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Health and Safety

Executive
The selection, installation
and maintenance of electrical
equipment for use in and around
buildings containing explosives
Guidance Note PM82
This is a free-to-download, web-friendly version of PM82
(First edition, published 1997). This version has been adapted for online use
from HSEs current printed version.
You can buy the document at www.hsebooks.co.uk and most good
bookshops.
ISBN 978 0 7176 1217 8
Price 5.00
This guidance is to assist those who are responsible for the design, selection,
installation, operation and maintenance of electrical systems and equipment
(including mobile mechanical handling equipment) used within premises
which manufacture, handle or store explosives, either above or below ground
level.
HSE Books
Page 2 of 20
Crown copyright 1997
ISBN 978 0 7176 1217 8
All rights reserved. No part of this publication may be reproduced, stored in
a retrieval system, or transmitted in any form or by any means (electronic,
mechanical, photocopying, recording or otherwise) without the prior written
permission of the copyright owner.
Applications for reproduction should be made in writing to:
The Office of Public Sector Information, Information Policy Team,
Kew, Richmond, Surrey TW9 4DU or e-mail: licensing@opsi.gov.uk
This guidance is issued by the Health and Safety Executive. Following the guidance
is not compulsory and you are free to take other action. But if you do follow the
guidance you will normally be doing enough to comply with the law. Health and
safety inspectors seek to secure compliance with the law and may refer to this
guidance as illustrating good practice.
Health and Safety
Executive
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Contents
Introduction 4
Scope and application 4
Site electrical supplies 4
Area and building zoning/categorisation 6
Selection of electrical equipment 7
Siting of electrical equipment 9
Earthing 10
Lightning protection 10
Static electricity 11
Radio frequency ignition hazards 11
Portable electrical equipment 12
Fork lift and other trucks 12
Heating appliances 15
Wiring systems 16
Maintenance and testing of electrical systems and equipment 16
References 16
Appendix 1: Protection standards for explosives buildings 19
Further information 20
Health and Safety
Executive
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Introduction
1 The purpose of this publication is to assist those people who are responsible
for the design, selection, installation, operation and maintenance of electrical
systems and equipment (including mobile mechanical handling equipment) used
within premises which manufacture, handle or store explosives. The advice given
is generally consistent with current guidance issued by the Ministry of Defences
Explosives and Storage and Transport Committee for military facilities.
2 To assist the reader, buildings and locations used for the manufacture, handling
and storage of explosives will be referred to in the rest of this document as
explosives buildings.
Scope and application
3 Previous draft guidance,
1
in widespread use in the industry, is now out of date.
This publication is intended to rectify that through practical, broad-based advice. It
applies only to premises which manufacture, handle and store explosive materials,
either above or below ground level. Its advice is not relevant to administration,
workshop, or other buildings within the perimeter of an explosives area when there
is no likelihood of explosives being present in those buildings. However, electrical
installations and equipment for all these facilities should conform to accepted
standards, eg BS 7671
2
(formerly the IEE Wiring Regulations), or its equivalent
European standard.
Site electrical supplies
4 On-site electrical supplies are normally either overhead or underground
distribution systems but are occasionally a combination of both. For new
installations, underground systems are the preferred option.
Overhead line systems
5 Where overhead line systems are used, their design should conform to the
requirements set out in the Electricity Supply Regulations 1988. In these locations,
lines are likely to operate at 33 000 volts and below. The minimum ground clearance
for the lowest conductor at maximum temperature should be not less than:
(a) 5.8 metres at any point where there is access for vehicular traffic; and
(b) 5.2 metres at any other point.
6 The Regulations also require that all points where overhead lines cross
roadways should be clearly marked, and suitable measures taken to ensure that
vehicles carrying explosive materials do not park or stop at or near these crossings.
7 Normal site distribution is at a nominal 400 volts a.c. to switch rooms in
explosives buildings with the internal supplies to explosives buildings being at a
nominal voltage not exceeding 230 volts a.c. or d.c. One point of such a supply
system should be connected to earth at source. Further guidance on earthing is to
be found in BS 7430: 1991.
3
It is recommended that appropriate precautions, such
as the use of certified Ex equipment, are taken when there is a requirement for
voltages exceeding a nominal 230 volts in explosives buildings. It is not advisable to
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provide direct access from switch rooms to the interior of explosives buildings (see
also paragraph 27).
8 Try to avoid overhead lines crossing over, or being terminated on, any
explosives building. It is recommended that they are routed so that the nearest
conductor is at least 15 metres from any explosives building, the distance being
measured perpendicular to the line and from the nearest conductor to the building.
Similarly, it is recommended that overhead lines are terminated on poles at least 15
metres away from an explosives building, with the final connection being by way of
underground cable and appropriate surge protection devices fitted.
9 Overhead lines owned and operated by electricity supply companies, the
National Grid Company, or other authorities are outside the scope of this guidance
except where they are located within the explosives site. In this case it is advisable
that they comply with the separation requirements set out in paragraphs 5 and 8.
Where the minimum height of the lowest conductor measured at the support
position is greater than 15 metres, it is recommended that the separation distance
from any explosives building is not less than this actual height value. As a general
guide the minimum separation between any overhead line and the nearest explosives
building should not be less than the required separation for a private dwelling.
Where the overhead line has strategic importance this separation distance can be
increased up to 150% of this value. However, the location of such overhead lines
and of those outside the site is a matter for agreement between the parties involved.
10 Try to route communication cables and telephone wires used in conjunction
with alarm systems underground. However, when they are located overhead, the
recommendations for power lines should be similarly applied.
Underground cable systems
11 The following are the preferred options for all new works and where facilities
are being upgraded. However, it is not advisable to lay cables underneath
explosives buildings. Cable supplies to several buildings can be safely provided
from central distribution points as long as they are located at least 15 metres from
any explosives building. There are many proprietary units on the market suitable for
this purpose, but they may need to be protected from impact with site traffic.
12 It is recommended that all cables are laid so that they are protected from
foreseeable mechanical damage. At road crossings it is advisable to lay them in
ducts or provide an equivalent level of protection. Suggested minimum depths of
burial are:
n 500 mm for cable voltages up to 1000 volts a.c;
n 800 mm for cable voltages 1000 to 33 000 volts a.c;
13 It is recommended that cables are laid on a bedding free of stones and other
sharp materials, and the backfill over the cable or protective duct or pipe is free of
stones etc and compacted. It is advisable to use plastic tape or similar to mark the
cable route with surface markers at suitable intervals.
14 It is advisable to route cables owned or operated by other authorities outside
the boundary. If this is not possible then consider routing them away from
explosives buildings and providing a separation of at least 15 metres. Where
possible, clearly mark these cable routes with appropriate cable markers and
ownership identification.
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Records
15 It is recommended that records of overhead line and underground cable routes,
including all cable joint positions, are kept at the site, including schedules of
conductor sizes, earthing resistances and other parameters. It is easiest to do this
at the time of installation when systems to record routine inspections and tests of
the distribution system can also be established and subsequently kept up to date. It
is also advisable to keep route plans of other authorities overhead lines and cables
on site for reference purposes and updating as necessary.
Area and building zoning/
categorisation
16 Before considering the appropriate electrical systems and equipment for a
particular location, it is necessary to assess the type of risks involved. The industry has
for many years adopted a classification system based on Ministry of Defence criteria:
Category A: Buildings used or which may be used to manufacture, handle or
store explosives which may give rise to atmospheres of flammable gases and
vapours, but not explosive dusts.
This category is further subdivided into zones as follows:
Zone 0: An area in which a flammable gas or vapour and air mixture is continuously
present or is present for long periods (in excess of 1000 hours per year);
Zone 1: An area in which a flammable gas or vapour and air mixture is likely to
occur during normal working operations (between 10 and 1000 hours per year);
Zone 2: An area in which a flammable gas or vapour and air mixture is not likely to
occur during normal working operations, and if it does occur it will exist only for a
short time (less than 10 hours per year).
Category B: Buildings used or which may be used to manufacture, handle or
store explosives in a form which may give rise to atmospheres of explosive dusts,
but not flammable gases and vapours.
This category is further subdivided into zones as follows:
Zone Z: An area where exposed or other explosives give rise to an atmosphere of
explosive dust either continuously or for long periods or during normal working
operations;
Zone Y: An area where exposed or other explosives do not give rise to an
atmosphere of explosive dust during normal working operations. The incidence and
quantities of explosive dust which arise are considered insignificant.
Category C: Buildings used or which may be used to manufacture, handle or
store explosives which do not give rise to any atmosphere of either flammable
gases, vapours or explosive dusts.
Examples of Category C buildings are explosives magazines at mines, quarries and
construction sites where only packaged water-based gels and slurry explosives in
closed boxes are held. However, it is the responsibility of the occupier to assess
the categorisation, building by building.
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17 There are locations not included in this categorisation system where the
process gives rise to atmospheres which are a combination of flammable gases or
vapours and explosive dusts. These locations need to be clearly identified and dealt
with in accordance with paragraphs 19-26 of this guidance.
18 When buildings are categorised, it is important to consider the likely changes in
the use of the building. It is sensible to specify electrical installation and equipment
suitable for the most onerous category, so that a change of process within the
building can be made at short notice without the need for extensive modifications.
It is recommended that the category for the building is displayed clearly on an
appropriate sign positioned outside and close to the building entrance. It is also
advisable to place a further sign at entrances to areas within the building of a
different category to that displayed at the building entrance, and to keep records
and details of the decisions made for each building for future reference.
Selection of electrical equipment
Category A buildings
19 Where it is necessary to install or use electrical equipment within the zoned
areas, it is strongly recommended that the guidance given in BS 5345
4
is followed.
It is therefore advisable to base the selection of equipment on Table 1 below:
20 BS 7671
2
may be used as a guide to the design of the fixed wiring within these
buildings. It is strongly recommended that the installation is in accordance with the
requirements of the appropriate part of BS 5345.
4
Category B buildings
21 Where it is necessary to install or use electrical equipment within the zoned
areas, it is advisable to follow the guidance given in BS 6467.5 In general terms
the selection of equipment for the appropriate zone is based on Table 2 below:
22 Again, BS 7671
2
may be used as a design guide for the fixed installation in
these areas provided that the actual installation meets the requirements of BS 6467.
5
Table 1: Category A buildings: Selection of equipment and systems according
to zone
Zone Type of protection Part of
BS 5345
4
0 ia intrinsically-safe equipment or system
s special protection (specially certifed for use in Zone 0)
4
8
1 Any explosion protection suitable for Zone 0 and:
d fammable enclosure
ib intrinsically-safe equipment or system
p pressurisation, continuous dilution and pressurised rooms
e increased safety
s special protection
3
4
5
6
8
2 Any explosion protection suitable for Zones 0 or 1 and N
non-sparking type protection N
o oil-immersion and q sand-flled
7
9
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Equipment certified as conforming to a harmonised European standard is provided
with the Ex Distinctive Community Mark. Some equipment (d, ia/ib, s) may
be divided according to the nature of the explosive atmosphere present. These
divisions are given in EN 50014
16
as IIA, IIB and IIC.
Note: These divisions are not to be confused with explosives building categories
A, B and C.
Table 2: Category B buildings: Selection of equipment and system according
to zone
Zone Type of protection Part of
BS 6467
5
Z Dust-tight, ie not less than IP 6X* 2
Y Any equipment suitable for Zone Z and dust-protected,
ie not less than IP 5X* 2
*Note: The recommended values of IP rating (BS EN 60529
19
) are at least IP 65 and
IP 54 respectively.
Category C buildings
23 Electrical equipment for use in Category C buildings is that which is suitable for
Category A buildings, Zones 0, 1 and 2, Category B buildings, Zones Z and Y, or
dust-protected equipment to a level of not less than IP 44. Design, construction and
other detailed requirements can be found in BS 6467
5
, BS 6941
8
and BS 4533,
section 102.51.
18
Protection against a normal risk of impact damage is recommended.
The use of plastic enclosures, including windows which are flame retardant, is
recommended with any transparent parts being positively secured to the main
enclosure (see BS 2782: Part 1 Method 140A:1992,
20
material classification FH-1).
Buildings with both flammable gas and explosive dust atmospheres
24 Where it is necessary to install electrical equipment in these combination
atmospheres, the two hazards ought to be considered separately so that the
enclosure needs can meet both requirements. Refer to BS 7535:1992 Guide to the
use of electrical apparatus complying with BS 5501 or BS 6941 in the presence
of flammable dusts,
6
which covers both hazards. However, this can only be part
of the preventive measures; where the dust is explosive, excellent housekeeping
is essential so that the quantities of free dust present can be kept to a minimum.
Guidance can be found in BS 5345, part 5.
4
Surface temperature limits for electrical equipment
25 It is important that all electrical equipment for use in the above categories of
buildings does not exceed the following surface temperature limits when in use:
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Category of building maximum surface temperature limit
Category of building Maximum surface temperature limit
A 100
o
C ( T5 )
B 100
o
C ( T5 )
C 135
o
C ( T4 )
Socket-outlets
26 It is recommended that socket-outlets are only provided where absolutely
necessary and then only in Category B, Zone Y, and Category C buildings. In Zone Y
it is preferable to use a type incorporating an interlock or integral switching device
which prevents them being connected and disconnected when live. In Category C
buildings, socket-outlets complying with BS 4343
25
fitted with spring-loaded covers
are suitable. Where non-standard supplies are to be provided, it is advisable to use
socket-outlets of a distinctive and different design to those used for conventional
supplies.
Siting of electrical equipment
27 Wherever possible, it is recommended that electrical equipment is sited in safe
areas, and installations within any Category A or B building are confined to that
equipment which is essential for production purposes. Where this is necessary,
conformity with the relevant standards is recommended. It is inadvisable to site
switchgear and distribution boards inside a room containing explosives.
28 Where electrical equipment is sited on the outside of buildings, appropriate
weather protection should be provided that includes adequate ventilation or heating
to prevent condensation.
29 It is advisable to have a master switch outside each building that is capable of
disconnecting and isolating all phase and neutral conductors entering that building.
All such switches should be clearly identified. It is recommended that indicator lights
are fitted to show that the supply is energised with a duplicate light adjacent to the
particular master switch for that supply.
Generating plant
30 Care should be taken when siting buildings which could endanger any
explosives building, eg a high-voltage substation, or a standby generation complex.
It is advisable to site all generating plant and associated equipment operating in
excess of 400 volts a.c. at least 45 metres from any explosives building.
31 It is recommended that other generating plant etc operating at less than
400 volts a.c. and completely housed in a building or structure which will provide
containment in the event of any fault is sited at least 10 metres from an explosives
building. In some cases it may be necessary to increase these separation distances
to protect the generating plant from the explosives risk.
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High-voltage transformers and switchgear
32 It is advisable to separate both high-voltage transformers and switchgear from
explosives buildings by at least 45 metres and more if the plant is endangered
by the explosion risk. In many cases these units will contain insulating oil which
is flammable. It is recommended that a sump filled with gravel or shingle is
provided so that in the event of any leakage the insulating oil can drain into it.
This sump should be sealed to prevent contamination of the surrounding ground
or water courses. It is recommended that the sump is at least 45 metres from
other buildings and that its volume exceeds the total oil volume of the plant to be
protected by at least 10%.
Earthing
33 All main structural metalwork in and on explosives buildings, the lightning and
the antistatic protection systems should be connected to a common system of
earthing and equipotential bonding. It is recommended that the earthing installation
meets the requirements of BS 7430
3
and also BS 7671,
2
where protection against
shock from electrical equipment is necessary, the resistance of the system to
earth being the lowest to comply with the requirements of any one of the systems
involved. The lightning protection, equipotential bonding and antistatic protection
systems should be connected together at the main earthing terminal of the
electrical installation.
34 Metallic enclosures of all electrical switchgear, starters, motors and other
electrical appliances should be earthed via an earth continuity conductor. Metallic
cable sheaths or armouring, metal projections through walls, for example conduit,
pipes, rails, guides etc, should be bonded at their point of entry to buildings to
the nearest part of the lightning protection system above the test point. Where
such metalwork has straight sections in excess of 15 metres long it is advisable to
provide bonding at each end. It is not necessary to bond metal window frames,
small ventilators and other small metal fittings which are less than two metres long,
provided they are more than 0.3 metres from a lightning conductor. The use of
metal service pipes as earth electrodes is not recommended.

Lightning protection
35 Explosives legislation requires that all magazines are provided with lightning
protection, unless specifically exempted by the licence. The provision of lightning
protection should be based on the requirements set out in BS 6651.
9
It is important
that provision is made to gain access to earth electrodes for testing purposes. This
is readily achieved by using pre-formed earth pits.
36 All metallic reinforcement, crane and railway rails which enter explosives
buildings should be bonded to the nearest point of the lightning protection system.
37 Steel framed structures with metallic cladding may be regarded as self-protecting
provided the individual earth resistance of each stanchion, in a stand alone
condition, does not exceed ten ohms. The metallic cladding should be bonded
to the structure. This may be achieved by the use of suitable metal fixings. Where
these conditions cannot be met, a ring electrode should be installed to connect all
stanchions together and appropriate measures taken to bond the metallic cladding
to the structure.
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Static electricity
38 Static electricity is created by two dissimilar materials being brought together
and then being separated, carrying equal and opposite charges. Conducting
objects may become charged by induction from another charged object or objects
in the vicinity. Objects can also be charged by direct transfer from another charged
object or as a result of a stream of ions striking them. People are objects in this
context and can be charged by the above processes.
39 Certain explosives are sensitive to electrostatic discharges, and these are
sub-categorised in BS 5958 Parts 1 and 2
10
into two groups according to their
minimum ignition energy levels:
n Sensitive materials - those materials with ignition energies 1 mJ - 450 mJ;
n Very sensitive materials - those materials with ignition energies < 1 mJ.
Examples of explosives which are very sensitive to static electricity include:
n all initiatory compositions;
n most Electro Explosive Devices (EEDs);
n pyrotechnic delay compositions (gasless) based on boron as fuel and lead
dioxide, chromium, bismuth and molybdenum trioxides as oxidant;
n pyrotechnic igniter and primary compositions based on either zirconium as fuel,
with molybdenum and chromium trioxides as oxidant, and/or magnesium as
fuel with tungsten trioxide as oxidant;
n pyrotechnic flame compositions based on titanium as fuel.
40 When handling explosives substances or articles which are either sensitive or
very sensitive to electrostatic discharges, certain electrostatic safeguards are
necessary to prevent accumulations of static electrical charges. Guidance on the
control of undesirable static electricity is given in BS 5958 Parts 1 and 2.
10

Particular advice relevant to the above types of materials is contained in Part 2.
41 It is important that where antistatic or conducting floors are used, the advice of
the floor manufacturer is followed; incorrect cleaning techniques and polishes can
adversely affect the conducting properties of the flooring. The use of such flooring
also means that additional care should be exercised with maintenance and other
work on electrical equipment, since it increases the risk of electrocution.
42 Where staff are required to wear conducting footwear and low resistivity clothing,
training in the correct care of such clothing is usually advised by the manufacturer.
43 It is important that pipework which is bonded to earth is continuous and that
sections are not isolated due to the use of PTFE or similar insulating thread sealing
tape. Where such tape is used, it is advisable to individually bond all sections of
pipework, valves etc.
44 It is recommended that Personal Monitoring Devices with clear operating
instructions alongside are installed at the entrances to buildings where conducting
floors and conducting shoes are used.
Radio frequency ignition hazards
45 There are circumstances where radio-frequency energy emitted from radio
transmitters and other transmitting devices can be collected by pipework or
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other metal structures acting as aerials. This energy can be released as an
incendive spark when either the aerial system is broken or contact is made
with it. Alternatively, the signal strengths may be sufficient either individually or
in combination to activate electro-explosive devices. Guidance on dealing with
these matters is set out in two British Standards: BS 6656 Guide to prevention of
inadvertent ignition of flammable atmospheres by radio-frequency radiation
11
and
BS 6657 Guide to prevention of inadvertent initiation of electro-explosive devices by
radio-frequency radiation.
12
46 It is important to consider all potential sources of radio-frequency radiation
including all forms of portable communications equipment. This is a separate
consideration to the possible ignition sources arising from the batteries and circuitry
of such equipment.
47 The use of fixed communication systems, suitable for the particular areas
concerned, which provide for two-way communication is preferred so that the
carrying and use of portable units becomes unnecessary. Where personal
communications equipment (such as bleepers, pagers, cellphones) have to be
used, an assessment of the risks posed by the transmission characteristics of the
equipment should be made. It is recommended that a safety margin of at least
12dB below the no fire hazard threshold of the most sensitive device present is
applied. A similar assessment of radio communications equipment used by security,
emergency and other similar services should be carried out.
48 Concern has been expressed about vehicles fitted with CB radios or similar
devices being admitted to plants. The best advice is that where such vehicles
require access, the communications system should be rendered inoperable before
the vehicle is allowed on site.
Portable electrical equipment
49 Portable electrical equipment can be readily divided into two groups:
n Mains powered equipment, (kettles, heaters, radios etc); and
n Battery operated equipment (torches, hand lamps etc).
50 Mains powered equipment should not be used in any Category A building nor
in a Category B building, Zone Z, unless the building is cleared of all explosives
and hazardous materials. Where mains-powered equipment is used elsewhere, the
equipment should be suitable for the environment including, where appropriate,
means to prevent dust entering. Guidance can be found in Selection of electrical
equipment (see paragraph 23).
51 Battery-operated equipment should only be used in Category B, Zone Y, and
Category C buildings. Batteries should not be charged or changed in these areas.
Electrical equipment should never be left unattended when connected to a supply.
Fork lift and other trucks
52 The following advice recommends measures to be applied in addition to those
mentioned in Selection of electrical equipment. The surface temperature limitations
specified for electrical equipment elsewhere in this guidance apply equally to
mechanical items such as transmissions, brakes and exhaust systems of lift trucks
unless stated otherwise.
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53 It is recommended that antistatic precautions are considered for the road
wheels and drive belts of all trucks. They can be found in BS 2050:1978.
13
Battery-operated trucks
54 Note the following points:
n It is advisable to use a secure battery connector which is designed to prevent
inadvertent separation, or alternatively the connector should be electrically
interlocked with the battery supply;
n An accessible switch which is capable of fully isolating the battery under full
load conditions and a safety (dead mans) device should also be fitted;
n It is recommended that wiring is preferably double pole, ie the return insulated
from the chassis, and double pole switching of traction circuits is provided;
n It is recommended that all cabling which is external to the truck structure has
stranded copper conductors. It is also advisable to fit bonding between
electrical enclosures and the truck chassis. Flexible battery connections are
recommended which also comply with at least the requirements of
BS 638 Part 4:1979.
14
Diesel engined trucks
55 If cold starting fluid for diesel engined trucks is to be used, the provision of a
permanent installation which injects the fluid downstream of the inlet flame arrestor
is recommended.
Note: Petrol or LPG driven trucks are not considered suitable for operation inside any
explosives buildings due to the increased risk from the use of spark ignition engines.
Use in Category A buildings

Zone 1

56 It is strongly recommended that battery-operated trucks are certified to at least
BASEEFA standard SFA 3006:1981.
15
Note: It is inadvisable to use diesel engined trucks due to the potential danger of
induction of a flammable atmosphere into the engine air intake.
Zone 2
Battery-operated and diesel engine powered trucks
57 Note the following points:
n It is not advisable to use light alloy metals in the construction of handling
equipment such as forks, or to use materials based on light alloy powders to
paint it because of the risk of ignition due to frictional sparking.
n Compliance with clauses 4.1 and 4.2 of BASEEFA standard SFA 3006:1981
15

is recommended for the battery and its container as is the fitting of a suitable
temperature sensor to equipment which is liable to exceed the maximum
permitted temperature due to short-term loading. Such sensors may disconnect
the component automatically or provide the operator with a warning.
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58 It is recommended that electrical equipment, including cables, is selected and
installed to comply with the requirements of BS 5345 Part 1:1989.
4
However,
enclosures meeting both the following requirements for restricted breathing, ie
where the risk of an external explosive atmosphere being drawn into the enclosure
is minimised, may also be used:
n if, after pressurisation to 300 mm water gauge, the internal pressure is at least
150 mm water gauge after 30 seconds; and
n if, after evacuation to 200 mm water gauge, the internal vacuum is at least
100 mm water gauge after 30 seconds.
Diesel engine powered trucks
59 Note the following points:
n The use of double pole wiring and isolation is recommended. It is recommended
that the maximum surface temperature of the exhaust system and its emissions
does not exceed 200C; it may be necessary to fit a water-cooled manifold and
heat exchanger to achieve this.
n In the event of overspeed, excess coolant or exhaust temperature, or
low lubricating oil pressure, it is advisable for the engine to be shut down
automatically using a device with a manual reset facility on fault clearance.
n The following measures are recommended:
Use of a dry air filter and a flame trap in the air intake system;
Testing of the exhaust system including its spark arrestor and upstream
flame-trap to withstand an internal pressure of 10 bar for one minute; and
Testing to ensure the prevention of the passage of flame.
Use in Category B buildings

Zone Z

60 Note the following points:
n It is not advisable for handling equipment such as forks to be constructed from
light alloy metals and to be painted using paints based on light alloy powders;
n It is advisable to fit a suitable temperature sensor to equipment which may
exceed the highest permitted temperature (100C) due to short-term loading, to
automatically disconnect the component or warn the operator;
n Compliance with the requirements of clauses 4.1 and 4.2 of BASEEFA standard
SFA 3006:1981
15
is recommended for batteries and their containers;
n It is advisable to apply the mechanical testing specified for high-risk locations
in EN 50014
16
(BS 5501
7
Part 1) clause 22.4.3 and Annex B to electrical
enclosures and cable entries. Clause 19 of BS 5345 Part 1 :1989
4
applicable
to use in Zone 1 gives recommendations for cabling;
n Clause 1.1 of BASEEFA standard SFA 3006:1981
15
gives recommendations for
electrical leakage to frame protection.
Zone Y

61 It is recommended that:
n the maximum surface temperature of equipment does not normally exceed
100C, or 135C if an assessment of the associated risk permits it;
n electrical enclosures and cable entries are designed to withstand the
mechanical testing specified for low-risk locations in EN 50014
16
(BS 5501
7
,
Part 1) clause 22.4.3 and Annex B;
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n batteries are housed in a robust, ventilated container with an internal insulating
liner and lockable cover and the intercell connections are fully insulated;
n the truck cabling complies with the requirements of clause 19 of BS 5345 Part
1:1989,
4
applicable to use in Zone 2.
Note: The use of diesel engined trucks is not recommended for use in Category B
buildings (see paragraph 55).
Use in Category C buildings

Battery-operated and diesel engine powered trucks

62 It is recommended that:
n the surface temperature of internal components of equipment does not exceed
400C and external exposed surfaces do not exceed 135C;
n the requirements for batteries are as previously specified for Category B, Zone
Y, buildings (see paragraph 61);
n electrical enclosures are designed to withstand the impact test specified in
clause 4.4 of BS 6467 Part 1:1985,
17
access being by the use of keys or tools;
n cable sheaths are resistant to diesel oils, lubricating oils, hydraulic fluids and
electrolytic fluids.
63 It is recommended that:
n single pole wiring (ie the return connected to the chassis) and isolation are used
provided a suitably rated main fuse is fitted close to the battery;
n the air inlet has a dry filter and, if a cold start device which ignites fuel in the
inlet is provided, a flame trap fitted between the inlet and the device;
n the exhaust system is fitted with a spark arrestor and emissions do not exceed
200C.
Requirements for road vehicles brought into a Category C building
to be loaded or unloaded
64 It is advisable to inspect the vehicle exhaust system to ensure it is in good
condition before it is allowed to go beyond the entrance or designated loading
bay. It is recommended that the engine is stopped during loading or unloading
operations.
Heating appliances
65 Note the following points:
n It is recommended that all heating appliances are permanently installed, and
portable heaters are not used;
n Unless electrically heated water-filled radiators carry suitable third party
certification to demonstrate a limitation of their maximum surface temperature
to T6, they should be fitted with a latching thermal cut-out to ensure their
hottest part does not exceed 85C. To prevent physical contact it may also
be necessary to either provide a suitable guard or locate the radiator in an
inaccessible position;
n It is advisable for heating units for explosives to be fitted with tamperproof
controls and a clear indication showing when they are energised;
The selection, installation and maintenance of electrical equipment for use in and around buildings containing explosives Page 16 of 20
Health and Safety
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n The use of electrically heated air re-circulating systems is not recommended
in Category A or B buildings or in heating appliances which contain exposed
explosives. It is inadvisable to use electrically heated floors.
Wiring systems
66 It is recommended that:
n the types of cable and cabling/conduit-systems to be used in explosives
buildings are as detailed in the relevant parts of BS 5345.
4
Cables with a single
strand conductor are not to be used;
n in conduit and trunking systems, power cables comply with BS 6007
21
or
BS 6004,
22
the conductor cross-sectional area being at least 1.5 mm
2
.
Communications and alarm systems cables meet BS 6500
23
and have
conductor cross-sectional areas of at least 0.35 mm
2
;
n black enamel conduit and metallic trunking are used only in Category C areas;
running couplers are not used in Category A and B areas; and the use of
flexible conduit is kept to a minimum;
n rigid PVC conduit complying with BS 4607
24
and non-metallic trunking may be
used in Category C areas, any earth continuity conductors being enclosed
throughout.
Maintenance and testing of
electrical systems and equipment
67 It is necessary to maintain all systems and equipment periodically to ensure that
they remain in a safe condition for use. This requires visual inspections of systems
and equipment accompanied in some cases by testing to verify, for example, the
integrity of insulation and earth paths. The precise nature of such inspections needs
to be set out by the management for the area concerned, taking account of the
environment and the likely use and abuse of systems and equipment etc.
68 It is advisable to set out the testing requirements in detail for each area or
building. The precise nature of tests should reflect the needs of the types of
system and equipment involved. Records of inspections and tests are useful in
showing such matters as trends of deterioration and for establishing appropriate
renewal or refurbishment policies.
69 BS 7671
2
sets out requirements for the initial verification of fixed installations
and subsequent periodic testing. There is also additional guidance on inspection
and testing available from the Institution of Electrical Engineers and in the relevant
parts of BS 5345.
4
Other guidance may be found in BS 7430
3
and BS 6651
9
in
relation to earthing and lightning protection respectively.
References
1 Guidance on the selection, installation and maintenance of electrical apparatus
for use in buildings containing explosives (Draft) HSE XI/6015/4/8A Feb 1988
(no longer available)
2 BS 7671:1992 Requirements for electrical installations IEE Wiring Regulations
(16th edition)
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3 BS 7430:1991 Code of practice for earthing
4 BS 5345: Part 1:1989 Code of practice for selection, installation and
maintenance of electrical apparatus for use in potentially explosive atmospheres:
General recommendations

5 BS 6467: Part 2:1988 Electrical apparatus with protection by enclosure for use
in the presence of combustible dusts: Guide to selection, installation and maintenance
6 BS 7535: 1992 Guide to the use of electrical apparatus complying with BS
5501 or BS 6941 in the presence of combustible dusts
7 BS 5501: Part 1: 1977 Electrical apparatus for potentially explosive
atmospheres: General requirements
8 BS 6941: 1988 Specification for electrical apparatus for explosive atmospheres
with type of protection N
9 BS 6651: 1992 Code of practice for protection of structures against lightning
10 BS 5958: Part 1: 1991 Code of practice for control of undesirable static
electricity: General considerations. BS 5958: Part 2: 1991 Control of undesirable
static electricity: Recommendations for particular industrial situations
11 BS 6656: 1991 Guide to prevention of inadvertent ignition of flammable
atmospheres by radio-frequency radiation
12 BS 6657: 1991 Guide to prevention of inadvertent initiation of electro-explosive
devices by radio-frequency radiation
13 BS 2050: 1978 Specification for electrical resistance of conducting and
antistatic products made from flexible polymeric material
14 BS638: Part 4: 1979 Arc welding power sources, equipment and accessories:
Specification for welding cables
15 SFA 3006: 1981 Battery operated vehicles
16 EN 50014: 1992 Electrical apparatus for potentially explosive atmospheres:
General requirements
17 BS 6467: Part1:1985 Electrical apparatus with protection by enclosure for use
in the presence of combustible dusts: Specification for apparatus
18 BS 4533: Part 102: Section 102.51: 1986 Specification for luminaires with type
of protection N
19 BS EN 60529: 1992 Specification for degrees of protection provided by
enclosures (IP code)
20 BS 2782: Part 1: Method 140A:1992 Determination of the burning behaviour of
horizontal and vertical specimens in contact with a small flame ignition source
21 BS 6007: 1993 Specification for rubber-insulated cables for electric power and
lighting
22 BS 6004: 1995 Specification for PVC-insulated cables (non-armoured) for
electric power and lighting
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23 BS 6500: 1994 Specification for insulated flexible cords and cables
24 BS 4607 Non-metallic conduits and fittings for electrical installations (Four parts)
25 BS 4343: 1992 Plugs, socket-outlets and couplers for industrial purposes
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Does the
explosive
sublime?
Does the
explosive produce
flammable
vapour?
Is the flammable
atmosphere
present for long
periods or
continuously?
Is the flammable
atmosphere likely
to occur during
normal operation?
Flammable
atmosphere is
unlikely to occur in
normal operation.
If it does occur it
will exist for only a
short time.
Does explosive
give rise to
significant
amounts of dust?
Incidence and
amount of dust
is judged to be
insignificant.
Is the
explosive
exposed?
The explosive
does not emit
dust, flammable
vapours or gas.
Special requirements to be advised by
explosives chemists. NO electrical
installation or equipment unless vital.
If vital use Ex.p or Cat. B, Zone Z
specifications, temp class to suit
substance in process; T5 maximum.
CATEGORY A, ZONE 0.
No electrical installations, or equipment
unless vital. If vital use Ex.ia, Temp
class to suit substance in process;
T5 maximum.
CATEGORY A, ZONE 1.
Use BS 5345: Part 1:1989, Table 2
Zone 1, Temperature Class T5.
CATEGORY A, ZONE 2.
Use BS 5345: Part 1:1989, Table 2
Zone 2, Temperature Class T5.
CATEGORY B, ZONE Z.
Installations and equipment are to
comply with paragraphs 21 and 22 of
this leaflet, temperature Class T5
maximum.
CATEGORY B, ZONE Y.
Installations and equipment are to
comply with paragraphs 21 and 22 of
this leaflet, temperature Class T5
maximum.
CATEGORY C.
Installations and equipment are to
comply with paragraph 23, temperature
Class T4 maximum.
YES
YES
YES
YES
YES
YES
NO
NO
NO
NO
NO
NO
Appendix 1: Protection standards
for explosives buildings
Further information
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HSE priced and free publications can be viewed online or ordered from
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Published by HSE 04/10 Page 20 of 20
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