IEC 60079-19 Explained: Repair, Overhaul and Reclamation of Ex Equipment

Explosion-protected equipment is often expected to operate for decades in harsh industrial environments. During its service life, however, equipment may suffer from corrosion, mechanical damage, worn components, or accidental modifications that require repair or overhaul.

Unlike ordinary industrial equipment, Ex equipment cannot simply be repaired using conventional methods. Improper repairs may compromise the explosion protection concept and create significant ignition hazards.

For this reason, the explosion protection industry relies on IEC 60079-19 – Explosive Atmospheres – Equipment Repair, Overhaul and Reclamation.

IEC 60079-19 establishes the requirements and procedures necessary to ensure that repaired or overhauled Ex equipment continues to provide the intended level of protection after maintenance activities have been completed.

The standard is widely used by repair facilities, equipment owners, maintenance organizations, inspection companies, and regulatory authorities because it provides a structured framework for preserving the integrity of explosion-protected equipment throughout its lifecycle.

This article explains what IEC 60079-19 is, why it is important, and the major requirements that engineers, inspectors, and repair organizations should understand.

Quick Answer

What Is IEC 60079-19?

IEC 60079-19 is the international standard that governs how explosion-protected equipment should be repaired, overhauled, and reclaimed during its operational life.

The standard provides requirements for organizations performing repair activities and establishes procedures intended to preserve the original explosion protection characteristics of the equipment.

The standard covers:

• Repair procedures.
• Overhaul requirements.
• Reclamation activities.
• Documentation requirements.
• Inspection and testing after repair.
• Competency requirements.
• Responsibilities of repair facilities.

IEC 60079-19 forms the final stage of the hazardous area equipment lifecycle and works closely with IEC 60079-14 and IEC 60079-17.

Why Is IEC 60079-19 Important?

Many explosion protection incidents occur after equipment has been repaired incorrectly or modified without proper engineering controls.

Examples of improper repair practices include:

• Machining flamepaths beyond allowable tolerances.
• Replacing certified components with non-approved parts.
• Drilling additional cable entries.
• Changing internal wiring arrangements.
• Using incorrect fasteners.
• Modifying equipment markings.
• Removing protective components.

Even seemingly minor modifications can invalidate certification and significantly reduce the level of explosion protection provided by the equipment.

IEC 60079-19 establishes requirements intended to prevent these situations and ensure that repaired equipment remains safe for use in hazardous areas.

Who Uses IEC 60079-19?

The standard is primarily intended for organizations responsible for repairing and maintaining explosion-protected equipment.

Typical users include:

• Equipment repair workshops.
• Motor rewind facilities.
• Maintenance contractors.
• Asset owners and operators.
• Inspection organizations.
• Third-party service providers.
• Reliability engineers.
• Regulatory authorities.

Many industries require repair facilities to demonstrate competency and documented procedures before they are permitted to repair Ex equipment.

Where Does IEC 60079-19 Fit in the Hazardous Area Lifecycle?

The hazardous area lifecycle can generally be summarized as:

1. Hazardous area classification.
2. Equipment selection.
3. Installation.
4. Inspection and maintenance.
5. Repair, overhaul, and reclamation.

IEC 60079-19 governs the final stage of this lifecycle and ensures that equipment can continue operating safely after repair activities have been completed.

What Is the Difference Between Repair, Overhaul, and Reclamation?

IEC 60079-19 distinguishes between several different maintenance activities because each activity has different technical requirements and levels of complexity.

• Repair – Restoring equipment to a fully serviceable condition while maintaining its original explosion protection characteristics.
• Overhaul – A series of actions intended to restore equipment to a satisfactory operating condition through detailed examination and replacement of worn parts.
• Reclamation – Restoring damaged components through approved techniques such as metal spraying, sleeving, or other engineering methods.

Understanding these distinctions is essential because the procedures and acceptance criteria may differ depending on the type of work being performed.

Scope of IEC 60079-19

IEC 60079-19 specifies the requirements for the repair, overhaul, reclamation, and modification of explosion-protected equipment.

The standard applies to equipment that has already been placed into service and subsequently requires maintenance activities intended to restore or preserve its explosion protection characteristics.

The requirements cover:

• Repair procedures.
• Overhaul activities.
• Reclamation techniques.
• Replacement components.
• Inspection and testing after repair.
• Documentation requirements.
• Competency requirements.
• Responsibilities of repair facilities.

The standard applies to both gas and dust explosive atmospheres and covers many different protection concepts, including Ex d, Ex e, Ex i, Ex p, and Ex t equipment.

Major Requirements of IEC 60079-19

Although IEC 60079-19 contains extensive technical requirements, the major topics generally include:

• Assessment before repair.
• Repair procedures.
• Use of replacement parts.
• Inspection and testing.
• Documentation requirements.
• Marking requirements.
• Quality management systems.
• Competency requirements.

These requirements are intended to ensure that repaired equipment continues to provide the same level of explosion protection as originally certified equipment.

Assessment Before Repair

Before any repair activity begins, the equipment should be carefully evaluated to determine:

• The extent of damage.
• The original protection concept.
• The applicable certification requirements.
• The availability of manufacturer documentation.
• The suitability of proposed repair methods.

This assessment is critical because inappropriate repair techniques may permanently compromise the explosion protection characteristics of the equipment.

Use of Manufacturer Documentation

IEC 60079-19 places significant importance on the use of original manufacturer documentation whenever possible.

Examples include:

• Certification drawings.
• Assembly drawings.
• Component lists.
• Dimensional tolerances.
• Repair instructions.
• Testing requirements.

The availability of accurate technical information greatly improves the likelihood that repairs can be completed successfully while preserving equipment certification.

Replacement Components

One of the most important principles of IEC 60079-19 is that replacement parts should not adversely affect the explosion protection characteristics of the equipment.

The standard generally requires:

• Equivalent replacement components.
• Suitable materials.
• Compatible dimensions and tolerances.
• Maintenance of temperature classifications.
• Preservation of original protection concepts.

Using incorrect components may compromise safety and can potentially invalidate equipment certification.

Requirements for Ex d Equipment

Repairs involving flameproof equipment require particular care because the integrity of flamepaths is critical to explosion containment.

Examples of items that may require evaluation include:

• Flamepath dimensions.
• Joint surfaces.
• Threaded joints.
• Fasteners.
• Corrosion damage.
• Mechanical deformation.

Unauthorized machining or modification of flamepaths is one of the most common causes of non-compliance identified during Ex equipment inspections.

Requirements for Ex e Equipment

Repairs involving Increased Safety equipment typically focus on maintaining:

• Electrical clearances.
• Creepage distances.
• Terminal integrity.
• Insulation systems.
• Temperature limitations.
• Ingress protection.

Because Ex e protection relies heavily on proper construction, even seemingly minor modifications may affect equipment safety.

Requirements for Ex i Equipment

Repairs involving intrinsically safe equipment require careful consideration because modifications may alter the energy characteristics of the equipment.

Examples include:

• Component replacement.
• Printed circuit board modifications.
• Changes to electrical parameters.
• Modifications to associated apparatus.
• Alterations to entity parameters.

Changes affecting intrinsic safety parameters generally require careful engineering evaluation and may require recertification.

Inspection and Testing After Repair

IEC 60079-19 requires repaired equipment to be inspected and, where necessary, tested before being returned to service.

Verification activities may include:

• Visual inspections.
• Dimensional inspections.
• Electrical testing.
• Continuity testing.
• Pressure testing where applicable.
• Verification of markings.
• Functional testing.

These activities help ensure that repaired equipment continues to meet the intended level of explosion protection.

Repair Documentation Requirements

Proper documentation is a fundamental requirement of IEC 60079-19.

Typical records may include:

• Equipment identification details.
• Description of defects.
• Repair procedures performed.
• Replacement parts used.
• Inspection and test results.
• Dimensional measurements.
• Name of the repair organization.
• Date of repair.

Maintaining complete repair records is essential for demonstrating compliance and supporting future maintenance activities.

Advantages of IEC 60079-19

IEC 60079-19 plays a critical role in extending the service life of explosion-protected equipment while maintaining safety in hazardous areas.

Without an internationally recognized repair standard, organizations would have no consistent methodology for restoring damaged Ex equipment or verifying that repairs have preserved the original protection concept.

Key advantages of IEC 60079-19 include:

• Provides standardized repair procedures for Ex equipment.
• Helps preserve the original explosion protection characteristics.
• Extends equipment service life.
• Reduces unnecessary equipment replacement costs.
• Improves maintenance quality and consistency.
• Provides traceability through documentation requirements.
• Supports safe return of equipment to service.
• Encourages competency and quality management within repair organizations.

For many facilities, compliance with IEC 60079-19 forms an important part of their asset integrity and process safety management systems.

Limitations of IEC 60079-19

Although IEC 60079-19 provides comprehensive guidance for Ex equipment repairs, the standard also has certain limitations.

• Repairs may require specialized knowledge and equipment.
• Manufacturer documentation may not always be available.
• Certain modifications may require recertification.
• Some damage may be beyond acceptable repair limits.
• Repair activities can be costly and time-consuming.
• Not all repair organizations possess the necessary competency.

For these reasons, organizations should carefully evaluate whether repair, replacement, or recertification is the most appropriate solution.

Competency Requirements

One of the most important principles of IEC 60079-19 is that Ex equipment should only be repaired by competent organizations and personnel.

Repair organizations should possess:

• Technical knowledge of explosion protection principles.
• Suitable repair procedures.
• Qualified personnel.
• Appropriate tools and measuring equipment.
• Access to technical documentation.
• Documented quality management procedures.

The competency of the repair organization directly affects the safety and reliability of the repaired equipment.

Quality Management Requirements

IEC 60079-19 places significant emphasis on quality management because the integrity of repaired Ex equipment depends heavily on the effectiveness of repair controls.

A repair organization should have documented procedures covering:

• Equipment identification.
• Repair processes.
• Inspection and testing.
• Control of replacement components.
• Calibration of measuring instruments.
• Management of repair records.
• Personnel competency.

These controls help ensure consistent repair quality and reduce the likelihood of errors.

Modification of Ex Equipment

One of the most misunderstood aspects of IEC 60079-19 concerns equipment modifications.

Not all modifications are permissible.

Examples of modifications that may affect certification include:

• Adding cable entries.
• Changing enclosure dimensions.
• Replacing certified components with non-approved parts.
• Changing electrical ratings.
• Modifying internal circuitry.
• Changing thermal characteristics.

Depending on the nature of the modification, engineering evaluation or recertification may be required.

When Does Equipment Lose Certification?

A common misconception is that Ex certification automatically remains valid after any repair activity.

In reality, certification may be compromised if:

• Repairs are performed incorrectly.
• Unauthorized modifications are made.
• Critical dimensions are altered.
• Non-approved components are installed.
• Testing requirements are not satisfied.
• Required documentation is not maintained.

This is one of the primary reasons why IEC 60079-19 places such strong emphasis on repair procedures and documentation.

Common Mistakes During Ex Equipment Repairs

Experience throughout the industry has shown that certain repair deficiencies occur repeatedly.

Examples include:

• Grinding or machining flamepaths without engineering approval.
• Replacing bolts with incorrect materials.
• Using non-certified cable glands.
• Changing winding characteristics of Ex motors.
• Installing non-approved replacement components.
• Failing to document repair activities.
• Removing or altering equipment markings.
• Returning equipment to service without inspection or testing.

Many of these deficiencies can significantly compromise explosion protection and create serious ignition hazards.

Relationship Between IEC 60079-19 and Other Standards

IEC 60079-19 forms part of the broader hazardous area lifecycle and should be used together with several other IEC 60079 standards.

Standard	Purpose
IEC 60079-14	Design, selection, and installation of Ex equipment.
IEC 60079-17	Inspection and maintenance of Ex installations.
IEC 60079-19	Repair, overhaul, and reclamation of Ex equipment.

Together, these standards provide a complete framework for maintaining the safety and integrity of explosion-protected equipment throughout its lifecycle.

Why Engineers Should Understand IEC 60079-19

Even engineers who do not directly perform repairs frequently encounter the requirements of IEC 60079-19 during maintenance planning, asset integrity assessments, and equipment failure investigations.

A basic understanding of the standard helps engineers:

• Determine whether equipment can be repaired.
• Evaluate repair organizations.
• Identify unacceptable modifications.
• Preserve equipment certification.
• Reduce the likelihood of unsafe repairs.
• Improve long-term asset reliability.
• Enhance hazardous area safety.

Because Ex equipment frequently remains in service for decades, IEC 60079-19 remains one of the most important standards for maintaining the integrity of explosion-protected installations.

Frequently Asked Questions (FAQ)

What is IEC 60079-19?

IEC 60079-19 is the international standard that specifies the requirements for the repair, overhaul, reclamation, and modification of explosion-protected equipment used in hazardous areas.

Can Ex equipment be repaired?

Yes. Ex equipment can often be repaired, provided the repair activities comply with IEC 60079-19 and do not compromise the original explosion protection characteristics of the equipment.

Can any workshop repair Ex equipment?

No. Repair organizations should possess appropriate competency, procedures, technical documentation, measuring equipment, and qualified personnel to perform repairs on explosion-protected equipment.

Does repairing Ex equipment automatically invalidate certification?

No. Proper repairs performed in accordance with IEC 60079-19 generally do not invalidate certification. However, unauthorized modifications or improper repairs may compromise the equipment's certification status.

Can flamepaths be machined during repair?

Only under specific circumstances and within acceptable limits. Unauthorized machining or modification of flamepaths can compromise explosion protection and may require engineering evaluation or recertification.

Can certified components be replaced with similar commercial parts?

Not necessarily. Replacement components must not adversely affect the explosion protection characteristics of the equipment and should be equivalent to the original components.

Conclusion

IEC 60079-19 is one of the most important standards within the hazardous area lifecycle because it establishes the requirements for safely repairing, overhauling, and reclaiming explosion-protected equipment.

The standard recognizes that Ex equipment often remains in service for many years and may require maintenance activities to restore its functionality. However, these activities must be performed carefully to ensure that the original level of explosion protection is maintained.

Proper repair procedures, competent personnel, suitable replacement components, and adequate inspection and testing are all essential elements of maintaining the integrity of Ex equipment.

A solid understanding of IEC 60079-19 also helps engineers avoid common mistakes such as unauthorized modifications, improper replacement parts, and undocumented repairs that could compromise equipment safety and certification.

Technical Review

References

• IEC 60079-19 – Explosive Atmospheres – Equipment Repair, Overhaul and Reclamation.
• IEC 60079-0 – Explosive Atmospheres – Equipment – General Requirements.
• IEC 60079-14 – Explosive Atmospheres – Electrical Installations Design, Selection and Erection.
• IEC 60079-17 – Explosive Atmospheres – Electrical Installations Inspection and Maintenance.
• IECEx System – International Certification System for Equipment Used in Explosive Atmospheres.
• International Electrotechnical Commission (IEC).
• EN IEC 60079-19 – Explosive Atmospheres – Equipment Repair, Overhaul and Reclamation.