Hazardous Area Classification

Dusts and Mists

 Dusts
The ignition and burning properties of any dust or
particulate matter will be principally determined by:-
 particle size
 concentration in air of an airborne cloud, and
 moisture content
Since these properties are inconsistent, unlike gases, then
actual characteristic will vary and are unique to the
circumstances of the method of processing and handling
the dust.
 Clouds and Layers
There are two further considerations for the form of dusts:-
In ‘Cloud’ form, the air and dust are mixed and the dust is
readily ignitable by sparks and heat.
In ‘Layer’ form, the dust is not subject to mixing with air. A
layer may be easily converted into a dust cloud by air
movement or shockwaves transmitted through the air.
A dust layer on the surface of equipment will act as thermal
insulation, causing the surface temperature underneath the
layer to rise because it cannot shed the excess heat.
 Fire Pentagon
The Fire Triangle needs to be expanded to a Fire Pentagon
to explain the additional circumstances of dust ignition.
 Dust Explosion Mechanism

Flame propagation within a dust is two phase effect.

If dust is dislodged and mixed with air, it forms a relatively
small cloud which may ignite if it contacts an ignition
source or self-ignites due to static.
This causes the second phase – a more powerful pressure
wave causing more dust in the layer to be converted into a
cloud which ignites and so the process propagates the
explosion with increasing destruction.
Ignition Data for Typical Dusts
 Dust Area
Classification Example

Zone 20:
The dust is mixed with air above its
lower flammable limit within the
confines of the process plant.
Zone 21
The dust collection drum is unsealed so
dust is likely to be normally present.
Zone 22:
A release is not expected from the area
above the collection point adjacent to
the fan.
Unclassified :
Dust travel around an air sealed joint is
unlikely and so the outer area is not
classified.
 Types of Protection for Dusts
The primary protection is good ‘house-keeping’. Due to the variable nature
of dust , other specific types of protection are emerging such as ‘tD’. This
consists of a dust-tight enclosure where temperature rise is the main
concern. Generally three methods are used:-
1. Operating under inert atmosphere
The concentration of oxygen is monitored and is limited to prevent the
explosion. It is essential that the Limiting Oxygen Concentration (LOC) of
the dust or powder is known.
2. Containment
Explosion containment is achieved by making the process equipment
strong enough to withstand the maximum pressure of the explosion.
Pressure relief is provided to limit the over-pressure.
3. Ingress Protection – next slide.
 Ingress Protection of Enclosures
The two-digit Ingress Protection Code (in IEC 60529)
specifies the degree of protection provided by enclosures
to levels of solids and liquids.
A similar coding is provided by NEMA in USA.
 Ingress Protection
Equipment for use in a dust atmosphere often simply
requires the protection provided by a suitable enclosure to
prevent the ingress of dusts to potential sources of ignition
within.
However, it is not sufficient to just use an enclosure with an
adequate IP rating (according to IEC 60529) as a layer of dust
could raise its surface temperature.
IEC Ex ‘t’ protection method. IEC60079-31 defines Ex ‘t’ as:
The type of protection for explosive dust atmospheres where
electrical equipment is provided with an enclosure providing
dust ingress protection and a means to limit surface
temperatures.
 Ex ‘t’ Ingress Protection
There are 3 levels of protection (ta, tb and tc) which are based on
the IP rating and dust group.
 Mists
Non-hazardous liquids at process temperatures may form a
flammable mist and explosion hazard. Examples include high
flash point liquid fuels, heat exchange oils and lubricating oils.
Mist flammability depends upon the concentration of the
droplets plus any vapour, and is difficult to predict. A jet of mist
impacting on a nearby flat surface can also increase the fractions
of particles that are flammable.
Droplet size depends upon the pressure at which the liquid is
being released, the physical properties of the liquid and the
size / shape of the hole.
IEC 60079-10-1 includes an annex covering mists.
Case Study : diesel pump room
Diesel Pump Room
 Case Study : diesel pump room
 Upgrades at 3 locomotive re-fuelling depots in UK.
 Diesel pumps were not ATEX-compliant; electrical panels, starters, etc.
had no ingress protection and so a potential fire risk.
 Diesel (flash point >58 deg C.) at ambient temperature is a combustible
liquid, but a release could form a flammable mist.
 Normally, 5 entire pump sets would be
replaced to comply with ATEX 95
(equipment) and ATEX 137 (workplace) .
Cost > £50K.
 Alternative solution was to fit flange
guards to all flanges and screwed
connections, to block and coalesce any
mist jet (<£1K). Happy client !