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Explosion-proof Knowledge
1.1Types protection:

An explosion occurs when the three following conditions happen:

• presence of a potentially explosive atmosphere;
• possibility of transmission of the explosion;
• existence of an ignition source.

The recognized types of protection eliminate one of these conditions and thus make an explosion impossible.
Two types of protection prevent the presence of a potentially explosive atmosphere inside the electrical apparatus:
• oil immersion (safety “o”);
• pressurized apparatus (safety “p”).

Two types of protection make the transmission of an internal explosion to the potentially explosive atmosphere
surrounding the electrical apparatus impossible:
• sand filling (safety “q”);
• flameproof enclosure (safety “d”).

Lastly, three types of protection eliminate any source of ignition such as sparks,overheating, etc.:
• increased safety (safety “e”);
• intrinsic safety (safety “i”);
• protection “n” (restricted to zone 2).

In practice, only four of these seven types of protection are applicable to electric motors:
• pressurized apparatus (symbol Ex-p);
• flameproof enclosure (symbol Ex-d);
• increased safety (symbol Ex-e);
• non sparking protection (symbol Ex-n).

For electric motors,they have an additional type of protection (symbol Ex-de) which is a combination of:
- flameproof enclosure “d” for motor frame;
- increased safety “e” for terminal box.

Table 1:Relations between Protection Type and Group

Protection Type Protection Marking Group allowed
Intrinsic Safety Type”ia” Exia 0
Flameproof Type”d” Exd
Intrinsic Safety Type”ib” Exib
Increased-Safety Type”e” Exe
Pressurized Type”p” Exp 1
Oil Immersion Type”o” Exo
Sand Filling Type”q” Exq
Encapsulated Type”m” Exm
Non-sparking Type”n” Exn 2

1.2 Dangerous Areas and Zones

Dangerous areas include any area in which explosive atmospheres may occur under specific conditions.
An explosive atmosphere is a mixture of air and combustible gases, vapours, fumes or dust under atmospheric
conditions where combustion expands itself (explosion) after ignition.Only local authorities can classify hazardous
areas.

International standards IEC 60079-10(IEC EN 60079-10) provide instructions on how to classify the hazardous

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areas in relation to the chemical nature, to the physical characteristics and to the amount of substances used and
based on the frequency and period of time in which an explosive mix may develop.

Zones susceptible to gas

When the hazard is due to the presence of gas, vapours or mists of flammable substances, the IEC envisage a
classification in three zones defined as follows:
Zone 0 - Areas constantly susceptible to an explosive atmosphere, or for long periods of time. Power equipment
with double insulation must be installed in this area.
Zone 1 - Areas where an explosive atmosphere is likely to develop during normal conditions.Flameproof electric
motors or motors with added protection means can be installed in this zone (for the latter, restrictions by the
standards apply).
Zone 2 - Areas rarely susceptible to an explosive atmosphere and for a short period of time. Flameproof motors or
motors with added protection can be installed in this zone, as well as non-sparking motors.
Zones susceptible to dust
When the hazard is due to the presence of combustible dust, the IEC envisages a classification in
three zones defined as follows:
Zone 20 - Areas constantly susceptible to an explosive atmosphere, or for long periods of time. Power apparatus
cannot be installed in this zone.
Zone 21 - Areas where an explosive atmosphere is likely to develop during normal conditions. Electric motors
certified in compliance with the standard ,such as ATEX directive with IP6X protection rating can be installed in this
zone
Zone 22 - Areas rarely susceptible to an explosive atmosphere, and only for a short period of time. In the presence
of conductive dust, electric motors certified in compliance with the standard, such as the ATEX directive with
protection rating IP6X can be installed in this zone, whereas in the presence of non conductive dust, motors with
protection rating IP5X and a declaration of conformity issued by the manufacturer can be installed

Table2:Dangerous areas classified into ZONES

Usage area in presence of Usage area in presence of Hazardous level of the Operational
Gas Dust Zone
Explosive atmosphere
Zone 0 Zone 20
ALWAYS PRESENT
explosive atmosphere
Zone 1 Zone 21
PROBABLE
Explosive atmosphere
Zone 2 Zone 22
UNLIKELY

Table3:Equipment Categories
Protection Level Mine Surface
Guaranteed by the equipment Category Gas Category Dust Category
Very High M1 1G 1D
High M2 2G 2D
Normal / 3G 3D
NOTE: Equipment of higher categories consequently can also be installed instead of those of a lower category.

1.3 Enclosure Groups

The standards classify electrical equipment into two groups.
Group I: electric apparatus to be installed in mines or galleries susceptible to firedamp or coal dust.
Group II: electric apparatus to be installed in surface plants susceptible to other explosive atmospheres.

The enclosures for equipment intended for use on the surface, providing “d” protection (flameproof), are in turn
broken down into three sub-groups, in relation to the inflammable substances for which they are suitable:
Group IIA, Group IIB, Group IIC.
A motor that belongs to a certain enclosure group is also suitable for lower enclosure groups: a motor in group IIB
is also suitable for group IIA; a motor in group IIC is also suitable for group IIA and IIB.

1.4 Temperature Classes (for Gas Atmospheres)

The electrical apparatus is classified into 6 classes according to the maximum surface temperatures. The

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maximum surface temperature is the highest temperature which is attained in service under the conditions
described in the standards, by any part of the electrical apparatus, which, could ignite the atmosphere.
For electric motors this is:
• the temperature of the outside surface of the enclosure for “d” and “p” protection modes;
• the temperature of any internal or external point for type of protection “e” or “n”.

Table4:Temperature Classes
Ignition temperature Temperature Class Maximum surface temperature of electrical
of medium relative to limit temperature equipment including 40 °C ambient temperature
[°C] [°C] [°F]
Over 450 T1 450 842
from 300 to 450 T2 300 572
from 200 to 300 T3 200 392
from 135 to 200 T4 135 275
from 100 to 135 T5 100 212
from 85 to 100 T6 85 185

1.5 Combustion temperatures of Gases, Vapours and Groups

Combustible gases and vapours are divided into classes according to their ignition temperature and into groups
according to their explosive capacity.
Markings on motors and other electrical equipment with the symbols used to indicate the protection mode, the
enclosure group,and the temperature class, indicate the zone in which such equipment can be installed.

Table 5:Classification of the More common Combustible Gases and Vapours According to Temperature
Class and Group:
Temperature Class
Group
T1 T2 T3 T4 T5 T6
Methane
I
(firedamp)
Acetic acid Acetic anhydride Cyclohexane Acetaldehyde
Acetone I amyl acetate Cyclohexanol Ether
Ammonia n butane Decano
Benzole n butyl alcohol Diesel fuels
Benzene Amylic alcohol Gasoline
Butanone Butyl acetate Heating oil
Carbon monoxide Cyclohexanon Heptane
Ethane Ethyl alcohol Hexane
Ethyl acetate Iso butylic alcohol Jet fuels
IIA Ethyl chloride Liquefied gas Pentane
Methane Natural gas Petroleum*
Methanol Propyl acetate
Methyl acetate
Methyl alcohol
Methyl chloride
Naphtalene
Propane
Toluene
Xylene
Coke-oven gas 1,3- butadiene Hydrogen sulphide Ethyl ether
Water gas Ethylene Isoprene
IIB
(carburetted) Ethylbenzene Petroleum*
Ethylene oxide
Hydrogen Acetylene Carbon disulphide
IIC
Ethyl nitrate
* Depending on composition

1.6 Temperature for Dusty Atmospheres

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The flash point of the dust must be taken into account in providing protection against flammable dust, both where
this is in cloud form and in layers.
The surface temperature of the enclosure indicated on the motor nameplate must be less than the reference
ignition temperature.
The reference temperature is the lowest between the two values thus calculated:TS1 = 2/3 Tcl (Tcl = ignition
temperature of the cloud of dust) TS2 = T5mm – 75K (T5mm = ignition temperature of a 5mm layer of dust).
Tamm = lowest between TS1 and TS2.

Table 6:Calculating the flash point for DUSTS

Dust Cloud Layer
Ignition Temperature Tcl T5mm

Safety Temperature Ts1 = 2/3 Tcl Ts2 = T5mm - 75K

Maximum Surface Temperature Tamm = lowest between Ts1 and Ts2

Surface temperature of the motor m Tamm

Table 7:Some examples of flash points for DUSTS

Cloud Layer
[°C] [°C]
Aluminium 590 <450
Carbon dust 380 225
Flour 490 390
Wheat dust 510 300
Methylcellulose 420 320
Polyethylene 420 melting
Soot 810 570
PVC 700 <450
Sugar 490 460

Table 8:Choosing the protection mode for ZONES in which GAS is present
Explosive Danger Zone Protection Category Protection Mode
Atmosphere Guaranteed by
Equipment
Always Present 0 Very High 1G Double Protection
Exd-d
Probable 1 High 2G Exd-de
Ex-e
Improbable 2 Normal 3G Ex-nA

Table 9:Choosing the protection mode for ZONES in which DUST is present
Explosive Danger Zone Protection Category Protection Mode
Atmosphere Guaranteed by
Equipment
Always Present 20 Very High 1D /
Probable 21 High 2D IP6X
22
Improbable Normal 2D IP6X
Conductive dusts
22
Improbable Normal 3D IP5X
Non-conductive dusts
N. B. Equipment of a higher category can be installed in place of equipment of a lower category

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