Unit 3

Flameproof
EEx d / Ex d

1
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Objectives

On completion of this unit, ‘flameproof EEx d / Ex d apparatus, you should

know:

a. The general constructional features including types of joints.

b. The principle of operation and causes of pressure piling.

c. The installation requirements with regard to thread engagement of cable entries and
blanking elements (stoppers), obstruction of flamepaths, additional weatherproofing
methods in accordance with BS EN60079-14 and circuit protection.

d. The inspection requirements with regard to BS EN60079-17 for the identification of

faults that can cause operational failure

November 2013 3 ©
November 2013 4 ©
Flameproof EEx d / Ex d
Flameproof is one of the original methods of explosion protection developed for use in the
mining industry. It has a wide range of applications, typically junction boxes, lighting fittings,
electric motors etc.
The letter ‘d’, which symbolises this type of protection, is from the German word ‘druckfeste’
(kapselung), which roughly translated means ‘pressure tight’ (enclosure).

Flameproof apparatus, when properly installed in the intended location, enables components
such as switches, contactors and relays etc. to be safely used in hazardous areas.
Flameproof is the only one of the eight different methods of explosion protection in which an
explosion is permitted. This explosion, however, must be contained by the robustly
constructed flameproof enclosure so that ignition of the surrounding flammable atmosphere
cannot occur.

Standards

BS EN60079-1: 2007 Flameproof enclosures ‘d’

BS EN50 018: 2000 Flameproof enclosures ‘d’
BS 5501: Part 5: 1977 Flameproof enclosures ‘d’
The construction and testing of flameproof enclosures of electrical
BS 4683: Part 2: 1971
apparatus (Ex d)
BS 229: 1957 Flameproof enclosures of electrical apparatus
Electrical Apparatus for explosive gas atmospheres –
IEC 60079-1: 2007
Part 1: Flameproof enclosures ‘d’
Electrical Apparatus for explosive gas atmospheres: Part 14
BS EN60079-14: 2008
Electrical installations in hazardous areas (other than mines)
Electrical Apparatus for explosive gas atmospheres: Part 17
BS EN60079-17: 2007 Inspection and Maintenance of electrical installations in hazardous
areas (other than mines)
BS 5345: Part 3: 1979 Code of Practice for the Selection, Installation and Maintenance of
(Withdrawn) flameproof apparatus

November 2013 5 ©
Definition
The construction standard BS EN60079-1 defines flameproof as:

‘An enclosure in which the parts which can ignite an explosive atmosphere are
placed and which can withstand the pressure developed during an internal explosion
of an explosive mixture, and which prevents the transmission of the explosion to the
explosive atmosphere surrounding the enclosure’

EPL: Gb (ATEX Cat 2G)

Zone of Use: 1 & 2 (Based on traditional selection approach)

Ambient rating
Flameproof enclosures are normally designed for use in ambient temperatures in the range
- 20°C to +40°C unless otherwise marked.

Sample certification label

November 2013 6 ©
Principle of Operation
Flameproof enclosures are not gas tight and a gas or vapour will enter the enclosure where,
for example, joints or cable entries exist. Since these enclosures are designed to contain
components which are an ignition source, ignition of the gas or vapour may occur, and the
resulting explosion pressure can reach a peak value of around 150 p.s.i.

The enclosure must, therefore, be strong enough to contain this explosion pressure, and the
gaps at the joints and threads of cable entries must be long and narrow to cool the
flames/hot gases before they reach and cause ignition of a flammable atmosphere which
may exist out with the enclosure.

Typical materials used for the construction of flameproof apparatus include cast iron,
aluminium alloys, and where corrosion resistance is required, gun metal bronze, phosphor
bronze and stainless steel may be used. Plastic materials are also used but the free internal
volume must not exceed 10cm3. The latest standard specifies that for flanged joints ‘THERE
SHALL BE NO INTENTIONAL GAP AT THE JOINTS’ and infers the same for other joint
types. The average roughness Ra of the flamepath surfaces must not exceed 6.3μm.

Flammable MIxture

Arcs, Sparks
Hot Surfaces

Contactors, Relays
etc

Gap

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Gap Dimensions
It is not necessary for a gap to exist at the flamepaths of a flameproof enclosure. The latest
standard BS EN60079-1 states there shall be no intentional gap between the surfaces of
enclosures with flanged joints.

This said, however, a gap will be necessary at cylindrical joints of rotating machines, i.e.
where the rotor shaft exits the end-shield and also where push-button spindles pass through
flameproof enclosures to operate the internal switches.

Flameproof enclosures with spigot or screwed joints also require some clearance to enable
covers to be removed relatively easily for installation and maintenance purposes. These
clearance/gap dimensions, and also those for rotating machines and push-button stations,
must be within the dimensions specified in the tables for gap dimensions in the construction
standard for flameproof equipment, e.g. BS EN60079-1.

Factors which influence the dimension of the gap are:

a. The width of the joint

b. The gas group

c. The internal volume of the enclosure

d. The type of joint

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Flamepath joints
The diagrams below illustrate examples of three joint types specified in the British standard
BS EN60079-1 for use in flameproof apparatus. In a flanged joint, the machined surface on
the cover makes face-to-face contact with the corresponding surface on the base to give a
gap dimension normally less than that specified in the tables of gap dimensions in the
standard when the cover is properly bolted down. This type of joint will be used at the covers
of, for example, junction boxes.

Spigot joints will be used at junction box covers and motor enshields.

Threaded joints are used for cover joints, cable gland and conduit entries. An adequate
flamepath length is normally achieved with a thread engagement of five full threads.

In contrast to BS EN50019, the most recent standard, BS EN60079-1 permits the use of
flanged joints when a IIC gas such as acetylene is the hazard only if the gap is ≤ 0.04mm,
has a length L ≥ 9.5mm and the free internal volume does not exceed 500 cm3.

a) Flanged joint
Interior

b) Spigot joint Interior

c) Screwed joint Interior

November 2013 9 ©
Flamepath joint types (rotating machines)

(d) cylindrical (shaft gland) joint

Flamepath Joints (other examples)

Flamepaths other than those at cover joints are also necessary where, for example, an
actuator spindle passes through the wall of an enclosure, or where a cable gland or conduit
enters an enclosure. Examples are shown below.

Push-button spindle

Flamepath

November 2013 10 ©
Cable glands
The installation of cables to flameproof equipment must either be via either flameproof Ex d
or dual certified Ex de cable glands. Cable glands certified Ex e only are not suitable.
Cable glands must enter flameproof Ex d enclosures only via threaded entries since a
flamepath is established at this point – clearance entries are not permitted - and is
illustrated in the diagrams below. The thread engagement requirements for cable and
conduit entries are specified in the standard BS EN60079-1 and apply to the three sub-
groups IIA, IIB and IIC. These requirements are shown below in the table from the standard.

Thread
engagement

Flamepath

Volume

≤ 100 cm3 > 100 cm3

Thread Axial Thread Axial

Engagement Length Engagement Length

> 5 Full Threads > 5mm > 5 Full Threads > 8 mm

Note: Flameproof equipment manufactured to the older British standards, e.g. BS229, may
have non-metric thread forms at cable gland entries. This difference can be
overcome by the use of certified Ex d adaptors having compatible thread forms to
suit both the entry in the enclosure and the cable gland. A typical component
certified Ex d adaptor is shown in the left-hand picture below. Certified Ex d
reducers enable a reduction in the entry diameter to allow a smaller cable gland to
be fitted.

Non-metric threads Cable

gland

Certified Certified
adaptor reducer Certified
Metric threads reducer

November 2013 11 ©
Unused Cable or Conduit Entries
It is important that unused cable/conduit entries in flameproof enclosures are closed using
appropriate blanking elements, commonly known as stoppers. Several types are specified in
BS EN60079-1 and will be metal ‘component certified’ items usually manufactured from
brass or stainless steel. Only metal component certified stoppers fully engaged by 5 full
threads may be used – plastic stoppers are unacceptable. The construction standard
specifies suitable types, examples of which are illustrated below.

Split pin

Hexagonal
(a) recess

(b)
Exterior
Interior

(c)

Shearable
neck

Example (a) above can only be removed from the exterior when the internally fitted split pin
is removed. Removal of example (b) requires the use of an allen key, and example (c) is
where the method of removal differs from the fitting method which involves the neck being
sheared after insertion. Of the three types, example (b) is the most commonly used with
certification markings on either the plain side or the same side as the hexagonal recess.
Ideally these should be fitted with the plain side outermost to make unauthorised removal
more difficult. The illustration below shows stoppers fitted either way and with the
certification markings visible for those carrying out inspections. These markings, however,
are not visible in the picture.

Component
certified stoppers

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 Maximum gap

November 2013
Minimum mm
width of
Type of joint joint L For a volume For a volume For a volume For a volume
cm3 cm3 cm3 cm3
mm V < 100 100 < V < 500 500 < V < 2000 V > 2000
Table 1 from BS EN60079-1:

I IIA IIB I IIA IIB I IIA IIB I IIA IIB

Flanged, cylindrical or 6 0.30 0.30 0.20 - - - - - - - - -
spigot joints 9.5 0.35 0.30 0.20 0.35 0.30 0.20 0.08 0.08 0.08 - - -
12.5 0.40 0.30 0.20 0.40 0.30 0.20 0.40 0.30 0.20 0.40 0.20 0.15
25 0.50 0.40 0.20 0.50 0.40 0.20 0.50 0.40 0.20 0.50 0.40 0.20

13
6 0.30 0.30 0.20 - - - - - - - - -
9.5 0.35 0.30 0.20 0.35 0.30 0.20 - - - - - -
Sleeve 12.5 0.40 0.35 0.25 0.40 0.30 0.20 0.40 0.30 0.20 0.40 0.20 -
Cylindrical
bearings 25 0.50 0.40 0.30 0.50 0.40 0.25 0.50 0.40 0.25 0.50 0.40 0.20
joints for
shaft glands 0.4 0.60 0.50 0.40 0.60 0.50 0.30 0.60 0.50 0.30 0.60 0.50 0.25
of rotating
electrical 6 0.45 0.45 0.3 - - - - - - - - -
machines Rolling- 9.5 0.50 0.45 0.35 0.50 0.40 0.25 - - - - - -
with: element 12.5 0.60 0.50 0.40 0.60 0.45 0.30 0.60 0.45 0.30 0.60 0.30 0.20
bearings 25 0.75 0.60 0.45 0.75 0.60 0.40 0.75 0.60 0.40 0.75 0.60 0.30
0.4 0.80 0.75 0.60 0.80 0.75 0.45 0.80 0.75 0.45 0.80 0.75 0.40
Minimum width of joint and maximum gap for groups I, IIA & IIB enclosures

Note: The constructional values rounded according to ISO 31-0 should be taken when determining the maximum gap

©
 Maximum gap
Minimum
mm
width of

November 2013
Type of joint joint L For a volume For a volume For a volume For a volume
cm3 cm3 cm3 cm3
mm V < 100 100 < V < 500 500 < V < 2000 V > 2000

6 0.10 - - -
Flanged joints 9.5 0.10 0.10 - -
Table 2 from BS EN60079-1:

15.8 0.10 0.10 0.04 -

25 0.10 0.10 0.04 0.04
c < 6mm 12.5 0.15 0.15 0.15 -
d < 5L b b b
Spigot joints L = c+d 25 0.18 0.18 0.18 0.18b
f < 1mm 40 0.20c 0.20c 0.20c 0.20c

14
6 0.10 - - -
Cylindrical joints, 9.5 0.10 0.10 - -
spigot joints 12.5 0.15 0.15 0.15 -
25 0.15 0.15 0.15 0.15
40 0.20 0.20 0.20 0.20
6 0.15 - - -
Cylindrical joints shaft glands of 9.5 0.15 0.15 - -
rotating electrical machines with 12.5 0.25 0.25 0.15 -
Minimum width of joint and maximum gap for group IIC enclosures

rolling element bearings 25 0.25 0.25 0.15 0.25

40 0.30 0.30 0.30 0.30
a) Flanged joints are permitted for explosive mixtures of acetylene and air only in accordance with 5.2.7
b) Maximum gap of cylindrical part increased to 0.20 mm if f < 0.5 mm
c) Maximum gap of cylindrical part increased to 0.25 mm if f < 0.5 mm

Note: Constructional values rounded according to ISO 31-0 should be taken when determining the maximum gap

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Pressure piling
Defined as: the result of an ignition, in a compartment or subdivision of an enclosure, of a gas
mixture recompressed, for example, due to a primary ignition in another compartment
or subdivision.

If a flammable mixture us compressed prior to ignition, the resulting explosion will be

considerably higher than if the same mixture was ignited at normal atmospheric pressure.
Pressure piling can materialise as a result of sub-division of the interior of a flameproof
enclosure, which prevents the natural development of an explosion. An explosion at one
side of an obstacle pre-compresses the flammable mixture at the other side, resulting in a
secondary explosion that can reach an explosion pressure around three times that of the first
or normal explosion pressure. Manufacturers, guided by relevant construction standards,
must ensure that, in any cross-section within an enclosure, there is adequate free space
(typically 20 – 25% of the total cross-section) around any potential obstruction, which may be
a large component or a number of components. This will ensure that pressure piling is kept
under control.

Obstruction of Flamepaths
Obstruction by solid objects of the flamepaths of flameproof equipment with flanged joints
should be avoided my maintaining the distances given in the table below. A solid obstruction
such as a wall, steelwork, conduit, mounting brackets, weather guards or other electrical
equipment etc., in close proximity to the flamepath can, in the event of an internal explosion,
reduce the efficiency of the flamepath to the extent that ignition of the external gas or vapour
could occur.

Group Distance
IIA 10 mm
IIB 30 mm
IIC 40 mm

Insufficient clearance
between flamepath
and obstruction

Solid obstruction

Solid obstruction

March 2010 ©
15
Ingress Protection Methods
Flameproof equipment must have a level of ingress protection to suit the environmental
conditions of the location in which the equipment is installed and hence equipment should
have, as part of their certified design, seals or gaskets to prevent the ingress of water and/or
dust.
The diagrams below illustrate the location of gaskets or rubber ‘O’ rings for ensuring a high
level of ingress protection. The gaskets etc. must be an integral part of the original design,
i.e. they cannot be added at a later date to an enclosure manufactured without
gaskets. Typical examples for outdoor use are illustrated below.

Spigot joints

Gasket is clamped
between the
horizontal faces of
the spigot joint

Rubber ‘O’ ring

located in a slot
in the the cover

Flanged joints

Rubber ‘O’ ring Flanged joint flamepath

located in a slot surfaces
in the cover
Note: Gaskets clamped
between these
surfaces is not
permitted

November 2013 16 ©
Weatherproofing / protection of flamepaths

Flamepaths must also be protected in accordance with manufacturer’s instructions and the
requirements of BS EN60079-14 which will involve additional measures as detailed below.
This is particularly important where environmental conditions are extreme.

Protection of flamepaths

The following measures are not permissible:

a) painting of flamepath surfaces - enclosures may be painted after assembly;
b) fitting of unauthorised seals/gaskets – replacement seals/gaskets may only be
fitted where the originals, which are part of the certified design, are degraded or
damaged.

Permitted measures:
c) application of non-setting grease or anti-corrosive agents having no
evaporating solvents;
d) non-hardening grease-bearing (Denso) tape – see application/limitations of use
on following page.

Note: The use of non-setting grease on the machined surfaces of flamepaths has
two advantages since, in addition to providing an additional level of ingress
protection, it also inhibits the formation of rust on these surfaces.
Silicone based grease requires careful consideration in order to avoid
possible damage to the elements of gas detectors.
The non-setting grease or compound used on the flamepath surfaces
should be that recommended by the manufacturer.

November 2013 17 ©
Weatherproofing / protection of flamepaths (continued)
For flameproof equipment, the limitations for the use of non-hardening grease-bearing
textile tape for enclosures with flanged joints, as specified in BS EN60079-14, are as
follows:
a. In areas where group IIA gases or vapours may be present, non-hardening tape
maybe applied around the flamepaths of apparatus with flanged joints - one layer
only to be applied with a short overlap.
b. In areas where group IIB gases or vapours may be present, one layer only with a
short overlap may be applied around the flamepaths of apparatus with flanged joints,
but only if the flamepath gap is less than 0.1mm regardless of the joint width.
c. In areas where IIC gases or vapours may be present the tape must not be used.

Non-hardening
grease-bearing
textile tape

Direct / Indirect Entry

The selection of cable glands for flameproof apparatus is influenced by several factors, one
of which is the method of entry into the apparatus. There are two entry methods, namely
direct and indirect, examples of which are shown below.
Direct entry comprises a single flameproof chamber within which components such as
switches, relays or contactors may be installed. Flameproof apparatus with indirect entry
has two separate chambers, one of which contains only terminals for connection of the
conductors of incoming cables or conduit. Connection to the arcing components in the
second compartment is made via these flameproof terminals which pass through the
flameproof interface between the two compartments.

EEx d
EEx d Flamepaths Enclosure
Enclosure

Terminals

EEx d cable
glands

Direct entry Indirect entry

November 2013 18 ©
Cover bolt (fastener) requirements
Should the requirement arise where it is necessary to replace the cover bolts etc of a
flameproof enclosure, only steel bolts, as specified by the manufacturer, having the correct
length, type of thread, type of head and tensile strength should be used.
Regarding cover bolt tightness the torque values specified by the manufacturer should be
observed. In the absence of manufacturer’s torque values the minimum requirement is
spanner tight, however, care must be exercised to avoid under-tightening as this can allow
an increase in the flamepath gap. Also, over-tightening of the bolts can result in them
stretching and hence reducing their strength with the consequence that an internal explosion
may not be contained within the enclosure.
It is important that all cover bolts are in place and correctly tightened prior to
energising a flameproof enclosure.

Cover bolt retainers

Some flameproof enclosures are fitted with retainers to avoid loss of bolts after removal of
the cover. The retainers are designed to allow access by, for example, an allen key and,
therefore, it is unnecessary to bend them back to loosen cover bolts.

Cover bolt retainers

Allen key in place

without distortion of
bolt retainer

Displacement of
bolt retainer allows
bolts to fall out

November 2013 19 ©
Modification of Flameproof Enclosures
Flameproof enclosures are normally supplied complete with all internal components fitted
and certified as a single entity by a certification/notified body. The testing procedure will take
into consideration the arrangement of the internal components so as to avoid pressure piling,
the free internal volume after all the components have been fitted, the temperature rise
(determined by the maximum power dissipation), creepage and clearance distances, and
the rise in pressure as a result of an internal explosion using a gas/air mixture in its most
explosive proportions.
The certification, therefore, “seals” the design of the apparatus so that any unauthorised
modifications will effectively invalidate the certification. Modifications would alter the
original test results recorded by the test/certification body and, consequently, the following
points should be observed.

Replacement components should always be exactly the same as the original specified
components in order to avoid infringement of the certification. For example, a component
larger or smaller than the original will affect the internal geometry of the enclosure. Pressure
piling is a possibility if a larger component is fitted, and increased volume will result if a
smaller component is fitted.

Drilling and tapping of cable gland/conduit entries should only be carried out by the
manufacturer of the enclosure, or his approved agent. The threads of the entries are
required to be compatible with those of cable glands or conduit in terms of type of thread,
thread pitch and clearance tolerance since flamepaths exist at these points. Correct
alignment of the threaded entry is also important, so that the cable gland is
perpendicular to the enclosure wall and not as illustrated below.

The strength of a flameproof enclosure may be impaired if

the number and size of entries exceeds that permitted in the
original design certified by the test authority. Compliance with the
original design is paramount with regard to number, size and
location of entries to ensure the enclosure will contain an internal
explosion.

Electrical Protection
Flameproof enclosures are tested for their ability to withstand internal gas explosions only;
they are not capable of withstanding the energy which may be released as a result of an
internal short-circuit. In order to avoid invalidation of the certification, it is important that
properly rated/calibrated electrical protection, e.g. fuses and/or circuit breakers, are utilised.

November 2013 20 ©
Typical faults

The following list illustrates some examples of faults which will impair the integrity of
flameproof equipment.

1) Missing cover bolts;

2) Loose cover bolts;

3) Incorrect cover bolts;

4) Loose cable glands;

5) Incorrect cable glands;

6) Missing blanking elements (stoppers);

7) Incorrect blanking elements (stoppers);

8) Flamepaths of flanged joints obstructed;

9) Incorrect gas group;

10) Incorrect temperature class;

11) Incorrect ambient rating;

12) Damaged, corroded or scored flamepath surfaces;

13) Lamp wattage too high;

14) Incorrect type of lamp;

15) Damage to enclosure.

November 2013 21 ©
BS EN 60079-17 Table 1: Inspection Schedule for Ex’d’, Ex’e’, and Ex ‘n’
Installations (D = Detailed, C = Close, V = Visual)
Check that: Ex’d’ Ex’e’ Ex’n’
Grade of Inspection
D C V D C V D C V
A APPARATUS

1 Equipment is appropriate to the EPL / Zone classification * * * * * * * * *

2 Equipment group is correct * * * * * *
3 Equipment temperature class is correct * * * * * *
4 Equipment circuit identification is correct * * *
5 Equipment circuit identification is available * * * * * * * * *
6 Enclosure, glass parts and glass-to-metal sealing gaskets * * * * * * * * *
and/or compounds are satisfactory
7 There are no unauthorised modifications * * *
8 There are no visible unauthorised modifications * * * * * *
9 Bolts, cable entry devices (direct and indirect) and blanking
elements are of the correct type and are complete and tight
- Physical check * * * * * *
- Visual check * * *
10 Flange faces are clean and undamaged and gaskets, if any, *
are satisfactory
11 Flange gap dimensions are within maximal values permitted * *
12 Lamp rating, type and position are correct * * *
13 Electrical connections are tight * *
14 Condition of enclosure gaskets is satisfactory * *
15 Enclosed-break and hermetically sealed devices are undamaged *
16 Restricted breathing enclosure is satisfactory *
17 Motor fans have sufficient clearance to enclosure and/or covers * * *
18 Breathing and draining devices are satisfactory * * * * * *

B INSTALLATION

1 Type of cable is appropriate * * *

2 There is no obvious damage to cables * * * * * * * * *
3 Sealing of trunking, ducts, pipes and/or conduits is satisfactory * * * * * * * * *
4 Stopping boxes and cable boxes are correctly filled *
5 Integrity of conduit system and interface with mixed system is maintained * * *
6 Earthing connections, including any supplementary earthing bonding
connections are satisfactory (e.g. connections are tight and conductors are
of sufficient cross section)
- Physical check * * *
- Visual check * * * * * *
7 Fault loop impedance (TN system) or earthing resistance * * *
(IT systems) is satisfactory
8 Insulation resistance is satisfactory * * *
9 Automatic electrical protective devices operate within permitted limits * * *
10 Automatic electrical protective devices are set correctly (auto reset not * * *
possible)
11 Special conditions of use (if applicable) are complied with * * *
12 Cables not in use are correctly terminated * * *
13 Obstructions adjacent to flameproof flanged joints are in accordance with * * *
IEC 60079-14
14 Variable voltage/frequency installation in accordance with documentation * * * * * *

C ENVIRONMENT

1 Equipment is adequately protected against corrosion, weather, vibration * * * * * * * * *

and other adverse factors
2 No undue accumulation of dust and dirt * * * * * * * * *
3 Electrical insulation is clean and dry * *

November 2013 22 ©
Note 1

Apparatus using a combination of both ‘d’ and ‘e’ types of protection will require reference to
both columns during inspection.

Note 2

The use of electrical test equipment, in accordance with items B7 and B8, should only be
undertaken after appropriate steps are taken to ensure the surrounding area is free of a
flammable gas or vapour

November 2013 23 ©