADA
Zone 2
Class 1 Division 1
Class 1 Division 2
North America
nes 0 and 1 correspond with the American
American classification and marking follow
Class I Division 2. We can conclude that
the method of Classes and Divisions, while
the equipment specifically designed for use
both the ATEX European and the IEC inter-
in Zone 1 in Europe cannot always be used
national standards follow the method of Are-
in American Class I Division 2.
as. Hazardous areas are, therefore, subdivi-
Compared to IEC zone system:
ded into 3 classes depending on the type of
- Class I only (stated by article 500 in NEC
explosive atmosphere:
standards) is divided into three zones depen-
- Class I (gases, vapors, combustible mists);
ding on IEC standard: Zone 0, Zone 1 and
- Class II (dusts);
Zone 2;
- Class III (combustible fibers).
- temperature classes T1-T6 are the same;
Each class is divided into two types of are-
- gases groups IIA, IIB, IIC are the same.
as at risk of explosion depending on the
Article 505 allows to choose how to classify,
frequency or duration of the explosive at-
with the aim of giving a global recognition to
mosphere formation.
IEC system, promoting the free movement of
- Division 1: areas with constantly or occa-
equipment suitable for areas classified accor-
sionally dangerous concentrations of gases,
ding to IEC system.
vapors or combustible mists during normal
Therefore, products can be approved both by:
operations.
Classes, Divisions and Groups of sub-
- Division 2: areas without dangerous con-
stances
centrations of gases, vapors or combustible
For example: Class 1, Division 2, A, B, C, D T3;
mist during normal operations but only in
and by:
case of failure.
Classes, Divisions and Groups of gases
It is clear that Zone 2 of the European
For example: Class 1, Area 2, IIA, IIB, IIC, T3.
classification is the same as the American
The Table 19 highlights the differences
Class I Division 2, while European Zo-
between North-American and IEC/ Euro-
44
pean classification.
methods. The marking must contain:
Explosion-proof equipment must be tested
the protection level;
and certified by American Notified Bodies
the Ex symbol;
(such as, for example, the Underwriters La-
the symbol of the type of protection ap-
boratories (UL) or Factory Mutual) and by
plied;
Canadian ones (such as the Canadian Stan-
the equipment group (I, II or IIA, IIB, IIB);
dards Association).
the temperature class;
The Image 38 describes the geographical
and the symbol X, if certain use condi-
distribution of the NEC and IEC standards,
tions must be followed or if the product
highlighting the countries in which both are
is an Ex component.
applicable and valid.

3.6.4. THE AMBIENT TEMPERATURE OF OUR
EQUIPMENT
Image 38
The ambient temperature is the air temperature or the temperature of another material
NEC-Standard
IEC-Standard
Both standards
very close to the equipment. Usually, for Ex

equipment, the interval considered is -20
+40 (C). For the Cortem Group equipment
the interval is wider: -60 +60 (C) to
meet the needs of extreme areas where our
equipment is installed. To do so, we have looked for materials suitable to this temperature range.
3.6.5. OUR TEMPERATURE CLASSES
The temperature class is the maximum surface or absolute temperature, depending on
Image 38 Geographical distribution of the NEC

and IEC standards
the protection method, that the equipment

can reach while operating.
The less the equipment heats up, the fewer
Russia
The
marking
are the chances that they cause an explosion.

of
the
explosion-proof
The average ignition temperature of the
equipment must comply with the GOST R
classified gases is about 360C (T2) see
51330.0-99 standards and with the stan-
Graph 5, chapter 2.
dards concerning the single protection
Find comparison between European/Inter-
45
3. Equipment choice
Tab. 20 Comparison between European/international
and North-American temperature classes
When choosing the best materials to be

transformed into finished products, it is im-
[C]
[F]
450
842
300
572
280
536
T2A
260
500
T2B
230
446
T2C
215
419
T2D
200
392
180
356
T3A
(which can be controlled by laboratory tests
165
329
T3B
and guaranteed by certification), but rather
160
320
T3C
135
275
120
248
100
212
85
185
portant to consider the limiting factors of

nature.
All materials, including the ones we use,
T1
have three enemies:
T2
environment;
temperature;
time.
Temperature and time are familiar factors,
while the environment, where our products
are used, is not easy to control.
We are not talking about familiar potential
T3
hazards caused by an explosive atmosphere
deterioration caused by highly aggressive

environments like chemical and petrochemical plants.
T4
T4A
T5
T6
Corrosion resistance is a relative factor, as it

depends on the actual environmental conditions that significantly influence the nature
of the attack.
This is why Cortem Group constantly tests its materials in accordance
with ASTM standards (American So-
national and North-American temperature
ciety for Testing and Materials) for
classes in Table 20.
example B117 in salt fog, G31 in hydrogen sulphide and hydrochloric acid,
3.6.6. MATERIALS USED IN OUR EQUIPMENT
etc. - and carries out in-depth rese-
Today, we use many different materials for
arch into their resistance in outdoor
producing equipment and components de-
environments. It is therefore able to
signed for areas with a potentially explosive
choose the right material based on
atmosphere. They can be basically classified
objective experience and to guarantee
in Table 21.
long-term product safety.
46
3.6.6.1. ALUMINIUM ALLOY
stainless steel. The mechanical properties
Aluminium alloy is one of the worlds most
of aluminium alloy castings are more than
widely used materials in the production of
adequate for ensuring explosion-proof elec-
explosion-proof enclosures.
trical protection.
It is highly corrosion-resistant and, there-
In the past, either aluminum-copper alloys
fore, universally known as the most effec-
were used, but they were not at all corro-
tive and versatile material for most appli-
sion-resistant, or aluminium-magnesium.
cations.
Although being corrosion-resistant, magne-
It is much lighter than cast iron, so it ma-
sium, when mechanically hit, can generate
kes the equipment much easier to install
sparks with energy values able to trigger an
and maintain; moreover, it is highly corro-
explosion (technical standards limit the ma-
sion-resistant and does not require surface
gnesium presence at 7,5% in mass). Today
protection, unlike cast iron which has to be
we use the aluminum-silicon alloys, where
galvanized or coated.
copper is present as impurity. Its main fea-
Nevertheless, Cortem Group protects its
tures can be summarized as follows:
products with a surface coating, RAL 7035,
fairly high mechanical resistance;
that contains stainless steel particles, a
adequate ductility;
protection against mechanical impact, and
good denseness;
characterizes our production avoiding imi-
corrosion resistance.
tations and fake products.
The aluminium- silicon alloys we use mostly
Aluminium is also much cheaper than
are the AlSi10Mg(a) (EN AB 43000) and the
Tab. 21 Materials used by Cortem Group for the production of explosion-proof equipment
Equipment
Metallic
Plastic
Transparent
material
materials
parts
aluminium alloys
stainless steel
Gaskets
neoprene, silicone
Ex entry
nickel-plated brass
aluminium alloy
stainless steel
galvanized steel
external part
reinforced polyester
with glass fiber
polyamide 6
borosilicate glass
polycarbonate
47
3. Equipment choice
Tab. 22 Chemical composition of aluminum-silicon alloys
Fe
AlSi10Mg(a) max
0,55
AlSi12(b)
max
0,65
Si
Mn
Ni
Ti
Cu
Pb
Mg
Zn
Sn
other
9 11
max
0,45
max
0,05
max
0,15
max
0,05
max
0,05
0,2 0,45
max
0,1
max
0,05
each 0,05;
total 0,15
10,5 13,5
max
0,55
max
0,1
max
0,2
max
0,15
max
0,1
max 0,1
max
0,15
//
each 0,05;
total 0,15
AlSi12(b) (EN AB 44100), and their chemical
tion layer. It is formed when the materials of
compositions, in accordance with EN 1706
the alloy come into contact with the air or wa-
standard, are contained in Table 22.
ter oxygen.
The stainless steels are traditionally divided
3.6.6.2. STAINLESS STEEL
into three big families, depending on their
The stainless steels, because of highly aggres-
metallographic structure:
sive environments or for technical/legislative
martensitic;
reasons (for example in the food and phar-
ferritic;
maceutical sectors), have been so much re-
austenitic.
quested in the last years, that almost all our
In order to meet the market needs, such as
equipment is being made also of this mate-
providing highly resistant materials to chlo-
rial, regardless of the protection method.
ride corrosion, we have chosen the AISI 316
The stainless steels are iron-, coal- and chro-
(X5CrNiMo17-12-2) stainless steel, belonging
me-based alloys that combine the mechanical
to the austenitic family.
properties typical of carbon steels with the
In general this family has the following pro-
corrosion resistance properties, due to a thin
perties:
and transparent surface layer called passiva-
high corrosion resistance;
Tab. 23 Chemical composition of stainless steel AISI 316
X5CrNiMo17-12-2
48
Si
Mn
0,07
1,00
2,00
Ni
Cr
10,0 13,0 16,5 18,5
Mo
other
2, 2,5
0,11
each 0,03;
total 0,045
ease of cleaning and excellent hygienic

coefficient.
typical dark grey color.

Fibers are highly traction-resistant and re-
But stainless steel presents also some di-
present, therefore, the resistant elements of
sadvantages:
the fiber-reinforced material.
in low temperatures the corrosion resi-
In fact, when a fiber-reinforced material un-
stance decreases dramatically. Acids bre-
dergoes an axial traction, the real efforts are
ak the oxide film creating generic corro-
absorbed by the fibers, while the polymer ma-
sion in these steels;
trix has only to distribute them to the fibers,
in the interstices and in the protected are-
leveling the stress.
as, oxygen quantity may not be sufficient
Moreover, the resin protects the fibers from
to preserve the oxide film, and may there-
the wear and ensures a good fiber alignment.
fore provoke interstitial corrosion;
Thanks to flame retardants present in the
halide ions, especially the (Cl-) anion,
chemical formulation, our material complies
break the passivation film on the au-
also with Vo degree according to UL94 stan-
stenitic stainless steels and provoke
dard.
the so-called corrosion to alveoli (cal-
The main properties are:
led also pitting corrosion); another
high lightness;
chlorines effect is the SSC (Stress Cor-
high mechanical resistance;
rosion Cracking).
high thermal insulation;
Chemical composition, in accordance with
high dielectric and magnetic properties.
EN 10088 standard, is contained in the

3.6.6.4. BOROSILICATE GLASS
Table 23.
Borosilicate glass is a strong material, known

3.6.6.3. POLYESTER REINFORCED WITH GLASS
for its resistance to thermal shocks and for its
FIBERS
low expansion; it is resistant to chemical agents
This material appeared in Italy in the Ex sec-
and has excellent features of transparency.
tor in the second half of the 80s, and was ap-
For our equipment we use the one in class
plied mostly in the increased safety deriva-
3.3, in accordance with ISO 3385 standard,
tion boxes.
that has the following characteristics:
The material we use is an unsaturated polye-
smooth, non-porous surface, easy to clean;
ster resin, reinforced with glass fibers to im-
excellent and wide chemical compatibili-
prove its mechanical characteristics, and
ty; it is moreover highly resistant to wa-
graphite, to make the surface conductive in
ter, salt solution, organic substances, ha-
order to reduce the risk of accumulation of
logens and acids;
electrostatic charges; graphite provides the
no catalytic effect in chemical processes;
49
3. Equipment choice
Tab. 24 Chemical composition of borosilicate glass 3.3
SiO2 B2O3 Na2O Al2O3 other

Borosilicate
80,6 % 12,5 % 4,2 %
bon, petrol, greases, oils, alcohols (except

methyl alcohol) and water under 70C;
good electrical properties.
2,2 % 0,5 %
glass,
3.6.6.6. NICKEL-PLATED BRASS
class 3.3.
We use this material (leaded brass with Cu

58%, Zn 40% and Pb 2%) exclusively for the
construction of Ex cable entry (Cable glands).
no harmful physiological characteristic in

biochemical process;
Besides the traditional copper (Cu) and zinc

(Zn) alloy, our material has also a low lead
transparency;
(Pb) percentage on the external part of the
good stability and thermal resistance;
bar, which simplifies the turning since it does
low thermal expansion.
not create a solution with the alloy Cu-Zn, and
The chemical composition, adherent to ISO
since it has a lower solidification temperature
3585 standard, is contained in the Table 24.
than the other two elements. Subsequently, it

undergoes a surface treatment of electrolytic
3.6.6.5. POLYCARBONATE
nickel plating, to provide the product, more
Polycarbonate (PC) is a generic polyester of
than with an aesthetic aspect, with a higher
carbonic acid. Notwithstanding Du Pont has
corrosion-protection level by external agents.
studied it as a possible cotton fiber replacer

since the end of the 20s, it is the most recent
3.6.6.7. GALVANIZED STEEL
among the materials above described since
We use even this type of material, an iron (Fe)
Bayer (Makrolon) and General Electric (Le-
carbon (C) alloy, as well as nickel-plated brass,
xan) started its commercial use in the 60s.
for connection elements of Ex entries. It is a
The polycarbonate we use is of bisphenol-A, a
stainless steel, sweet, for general use, with small
polymer composed of many (poly) identical
amounts of lead, bismuth, tellurium or sulfur.
units of bisphenol A connected to carbonate
To protect the component from corrosion, at
in the main chain. Main features of this ther-
the end of machining it undergoes a galvani-
moplastic material are:
zing process.
transparency: high refractive index due

to its aromatic feature; transparency and
3.6.6.8. POLYAMIDE 6
absence of color allow a light permeability
We use also this material, as well as the pre-
of 89% in the visible spectrum;
vious ones, exclusively for the construction of
thermal and mechanical resistance;
Ex cable entries. The polyamides (Pa) are linear
resistance to mineral acids, hydrocar-
polymers characterized by the presence of the
50
amide group -NH-CO-. In the range of polya-
(R) linked to the silicon atoms. Typically, the
mides, commonly known as nylon, different
silicone rubbers (VMQ) are remarkably resi-
types may be distinguished. The single types
stant to temperature, chemical attack and oxi-
of polyamide do not differ much: relatively low
dation, and are excellent electrical insulators.
specific weight, resistance to impact and wear,
They are excellent non-stick, flexible, resistant
discreet electrical insulation, resistance to sol-
to aging and to high temperatures.
vents, oils, greases and fuels. We use the polyamide 6 (Pa6) or polycaprolactam, that belongs
3.6.7. OUR CERTIFICATIONS (PART I)
to the family of aliphatic polyamides.
3.6.7.1. THE 94/ 9/CE ATEX 95

DIRECTIVE
3.6.6.9. NEOPRENE
Most of the equipment we produce belongs to
Neoprene is one of the main materials we use
group II, category 2G and 2D. On the basis of this
for our seals. The neoprene (originally called
and considering that it is electrical equipment,
duprene) was the first residue of the synthe-
our conformity assessment procedures were
tic rubber produced in a large scale with more
aimed to obtain the various CE type-examina-
than 75 years of proven performance in a wide
tion certificates for the design aspects of the Ex
spectrum of areas. It was originally developed
equipment and the notification of product war-
as oil-resistant replacer for natural rubber.
ranty (Image 39) to cover the manufacturing
The basic chemical composition of the Neopre-
aspects of the equipment itself.
ne synthetic rubber is polychloroprene (CR).

It belongs to the family of elastomers synthesis (i.e. synthetic rubber) and it looks like a
Image 39 ATEX Certification of production quality

Image 39
porous rubber, whose mass is made up of gas

cells uniformly distributed. The main features
are: the elasticity, shear strength and crushing,
resistance to aging, air pollution and heat, and,
moreover, it appears to be inert towards many
chemical agents, oils and solvents.
3.6.6.10. SILICONE
The silicone, as well as the neoprene, is one of
main materials we use for our seals. Silicones
or polysiloxanes (methylvinyl polysiloxane)
are inorganic polymers based on a siliconoxygen chain and organic functional groups
51
3. Equipment choice
Even if it is not required by the conformity
Image 40
assessment procedures of the directive, for

greater transparency to our customers, our
equipment belonging to categories 3G
and 3D underwent the design assessment obtaining the type-examination
certificate.
To satisfy essential safety and health requirements we use the harmonized standards. Representing the state of the art,
they are in continuous evolution (a standard is valid for about 5 years). The Official Journal of the European Union (OJ)
publishes periodically, on C series, the
list of standards satisfying the essential
requirements of each Directive issued by
the Union and defines the end date of the
presumption of conformity with the requirements themselves.
Therefore, our certificates are always updated so that our equipment projects meet the
Image 40 Example of certificate IECEx
state of the art present when we put the products on the market.
Moreover, we have chosen the Notified Body
3.6.7.2. IEC-EX
as our partner on the product certification.
Since the beginning of 2000, outside EU a
At the beginnings there were about 15; now
voluntary certification scheme has been ap-
there are 64, among those more than 10 in
plied internationally. We talked about it in
Italy. We have chosen a Body whose com-
chapter 3.6.3.: IECEx (http://www.iecex.
petence, impartiality and toughness were
com/) scheme.
recognized not only at a national but also
This scheme is very similar to that of the 94/
at an international level. So we have chosen
9/CE Directive and foresees both the design
CESI - Italian Experimental Electrotechni-
control (Ex-TR) and the manufacturing con-
cal Centre Giacinto Motta based in Milan;
trol (QAR) by a Certification Body accredited
its first test report on an explosion-proof
by this scheme. With these two documents it
equipment took place in 1969.
is possible to require the conformity certifi-
52
an international database;
Image 41
maintenance of a confidence level towards

the equipment and the services expressed
in the IECEx certification.
This scheme and its certificates are recognized
internationally by more and more countries.
Certificates by IECEx system are issued as
electronic certificates and are available on
IECEx website (Image 40). This allows public
access in order to view and print.
3.6.7.3. RUSSIA
Standards in Russia are very different from
the European contest, where we can move easily. In the EU we find the principle of mutual
recognition, and the mandatory certification
(CE mark) is required only for certain hazardous product families or products associated
to serious risks; by contrast, in Russia, according to the law No. 508 of 22/07/92 on
Image 41 GOST R certification
the defense of consumer rights, most of the

products meant to be marketed within the
confederation, must be certified to verify the
cate (CoC). The reference standards are those
product conformity to the Russian national
of the IEC 60079 and IEC 61241 series.
standards.
The IECEx system aims to facilitate the inter-
Since the safety and quality control of the
national marketing of equipment meant to be
imported products does not depend on the
issued in the environment with explosive at-
custom bodies, they verify only presence
mospheres, maintaining the necessary safety
and authenticity of documents certifying
level:
the imported product properties.
reduction of trial and certification costs
In the Customs control of goods, the main document is the certificate of conformity issued
for the producer;

reduction of the time to market;
within the compulsory product certification
international confidence in the product
system GOST R (Image 41); another impor-
assessment process;
tant document is the permission to use, is-
53
3. Equipment choice
sued by Rostechnadzor (RTN).
other liquids at high pressure/high tempe-
GOST is the short form for Gosudarstven-
rature belong to this category, since they
nyj Standart (State standard in Rus-
are considered hazardous liquids used in
sian). This national certification system
hazardous operations. The permission is
has been introduced to protect public he-
necessary to use the equipment and start
alth and to guarantee the safety and quali-
the plant. Without permission the plant
ty of imported products that have invaded
cannot be authorized. In general, they un-
the national markets in the former-USSR
dergo all the necessary controls (revision
countries.
of the maintenance and repair procedures,
The products labelled with GOST R com-
of systems, hydraulic tests, non-destructi-
ply with the applicable standards and have
ve tests, etc.). A revision of possible effects
received a GOST R certificate by an accre-
on the environment, such as drains, sewa-
dited certification office. Therefore, they can
ge spills, etc.
be custom cleared only if they have this cer-
According to the Russian law, the permis-
tification issued by a Russian official body
sion is valid for 5 years. Technical passes
accredited by Goststandart; the certificate of
and user manual in Russian are required to
conformity must be shown together with the
obtain the permission to use.
cargo customs declaration and is fundamental to import the products into the Russian
3.7. OUR CERTIFICATIONS (PART II)
Federation.
On each product put on the market, the
Deliveries with official copy of the certificate
subject applying the
will be custom cleared and will be accepted
prepare the CE conformity statement
mark must:
by the Russian customer.
for devices, or the conformity certifica-
An extra permission is required for many
te with the embedding conditions for
products meant to be used in industrial
components;
and potentially hazardous areas based
provide the user instructions.
in Russia, among which we find the Ex
From a legal point of view, the EU considers
equipment. Among these we find also the
producer:
Rostechnadzor (RTN), issued by the Ser-
i) the manufacturer of the product defined
vice for ecology, technology and Nuclear
in the European Community and every other
monitoring. This permission is necessa-
person who introduces him/herself as ma-
ry to state that the potentially hazardous
nufacturer by applying on the product his/
equipment satisfies Russian safety pa-
her name, label, or still who makes the pro-
rameters and can be used without risks.
duct new;
All the goods handling oil, natural gas or
ii) manufacturers representative, if the
54
manufacturer is not defined in the Europe-
last two digits of the year in which the CE
an Community, or the importer of the pro-
mark was applied;
duct itself;
the machinery Directive requires the
iii) the other professional operators if their
description and the identification of the
activity affects the product safety features.
machinery, with generic denomination,
Lets have a further look at these two docu-
function, model, type, serial number,
ments.
commercial denomination;
ATEX 95 Directive requires, if it is gi-
3.7.1. THE CE CONFORMITY STATEMENT
ven, name, identification No. and ad-
The CE conformity statement is the formal
dress of the Notified Body that issued the
and final act in which the producer declares
CE type-examination certificate and the
to the single market of the European Union,
certificate No.
that he has followed the Essential Safety and

Health Requirements of all the community
3.7.2. USER INSTRUCTIONS
Directives.
Instructions provide information about the

correct use of the product in safety condi-
The CE conformity statements are prepa-
tions; for this reason they are written not
red considering the following legislative and
only in the language of the producer, but
normative references:
also in English. Instructions are part of the
CE conformity statement annex III
product supply.
of the European Parliament and Board
Also in this case, instructions are prepared
Decision No. 768/2008/CE of 9th July
considering the following legislative and
2008 concerning a common scheme for
normative references:
marketing of products and that repeals
IEC 62079 Technical standard Prepara-
the Decision 93/465/CEE (G.U.U.E. , L
tion of instructions structure, content
series, No. 218 of 2008-08-13);
and presentation;
ISO/IEC 17050-1 and 17050-2 technical
Depending on the applied Directives, spe-
standards Evaluation of conformity -
cific requirements can be found, such as:
conformity statement issued by the sup-
the machinery Directive requires at
plier.
least a series of information defined in

chapter 1.7.4. and/or in chapter 3.6.3
Depending on the applied Directives, par-
and/or in chapter 4.4, etc. of annex I;
ticular extra requirements can be made,
ATEX 95 Directive requires at least a
such as:
series of information defined in chapter
the Low tension Directive requires the
1.0.6 of annex II.
55
4. Installation
afety in the potentially explosive
maintenance activity.
areas can be guaranteed only with
Installation design, equipment choi-
a tight and effective collaboration
ce and assembly must be carried out
among all the parts involved (Image 42).
by competent personnel trained in the
The employer is responsible for the safety of
different protection and installation
his plants. He must verify where there is a
methods, as well as in the rules and le-
risk of explosion and subdivide the zones into
gislative standards about areas classi-
Areas. He must guarantee that equipment is
fication.
installed in accordance with the standards
Producers
and that it is checked before its use. Moreo-
equipment are responsible for routine tests,
ver, he must verify that equipment is properly
product certification and documentation.
used, and carry out periodical inspection and
They have to guarantee that each device com-
56
of
explosion-proof
electrical
plies with the approved design.
sheath. Each sealing ring is suitable for
After that, the installer will have to consi-
single cable diameters.
der both normative standards (such as the
Cable glands must be chosen considering
EN 60079-14) and what is reported on the
the cable diameter. The tightness is ensu-
user instructions provided by the manu-
red by the compression of a rubber gasket
facturer, in particular if there are special
that tightens on the external diameter and
conditions for safe use (X).
prevents the flame from spreading elsewhe-
Our choice of cable glands for Ex d
re. Usually the sealing ring is as long as the
equipment is relevant. Cable glands fol-
lamination joint; some cable glands with a
lowing Ex d protection method can be of
shorter sealing ring can be used in enclosu-
different types, depending on the their use.
res whose internal volumes are limited by
Generally, they are divided into two catego-
the certificate. Min and max diameters of
ries:
the use of the cable are reported on the sea-
for armored cable: used for the armo-
ling rings. It is forbidden to insert more ca-
red cable direct entry into explosion-proof
bles into the same cable gland, as well as to
enclosures, they can be built for different
increase the sealing ring diameter with in-
types of armors;
sulating tape or similar, in order to make it
for normal cable: used for the non-armo-
match with the sealing ring diameter. Cable
red cable entry into explosion-proof en-
glands for armored cables have two sealing
closures. The sealing is carried out with a
rings: the front one tightens on the inter-
sealing ring directly on the external cable
nal diameter and guarantees the explosion-
Image 42 Cooperation among all parts involved

Image 42
Manufacturer
Authority
Installator
Employer
Certification
authority
Standards
57
4. Installation
Graph 9 Flowchart to choose the right cable gland
Does equipment have a

potential ignition source
inside?
yes
no
Does hazardous gas require

a IIC construction?
yes
no
Is installation area
zone 1?
yes
Use as an alternative:
A. an Ex d sealing device,
containing a sealant (EYS,
EYD or EZS sealing joint)
B. an Ex d cable gland, that
incorporates the joints filled
with sealant (FB or FGAB type
barrier cable gland)
no
Is equipment free
volume higher
than 2 dm2?
yes
no
Use Ex d entry cable

devices with sealing
ring (REV or REVD
type cable gland)
proof protection; the rear one tightens on
mes, either barrier or normal cable glands
the external diameter and prevents liquids
with sealing rings can be used. Graph 9 helps
from penetrating into the cable gland, whe-
you choose the right cable gland. This flux
re the armor is sealed by two conic rings
diagram considers whether the equipment is
guaranteeing the electronic continuity of
marked IIC and if its volume is > 2 dm3.
grounding.
Since we understand that the production of
There are also barrier cable glands. In this
AD-PE = explosion-proof safety plants
case the cable is sealed with a resin in a slee-
and its maintenance above all if sealant has
ve. It is inserted in the cable gland and forms
been used in the Ex entry - is tough work, we
a lamination joint with its internal part of the
have chosen to help plant operators by provi-
object.
ding them with high-safety level equipment,
The use of different types of cable glands must
that is more simple to manage. This is Ex de
follow EN 60079-14 standards. Depending
protection method equipment, above men-
on the plant type and on the enclosure volu-
tioned (chapter 3.6.2.5.).
58
5. Inspection
hat is the aim of inspection?
nel trained in the different protection and
To verify with an inspec-
installation methods, as well as in the na-
tion that the installation has
tional rules about plants and about hazar-
been properly made, and that it main-
dous areas classification.
tains its safety characteristics. We remind
The normative standard concerning in-
you once more that plant inspection and
spection and maintenance activities is
maintenance have to be made by person-
IEC/EN 60079-17.
59
Graph 10 Types of inspections depending on frequency, quantity and quality parameters
Inspection
frequency
Total
quality (degree)
Initial
quantity
Inspections
Detailed
Periodical
Random
At sight
The inspections consider three aspects
Total
Close
Detailed
qualitative: able to detect defects visi-
(Graph 10):
ble to the naked eye without any extra
temporal: carried out before the
tool (visual; also able to identify defects
equipment is used (initial) or periodi-
detected only with means of access (clo-
cally;
se); and finally able to detect defects by
quantitative: made on all equipment

(total) or on part of it (random);
60
opening the equipment and/or by using

tools (detailed).
6. Maintenance
and repairs
6.1. MAINTENANCE
the preventive one, such as maintenance
he maintenance is the combi-
carried out at scheduled intervals or accor-
nation of all the administrative
ding to defined criteria and aimed at redu-
techniques, including the super-
cing the probability of failure or the degra-
visory actions, aimed at maintaining or at
dation of the operation of an entity, to the
bringing an entity into a state where it can
accidental one, such as as maintenance
perform the required function.
after the detection of failure and aimed at
Over the years, the approach to maintenan-
bringing an entity in the state where it can
ce has changed dramatically, passing from
perform the function required.
61
The time interval between two maintenance
that high-quality objects can be repaired, this
operations depends on different aspects, such
action can be made by specialized centers or
as the design choices, the environment where
by the equipment manufacturer.
it is installed, the care for the equipment.
Repairing our equipment
Since we handle equipment aiming at re-
We design and make our equipment long-
ducing the risk of explosion, maintenance
lasting and able to maintain the safety level
should be made punctually, following the in-
requested in the hazardous environment
structions carefully.
where it is installed. Our equipment can be

repaired.
6.2. REPAIRS
In our Italian factory based in Villesse (GO)
Repairs in general
and in the authorized Cortem centers, our
Repairing is aimed at bringing failed
equipment is repaired and restored in ac-
equipment in its suitable operating condition
cordance with the design documents ap-
to service in accordance with the appropria-
proved by the Notified Bodies. It can gua-
te standard. Even though we have forgotten
rantee again the initial safety level.
62
7. End-of-life
equipment
7.1. DISPOSAL
electronic equipment: 2012/19/EU directive
nd-of-life electrical equipment
of 4th July 2012, according to which some
must be disposed of
equipment (like some of ours)
properly. Starting from
has to be disposed of in a cer-
the title XX environment of the
tain way. This is why we apply on
Treaty on the Functioning of the Eu-
them the symbol here represen-
ropean Union, EU has issued a new
ted (left below).
Directive about waste electrical and
Cortem Group, as well as other
63
companies, in ac-
our products we
cordance
use generally:
with
ISO 14001 stan-
- cardboard boxes;
dard, has adopted
- wooden boxes.
an environmental
the
management
sy-
yer is related to
stem with speci-
the material of the
fic ways to dispo-
equipment
se of end-of-life
sure; our choice is
equipment, which
based on both fun-
is a waste. Each
ctional and envi-
country can have
ronmental aspects
established
of the product, and
spe-
second
enclo-
cific environmen-
we
tal
the certification of
management
have
la-
created
our
environmen-
ning waste collec-
tal
management
tion and disposal.
system
Have a look at it
Certification
for further infor-
78704-2010-AE-
mation.
ITA-SINCERT).
system
concer-
(DNV
No.
Therefore, most of the materials, descri7.2. RECYCLABILITY
bed in chapter 3, are recyclable:
Recyclability is strictly connected to di-
- aluminium;
sposal. Because of non-endless material
- steel;
availability and of production costs, for
- polyester, polycarbonate, polyamide;
several years we have been accustomed to
- glass.
choose materials that can be recycled.
The third layer is related to the mate-
In almost all cases, equipment has three
rial of the equipment installed inside
layers:
the equipment enclosure. Even thou-
the first is related to the packaging, and
gh it is electric equipment, the com-
for its correct disposal EU has issued a
ponents are various: wires, terminals,
Community Directive: 94/64/CE of 20th
transformers, switches, lamps (fila-
December 1994 on the packaging and
ment and discharge, led), electronic
packaging waste. For the packaging of
circuits, batteries, etc.
64
8. Application
examples for different
types of plants
8.1. PHARMACEUTICAL INDUSTRIES
tures able to emit flammable vapors, or they
roduction processes in compa-
can reach temperatures even higher than the
nies producing drugs for mixing,
flashpoint.
emulsion and chemical reaction
Besides industrial plants, where a product
of organic compounds, can generate envi-
process takes place, there are research and
ronmental conditions able to create poten-
development chemical laboratories, in which
tially explosive atmospheres. In the produc-
liquids, gases or combustible dusts could be
tion process, liquid substances are very often
present in such quantities that they can beco-
used; they can be brought to such tempera-
me a risk of explosion.
65
Substances are usually contained in sealed
list and to map the areas where the substan-
enclosures and kept in storage areas, before
ces are used or stored. Only highly qualified
being produced.
staff should carry out this activity. Each ha-
If we quantify the explosion risk, we have to
zardous substance must have a form indica-
consider the following possibilities:
ting all the chemical and physical properties
1. potentially explosive atmosphere due to
required for the classification (flashpoint,
the production process for the presence of:
ignition temperature, U.E.L, L.E.L., etc.)
gases, vapors of flammable liquids processed

at temperatures higher than the flashpoint,
8.1.1. REFERENCE STANDARDS
combustible dusts;
Hazardous areas classification must be car-
2. potentially explosive atmosphere due to
ried out in compliance with EN 60079-10-1
plants serving the production process, such
standard for the plant sections with gases,
as power plants of gas;
vapors or mists, and in compliance with
3. potentially explosive atmosphere in che-
EN 60079-10-2 standard for the zones with
mical plants where studies and researches
combustible dust. The latter allows the clas-
with flammable substances are carried out
sification considering all the hazards due to
(substances such as gases, vapors or mists
the presence of dusts in a cloud and/or of
and combustible dusts), in presence of po-
layers of dusts, taking into account the in-
tential ignition sources.
formation about the processing.
For areas classification, the first step is to verify the characteristics of all the substances
8.1.2. PLANT EMISSION SOURCES
present in the production process, to make a
Lets analyze the plant emission sources of an
66

industrial pharmaceutical plant.
of points of discontinuity of the plant.
The emission sources of continuous grade
Hazardous areas extension may be determi-
are:
ned by dz distance, starting from the emis-
open enclosures containing the substan-
sion source in direction dependent on the
ces in processing;
type of gas.
enclosures in open air used for the preparation of compounds for hand or automa-
8.1.4. CLASSIFICATION FOR DUSTS
tic mixing and/or in which additions to
In presence of dust in the process, we could
the processing liquid solution are made.
have:
Depending on the operation procedures, firstdegree emission sources are the following:
loading and unloading in open air;
Zone 20, inside containment systems, loading hoppers, etc.;

Zone 21, originated by the emission
pickup points for sampling.
sources due to loading and unloading
Second-degree emission sources are flanges,
operations, etc.;
unions, valves and, in general, points of di-
Zone 22, originated by points of disconti-
scontinuity of the production plant, of con-
nuity of containment systems, by the se-
tainment or conveying.
aled inlets and possibly around Zone 21.
In presence of combustible dusts in the process (such as lactose, used as adjuvant), the
8.2. DEPOSIT OF CEREALS
probability that layers are formed as well as
Cereal storage silos are deposits, inside or
the risk that layers rise in clouds becoming
outside a building, where food industry pro-
emission sources must be verified.
ducts (such as wheat, grain, rice, or similar

Tab. 26) are stored. Loading operations
8.1.3. CLASSIFICATION FOR GAS
are performed by means of mechanical devi-
The result of classification depends on ope-
ces such as tubes, conveyor belts, augers etc.,
rating conditions, plant parameters, volume
through inlets placed on the top of the tower
of environment, ventilation and coefficient of
silo. Once disconnected, products are picked
performance f.
up by unloading doors place on the lower
In general, for gases, vapors and mists we
part, or transported through pneumatic con-
could have:
veying systems or manually.
Zone 0, inside containment systems and
All food products are made of coal, hydrogen,
inside open enclosures;

Zone 1, around mixing operations, pickup
points, loading, unloading, etc.;
Zone 2, originated by the emission sources
nitrogen, sulfur, oxygen, etc. Therefore, they

are combustible and may provoke fires and
explosions. If cereals are ground before being
stored, they can have an extra-thin consi-
67
the layers, due to air circulation, generate a

continuous cloud.
Airborne combustible dusts form clouds of
explosive atmosphere. Clouds, if triggered,
can oxidize so rapidly that they can generate an explosion. The greater the reactivity of
dust is, the smaller its particles are.
Cloud is explosive when the concentration of
dust inside substance explosion ground ranges between L.E.L (Lower Explosive Limit)
and U.E.L. (Upper Explosive Limit), expressed in dust grams per air volume, g/m3.
8.2.2. AREAS CLASSIFICATION
Hazardous areas classification in a silo can be
made according to EN 60079-10-2 standard,
that allows classification considering the hazards due to the presence of dusts in a cloud
or of layers of dust.
8.2.3. AREAS INSIDE CONTAINMENT SYSTEM
stency and, if particle size is lower than 500
Inside silo volume, the layer of stored cere-
mm, particles themselves can originate an
als is continuous-degree emission source and
explosive atmosphere if mixed with air.
may generate a Zone 20 extended to all the
In any case, even if cereals have higher sizes,
internal silo volume.
we have to consider that solid parts usually
If loading and unloading operations are car-
generate dusts. The rule says that dusts gene-
ried out through automatic conveying sy-
rate thinner and thinner dusts.
stems, a dust/air mixture is formed and it
Presence of combustible dust always genera-
may generate a risk of explosion. In this case,
tes risk of explosion, if triggered.
the interior of the transport system is classified as Zone 20.
8.2.1. RISK OF EXPLOSION BY CLOUDS OF DUST

Air is always present inside the silos, and
8.2.4. AREAS OUTSIDE CONTAINMENT SYSTEM
stored cereals form deposited layers of dust.
During loading and unloading operations, a
During loading and unloading operations,
certain quantity of dust is emitted through
68

the inlets connected with the outside. In case
of frequent or continuous operations, inlets
Tab. 25 ATEX markings that must be present in each

Zone
and outfalls are to be considered first-degree
ZONE
MARKING
emission sources, they may originate a Zone
ZONE 20
CE EX II 1D
ZONE 21
CE EX II 2D
ZONE 22
CE EX II 3D
21 and, possibly, a Zone 22 all around.

Open systems of automatic transport, such
as conveyor belts, open bucket elevators, can
be considered first-degree emission sources,
and they may generate a Zone 21 and, possi-
8.3. COATING BOOTHS
bly, a Zone 22 all around.
The coating booths where spray coating is

8.2.5. ELECTRICAL INSTALLATIONS
used, are areas with risk of explosion. Spray
Possible electrical installations controlling
coating is based on the forced passage of
loading / unloading equipment, must be ma-
flammable liquid or of dust coatings through
nufactured and certified in order to be used in
the gun nozzle.
areas with presence of explosive atmosphere.

As far as electrical equipment classification is
8.3.1. COATING BOOTHS WITH LIQUID
concerned, please refer to Tab. 25 indicating
COATINGS
the ATEX markings that must be present in
The protection methods to use in order to
each Zone.
prevent risks of explosion in the coating bo-
Tab. 26 Some examples of dusts and their characteristics
Substance
Particles
medium
dimensions
[m]
L.E.L [g/m2]
Cloud
ignition
temperature
Tcl [C]
Layer ignition
temperature
5mm T5mm
Dust
conductivity
(C/NC)
Wheat flour
57
40
440
325
NC
Grain
80
60
370
370
NC
Soybean flour
59
125
430
430
NC
69
oths with liquid coatings are contained in the
L.E.L is reached. The internal volume of bo-
UNI EN 12215 standard Coating booths for
oth (ducts for air recirculation included) is
the application of liquid coating products
classified as Zone 1, while the external one,
Safety requirements.
up to 1m from the permanent openings, is
According to this standard, the concentration
classified as Zone 2.
of flammable substances must be kept below

L.E.L. (Lower Explosive Limit) by means of
8.3.2. COATING BOOTHS WITH DUST COATINGS
forced ventilation. In particular, the standard
Protection against risks of explosion in coa-
contemplates two possibilities:
ting booths with dust coatings is regulated by
1. Concentration within 25% of L.E.L. (bo-
the UNI EN 12981 standard Coating booths
oths with the presence of an operator). In this
for the application of dust coating products
case, the internal volume of the booth (ducts
Safety requirements.
for air recirculation included) as well as the
According to this standard, the concentration
external one, up to 1m from the permanent
of flammable substances must be kept below
openings, are classified as Zone 2.
50% of the dust L.E.L., by means of forced
2. Concentration within 50% of L.E.L. (bo-
ventilation; if L.E.L. value is not reliable, me-
oths without the presence of an operator). In
dium concentration must not exceed 10 g/m3.
this case, the booth must be provided with a
The following classification is foreseen:
control system of the L.E.L. able to stop the
Zone 22: internal volume of booth (ducts for
influx of flammable substances when 50% of
air recirculation as well as the open dust col-
70

lection systems included);
nic compounds in fermentation. Such biogas
Zone 22: external volume of booth, up to 1m
is used for the production of electrical energy
from the permanent openings;
and heat.
Zone 20: sealed dust collection systems.

Dust characteristics vary and depend on the
8.4.1. PLANT TYPE
product used. Usually, L.E.L. ranges betwe-
These biogas plants (Image 43) are composed
en 10100g/m3, while ignition temperatu-
of a primary mixing tank, possibly of a sanita-
res vary between 350400C (cloud) and
tion tank, of a main heated fermenter, a final
200250C (layer). Information stated in the
storage tank and, sometimes, of a secondary
product safety form must be verified.
fermenter.
Once the biogas is produced, it must be pro-
8.4. BIOGAS PLANTS
cessed and stored before being reused.
In the modern biogas plants, biodegradable
The co-generator is composed of a gas engi-
organic substrates such as grass, straw, ma-
ne with heat exchanger and generator. On the
nure, biodegradable waste, residues of food
basis of the energy content of biogas, this pro-
production, leftovers and greases are fermen-
duces electrical energy with a 30% efficiency
ted. For this purpose fermenters, that are se-
and heat with a 60% efficiency. The electri-
aled containers, are filled with organic ma-
cal energy is fed into the network. The heat is
terials. In this environment without oxygen,
used for the fermenters, and the excess heat
bacteria produce biogas starting from orga-
for houses, agricultural structures or similar.
Image 43 Biogas plant scheme

Image 43
Thermal energy
Cogeneration unit
Electrical energy
Biogas
Process heat
Process
heat
Pump
Main fermenter
Organic substrates
Thermal decay
Second fermenter
Fertilizer
Depot
Pump
Sewage sludge
71
8.4.2. RISK OF ESPLOSION
8.4.3. REGULATIONS
Since in a biogas plant there is always the
The employer must survey and evaluate
presence of explosive atmosphere, especial-
all risk factors for the areas with risk of
ly in the gas tank area and in the fermenters,
explosion. Environments with explosive
these plants are to be considered at risk of ex-
atmosphere must be subdivided into are-
plosion.
as, following the EN 60079-10-1 standard
Currently ATEX 94/9/CE and ATEX 99/92/CE
for gases and EN 60079-10-2 standard for
are the reference directives for equipment and
dusts.
protection systems meant to be used in explosi-
Depending on the results of risk asses-
ve atmosphere.
sment, the areas with risk of explosion must
Their reference standard is EN UNI 1127-1
be defined and described in a document for
Explosive atmospheres Explosion preven-
the protection against the risk of explosion.
tion and protection Part 1: Main concepts
In case of protection against lightning, the
and methods, where 13 different ignition
series CEI EN 62305 standards must be fol-
sources are listed.
lowed.
It is a general protection standard that con-
All the electrical equipment placed in classi-
siders each possible ignition source and, in
fied areas must comply with safety require-
particular, protection from lightning. All of
ments and belong to the protection degree
these plants are isolated in the countryside
suitable to the type of classified area, accor-
and, therefore, are exposed to lightning risks.
ding to the ATEX 94/9/CE standard.
72
9. Appendix
9.1. BRIEF DESCRIPTION OF PROTECTION METHODS FOR ELECTRICAL EQUIPMENT ADDRESSED
TO AREAS WITH RISK OF EXPLOSION FOR PRESENCE OF GAS (TAB. 27)
Tab. 27 Gas protection modes
Protection
mode
IEC/EN
Base
standard principle
Main characteristics
Applications
d explosion-proof
enclosures
IEC 60079-1 Containment Gas may enter. If triggered, the atmosphere explodes. Enclosure
EN 60079-1
contains explosion and joints are designed so that flame cools
while going out, and only the combustion product, unable to
trigger the surrounding atmosphere, arrives outside.
e increased safety
IEC 60079-7
EN 60079-7
Prevention
Building requirements preventing arcs, sparks or high tempera- Non-sparkling equipment such
tures, such as isolation distances in air and enlarged surfaces. as: enclosures, terminals, lighting
equipment, revolving machines.
i intrinsic safety
IEC 60079-11
EN 60079-11
Prevention
Electrical equipment installed in hazardous area is part of a system of circuits and electronic barrier limiting its performance
at such energies that the ignition of explosive atmosphere is prevented by the control of electrical parameters (power, current,
inductances and cable grounding capacity, etc.). Intrinsic safety
protection mode is achieved with an equipment inside the area,
a connection circuit and a barrier, generally installed outside
hazardous area.
n protection mode
IEC 60079-15
EN 60079-15
Prevention
Protection mode made according to building prescriptions Lighting equipment, control panels,
and less strict values in order to prevent the ignition of ex- control stations for Zone 2.
plosive atmosphere only in normal equipment functioning.
Ex nA= sparkling equipment
Ex nC= protected contacts
Ex nR= limited respiration
Ex nP= simplified pressurization
p internal
overpressure
IEC 60079-2
EN 60079-2
Segregation
Live equipment and circuits enclosed in an enclosure, in which

pressure is kept higher than the outer one by the insertion of an
inert gas or air. In this way, the ingress of explosive atmosphere
is prevented. It requires sophisticated control and alarm systems.
immersion in oil o
IEC 60079-6
EN 60079-6
Segregation
Electrical equipment is fully immersed in oil so that explosive It is applied above all to devices not
atmosphere, that is outside or above the liquid, cannot be trig- provided with moving parts.
gered.
q powdery filling
IEC 60079-5
EN 60079-5
Segregation
Enclosure containing electrical equipment is filled with dust It is applied to small components
(for example, quartz powder) that prevents the ignition of exter- such as capacitors, transformers, or
nal explosive atmosphere.
electronic devices such as starters
for tubular lamps.
Encapsulation m
IEC 60079-18 Segregation

EN 60079-18
Components which may cause sparks or over temperatures are

fully covered with a compound (usually resin), in order to separate
them from explosive atmosphere. Compound resists to ambient
conditions in which the equipment operates and it is tested to
guarantee the maintenance of its properties in the time (aging).
Control panels, lighting fixtures, switches, control unit. All the

equipment that, in normal operating
conditions, can provoke sparks or
over temperatures.
Electrical parameter limitations

exclude the application to power
equipment. It is applied to measure
and control machinery as well as to
regulate the production processes.
It is suitable to carry out complete

controls because of the lack of a
construction dimensional limit as
well as of electrical measurements
of the equipment it contains.
Small sized equipment such as capacitors, reactors, transformers, level

and proximity sensors and electronic
equipment in general.
73
9.2. BRIEF DESCRIPTION OF PROTECTION METHODS FOR ELECTRICAL EQUIPMENT ADDRESSED

TO AREAS WITH RISK OF EXPLOSION FOR PRESENCE OF DUSTS (TAB. 28)
Tab. 28 Protection methods Dusts
Protection
mode
IEC/EN
standard
Applications
Absence of ignition
source. Protection
with t enclosures
(ta, tb, tc)
IEC 60079-31
EN 60079-31
Enclosure sealing prevents the ingress of dust or reduces it Control panels, lighting fixtures, engines, conto a minimum non dangerous quantity.
nection enclosures and terminal strips.
In this way equipment can be mounted inside the enclosure. Enclosure surface temperature must not trigger the
surrounding atmosphere.
Absence of ignition
source. i intrinsic
safety protection
(ia, ib, ic)
IEC 60079-11
EN 60079-11
Equipment used in a potentially explosive area con- Sensors, actuators, measure and control technotaining only intrinsic safety electrical circuits. Each logy.
electrical circuit is intrinsically safe when any spark or
thermal effect produced in conditions such as normal
functioning and specific failure conditions are not able
to cause a combustion of an explosive atmosphere.
Absence of explosive IEC 60079-11

atmosphere.
EN 60079-11
p pressurization
The Ex p internal overpressure protection mode consists in injecting protection gas in the enclosure to keep
it in overpressure comparing to external atmosphere,
preventing the creation of explosive atmosphere inside
the enclosure.
Protection gas can consist in air or inert gas, such as
nitrogen.
Ignition source
segregation. m
encapsulation
(ma, mb, mc).
Components that may produce sparks or overpressures Small-sized equipment such as capacitors, reacare fully covered with a compound (generally resin), tors, transformers, level and proximity sensors
in order to separate them from explosive atmosphere. and electronic equipment in general.
Compound resists to ambient conditions in which the
equipment operates and it is tested to guarantee the
maintenance of its properties in the time (aging).
IEC 60079-18
EN 60079-18
MT/BT transformers, big electrical machinery,

(alternative to Ex e protection), automation
and instrumentation panels, industrial processes control systems (gas chromatographs,
analyzers), analysis cabin and pressurized cabins.
9.3. BRIEF DESCRIPTION OF PROTECTION METHODS FOR NON-ELECTRICAL EQUIPMENT ADDRESSED

TO AREAS WITH RISK OF EXPLOSION FOR PRESENCE OF GAS AND DUSTS (TAB. 29)
Tab. 29 Protection methods for non-electrical equipment in presence of gas and dusts
Protection
mode
ISO/EN
standard
Applications
Absence of ignition
source. c constructive
safety
EN 13463-5
Technical principles tested on equipment with no ignition source in normal opera- Joints, pumps, gears,
ISO 80079-37* tions are applied. The risk of mechanical breaks, that can cause flammable tempe- transmission chains, conratures and sparks, is therefore reduced to minimum.
veyor belts.
Protection. d
explosion-proof
EN 13463-3
Gas may enter. If triggered, the atmosphere explodes. Enclosure contains explosion Brakes, joints.
and joints are designed so that flame cools while going out, and only the combustion product, unable to trigger the surrounding atmosphere, arrives outside.
Absence of explosive
atmosphere. fr limited
respiration enclosure.
EN 13463-2
An effective sealing can reduce the entry of explosive atmosphere so that no poten- Equipment only for Zone
tially explosive atmosphere may occur inside. Pressure differences between the inside 2 or 22.
of the enclosure and the outside environment, due to temperature changes, must be
considered. Application only to category 3 equipment.
b ignition source
control
EN 13463-6
Sensors inside the equipment survey possible risks of explosion in the initial phase, Pumps, conveyor belts.
ISO 80079-37* so that countermeasures can be applied before potential ignition sources become
effective. The measures applied can be started automatically by a direct connection
between sensors and ignition protection system, or manually by sending an information message to the operator.
Ignition source segmentation. Immersion in liquid

k
EN 13463-8
Ignition sources become inactive by being immersed in a protective liquid or by Submergible pumps, gears,
ISO 80079-37* being constantly kept humidified with a liquid film.
immersion in liquid.
standards about to be published by ISO
74
9. Appendix
9.4. STRUCTURAL REQUIREMENTS FOR EXPLOSION-PROOF ELECTRICAL EQUIPMENT FOR POTENTIALLY
EXPLOSIVE ATMOSPHERES FOR PRESENCE OF GAS (TAB. 30 AND 31)
Tab. 30 Structural requirements in Europe, USA, Canada and international comparison
Protection
method
General
requirements
Abbreviation
Region
Installation
Zone
Standards
AEx
Ex
Ex
Ex
US
US
CA
EU
IEC
Class I, Division 1 e 2
Class I, Zone 0, 1 e 2
Class I, Zone 0, 1 e 2
Zone 0, 1 e 2
Zone 0, 1 e 2
FM 3600
ISA 60079-0
CSA E60079-0
EN 60079-0
IEC 60079-0
Increased safety
AEx e
Ex e
Ex e
Ex e
US
CA
EU
IEC
Class I, Zone 1
Class I, Zone 1
Zone 1
Zone 1
ISA 60079-7
CSA E60079-7
EN 60079-7
IEC 60079-7
Ignition-proof
(NI)
(NI)
US
CA
Class I, Division 2
Class I, Division 2
FM 3611
C22.2 No. 213
Non sparkling
equipment
AEx nA
Ex nA
Ex nA
Ex nA
US
CA
EU
IEC
Class I, Zone 2
Class I, Zone 2
Zone 2
Zone 2
ISA 60079-15
CAS E60079-15
EN 60079-15
IEC 60079-15
Explosion
Prevention
(XP)
(XP)
US
CA
Class I, Division 1
Class I, Division 1
FM 3615
C22.2 No. 30
Flame-proof
enclosures
AEx d
Ex d
Ex d
Ex d
US
CA
EU
IEC
Class I, Zone 1
Class I, Zone 1
Zone 1
Zone 1
ISA 60079-1
CSA E60079-1
EN 60079-1
IEC 60079-1
Filling with dust
AEx q
Ex q
Ex q
Ex q
US
CA
EU
IEC
Class 1, Zone 1
Class I, Zone 1
Zone 1
Zone 1
ISA 60079-5
CSA E79-5
EN 50017
IEC 60079-5
Protected structures
and components
AEx nC
Ex nC
Ex nC
Ex nC
US
CA
EU
IEC
Class I, Zone 2
Class I, Zone 2
Zone 2
Zone 2
ISA 60079-15
CSA E60079-15
EN 60079-15
IEC 60079-15
Intrinsic safety
(IS)
(IS)
AEx ia
AEx ib
Ex ia
Ex ib
Ex ia
Ex ib
Ex ia
Ex ib
US
CA
US
US
CA
CA
EU
EU
IEC
IEC
Class I, Division 1
Class I, Division 1
Class I, Zone 0
Class I, Zone 1
Class I, Zone 0
Class I, Zone 1
Zone 0
Zone 1
Zone 0
Zone 1
FM 3610
C22.2 No. 157
FM 3610
FM 3610
CSA E60079-11
CSA E60079-11
EN 50020
EN 50020
IEC 60079-11
IEC 60079-11
75
Tab. 31 Structural requirements in Europe, USA, Canada and international comparison
Protection
method
Abbreviation
Region
Installation
Zone
Standards
Limited-energy
AEx nC
US
Class I, Zone 2,
ISA 60079-15
equipment
Ex nL
CA
Class I, Zone 2
CSA E60079-15
Ex nL
EU
Zone 2
EN 60079-15
En nL
IEC
Zone 2
IEC 60079-15
Pressurized
Type X
US
Class I, Division 1
FM 3620
enclosures
Type X
CA
Class 1, Division 1
NFPA 496
Type Y
US
Class I, Division 1
FM 3620
Type Y
CA
Class I, Division 1
NFPA 496
Type Z
US
Class 1, Division 2
FM 3620
Type Z
CA
Class 1, Division 2
NFPA 496
AEx px
US
Class I, Zone 1
ISA 60079-2
CA
Class I, Zone 1
CSA E60079-2
EU
Zone 1
EN 60079-2
IEC
Zone 1
IEC 60079-2
US
Class I, Zone 1
ISA 60079-2
CA
Class I, Zone 1
CSA E60079-2
EU
Zone 1
EN 60079-2
IEC
Zone 1
IEC 60079-2
US
Class I, Zone 2
ISA 60079-2
CA
Class I, Zone 2
CSA E60079-2
EU
Zone 2
EN 60079-2
IEC
Zone 2
IEC 60079-2
AEx nR
US
Class I, Zone 2
ISA 60079-15
Ex nR
CA
Class I, Zone 2
CSA E60079-15
Ex nR
EU
Zone 2
EN 60079-15
Ex nR
IEC
Zone 2
IEC 60079-15
Ex ma
EU
Zone 0
EN 60079-18
Ex ma
IEC
Zone 0
IEC 60079-18
AEx m
US
Class I, Zone 1
ISA 60079-18
Ex m
CA
Class I, Zone 1
CSS E60079-18
Ex mb
EU
Zone 1
EN 60079-18
Ex mb
IEC
Zone 1
IEC 60079-18
AEx o
US
Class I, Zone 1
ISA 60079-6
Ex o
CA
Class I, Zone 1
CSA E79-6
Ex o
EU
Zone 1
EN 50015
Ex o
IEC
Zone 1
IEC 60079-6
Pressurized
Encapsulation
Immersion in oil
76
Marking of electrical equipment in areas at risk of explosion
Marking
of electrical equipment in areas
at risk of explosion
77
78
0722
CE Marking
II
Ex
Ex
2(1)G
2(1)D
ATEX Marking
Equipment Group
I = equipment addressed to underground work in mines and in their surface plants
exposed to risk of release of firedamp gas and/or combustible dusts
II = equipment addressed to different than underground work in mines and their
surface plants which could exposed to risk of explosive atmospheres
European Community mark Epsilon-x specific for protection against

explosions, defined for the first time in the Directive 76/117/CEE of 18
December 1975
placed on the category M2 and 2 equipment. In our case it is the CESI - (Italian
Experimental Electrotechnical Centre)
0722 = dentification number of Notified Body responsible for production control;
Graphic symbol identifying that at least one European Directive has been
applied; it is placed only on the equipment, not on the components
tb [ia Da]
d [ia Ga]
IIIC
IIB+H2
T6..T5
T85..100C
Protection mode
IP66/IP67
Db
Gb
EPL
Equipment category
M2 = equipment addressed to underground work in mines and in their surface plants
exposed to risk of release of firedamp gas and/or combustible dusts in presence of
potentially explosive atmosphere, it should be possible to interrupt the power supply;
2G = equipment suitable for areas where, during normal activities, explosive
atmospheres due to gas, vapors or mists (zone 1) may occur; suitable to be installed
in Zone 1 and 2
2(1)G = equipment suitable for areas where, during normal activities, explosive
atmospheres due to gas, vapors or mists (zone 1) may occur, and that has inside
a bonded device that will be connected to a category 1 equipment; suitable to be
installed in Zone 1 and 2
2(2)G = equipment suitable for areas where, during normal activities, explosive
atmospheres due to gas, vapors or mists (zone 1) may occur, and that has inside a
bonded device that will be connected to a category 2 equipment; suitable to be installed
in Zone 1 and 2
3G = equipment suitable for areas where, during normal activities, explosive
atmospheres consisting of an air and flammable substances mixture in the shape of
gas, vapors or mist may occur and, if it occurs, it is really for a short time (zone 2);
suitable to be installed in zone 2
2D = equipment suitable for areas where, during normal activities, explosive
atmospheres due to a mixture of air and flammable dusts (zone 21); suitable to be
2(1)D = equipment suitable for areas where, during normal activities, explosive
atmospheres due to a mixture of air and flammable dusts (zone 21) and that has
inside a bonded device that will be connected to a category 1 equipment; suitable
to be installed in zone 21 and 22
3D = equipment suitable for areas where, during normal activities, explosive
atmospheres in the shape of cloud of flammable dust and, if it occurs, it is really for a
short time. (Zone 22); suitable to be installed in zone 22
Marking of electrical equipment in areas at risk of explosion
79
Letter indicating the protection mode adopted

d = equipment protected by means of a d explosion-proof enclosure
e = e increased safety equipment
i = i intrinsic safety equipment
de = equipment with a part protected by means of a d explosion-proof enclosure and an
e increased safety part
ed = equipment with an e increased safety part and a part protected by means of a d
explosion-proof enclosure
d [ia Ga] = equipment protected through a d explosion-proof enclosure with inside an ia
d [ib Gb] = equipment protected by means of a d explosion-proof enclosure with inside an
ib intrinsic safety associated device (usually a barrier)
nA = equipment created to reduce to minimum the risk of arcs or sparks able to originate an
ignition danger during normal working
nR = equipment designed to limit gas, vapors and mists ingress
tb = equipment with an enclosure that prevents dust ingress and with devices to limit surface
temperatures; protection level 2b
tD = equipment protected by an enclosure to prevent a cloud or a layer-of-dust ignition
tb [ia Da] = equipment with an enclosure that prevents dust ingress and devices to limit
surface temperatures with b protection level, with inside an ia intrinsic safety associated
device (usually a barrier)
Ex = indicates that protection mode against explosions has been applied
Equipment Protection Level

Mb = equivalent to M2 category
Gb = equivalent to 2G category
Gc = equivalent to 3G category
Db = equivalent to 2D category
Dc = equivalent to 3D category
Identifies equipment; for further info, refer to previous paragraph 3.6.2.4.1. Enclosures protection degrees (IP code)
Definition of temperatures generated by equipment

T6 = equipment that can reach, but not exceed 85C of absolute temperature (depending on
protection mode it can be either maximum temperature or surface maximum temperature)
T..C = equipment that can reach, but not exceed in surface C of absolute temperature
I = equipment addressed to underground work in mines and in their surface plants

exposed to risk of release of firedamp gas and/or combustible dusts
IIB = equipment not addressed to underground work in mines or their surface plants
which could exposed to risk of explosive atmospheres subgroup of B gas; suitable to be
installed in presence of gases of subgroup A and B
IIB+H2 = equipment not addressed to underground work in mines or their surface
plants which could exposed to risk of explosive atmospheres subgroup of B gas;
suitable to be installed in presence of gases of subgroup A, B and hydrogen
IIC = equipment not addressed to underground work in mines or their surface plants
which could exposed to risk of explosive atmospheres subgroup of C gas; suitable to be
installed in presence of any gas (subgroups A, B and C)
IIIC = equipment not addressed to underground work in mines and their surface plants
which could exposed to risk of explosive atmospheres subgroup of C dusts; suitable to
be installed in presence of any dust (subgroups A, B and C)
A21 = equipment not addressed to underground work in mines or their surface plants
which could exposed to risk of explosive atmospheres method A; suitable to be
A22 = equipment not addressed to underground work in mines and their surface
plants which could exposed to risk of explosive atmospheres method A; suitable to be
installed in zone 22
CORTEM GROUP
To be sure to be safe
Since 1968, Cortem S.p.A. has been designing and manufacturing explosionprotected electrical equipment addressed to hazardous areas (with risk of
explosion and fire).
Thanks to a continuous effort in technical innovation and improvement, it is today
a leader in this field, able to provide a whole range of products, meeting on-shore
and off-shore applications.
The peculiarity of Cortem Group, formed by the brands Cortem, Elfit and
Fondisonzo, is the experience gained in more than 40 years of activity in the field
which results not only in the supply of simple Ex-products, but also in customized
solutions.
All our products are internally designed and manufactured following different
protection methods, such as Ex d explosion-proof, Ex e increased safety, Ex
d mixed, Ex n non-sparkling, and using aluminium alloys, titled steels and
first-quality plastic materials that assure resistance and duration. Aluminium alloy
used by Cortem has passed all tests required by EN 60068-2-30 Standard (hot/
humid cycles) and EN 60068-2-11 Standard (salt spray test). All our products in
aluminium alloy are protected by an epoxy coating RAL 7035. This treatment,
only provided by Cortem Group, guarantees a durable protection.
Cortem production range can be summarized as follows:
- Lighting fixtures, obstruction lighting fixtures, floodlights and hand lamps.
- Junction and pulling boxes, control stations.
- Signaling and control equipment, plugs and sockets.
- Cable glands and electrical fittings.
- Special executions: switchgears and panel boards tailor made upon customers
specifications.
90% of our production are located in the Oil & Gas sector both off-shore and onshore, but also in chemical, pharmaceutical plants and in all those manufacturing
areas where the presence of explosive atmospheres may occur such as grain
silos, woodworks and paper mills. We invest every year some of our resources to
develop innovative products that meet the market needs and, for this reason, our
R&D department studies the best solution valuating normative and market price
issues, plant and security aspects.
With more than 30 agencies, 90 distributors, 7 partners and 3 production
centers displaced, Cortem provides a local and qualified presence around the
world. For Cortem displacing does not means transferring facilities, resources
and know-how in low cost Countries, but replicating a successful model of
industrial organization in which environment safety, product quality, compliance
with standards, technical and after-sales services are the fundamentals of our
corporate mission.
The pay-off to be sure to be safe represents our pride and passion for what we
design and manufacture.
Guide to the EX world
How to use the electrical equipment in areas with risk of explosion

Issued October 2013
Copyright
In accordance with copyright laws, the Italian Civil Code and other regulations in effect in the markets where the Cortem Group operates, all
the information, images, photographs, drawings, tables and anything else contained in the Cortem Group promotional material are the exclusive
property of the Cortem Group, which has all the moral rights to the aforesaid material as well as the right to use it for commercial and economic
purposes. It is therefore forbidden to reproduce all or part of the Cortem Group promotional material in any way, unless otherwise authorized
by the Cortem Group in writing. Any violation of the above is against the law. by Cortem - Villesse - Italy. All rights reserved.
Sales Offices
Piazzale Dateo 2
20129 Milan (ITALY)
Ph. +39 02 76 1103 29 a.m.
Fax +39 02 73 83 402
infomilano@cortemgroup.com
Export
Headquarters and Factory

Via Aquileia 10
34070 Villesse (GO), Italy
Ph. +39 481 964911 a.m.
Fax +39 0481 964999
info@cortemgroup.com

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

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

Raffaella Sesia
GUIDAEX10/2013 - K....
Ph. +39 02 76 1105 01 a.m.

Fax +39 02 70 00 54 71
export@cortemgroup.com
saleseurope@cortemgroup.com

Cortem Group - Guide To The Ex World

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Guide to the EX world

How to use electrical equipment in areas with risk of

2. Hazardous areas classification

8. Application examples for different types of plants

Marking of electrical equipment in areas with risk of explosion

repairing the equipment

plants inspection and maintenance

ASL o ARPA, DPR 462/2001

Image 2 CE Graphic symbol

to circulate freely within

been emended, integrated

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

83/189/CEE Directive by the Commission of

Law 21st June 1986, n 317, concerning the

(G.U.C.E., L series, n 109 of 26 April 1983)

(G.U.R.I., General series, n 151 of 2 July1986)

vision, dated 2008 (Table 1).

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

Directive 94/9/EC of the European Parliament

D.P.R. 23 March 1998, n 126 regulation laying

(G.U.C.E., L series, n 100 of 19 April 1994)

(G.U.R.I. General series, n 101 of 4 May1998)

Corrigendum to Directive 94/9/EC of the European

Over the years, the framework Directive

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

Council Directive 89/391/EEC of 12 June 1989

Leg. September 19, 1994, No. 626, concerning

(G.U.C.E., L series, n 183 of 29 June1989)

(G.U.R.I., General series, n 265 of 12 November

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

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

Directive 1999/92/EC of the European

Leg. June 12, 2003, No. 233 Implementation of

(G.U.C.E., L series, n 23 of 28 January 2000)

(G.U.R.I., General series, n 197 of 26 August

explosion 2.366 1.422

1% trapped, crushed, etc.

bite, kick, etc. (animal or

physical or mental stress

trapped, crushed, etc.

contact with sharp, pointed,

hit by a moving object, collision

horizontal / vertical impact

drowned, buried, wrapped

contact with electrical voltage

all contacts mode

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

4% contact with sharp, pointed,

60% contact with electrical voltage

2% horizontal / vertical impact

sed to the risk of explosive atmospheres.

pendent of the Notified Bodies for our product certification, there

0% contact with sharp, pointed, rough agent,

bite, kick, etc. (animal

physical or mental stress

0% physical or mental stress

25% hit by object in motion,

60% contact with electrical voltage,

4% horizontal / vertical impact

4% drowned, buried, wrapped

trapped, crushed, etc.

contact with sharp, pointed,

hit by object in motion, collision