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Electrical Safety

Hazardous Area Ex Installation and Inspection Compliance

We verify that the equipment installed in your classified areas matches the classification, carries the right certification and has been installed and maintained to the standard its protection concept requires

Technical overview

Hazardous Area Ex Installation
and Inspection Compliance

Hazardous area classification decides where the zones are. This is the separate and often neglected question of whether the equipment standing in those zones is actually suitable for them, correctly installed and still compliant. Our work runs the IEC 60079 14 installation verification and the IEC 60079 17 inspection regime across the classified areas, checking equipment group, temperature class and protection concept against the zone and the material present, verifying that certification is valid and that any conditions of certification have been met, and examining the installation detail that the protection concept depends on. For flameproof equipment that means flame path condition, gap and fastener integrity. For increased safety it means terminal condition and ingress protection. For intrinsic safety it means the loop calculation, the barrier and the segregation of the wiring. The findings that recur are the ones that come from ordinary maintenance rather than from design: a cable gland substituted for a non certified equivalent, a flameproof cover refitted with the wrong bolts, an IS loop extended without recalculating.

Hazardous Area Ex Installation and Inspection Compliance Overview
Engineering process

Hazardous Area Ex Installation and Inspection Compliance workflow

Documentation Review

Review the single line diagram, the statutory approvals, the test and calibration records and the previous audit closure status.

Statutory Compliance Mapping

Map the installation against the CEA Regulations, the state factory rules and the applicable Indian Standards, clause by clause.

Field Inspection and Measurement

Walk down substations, switchrooms, cable galleries and field distribution, with thermography, earth resistance and insulation measurement.

Protection and Interlock Checks

Verify relay settings against the coordination study, and test interlocks, earthing switches and safety interlocking on their proving.

Risk Ranking of Findings

Rank each non conformance on consequence and exposure rather than on clause number, so remedial spend follows the hazard.

Report and Closure Support

Issue the statutory format report with a prioritised action register, and support closure evidence for the inspecting authority.

Hazardous Area Ex Installation and Inspection Compliance Scope
Scope of work

Every deliverable from basis to handover

Complete Hazardous Area Ex Installation and Inspection Compliance scope covering every calculation, drawing, specification, and construction support activity.

We check equipment group, temperature class and protection concept against the zone and the material actually present
We verify certification validity and that the conditions of certification, the X marking, have been complied with
We inspect flameproof enclosures for flame path condition, gap and fastener integrity rather than only for a certificate
We check increased safety equipment for terminal condition, creepage and ingress protection
We recalculate intrinsic safety loops where they have been extended or modified since commissioning
We examine cable glanding and sealing, which is where non certified substitution most often appears
We assess earthing and bonding within the classified area to IEC 60079 14
We set the inspection grade and interval to IEC 60079 17, covering initial, periodic and sample regimes
We check repair history against IEC 60079 19, since an uncertified repair voids the protection concept
Engineering outcomes

Outcomes of Hazardous Area Ex Installation and Inspection Compliance

Ignition Source Control
  • We remove the ignition sources standing inside a classified area
  • We find the uncertified substitutions maintenance introduced
  • We verify intrinsic safety loops still hold after modification
  • We confirm the protection concept is intact, not just certified once
Ex Compliance Evidence
  • We verify installation to IEC 60079 14
  • We set the inspection regime to IEC 60079 17
  • We support PESO requirements for Indian installations
  • We produce the equipment register a DSEAR or ATEX position requires
Ex Asset Management
  • We build the hazardous area equipment register most sites lack
  • We define an inspection grade and interval that is actually workable
  • We identify repairs that void certification
  • We connect the register to the maintenance system
Ex Replacement Targeting
  • We avoid wholesale equipment replacement where inspection shows compliance
  • We prevent the cost of an uncertified repair being discovered late
  • We reduce the outage risk a non compliant installation carries
  • We concentrate replacement on the equipment that genuinely fails
Standards & references

Codes & standards we work to

IEC 60079 14 (electrical installations design, selection and erection)IEC 60079 17 (electrical installations inspection and maintenance)IEC 60079 19 (equipment repair, overhaul and reclamation)IEC 60079 0 (equipment general requirements)IEC 60079 10 1 and 10 2 (area classification, gas and dust)IS 5571 (selection of electrical equipment for hazardous areas)IS 5572 (classification of hazardous areas)PESO approval requirements (India)ATEX Directive 2014 34 EU and Workplace Directive 1999 92 EC (DSEAR)NFPA 70 NEC Articles 500 to 506
When to engage

Triggers that signal the need

No hazardous area equipment register existsA hazardous area classification study has been revised and the equipment not recheckedPESO, DSEAR or ATEX compliance being questionedMaintenance driven substitution suspected in the fieldAn ignition source investigation following a near missPlant modification or expansion into a classified area
Industries served

Where Hazardous Area Ex Installation and Inspection Compliance applies

Oil & Gas, Upstream
UpstreamOffshoreFPSO
Refineries & Petrochemicals
RefiningPetrochemical
LNG & Gas Processing
LNGCryogenic
Specialty Chemicals
ReactiveBatch
Power Generation
PowerHydrogen
Pharma & Food
PharmaFood & Bev
What we deliver

Tangible deliverables

  • Hazardous area equipment register with group, temperature class and protection concept
  • Certification validity and conditions of certification review
  • Installation verification report to IEC 60079 14
  • Inspection grade and interval schedule to IEC 60079 17
  • Non conformance register ranked on ignition risk
  • Intrinsic safety loop calculations for modified circuits
  • Repair and overhaul compliance review against IEC 60079 19
  • Remedial specification and replacement priority list
Get Started

Send us the scope

We will scope Hazardous Area Ex Installation and Inspection Compliance against your site and come back with what it would take. Send us the process conditions, the equipment list and the stage the design has reached.