Exd FLAMEPROOF ENCLOSURES- A Brief Guide

REFERENCE STANDARDS

IEC 79-0, IEC 79-1, BS 5501.1, BS 5501.5, EN 50 018, AS 2380.1, AS 2380.2

DEFINITIONS

Flameproof Enclosure: Type of protection for electrical equipment in which the enclosure will withstand
an internal explosion of a flammable mixture which has penetrated into the interior without suffering
damage and without causing ignition, through and joints of structural openings in the enclosure, of an
external explosive atmosphere consisting of one or more of the gases or vapours for which it is designed.

Flameproof Joint: Place where corresponding surfaces of the different parts of a flameproof enclosure
come together. Where the flame or products of combustion may be transmitted from the inside to the
outside of the enclosure.

Length of Flamepath: The shortest path through a joint from the inside to the outside of an enclosure.

Gap: The distance between the corresponding surfaces of a flameproof joint when the electrical equipment
has been assembled.

Pressure Piling: A condition resulting from ignition of precompressed gases in compartments or

subdivisions other than those in which ignition was initiated.

CONSTRUCTION REQUIREMENTS

Some of the other details that are covered by the standards are:-

 Minimum Surface Roughness, (machined surfaces).

 Inspection Access to measure the gap between flanged joints - usually with feeler gauges.
 Holes in joint surfaces. See drawing and table defining 'L' and 'I'.
 Joints, including, Class of Fit, Pitch, Minimum number of threads engaged.
 Gaskets and 'O' Rings.
 Operating Rods and Spindles.
 Shafts and Bearings.
 Breathing and Draining Devices.
 Fasteners. Especially the requirement that all holes must be blind holes, so that if a bolt is
removed there will not be direct access into the flameproof enclosure. Minimum wall
thickness-3mm or 1/3 the diameter of the hole-whichever is the greater. Minimum length
of thread engaged, and the depth of the hole to ensure the bolt does not 'bottom out'
before it is fully engaged.
 Mechanical Strength. Pressure piling.
 Cable glands and cable connection techniques.
 MINIMUM WIDTH OF JOINT AND MAXIMUM GAP FOR I, IIA, IIB
ENCLOSURES. A.S. 2380.2 TABLE 1.1
Maximum Gap for Volume, V (cm3), (mm)
Width of Joint L, (mm) V <100 100 < <> V > 2000
I IIA IIB I IIA IIB I IIA IIB
Flanged and spigot Joints
6 < 9.5 .30 .30 .20 - - - - - -
9.5 < 12.5 .30 .30 .20 - - - - - -
12.5 < 25 .40 .30 .20 .40 .30 .20 .40 .20 .15
25 <L< font> .50 .50 .20 .50 .40 .20 .50 .40 .20
Operating Rods and Spindles
6 < 12.5 .30 .30 .20 - - - - - -
12.5 < 25 .40 .30 .20 .40 .30 .20 .40 .20 .15
25 <L< font> .50 .40 .20 .50 .40 .20 .50 .40 .20
Shafts with Rolling Brgs
6 .45 .45 .30 - - - - - -
12.5 < 25 .60 .50 .40 .60 .45 .30 .60 .30 .20
25 .75 .60 .45 .75 .60 .40 .75 .60 .30
40 <L< font> .75 .75 .60 .75 .75 .45 .75 .75 .40

For Rods, Spindles, and shafts the gap is the maximum diametral clearance. Usually if equipment is to be
used for Groups I, IIA and IIB, it will be designed and built to meet with requirements of a IIB enclosure,
which exceeds the requirements of IIA and I. Separate tables apply for Group IIC with much tighter
tolerances and gaps. As IIC requirements are not common, standard equipment is not usually produced to
IIC to cover the requirements of the other groups. IIC is usually produced specially when required.

FLAMEPROOF THEORY

It is not possible or desirable to produce equipment with no gaps between the different parts, especially
with an electric motor with a revolving shaft. The allowable gap between the different parts is accepted, but
strictly defined. The 'gaps' help to relieve the pressure inside the enclosure caused by an explosion.
Experimental testing is used to establish the 'maximum experimental safe gap' for different gases and gas
mixtures. This data has been used to establish A.S. 2380.2 TABLE 1.1. It can be seen that the wider the
joint the larger the allowable gap, and that gases that explode more violently require a smaller gap. The
standard that covers the testing to establish the 'maximum experimental safe gap' is IEC79-1A (Appendix
D).

FLAMEPATH DIMENSIONS FOR JOINT SURFACES INTERRUPTED BY

HOLES

Width of Joint “L”mm Dimension “1”mm <12.5> 12.5 <25> 25 689

OTHER GENERAL REQUIREMENTS FOR EXPLOSIVE ATMOSPHERES

 Fasteners can only be undone by the use of a special tool, if the parts they are securing
are necessary to achieve a type of protection, (Ex d, Ex e, etc.). For Ex d equipment this
is usually achieved by using socket head cap screws with a counterbore, or hexagon head
bolts with a counterbore or shroud.
  Limits on the amount of aluminium of magnesium in external alloys, especially for
Group 1 applications. This is because Coal dust and aluminium under ideal conditions
can create spontaneous combustion at temperatures as low as 180 deg. C. For group 1
equipment it is usual for all external parts to be Cast Iron or Steel.
 External temperatures during normal operation - “T” ratings.
 IP ratings.
 Usual Electric tests including a High voltage test at 2 X the Operating Voltage plus 1500
volts. (2330 volts for 415 colt equipment)
 Impact tests.
 Marking, including information required on nameplates.

TESTING

Type tests are carried out on all Ex d equipment before it can be approved. these tests are performed in 2
stages.
1. Tests of the ability of the enclosure to withstand pressure, and the rate of rise of pressure, developed
inside the enclosure during an explosion - the “Reference Pressure”. The enclosure is then overpressure
tested to 1.5 times the “Reference Pressure” usually with compressed air or water, to ensure a factor of
safety. During manufacture all equipment that is of a steel fabricated construction must be Routine tested at
a static pressure of 1.5 times the “Reference Pressure” to ensure the integrity of the welding. If equipment
is of cast or moulded construction it can be exempted from the requirement for Routine Pressure Testing if
the sample passes a 4 times overpressure test.

2. Tests to ensure that the enclosure is flameproof, i.e. that an internal explosion does not create an external
explosion.

The equipment is modified by drilling and tapping suitable holes to install spark plugs, pressure
transducers, and gas pipes. to determine the explosion “Reference Pressure” at least 3 explosions are
performed inside the enclosure using the appropriate mix of gas to suit the Gas Group the enclosure is
designed for. For electric motors these tests are performed while the motor is running and while it is
stationary.

The equipment is placed in a test chamber which is filled with the same explosive gas mixture as is used in
the equipment under test. the gas inside the equipment is exploded at least 5 times to prove that the external
gas is not ignited by the internal explosions.

The equipment is considered to have passed the tests if no flame transmission has occurred, and the
enclosure has not suffered any damage or permanent deformation that may affect its flameproof properties.

Before any explosion testing is performed copies of the Approval drawings which are carefully checked to
ensure that the design details meet the requirements of the relevant standards. After explosion testing is
completed the samples, (prototypes), are disassembles and all the component parts are carefully measured
to ensure that they have been manufactured to the dimensions and tolerances specified on the Approval
drawings.

SUMMARY

To design, test and manufacture Flameproof equipment requires a great deal of attention to detail and a
high level of safety which is understandable as failure will put peoples lives a risk. The information above
is a brief summary of some of the detail that has to be complied with to meet the requirements of the
standards. While we believe this information to be correct we can accept no responsibility for any
inaccuracies.