PESO Approval for Flameproof Lighting: Complete Manufacturer Guide

• PESO Approval for Flameproof Lighting by PESO is needed for the electrical equipment to be used in hazardous area applications covered by the relevant petroleum safety standards.
• PESO tests the Ex electrical equipment depending on the type of protection, design of the equipment, and the documentation.
• The manufacturer is expected to determine the relevant standard, acquire the necessary test documentation, and then make the technical application.

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Introduction

Although a lighting manufacturer may develop an industrially good LED lighting, this does not imply its suitability for usage in a hazardous manufacturing industry.

Take the case of a chemical manufacturing plant with solvents, vapours, or flammable substances being processed. An ordinary industrial light will become a hazard when the ignition source enters a place with flammable vapour.

In such a case, the need for flameproof lighting arises.

For manufacturers, the challenge of developing a flameproof light is not all there is. In cases where the equipment is meant for use in hazardous areas governed by the Petroleum Rules, 2002, the equipment may need to get approval from the Chief Controller of Explosives through PESO. The guidelines provided by PESO are specific on the issue of Ex electrical equipment in hazardous areas.

It means that the following three things will be connected:

Product Design + Testing + Approval

A manufacturer that appreciates the above will be able to escape a common mistake of developing the product and then realizing that the test results, drawings, and the configuration of the product cannot fit in the proposed PESO application.

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What Is PESO Approval for Flameproof Lighting?

Flameproof Lighting PESO Approval is the type of PESO approval required for electrical equipment such as flameproof lights to be used in areas where petroleum safety rules apply.

PESO (Petroleum and Explosives Safety Organisation) functions as a part of the Department for Promotion of Industry and Internal Trade, Ministry of Commerce and Industry and is responsible for examining and approving flameproof, intrinsically safe and other types of electrical equipment to be used in hazardous areas with flammable gases/vapours.

Approval is required according to the Petroleum Rules for any equipment used in designated hazardous areas with petroleum products. PESO’s instructions state that the hazardous areas may be divided into Zone 0, Zone 1 and Zone 2 based on the frequency and length of exposure to flammable gas or vapour.

Therefore, for a manufacturer of industrial lighting equipment, it is important to ensure that the product is not just declared as an “industrial light” for the approval procedure.

It is necessary to clarify the following details:

• Protection concept
• Intended hazardous area
• Product category
• Applicable standard
• Electrical characteristics
• Enclosure construction
• Test requirements
• Manufacturing controls
• Supporting certificates
• Technical drawings

That information forms the foundation of the approval application.

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Why Is PESO Approval Important for Flameproof Lighting?

Flameproof lights are made in such a way that any internal source of ignition will not turn into an external source of ignition.

The PESO definition of flameproof protection is “an enclosure such that any explosion occurring within the enclosure is not transmitted to the surrounding hazardous atmosphere. This becomes more important in industries dealing with flammable substances.

These include:

• Chemical manufacturing
• Petrochemical manufacturing
• Paint and coating plants
• Pharmaceutical manufacturing involving flammable solvents
• Oil and petroleum facilities
• Fuel storage areas
• Solvent handling areas
• Certain gas processing facilities

The specific hazardous area classification needs to be determined for the real installation Thus, a producer should not make general statements like “suitable for all hazardous areas”. The applicability to hazardous areas depends on the protection principle, certification, gas group, temperature classification, and installation conditions.

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What Does PESO Check in Flameproof Lighting?

PESO approval is not merely a check of whether the light switches on The technical review concerns whether the equipment is appropriately designed, tested and supported by the required documentation.

Flameproof Enclosure Design

The enclosure is central to flameproof protection.

The design may involve:

• Enclosure material
• Joint construction
• Flame paths
• Fasteners
• Cable entries
• Glass or diffuser arrangement
• Internal components
• Earthing arrangement
• Mechanical construction

Small design changes can matter.

For example, changing an enclosure component after testing may affect the configuration covered by the test documentation. Manufacturers should therefore maintain proper design control throughout the approval process.

Electrical Components

The internal electrical arrangement should correspond with the approved product design.

Depending on the lighting product, this may include:

• LED modules
• Drivers
• Terminals
• Protection devices
• Wiring
• Connectors
• Earthing components
• Control electronics

The manufacturer should maintain traceability between the tested prototype and the production model.

Cable Entries and Accessories

Cable entries are usually ignored during the design process.

The design of the entries must be consistent with the approved design and use in a hazardous area A company should never replace parts such as cable glands without verifying whether it will affect the approved design.

Classification of Hazardous Area Zones

The guide provided by PESO has classified hazardous areas into three zones.

Zone 0

A zone wherein an explosive atmosphere consisting of flammable gases or vapours is usually present all the time or for long periods.

Zone 1

An area wherein flammable gases or vapours may be normally found during the operation.

Zone 2

An area wherein flammable gases or vapours do not normally exist but may be present under abnormal circumstances for short periods.

This classification is important since different protection methods can be approved for each of the zones.

According to PESO’s FAQ page, protection using flameproof, intrinsic safety and encapsulation methods is acceptable for Zone 1, whereas non-sparking and increased-safety equipment are acceptable for Zone 2 as per the requirements Hence, it is important for the manufacturer to know the specific zone first.

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What Documents Are Required for PESO Approval for Flameproof Lighting?

The documentation depends on the product and applicable approval route. PESO’s current SOP for Ex electrical apparatus identifies important technical documents for indigenous manufacturers.

These can include:

Product and Company Information

• Manufacturer details
• Manufacturing facility information
• Product description
• Technical manpower details
• Manufacturing equipment
• Quality-control facilities

Technical Documents

• Product drawings
• Assembly drawings
• Electrical diagrams
• Technical specifications
• Product photographs where required
• Component details
• Marking details

Testing Documentation

According to the current PESO SOP, the product should have test certificate, test report and certified drawing from an Indian test laboratory accredited by the Chief Controller of Explosives or relevant IECEx documents.

The testing document should correspond to the product under evaluation.

Information on Quality and Manufacturing

The manufacturer might need to prove that he possesses necessary technical and manufacturing infrastructure.

It is vital since the approval process cannot be considered as a once-and-for-all laboratory activity. The manufacturing sample should continue corresponding to the approved one.

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Does a Flameproof Light Need BIS and PESO Approval?

The answer needs to be handled with some caution since BIS certification and PESO approval have different purposes.

According to the latest SOP of PESO, a BIS license/IECEx Quality Assurance Report or other quality surveillance documentation is not compulsory while submitting the application online for Ex Electrical apparatus.

On the other hand, the earlier FAQ of PESO made it clear that BIS license was compulsory for flame proof equipment made in India.

As per the changes in SOP by PESO regarding the required documentation, the manufacturer should check the requirement as applicable to the product and the approval sought by him.

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PESO Approval Process for Flameproof Lighting

The process should begin before the final product is commercialised.

Step 1: Identify the Product

Establish exactly what is being submitted.

For example:

• LED flameproof floodlight
• Flameproof high-bay light
• Flameproof bulkhead light
• Flameproof street light
• Flameproof emergency light
• Flameproof tube light

Each product configuration should be clearly identified.

Step 2: Identify the Purpose

• Figure out where the equipment will be used.
• A plant for chemical production, paint factory and petrochemical storage facility will all have different hazardous areas.
• This should be known by the manufacturer prior to determining the compliance path.

Step 3: Identify the Relevant Standard

The relevant Ex standard needs to be determined depending on the product and protection technique.

Step 4: Finalise the Design

Complete the engineering drawings before testing.

Important details include:

• Enclosure
• Flame paths
• Cable entries
• Glass
• Fasteners
• Electrical components
• Earthing
• Markings

A manufacturer should avoid unnecessary design changes after testing.

Step 5: Prototype Testing

Forward the prototype for testing in the appropriate recognised test facility.

Under the present SOP of PESO, documentation is accepted from a recognised test laboratory in India or IECEx Certification and relevant documentation if applicable.

Step 6: Preparation of PESO Application

Documents to be prepared:

• Application
• Test report
• Test certificate
• Certified drawing
• Manufacturing details
• Technical manpower details
• Equipment & Quality control details
• Applicable fee

Present SOP of PESO states the scrutiny fees under Petroleum Rules.

Step 7: Technical Scrutiny

PESO scrutinises the technical documents submitted by the applicant In case of any question, answer to that should be based on the technicality of the document and not just resubmission of the same document.

Step 8: Approval

When all the requirements are fulfilled, the approval is granted for the concerned Ex Electrical Apparatus PESO’s present SOP mentions that the approval would be valid till there is any change in the product standard or design.

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Common Mistakes Made by Flameproof Lighting Manufacturers

Product Alteration Following the Testing Process

The manufacturing company may make changes to the housing, LED driver, or the cable entry Such alterations could lead to a divergence between the product being tested and the approved one.

Use of Generic Drawings

A drawing must depict the real product Any dimension alteration becomes significant in case it is related to the flameproof design.

Ignores the Intended Zone

It is expected that the manufacturer knows whether the item is intended for Zone 1, Zone 2 or for some other particular purpose.

Treats IECEx Certification as the Entire Approval

The IECEx certification documentation will help make the PESO application, however, the Indian approval requirement needs to be considered separately.

Marketing Claims

Phrases like “PESO certified for all hazardous locations” could be deceiving The description of approval must be accurate to the actual approved equipment and the relevant conditions.

Documentation Control

The model number found in the test certificate, the drawings, application and product labeling must match It is one of the easiest tests that can be performed by a manufacturer before submission.

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What Industries Use PESO-Approved Flameproof Lighting?

Flameproof lighting becomes especially relevant if manufacturing or process operations may produce hazardous environments.

Chemical Manufacturing

Vapors of solvents, chemicals, and processing operations may produce hazardous areas in some production and storage operations.

Paint and Coating Manufacturing

Paints, thinners, and solvents may produce flammable vapors. Lighting fitted in such classified zones requires proper protection.

Pharmaceutical Manufacturing

Some pharmaceutical operations use flammable solvents. The classification of the hazardous area determines the type of electrical equipment.

Petroleum and Petrochemical Industry Facilities

Refineries, storage facilities, and petroleum handling operations become part of areas covered under the petroleum safety system of PESO.

Process Industries

Depending on the process and materials used, other manufacturing industries may also require special lighting.

It is important to note that the mere fact of being in a specific industry is not enough to conclude whether flameproof lighting is needed. It is the hazardous area classification of a specific facility that really counts.

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What Is the Cost of PESO Approval for Flameproof Lighting?

There is no single project cost applicable to every manufacturer.

The overall expense can depend on:

• Product type
• Number of models
• Testing requirements
• Laboratory charges
• Design complexity
• Technical documentation
• Modifications after testing
• PESO scrutiny fees
• Certification requirements
• Consultancy support

Manufacturers should also consider the cost of redesign A failed test or major design modification can cost considerably more than preparing the compliance documentation correctly at the beginning.

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How Diligence Certification Supports Flameproof Lighting Approval

In case of a flameproof lighting manufacture, it is hard when documents related to testing, drawings of products and manufacturing are done separately.

Diligence Certification can help manufacturers comprehend which PESO route is applicable for them, evaluate technical documentation, apply for approval and answer any regulatory questions.

The key thing here is to make sure that test article, technical drawing and application do not conflict with each other, thus avoiding any unnecessary mistakes in the documents.

It will be especially helpful for those manufacturers who are developing new models of flameproof lighting or adding new products to their current product line.

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Conclusion

Approvals for Flameproof Lighting from PESO is an essential regulatory stage for suppliers who offer electrical lighting equipment to be used in dangerous locations, according to India’s petroleum safety regulations.

This process needs to begin with the product itself. This involves identifying the protection principle, determining the intended application of the product in the hazardous location, completing the design of the product, conducting all necessary tests and preparing the technical documents. PESO’s current SOP outlines the procedure for approval of Ex equipment and describes the documents to be provided by manufacturers.

The message for the manufacturers of flameproof lighting is clear - do not consider PESO approval as paperwork following the product development. The strategy of approval should guide the design, testing and documentation right from the start.

In case of developing/manufacturing flameproof lighting for chemical/petroleum/paint/pharmaceutical/manufacturing industries, our service at Diligence Certification could help you with applicability, documentation, preparation of application and regulatory coordination.

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Frequently Asked Questions