What is CompEx?

CompEx is the leading national training, assessment and certification scheme for electricians and other
electro-technical craftspersons working in potentially hazardous or explosive atmospheres. As a national
joint training initiative, CompEx is developed and implemented by the Engineering Equipment and Material
Users Association (EEMUA) and JTL and is supported by the Health and Safety Executive (HSE).

CompEx course covers the following areas,

- Area classification

- Gas groups

- Temperature classification

- I P Ratings

- Selection of equipment

- Ignition sources

- Legislation

- Directives and standards

- Earthing and bonding

- Ex’i’, Ex’d’, Ex’e’, Ex’p’, Ex’m’, Ex’n’, Ex’o’ and Ex’q’

- Wiring systems and glanding

Installation, maintenance, inspection and testing

COURSE SYLLABUS:

Unit 1 General Principles

Unit 2 Standards, Certification and Marking
Unit 3 Flameproof Ex d
Unit 4 Increased Safety Ex e
Unit 5 Type ‘n’ protection
Unit 6 Pressurization Ex p
Unit 7 Intrinsic Safety Ex i
Unit 8 Other methods of protection, Ex o, Ex q, Ex m & Ex s
Unit 9 Combined (Hybrid) methods of protection
Unit 10 Wiring Systems
Unit 11 Inspection & Maintenance to EN/IEC 60079-17
Unit 12 Sources of ignition
Unit 13 Induction to Competence Validation Testing
Unit 14 Permit to Work System and Safe Isolation

EX01 Preparation and Installation of Ex 'd' 'e' and ‘n’ Systems

EX02 Inspection and Maintenance of Ex 'd' 'e' and ‘n’ Systems
EX03 Preparation and Installation of Ex ‘i’ Systems
EX04 Inspection and Maintenance of Ex ‘i’ Systems
CompEx Basic Principle:

Standards:

Since the early 1920`s many standards have evolved both in Britain and all over the world. Most of these
standards are now obsolete so there is one international standard that is important to remember - IEC
60079.

IEC 60079-10 - Classification of Hazardous Areas

IEC 60079-14 - Construction of electrical installations

IEC 60079-17 - Inspection and maintenance

ATEX Directives:

ATEX is the European Directive 94/9/EC which applies to all equipment, both electrical and mechanical,
used in hazardous atmospheres (both dust and gas). It came in to effect on 1th July 2003.

ATEX 95 - deals with all equipment and protective systems in use in potentially explosive environments.

ATEX 137 - workplace directive that sets the minimum requirements for the safety and health protection of
workers in potentially explosive environments.

Definitions:

Spark - a form of electrostatic discharge; it can occur in various types (short circuit, lightning, static
electricity, operation of switches and relays). It is important to remember that there can be two types of
sparks - incentive spark and non-incentive spark.

An Incentive spark has sufficient energy to cause an explosion in a hazardous environment (i.e. Ignite a
gas source).

A non-incentive spark does not have the sufficient energy to cause an explosion in a hazardous
environment.

Flashpoint - the lowest temperature at which sufficient vapour is given off a liquid, to form a flammable
mixture with air that can be ignited by an arc, spark or naked flame.

Ignition temperature - the minimum temperature at which a flammable material will spontaneously ignite.

Ambient temperature - from -20 celsius to 40 celsius.

Zones:

Area classification is a method of analyzing and classifying the environment where explosive gas
atmospheres may occur. The main purpose is to give guidance in the selection and installation of apparatus
to be used in that environment, considering the properties of the flammable materials that will be present.

Hazardous areas are classified into zones based on an assessment of the frequency of the occurrence and
duration of an explosive gas atmosphere.

Zone 0 - an area in which an explosive atmosphere is present continuously, or for long periods, or frequently
(more than 1000 hours per year).

Zone 1 - an area in which an explosive atmosphere is likely to occur in normal operation occasionally (more
than 10, but less than 1000 hours per year).
Zone 2 - an area in which an explosive atmosphere is not likely to occur in normal operation, but if it does
occur, will persist for a short period only (less than 10 hours per year).

Explosive atmosphere equipment groups:

Group I - Mining activities - equipment designed for use below ground and associated areas where methane
is the flammable gas (not covered in the CompEx course).

Group II - Surface industries - Gas - Sub-divided IIA, IIB, IIC (types of gases) - equipment that is used
primarily used above ground where any other flammable gas may be present.

Group III - Surface industries - Dust - Sub-divided IIIA, IIIB, IIIC - equipment that is used where flammable
dust may be present.

Equipment Protection Levels (EPL):

EPL`s are the IEC`s equivalent of the ATEX categories. It is a complicated and illogical concept, but the
candidate must be able to remember the table below to successfully complete the CompEx course.

Zone ATEX Category IEC EPL

0 1G Ga
1 2G Gb
2 3G Gc

It is important to understand that equipment designed for a higher level of protection (i.e. Zone 0) can be
used in areas of lower requirements (i.e. Zone 1 or Zone 2).

However, equipment designed for lower levels of protection (i.e. Zone 1) must never be used in areas with
higher levels of protection requirements (i.e. Zone 0).

Gas sub-division groups:

Gas sub-division Gas Ignition Temp. °C

IIA Benzene 555
Butane 365
Gasoline 280
Propane 470
IIB Ethylene 425
IIC Hydrogen 560
Acetylene 305

Note: this table consists only of the most important gases and their ignition temperatures. During the course
you will learn about more gases in each group. In order to successfully complete the CompEx course the
candidate will have to memories the contents of this table.

Temperature Classification:
Temperature classification is based on the maximum temperature reached by any part of the equipment that
could be in contact with a flammable gas.

T Class Max. surface

temp.
T1 450 °C
T2 300 °C
T3 200 °C
T4 135 °C
T5 100 °C
T6 85 °C

In order to successfully complete the CompEx course the candidate will have to clear understanding and
memories the contents of this table.

Explosion protection Concept:

There are several methods and concepts which may be used in potentially explosive environments. The
table below identifies the types of protection based on the Zone/EPL/Category requirements. It is essential
to memories this table in order to successfully complete the CompEx course.

Zone/EPL/Category Types of protection

Zone 0 or EPL Ga or Cat 1 ia, ma
Zone 1 or EPL Gb or Cat 2 d, e, mb, o, p, q, ib
Zone 2 or EPL Gc or Cat 3 n, s, ic, mc

CompEx `e` - Increased Safety:

CompEx type of protection `e` is a type of protection in which additional measures are applied in order to
give increased protection against the possibility of excessive temperatures, and against the possibility of the
occurrence of arcs and sparks in normal conditions or under specified fault conditions.

Areas of usage:

- Zone 1 or Category 2 or EPL Gb

- Zone 2 or Category 2 or EPL GC
- All gas groups.

Ingress protection:

CompEx type of protection `e` requires IP54 as a minimum.

Terminations:

Type of protection `e` requires the use of certified terminals in every case. The following rules apply:
- One conductor per terminal.
- Wires must be crimped.
- Soldering is not allowed.
- 50mm separation between `normal` and `IS (intrinsically safe) ` terminals.
- All (even unused) terminals must be tight.

Accessories:

Accessories Required type

Glands Certified glands only:

 Ex `d`
 Ex `d` barrier
 Ex `de`
 Ex `e`

Blanks Certified blanks only:

 Ex `d`
 Ex `de`
 Ex `e`

IP washer  Clearance entry - required

 Threaded entry less than 6mm thread - required
 Threaded entry more than 6mm thread - not required

Serrated washer Required on painted surfaces

Locknut  Clearance entry - required
 Threaded entry less than 6mm thread - required
 Threaded entry more than 6mm thread - not required
 Plastic enclosures - required

Earth tag Required on plastic enclosures without earth continuity plates

CompEx `n` – Reduced Risk:

Electrical equipment within CompEx type of protection `n` is such that in normal operation and in certain
specified fault conditions it is not capable of igniting a surrounding explosive atmosphere.

Areas of usage:

- Zone 2 or Category 2 or EPL GC

- All gas groups

Ingress protection:

CompEx type of protection `n` requires IP54 as a minimum.

Protection details:

CompEx `n` standard is subdivided into several other types of which the following are most commonly used:
- Ex `n` C
- Ex `n` R
- Ex `n` L

Ex `n` C
Ex `n` C standard is further subdivided in to these categories:

- Hermetically sealed devices - Sparking contacts are enclosed within a hermetically sealed enclosure.

- Enclosed break devices – Break devices are incorporated within an enclosure that can withhold an
internal explosion (recently replaced by Ex `d` standard).

- Encapsulated devices – Similar to hermetically sealed devices (recently replaced by Ex `m`).

Ex `n` R`

Ex `n` R standard stands for Restricted Breathing devices. This type of protection is designed to restrict, but
not totally prevent the entry of gases.

Ex `n` R protection is very common with various types of luminaries used in the oil and gas industry.

Cable entries into restricted breathing enclosures must be fitted with an IP washer.

Ex `n` L

Ex `n` L stands for Energy Limited Apparatus. This is a type of protection where circuit components restrict
the maximum available energy in a circuit to a level incapable of causing an explosion.

Accessories:

Accessories Required type

Glands Certified glands only:

 Ex `d`
 Ex `d` barrier
 Ex `de`
 Ex `e`

Blanks Certified blanks only:

 Ex `d`
 Ex `de`
 Ex `e`

IP washer  Clearance entry - required

 Threaded entry less than 6mm thread – required
 Threaded entry more than 6mm thread – not required
 Ex `n` R - required

Serrated washer Required on painted surfaces

Locknut  Clearance entry – required
 Threaded entry less than 6mm thread – required
 Threaded entry more than 6mm thread – not required
 Plastic enclosures - required

Earth tag Required on plastic enclosures without earth continuity plates

CompEx `i` - Intrinsic Safety:

CompEx type of protection `i` is such that the energy available in the hazardous area is limited below that
which could ignite a flammable gas.

Intrinsically safe equipment is electrical equipment in which all the circuits are intrinsically safe ones.

Associated equipment is electrical equipment which consists of both intrinsically safe and non-intrinsically
safe circuits. By design and construction, the non-intrinsically safe circuits are limited to non-hazardous
areas; the intrinsically safe circuits inside a hazardous area must not be adversely affected in any way.

Clearances:

There are some important values to remember:

- Minimum clearance of 50 mm between the terminals of IS and non-IS circuits.
- Minimum 3 mm clearance to earth terminals.
- Minimum 6 mm clearance between IS circuits terminals.

Glands;

Glands on cables containing IS (intrinsically safe) circuits must be appropriate to the EPS of the equipment
containing the IS circuits.

For example, if a cable containing IS circuits is entering an Ex `d` type enclosure, then Ex `d` (or Ex `de`)
type gland must be used.

Safety barriers:

Safety barrier is the electric equipment installed in non-hazardous area and is designed to limit the energy
available for the intrinsically safe circuits located inside the hazardous area.
There are two basic types of safety barriers available: the shunt diode barrier (Zener barrier) and the
galvanically isolated barrier.

Zener Barrier:

Zener barriers are devices that contain at least two Zener diodes, a resistor and a fuse, in order to limit the
available energy entering the intrinsically safe circuit inside a hazardous area. The energy limitation is
provided by current and voltage limitation. The Zener diodes breakdown voltage is not exceeded in normal
operation. If this voltage is exceeded due to a fault in non-hazardous area, the diodes start to conduct,
causing the fuse to blow, thus preventing the transfer of unacceptable high energy into the hazardous area.

Zener barriers must have a dedicated earth connection which is called the intrinsically safe earth. The
connection must be done with at least 4 mm2 conductor and should ideally have less than 0.1 ohm
resistance.
Galvanically Isolated Barriers:

Galvanically isolated barriers allow the transference of energy without any directly wired interconnection.

This is usually achieved with the use of a transformer where the primary coil is connected to the source
located in the safe area, and the secondary coil is providing energy to the intrinsically safe circuits inside the
hazardous area.

Galvanically isolated barrier does not require an earth connection.

Types of protection (recap):

i - Intrinsic safety (ia, ib, or ic)

m - Encapsulation (ma, mb, mc)

d - Flameproof or explosion proof enclosure

e - Increased safety

o - Oil immersion

p - Pressurization

q - Powder filling

n - Reduced risk

s - Special

A full CompEx course for a practicing covers all these types, but only i, d, e, and n types will be covered in
full detail, simply because these are the most common protection types used in most cases.

Our guide for the electricians CompEx course will therefore only cover these most common protection types.

Once again, we emphasize these note is only a good orientation tool for the actual CompEx course, the
scope of which is much wider, with a great deal of important details not mentioned here. These notes focus
on the essential, by learning which the candidate will get a good head start for the actual course, which
otherwise could be surprisingly demanding.

CompEx `d` - Flameproof Enclosure

Ex d type of protection is a type of protection in which the parts that can ignite an explosive atmosphere are
placed in an enclosure that can withstand the explosion developed within the enclosure and prevent the
transmission of the explosion to the outside environment.

Area of usage:
- Zone 1 or Category 2 or EPL Gb
- Zone 2 or Category 2 or EPL Gc
- All gas groups.

Gaps in the enclosure:

Since these enclosures are not hermetically sealed, all gaps, cover flanges, cable inlets and other places
where a gas could enter or leave the enclosure are not to exceed these specified values:
- 0.1 mm with group IIC gases
- 0.15 mm with group IIA or IIB gases.

Threaded joints:

The treaded part must be at least 8 mm long, with 6 threads of which 5 threads must be engaged.

Minimum distances to other objects next to the enclosure:

These values will depend on the type of the hazardous gas potentially surrounding the enclosure:

Group Minimum distance

IIA 10 mm
IIB 30 mm
IIC 40 mm

Glands:

All glands used for cable entry to an Ex `d` enclosure have to be Ex `d` or Ex `de` certified. A barrier gland
may be required if one of these is true:
- Cable outside body not round (some old types of cables, usually not in use any more).
- Not a Compact Cable (some old types of cables, usually not in use any more).
- Hygroscopic fillers (some old types of cables, usually not in use any more).
- Group IIC gases.
- Group IIA and IIB gases and enclosure internal volume greater than 2 liters.

Ex `d` type enclosures are always made of metal, because of that there is no need for locknuts, serrated
washers, IP washers, or shrouds of any type. Blanks used to cover any unused entry holes must be Ex `d`
or Ex `de` certified.

Feedback and Review:

 IEC 60079-17 / BS EN 60079-17 Inspection and maintenance of electrical installations in hazardous

areas standard
 IEC 60079-14 / BS EN 60079-14 The specific requirements for the design, selection and erection of
electrical installations in hazardous areas associated with explosive atmospheres standard
 1999/92/EC (ATEX 137) The protection of workers at risk from potentially explosive atmospheres
Directive
 94/9/EC (ATEX 95) Equipment and protective systems in potentially explosive atmospheres
Directive
 DSEAR The Dangerous Substances and Explosive Atmospheres Regulations
 NEC (The National Electric Code) standard
Please note that some of the questions can have multiple answers.

1. Which of the following is not needed for a fire to take place?

a. Fuel
b. Oxygen
c. An enclosure
d. Spark of sufficient energy

2. Which of the following can ignite a gas atmosphere?

a. Electrical spark
b. Hot surface
c. Battery
d. Intrinsically safe circuit
e. Static electricity
f. Lightning
g. Vehicle
h. Friction

3. The temperature at which a gas ignites spontaneously is called:

a. Ambient temperature
b. Ignition temperature
c. Flash point
d. Thermal temperature

4. Which of the following are commonly adopted?

a. Zone 0, explosive atmosphere for more than 2000 hrs/year
b. Zone 0, explosive atmosphere for more than 1000 hrs/year
c. Zone 2, explosive atmosphere for less than 10 hrs/year
d. Zone 1, explosive atmosphere present between 10 and 1000 hrs/year

5. Which is an example of Group I gas?

a. Methane
b. Propane
c. Ethylene
d. Hydrogen and acetylene

6. The objectives of the ATEX Directive 95 are

a. Removal of technical barriers to trade
b. Incorporation of risk assessments
c. Standardization of 230V ac across Europe
d. Health and safety of workers

7. Concerning ATEX categories, which abbreviation is used for equipment?

a. IEC
b. APL
c. EPL
d. API

8. The term EPL stands for

a. Electrical Protection Level
b. Equipment Protection Level
c. Electrical Protection Load
d. Equipment Pressure Level

9. Ex `n` equipment can be used in

a. Zone 0
b. Zone 0 and Zone 1
c. Zones 0, 1 and 2
d. Zone 2

10. Equipment Protection Level `Gc`/Category 3 equipment can be used in

a. Zone 0
b. Zone 0 and Zone 1
c. Zones 0,1 and 2
d. Zone 2

11. Components which produce sparks, such as contactors and switches, are permitted inside Ex `d`
enclosures
a. True
b. False

12. Which Standard deals with the general requirements for the Ex`d` protection concept?
a. IEC 60079-1
b. IEC 60079-3
c. IEC 60079-14
d. IEC 60079-17

13. Flameproof equipments is so named because

a. An internal explosion is not permitted
b. An internal explosion is permitted
c. An external explosion is permitted
d. The enclosure is resistant to gas entering the enclosure

14. Ex `d` equipment can be used in

a. Zone 0
b. Zone 1 and 2
c. Zone 2 only
d. Zone 0 and 1

15. A switch is in flameproof enclosure less than 2 liters in volume in a IIC environment. The enclosure
requires
a. Industrial glands
b. Ex `e` glands
c. Ex `d` Barrier glands
d. An indirect entry Ex `e` chamber fitted with stuffing glands

16. Increased safety Ex `e` apparatus is designed to contain an internal explosion

a. True
b. False
c. True, providing barrier glands are used
d. True, providing the IP rating is at least IP54

17. In general, Ex `e` equipment can be installed in

a. Zone 0
b. Zone 1 and 2
c. Zone 0, 1 and 2
d. Zone 2 only

18. Ex `e` equipment can be installed in are requiring

a. Equipment to EPL `Ga` and `Gb`
b. Equipment to EPL `Ga`, `Gb`, and `Gc`
c. Equipment to EPL `Ga` or Category 1
d. Equipment to EPL `Gb` and `Gc`

19. Ex `e` equipment must have an IP rating of

a. IP 54
b. At least IP 54, but location conditions may require a higher value
c. IP 44
d. At least IP 44, but location conditions may require a higher value

20. Locknuts on an Ex `e` equipment are

a. Always required
b. Never required
c. Required on clearance holes
d. Required on 10mm thick threaded entries

21. In general, Ex `n` equipment can be installed in

a. Zone 0
b. Zone 1
c. Zone 2
d. Clear areas

22. Ex `n` equipment can be designed for

a. Group II
b. Group IIA and IIB
c. Group IIA only
d. Group IIB only

23. Which is not a recognized Ex `n` method of protection

a. Type A Non-sparking
b. Type d Flameproof
c. Type L Energy limited
d. Type R Restricted breathing
e. Type C Sparking with hermetically sealed, enclosed break or encapsulated

24. When terminating a cable into an 8 mm thick type `n` metal enclosure with a threaded entry, which of the
following is required?
a. Locknut
b. Star washer
c. IP washer
d. None of these

25. For Ex `n` restricted breathing, which one of the following must always be provided?
a. IP washer
b. Locknut
c. Earth tag
d. Threaded entry

26. Ex `ia` equipment can be installed in

a. Zone 0
b. Zone 1
c. Zone 2
d. Clear area
27. Galvanic isolators require
a. An intrinsically safe earth connection
b. At least two Zener diodes
c. A device providing electrical separation such as a transformer, relay or opto-coupler
d. At least three Zener diodes

28. Which of the following does not require an intrinsically safe dedicated earth?
a. Zener barrier with two Zener diodes
b. Galvanically isolated barrier
c. Zener barrier with three Zener diodes
d. Zener barrier supplying simple apparatus

29. What is the minimum distance between terminals for intrinsically safe circuits and terminals of non-
intrinsically safe circuits?
a. 100 mm
b. 50 mm
c. 6 mm
d. 3 mm 30.

What is the minimum clearance to earth (intrinsically safe circuits)?

a. 100 mm
b. 50 mm
c. 6 mm
d. 3 mm

Answers:

1. c
2. a,b,c,e,f,g,h
3. b
4. b,c,d
5. a
6. a
7. c
8. b
9. d
10. d
11. a
12. a
13. b
14. b
15. c
16. b
17. b
18. d
19. b
20. c
21. c,d
22. a
23. b
24. d
25. a
26. a,b,c,d
27. c
28. b
29. b
30. d