IECEx COPC Training

The IECEx Certificate of Personnel Competency (CoPC) Training at ISEP Training & Consultation Sdn. Bhd. aims to equip professionals with the necessary skills and knowledge to work safely in hazardous environments. This training is compliance with international IECEx standards, make individual or organization able to reduce risks and enhancing workplace safety in industries such as oil, gas, and petrochemicals. Earning this globally recognized certification also boosts career opportunities, demonstrating competency in handling, installing, inspecting, and maintaining Ex equipment.

Course Details

Units of Competence

Ex 000 – Basic Knowledge and Awareness to Enter a Site with a Classified Hazardous Area

This unit covers the fundamental safety obligations and basic knowledge required for individuals entering hazardous areas. It includes an understanding of hazardous area classifications, restrictions on devices brought into such areas, and essential health and safety responsibilities. This unit is theoretical and does not cover explosion protection for machinery or equipment.

Who should take this? – Personnel who need general awareness of hazardous areas, such as supervisors, safety officers, and administrative staff working near classified zones.

Ex 001 – Basic Principles of Protection in Explosive Atmospheres

Learning Outcomes:

Understand the properties and hazards of flammable gases, vapors, dusts, and mists.
Identify the types of explosive atmospheres and associated risks.
Explain the basic protection concepts (e.g., Ex d, Ex e, Ex i).
Interpret area classification (zones 0, 1, 2, 20, 21, 22).
Understand international standards (IEC 60079 series).
Recognize the importance of correct equipment selection and installation in Ex areas.

Agenda:

Time	Description
09:00 – 09:30	Introduction to Explosive Atmospheres & Industry Hazards
09:30 – 10:15	Flammable Substances & Ignition Sources
10:15 – 10:30	Break
10:30 – 11:30	Area Classification (Zones 0–2 for gas, 20–22 for dust)
11:30 – 12:30	Explosion Protection Concepts (Ex d, Ex e, Ex i, Ex p, etc.)
12:30 – 13:30	Lunch
13:30 – 14:30	Gas Groups & Temperature Classes
14:30 – 15:30	Case Examples, Hands-On Activities/Visuals
15:30 – 16:00	Q&A and Recap
16:00 – 16:30	Knowledge Assessment / Quiz

Ex 002 – Installation of Ex Equipment

Learning Outcomes:

Interpret installation requirements according to IEC 60079-14.
Select appropriate Ex-certified equipment based on zone classification.
Install Ex d, Ex e, Ex i, Ex n, Ex t, and other types of protection correctly.
Apply cable glanding and termination practices in Ex environments.
Follow documentation and inspection protocols during installation.
Understand environmental factors influencing installation (e.g., temperature, IP rating).

Agenda:

Time	Description
09:00 – 09:30	Installation Principles & Reference to IEC 60079-14
09:30 – 10:30	Equipment Types & Zone Suitability
10:30 – 10:45	Break
10:45 – 11:45	Cable Systems, Glands & Terminations in Ex Zones
11:45 – 12:30	Mechanical & Electrical Installation Requirements
12:30 – 13:30	Lunch
13:30 – 14:30	Environmental Considerations & Mounting Techniques
14:30 – 15:30	Review of Typical Installation Errors & Case Studies
15:30 – 16:00	Q&A, Recap and Practical Scenarios Discussion
16:00 – 16:30	Written or Oral Assessment

Ex 003 – Maintenance of Ex Equipment

Learning Outcomes:

Perform routine and preventative maintenance on Ex equipment per IEC 60079-17.
Identify faults and degradation in Ex equipment and protective systems.
Carry out corrective actions without compromising protection techniques.
Understand maintenance categories (visual, close, detailed).
Use appropriate tools and procedures to maintain Ex integrity.
Document maintenance activities for compliance and traceability.

Agenda:

Time	Description
09:00 – 09:30	Introduction to Maintenance under IEC 60079-17
09:30 – 10:15	Visual, Close & Detailed Maintenance Categories
10:15 – 10:30	Break
10:30 – 11:30	Common Maintenance Procedures for Ex d, Ex e, Ex i Equipment
11:30 – 12:30	Managing Non-conformities & Equipment Degradation
12:30 – 13:30	Lunch
13:30 – 14:30	Documentation & Maintenance Record Keeping
14:30 – 15:30	Fault-Finding Techniques & Case Studies
15:30 – 16:00	Recap, Discussion
16:00 – 16:30	Knowledge Check / Quiz

Ex 004 – Repair and Overhaul of Ex Equipment

Learning Outcomes:

Understand principles of repair, overhaul, and reclamation under IEC 60079-19.
Identify limitations on repairability for different Ex protection types.
Apply repair methods without altering safety characteristics of equipment.
Use correct materials, tolerances, and clearances as per original design.
Maintain repair records and quality assurance documentation.
Ensure repaired equipment remains compliant with original certification.

Agenda:

Time	Description
09:00 – 09:30	Scope of IEC 60079-19 and Legal Responsibilities
09:30 – 10:30	Repair Limits by Protection Type (Ex d, Ex e, etc.)
10:30 – 10:45	Break
10:45 – 11:45	Workshop Practices: Tolerances, Materials, Techniques
11:45 – 12:30	Testing & Inspection After Repair
12:30 – 13:30	Lunch
13:30 – 14:30	Marking, Traceability, and Documentation Requirements
14:30 – 15:30	Case Studies: Repair Failures & Lessons Learned
15:30 – 16:00	Recap & Practical Examples Discussion
16:00 – 16:30	Assessment

Ex 005 – Preparation and Installation of Cable Glands

Learning Outcomes:

Select and install cable glands suitable for Ex d, Ex e, and Ex t protection types.
Understand gland sealing requirements for gas- and dust-hazardous areas.
Recognize the role of barrier glands, compound filling, and IP protection.
Follow manufacturer specifications and standards (IEC 60079-0/14).
Ensure mechanical strength and flameproof integrity of glands and enclosures.

Agenda:

Time	Description
09:00 – 09:30	Gland Functionality & Selection (Ex d, Ex e, Ex t)
09:30 – 10:30	Gland Construction Types & Sealing Techniques
10:30 – 10:45	Break
10:45 – 11:45	Installation Steps & Termination Methods
11:45 – 12:30	Environmental Considerations (IP Ratings, Corrosion)
12:30 – 13:30	Lunch
13:30 – 14:30	Faults Due to Incorrect Glanding Practices
14:30 – 15:30	Demonstration or Hands-on Gland Installation
15:30 – 16:00	Q&A and Troubleshooting Checklist
16:00 – 16:30	Quiz / Skill Demonstration

Ex 006 – Testing and Verification of Ex Installations

Learning Outcomes:

Conduct testing and commissioning per IEC 60079-14 and IEC 60079-17.
Verify Ex equipment installation integrity through insulation resistance, continuity, and earth loop testing.
Interpret test results against acceptance criteria.
Understand responsibilities during initial inspection vs periodic inspection.
Use inspection checklists and documentation to validate installation quality.

Agenda:

Time	Description
09:00 – 09:30	Introduction to Testing Requirements (IEC 60079-14 & -17)
09:30 – 10:30	Pre-Commissioning vs Periodic Testing: Objectives & Scope
10:30 – 10:45	Break
10:45 – 11:45	Electrical Testing Procedures: Insulation, Continuity, Earth Loops
11:45 – 12:30	Verifying Equipment Ratings, IP, Markings & Mechanical Integrity
12:30 – 13:30	Lunch
13:30 – 14:30	Interpreting Results & Accept/Reject Criteria
14:30 – 15:30	Test Equipment Handling & Troubleshooting
15:30 – 16:00	Recap, Case Scenarios
16:00 – 16:30	Written Quiz / Verification Checklist Practical

Ex 007 – Visual and Close Inspection of Ex Installations

Learning Outcomes:

Carry out visual and close inspections on Ex equipment according to IEC 60079-17.
Identify potential non-conformities or defects affecting equipment integrity.
Classify inspection results and report findings.
Understand inspection intervals and categories.
Use proper inspection tools without compromising protection.

Agenda:

Time	Description
09:00 – 09:30	Principles of Inspection (IEC 60079-17)
09:30 – 10:30	Definitions: Visual, Close, Detailed – What’s Included
10:30 – 10:45	Break
10:45 – 11:45	Common Defects: Corrosion, Loose Fittings, Wrong Components
11:45 – 12:30	Using Checklists & Inspection Tools Effectively
12:30 – 13:30	Lunch
13:30 – 14:30	Review of Sample Photos / Hands-on Visual Exercises
14:30 – 15:30	Documentation & Reporting Non-Conformities
15:30 – 16:00	Recap, Peer Review Activity
16:00 – 16:30	Short Quiz or Inspection Simulation

Ex 008 – Detailed Inspection of Ex Installations

Learning Outcomes:

Conduct detailed (intrusive) inspectionsas per IEC 60079-17.
Disassemble equipment if necessary to verify internal condition.
Identify non-compliance or unsafe modifications.
Document and evaluate findings with risk-based judgement.
Understand the criticality of inspection for aging Ex equipment.

Agenda:

Time	Description
09:00 – 09:30	Introduction to Detailed Inspections (IEC 60079-17)
09:30 – 10:30	When to Perform Detailed Inspections: Criteria and Triggers
10:30 – 10:45	Break
10:45 – 11:45	Tools, Instruments, and Safe Disassembly Techniques
11:45 – 12:30	Evaluating Enclosure Integrity, Flamepaths, and Gland Seals
12:30 – 13:30	Lunch
13:30 – 14:30	Maintenance vs Detailed Inspection – What to Record
14:30 – 15:30	Fault-Finding Case Studies & Examples
15:30 – 16:00	Q&A and Best Practice Review
16:00 – 16:30	Knowledge Check or Practical Simulation

Ex 009 – Design of Ex Installations

Learning Outcomes:

Apply area classification data to design compliant Ex installations.
Select suitable equipment, wiring systems, and protection concepts.
Interpret and apply IEC 60079-14 in layout planning.
Design for environmental conditions and temperature classifications.
Ensure segregation, bonding, earthing, and control measures are in place.
Produce Ex-compliant documentation and design drawings.

Agenda:

Time	Description
09:00 – 09:30	Introduction to Hazardous Area Design Standards (IEC 60079-14)
09:30 – 10:30	Selecting Protection Concepts Based on Zone & Equipment Type
10:30 – 10:45	Break
10:45 – 11:45	Designing Cable Routing, Glanding, Earthing & Segregation
11:45 – 12:30	Using Area Classification Drawings in Design
12:30 – 13:30	Lunch
13:30 – 14:30	Preparing Design Documentation & Ex Equipment Schedules
14:30 – 15:30	Common Design Errors & Compliance Failures
15:30 – 16:00	Peer Design Review & Recap
16:00 – 16:30	Written Design Review Exercise or Quiz

Ex 010 – Audit and Inspection of Ex Installations

Learning Outcomes:

Plan and conduct formal audits and compliance inspections.
Evaluate installed systems for adherence to IEC 60079 standards.
Identify systemic deficiencies and recommend corrective actions.
Review maintenance, repair, and inspection records.
Ensure conformity of documentation, marking, and certification.
Prepare technical reports and compliance summaries

Agenda:

Time	Topic
09:00 – 09:30	Audit Principles: IEC 60079-17 & IEC 60079-14
09:30 – 10:30	Planning and Structuring an Ex Compliance Audit
10:30 – 10:45	Break
10:45 – 11:45	Evidence Gathering: Documents, Photos, Checklists
11:45 – 12:30	Risk Assessment in Compliance Gaps & Prioritization
12:30 – 13:30	Lunch
13:30 – 14:30	Conducting Interviews & Site Walkdowns
14:30 – 15:30	Writing a Compliance Audit Report
15:30 – 16:00	Discussion: Real-World Non-Compliance Cases
16:00 – 16:30	Audit Simulation / Summary Assessment

Who Shall Attend this training

This module is suitable for all personnel who need to understand the basics of hazardous areas and explosive atmospheres, including engineers, technicians, safety officers, inspectors, and managers.

Pre-requisites

No formal prerequisites, but a basic understanding of electrical or mechanical concepts can be helpful.