HAZARDOUS AREA CLASSIFICATION

Course Aims
course covers the following information:

Properties of explosive gases/vapours .

Hazardous area classification procedures and

techniques for gas and vapour installations .

Recommended methods for documenting the

classification

Type of Protection .

Equipment selection
 INTRODUCTION
A hazardous Area :

An area in which an Explosive Gas

Atmosphere is present, or may be
expected to be present in quantities such
as to require special precautions for
construction , installation and use of
apparatus.
 Definition: Areas where flammable liquids,
gases, vapors, dusts or fibers are present
creating risks for fires and explosions

So What? Equipment used in these areas

? must be specifically designed and installed
to prevent explosions

Hazardous Locations Present in Many Industries and

Plants
Other Industries include Waste Water Treatment, Chemical,
Grain Elevators, Pharmaceutical, Food Processing, Flour Silos,
Mills
Explosive Atmosphere Disasters

Refinery in Louisiana:
Explosion June 2013

West Texas Fertilizer Plant

Explosion June 2012
Is our Kitchen hazardous area ?
Non-Hazardous Area

An area in which an Explosive Gas atmosphere

is not expected to be present, in quantities such
as to require special precautions for the
construction, installation and use of apparatus.
 Some Potential Hazards

Energy
Release of
Source
material

Fire
Hazard

Process Env.
state Effects
 Fuel - the vapors from the flammable
liquid

Heat - the original ignition source,

ambient temperature, Chemical
reactions, flames or other hostile fires.

Oxygen - Already in the air

and the chemical chain reaction.

Control or eliminate any element prevents explosions

 A Definition of Fire

is a process involving rapid oxidation at elevated

temperatures accompanied by the evolution of heated
gaseous products of combustion, and the emission of
visible and invisible radiation.
Explosion

Rapid and Violent oxidation or coincidental

chemical reaction with an increase in temp.,
pressure or both at the same time.

SUPERSONIC explosions created by HIGH

EXPLOSIVES are known as DETONATIONS
and travel via supersonic SHOCK WAVES.

SUBSONIC explosions are created by LOW

EXPLOSIVES through a slower burning process
known as DEFLAGRATION.


.
.
Explosive Limits

) LOWER EXPLOSIVE LIMIT (LEL

( )
.

)UPPER EXPLOSIVE LIMIT (UEL

( )
.
Flammable Range
 Limits of Flammability of Some
Substances
Fuel Lower Limits Upper Limits

Motor Gasoline 1.6 % 7%

Kerosene 0.7 % 7.5 %

Propane Gas 2.2 % 9.5 %

Butane Gas 1.9 % 8.5 %

Hydrogen Gas 4% 75 %

Acetylene Gas 1.5 % 82 %

Methanol 6% 36.5 %

Ethanol 3.3 % 19 %

Ammonia Gas 15 % 28 %

Carbon Monoxide 12.5 % 74 %

Flammable :

A substances in the form of a Gas, Vapors, Liquid, Solid

or a mixture that can react exothermically (producing
heat energy) with air (oxygen) when ignited.

Flammability :

is defined as how easily something will burn or ignite,

causing FIRE or COMBUSTION
Flammable Liquid Warning Sign
Flash point & Auto-ignition Temperature

Flash Point:
Means the minimum temperature at which a liquid
gives off vapor in sufficient concentration to form
an ignitable mixture with air near the surface of the
liquid

Auto-ignition Temp .
It is the lowest temperature of a mixture of
flammable vapors with air , at which the mixture,
due to its own high temperature , will ignite and
explode without any external ignition process.
The Auto-ignition Temperatures of some gases

GAS TEMPERATURE
Methane 580 C
Hydrogen 560 C
Propane 493 C
Ethylene 425 C
Acetylene 305 C
Naphtha 290 C
Carbon sulphide 102 C
Temperature Maximum Surface
class Temperature C
T1 450
T2 300
T3 200
T4 135
T5 100
T6 85
 HAZARDOUS LOCATION STANDARDS

Electrical equipment installed in hazardous locations

are subject to regulations and standards

IEC Ex
North America
International Electrotechnical Commission ATEX Regulations established by
Global standard outside North NEC, CEC, OSHA and NFPA
Atmosphere Explosive NEC 500 is most common
America and European Union
Adopts IEC standards into series of
directives
Law in European Union

Different Standards Depending on Installation Location

FUNDAMENTALS FOR AREA CLASSIFICATION
CODES & STANDARDS

There are codes & standards define

Hazardous Area Classification , the design
and construction of electric equipment or
apparatus to different methods of
protection to be located in hazardous
location
In Europe In USA
BS (England) NEC (National Electric
IEC (International Code)
ElectroTechnical API RP-500 (American
Commission) Petroleum Institute-
Recommended Practice)
BASIS FOR AREA CLASSIFICATION

Europe USA
IEC NEC
(Publication (Article 500)
60079 10)
Classes Classes
Zones Divisions
Temp. Classes Temp. Classes
Objectives of Area Classifications

The basic philosophy is SAFETY of life and property

by quantifying the location.

An industrial location is analyzed and classified into

Classes & Zones , keeping in view the :
chemicals/substances involved & the industrial
procedures in that location.

Ref . : IEC 60079 -10-1

IEC 60079-10-1 : the basic elements for establishing the types
of Hazardous Area Zones are as follows:

Identification of Sources of Release

.. And Grades of Release

: .

: .
 HAZARDOUS LOCATION
TYPES
Class I Locations:
An area where flammable gases or vapors are
or can be present in the air in quantities
sufficient to produce explosive or ignitable
mixtures. For Example
* Petroleum Refineries, Gasoline storage and
dispensing areas, utility gas plants.
 Continued
Class II Locations:
An area where presence of combustible
dust present a fire or explosion hazard.
For example:
Grain elevators, flour and feed mills, Use
or store of magnesium or aluminum
powders, producers of plastics, fireworks.
 Continued
Class III Locations:
An area made hazardous due to the
presence of easily ignitable fibers or
flyings. For example:
Textile mills, cotton gins, cotton seed
mills, plants that shape or cut wood and
create sawdust or flyings.
 :

: Zone 0

1000

: Zone 1
10
1000

: Zone 2
.
Zone 0 A place in which an explosive atmosphere
consisting of a mixture of air & gas (vapour or
mist) is present continuously or for long periods .

Zone 1 A place in which an explosive atmosphere

consisting of a mixture of air & gas (vapour or
mist) is likely to occur in normal operation
occasionally.

Zone 2 A place in which an explosive atmosphere

consisting of a mixture of air & gas (vapour or
mist) is not likely to occur in normal operation , but
if it does occur, will persist for a short period only.
IEC / ATEX ZONES
Global and EU
Regulations established primarily
by European Union
Continuous
Presence
Presence during
normal operations

Presence just
in case of failure or
abnormal operations
 National Electric Code (NEC)
Hazardous Area Classification

In addition to the types of hazardous

locations, the kind of conditions under
which these hazards are present are very
important : Normal Conditions,
Abnormal Conditions.
Division 1: Normal Conditions
Division 2 : Abnormal Conditions
 Continued
Class I, Class II, and Class III hazardous
locations can be either Division 1 or
Division 2
Good examples of Class I, Division 1
locations: areas near open dome loading
facilities or adjacent to relief valves in a
petroleum refinery, because the
hazardous material would be present
during normal plant operations.
 Continued
Closed storage drums containing
flammable liquids in an inside storage
room would not normally allow
hazardous vapors to escape into the
atmosphere but, what happens if one of
the containers is leaking? You have got a
Division 2 Abnormal condition A
Class I, Division 2 hazardous location.
 Class I, Division 1
Areas where ignitable concentrations exist
under normal operation, frequently due to
repair- maintenance operations carried out.
 Class I, Division 2
Areas where:
- liquids or gases are stored, handled or processed in
containers or closed systems from where they could
escape in case of abnormal operation (fire, rupture etc)
or faulty operation.
Class I, Division 1 & Class I, Division 2
Class II, Division 1 & Class II, Division 2
Class III, Division 1 & Class III Division 2
NEC 500 CLASS / DIVISION

NEC 500 address hazardous locations

using Class & Division North America
Class I Gas Regulations established by
Sub Groups A (Ac), B (H), C (Et), D (Pro) NEC, CEC, OSHA and NFPA
Temperature Class (TRatings) based on
ignition Temp T1 (450C)T6 (85C) NEC 500 is most common and
used for decades
Class II Dust
Sub Groups E (Metal), F (Coal), G (Grain)
Temperature Class Same

Class III Flyings and Fibers

No Sub Groups or Temperature Class
 Nature of Hazardous Substances

The gases and vapors of class I locations

are broken into four groups : A, B, C,
and D. These materials are grouped
according to the ignition temperature of
the substance, its explosion pressure, and
other flammable characteristics.
 Group A
Group A is an atmosphere containing
acetylene.
Equipment with rating up to 536 F
(280C) can be utilized.
 Group B
Group B is an atmosphere containing
hydrogen, or gases or vapors with a
hazard equal to hydrogen. Butadiene,
and propylene oxide are included in this
group.
 Group C
Group C is an atmosphere containing
cyclo-propane, ethyl ether, or ethylene or
gases or vapors with hazard equal to
these gases.
 Group D
Group D is an atmosphere containing
acetone, alcohol, benzene, butane,
gasoline, propane, natural gases or gases
with vapors with a hazard equal to these
gases.
 Nature of Hazardous
Substances
In Class II - dust locations we find the
hazardous materials in Groups: E, F, G.
These groups are classified according to
the ignition temperature and the
conductivity of the hazardous substance.
Conductivity is an important
consideration in Class II locations,
especially with metal dusts.
 Group E
Group E is an atmosphere containing
metallic dusts or other dusts with a
similar hazard that is equivalent, such as
Aluminum and Magnesium dusts.
 Group F
Group F is an atmosphere containing
Carbon Black, Charcoal , or Coke dusts
with 8% or less total volatile material.
 Group G
Group G is an atmosphere containing
grain dusts, flour , starch, cocoa, and
similar types of materials.
 Continue

Class III locations are not

broken into groups.
North America Optional Area
Classification
Class I, Zone 0, 1, and 2
 Elements of Hazardous Area
Classification
Sparks can occur by electrical or mechanical
activity.
Electrically the sparks are usually made by:
Switching contacts
Loose contacts in circuit carrying current
Static discharge.
 Mixtures of Gases, Vapors and Air
Ignition can only lead to a fire or explosion if
three necessary components occur
simultaneously, these are:
1. Flammable gas or vapor is present in sufficient
quantities. (leakage)
2. Sufficient air (oxygen)
3. Source of ignition (this could be spark having
sufficient energy or hot surface that will cause
spontaneous or auto-ignition.
 Temperature Class
Six temperature classes are used T1 T6
The lower the number the higher the maximum
allowable surface temperature
T-class must be below Auto-ignition Temperature
of the gas.
 :

: Group I
.

: Group II
.
Group Definition

Electrical apparatus for potentially explosive

atmospheres is divided into 2 groups :

Group I Electrical apparatus for mines (for use

underground)

Group II Electrical apparatus for places with a

potentially explosive atmosphere, other than mines
 Apparatus Group
All flammable gases are sub-grouped into
IIA, IIB or IIC on the bases of:
1. How easily the burning gas will burn
through a narrow gap (measured as the
maximum experimental safe gap (MESG)
2. The minimum ignition energy (MIE)
 Gas groups Acc. IEC
Explosion group Typical gas MIE

I Methane
II A Propane > 180 j
II B Ethylene > 60 j
II C Hydrogen > 20 j

IIA IIB IIC
 Explosion Groups
The maximum experimental safe gap is determined
using a test apparatus.
Each gas or vapor/air mixture in its most volatile form,
under normal temp. and pressure is filled into the
interior and exterior chambers of the test apparatus.
The circumferential gap between the two chambers is
accurately adjusted to the desired value.
The explosive mixture in the interior chamber is ignited
and the flame propagation, if any is observed through
the windows in the exterior chamber.
To find the maximum value of gap which prevents
ignition of the explosive mixture in the exterior
chamber.
 MESG (Maximum Experimental
Safe Gap)
The maximum clearance between two
parallel metal surfaces that has been
found, under specified test conditions, to
prevent an explosion in a test chamber
from being propagated to a secondary
chamber containing the same gas or
vapor at the same concentration.
 MIC (Minimum Igniting Current)
Ratio
The ratio of the minimum current
required from an inductive spark
discharge to ignite the most easily
ignitable mixture of a gas or vapor,
divided by the minimum current
required from an inductive spark
discharged to ignite methane under the
same test conditions.
 Explosion Classes

Apparatus group Minimum Ignition

for flameproof Current for Intrinsically
Flammable
Group enclosure d Safe Circuits i
Material Limiting Gap Ratio in relation to
Width Methane
Propane Acetone
Benzene Butane
IIA Methane Petrol > 0.9 mm > 0.8
Hexane Paint
Solvents
Ehtylene Propylene
Oxide Ethylene
> Or = 0.5 to 0.9
IIB Oxide Butadiene > Or = 0.45 to 0.8
mm
Cyclopropane Ethyl
Ether
Hydrogen
IIC Acetylene Carbon < 0.5 mm < 0.45
Disulphide
 Apparatus Group
A group IIA gas or vapor is the hardest of
these sub-groups to ignite by a spark.
Conversely a group IIC gas or vapor is the
easiest to ignite.
 Example of MIE
Material Ignition Energy J
Hydrogen 40
Ethylene 120
Propane 320
Methane 525
 Equipment for Hazardous
Locations
Equipment for Class I locations:
The equipment used in Class I locations
are housed in enclosures designed to
contain any explosion that might occur if
hazardous vapors were to enter the
enclosure and ignite.
Also it is designed to cool and vent the
products of this explosion.
 Equipment for Class II
Locations
Class II locations make use of equipment
designed to seal out dust. The enclosures
are not intended to contain an internal
explosion, but rather to eliminate the
source of ignition so no explosion can
occur within the enclosure.
 Equipment for Class III
Locations
Equipment used in class III locations
need to be designed to prevent fibers and
flyings from entering the housing. It also
needs to be constructed in such a way as
to prevent the escape of sparks or
burning materials.
It must also operate below the point of
combustion.
 Types of Protection
1. Flameproof Enclosures d
2. Intrinsic Safety i
3. Increased Safety e
4. Powder/Sand Filled q
5. Pressurized Apparatus p
6. Oil Immersion o
7. Special Protection s
8. Encapsulation m
9. Type of protection N N
 Flameproof Enclosures d

Type of protection, for which
the parts which can ignite an
explosive atmosphere are
inside an enclosure which will
Withstand the pressure of the
Explosion within the enclosure.

Prevent the transmission of the

Explosion to an explosive
Atmosphere surrounding the
Enclosure.
 IEC 60079-1 EN 50018
 Main Application :

control systems, motors, transformers, heating

equipment, light fittings
 Abbreviation Region Classification

AEx d US Class I, Div.1

Ex d CA Class I, Div.1

Ex d (EEx d( EU Zone 1

Ex d IEC Zone 1
EPL da Ma or Ga

db Mb or Gb

dc Gc
 Buying a certified Empty Enclosure (Ex d),
And populating it with industrial type electrical
Components, in your own workshop and to sell it ?
 Increased Safety e
Type of protection, for
which measures are taken to
prevent the possibility of
non-permissible high
temperatures and the
formation of sparks or arcs
on inner or outer parts of
) ( electrical apparatus, on
which these do not occur in
normal operation, with an
increased level of safety.



.

.
Increased Safety is achieved by enhancing insulation values
and creepage and clearance distances above those required for
normal service, thus providing a safety factor against
accidental breakdown.

Abbreviation Region Classification

AEx e US Class I, Div.1

Ex e CA Class I, Div.1

Ex e (EEx e( EU Zone 1
Ex e IEC Zone 1
 Intrinsic Safety i

Type of protection, for which the
energy in the electrical circuit is held
so low that sparks, arcs or
temperatures capable of causing
ignition cannot occur.
Includes sub-division into the
categories ia & ib
The Power is reduced from the electrical
Parameters to a very low value of about

25 milliwatts.


By using multiple series resistors
(resistors always fail open)

Intrinsically safe apparatus and systems are
therefore designed such that a spark, even
if produced accidentally (by a coming loose or a
PCB track breaking, for example), will not cause
ignition of the gas .
 Abbreviation Region Classification

AEx ia US Class I, Div.1

Ex ib CA Class I, Div.1

Ex ia (EEx ( EU Zone 0

Ex ib IEC Zone 1
 Powder/Sand Filled q
( )
The electrical apparatus
enclosure is filled with
powder , sand or glass
beads.
An arc occurring in the
enclosure does not ignite an
explosive atmospheres
surrounding the enclosure.

Used for small transformers, capacitors & electrical components

that have no moving parts.
Pressurized Apparatus p

The idea is to create an

Artificial atmosphere
Inside the enclosure.

Thus, preventing any

Ingress of the surrounding
vapours
PURGE & PRESSURIZATION Ex p
What is Purge and Pressurization?
Enclosure is purged of hazardous Gas
or clean of hazardous Dust
Once purged and cleaned, the enclosure is
then pressurized to keep out hazardous Gas
and Dust
Allows for standard sealed enclosures
to be used in hazardous locations
ADVANTAGES
May be only practical solution especially for
large equipment needing large enclosures

DISADVANTAGES
Requires protective gas supply (Air is used commonly)
 Protective gas : non flammable , when mixed

With O2 in the ratio 4 parts to 1 part O2, does not make

the ignition.

The 3 stages of putting a Ex p (protected ) panel into service :

Preparation - Purging - Operation

 Oil Immersion o
( )

Electrical apparatus or
parts are made safe by
immersion in oil such
that potentially explosive
atmosphere above the
surface of the oil or
outside the enclosure
will not be ignited.

.
 Abbreviation Region Classification

AEx o US Class I, Div.1

Ex o CA Class I, Div.1

Ex o (Eex o ( EU Zone 1

Ex o IEC Zone 1
 Encapsulation m

Encapsulation ensures a good mechanical protection
and is very effective in preventing contact with an
explosive mixture.

Applications: Relay modules, command devices,

sensors, display units, valves, fusing elements .
Compounds used in encapsulation are :

Thermoplastic , epoxy resin or elastomeric materials

With or without fillers in their solid state .
Abbreviation Region Classification

AEx m US Class I, Div.1

Ex m CA Class I, Div.1

Ex ma (EEx ma ( EU Zone 0

Ex mb IEC Zone 1
 Type of protection n

Similar to Ex i , applies to equipment

Which has no arcing contacts or hot surfaces.

The main consideration is extra care to

Ensure locking of terminal connections to avoid
Any risk of sparking.
 Special protection s

This method of protection , as its indicates, has no

Specific parameters or construction rules.

It is any method of protection that provide a level

of safety protection.
 Selection of apparatus
Zone Type of Protection
0 Intrinsically safe Ex ia
Special protection Ex s
1 Any type of protection suitable for zone 0
Flameproof Ex d
Intrinsically safe Ex ib
Pressurized Ex p
Increased safety Ex e
Special protection Ex s
2 Any type of protection suitable for Zone 0 or Zone 1
Ex N or Ex n
Oil immersion Ex o
Quartz Filled Ex q