SECTION 2.

ELECTRICAL
HAZARDOUS
AREA
EQUIPMENT
(EEHA)
Emergency Procedures

If alarm sounds :
1. Listen to the alarm, do not panic
2. Calmly evacuate through nearest exit route
3. Follow the exit signs
4. Go to designated Muster Point

2
Section 2

 You will consider the various area classifications relating to the

probability of release of gases and the likelihood of danger from
such release.
 You will also consider temperature classifications of equipment in
terms of their temperature and the categories for operation in
explosive environments.

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AREA CLASSIFICATION

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Hazardous areas are classified by gas groups and zones.

▰ Zones are used to define the probability of the presence of flammable materials.
▰ Gas Groups consider the ignition energy of the substance and focuses on
ignition from a spark source.

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IEC 60079-10

Area classification is a method of

analysing and classifying the
environment where explosive gas
atmospheres may occur.

6
IEC 60079-10

This will facilitate the proper selection and installation of apparatus to be

used safely in that environment, taking into account gas groups and
temperature classes.

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To determine the Area Classification :

Assemble pertinent information

▰ Codes, standards, practices, and references
▰ Process and operating descriptions
▰ Process flow diagrams (PFDs) and material and heat balance charts
▰ Piping and instrumentation diagrams (P&IDs)
▰ Equipment arrangement drawings and plot plans
▰ Commissioning, testing, operating, and safety procedures.

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To determine the Area Classification (Continued)

▰ List all flammable and combustible materials, along with their pertinent
properties, such as ignition temperatures and flash points.
▰ Confirm the need for classification by assessing the likelihood of the
presence of flammable and combustible materials.
▰ Locate material release sources, such as:
▰ Open process points, Control valves, Pump seals, Drains, Metering
points, Sampling points, Vents, etc.

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UNDERSTANDING ZONES

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Zone Classification

The zone defines the probability of hazardous material being present in an

ignitable concentration in the surrounding atmosphere.

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The important factors that must be considered for zone classification are:

▰ The probability of the presence of gas or vapour

▰ The quantity of the gas or vapour present in the area
▰ The duration of the gas or vapour present in the area

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The amount of ventilation present in the area

▰ The nature of the gas. i.e. whether it is lighter or heavier than air
▰ The consequence of an explosion and possible chain reaction

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Zone 0 is generally found inside tanks or vessels containing flammable liquids.

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Zone 0

An area in which an explosive gas-air mixture is

present continuously, for long periods or
frequently.

> 1000 hours or more in any given year.

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Zone 0 gives rise to a Zone 1 as the tank vent is a primary source of release

Zone 1

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Zone 1

An area in which an explosive atmosphere is

likely to occur for short periods in normal
operation.

10 - 1000 hours in any given year.

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Zone 1 gives rise to a Zone 2

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Zone 2

An area in which an explosive atmosphere is not

likely to occur in normal operation, but if it does
occur, will persist for only a short period.

0 - 10 hours in any given year.

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Explosive Atmosphere

Total hours an explosive atmosphere will exist in any given year.

Zone 0 Zone 1 Zone 2 Zone 0 = 1000 hrs or more.
Zone 1 = 10 - 1000 hrs.

Zone 2 = 0 – 10 hrs.

Red zone explosive atmosphere:

Yellow zone no explosive

atmosphere present:

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Explosive Atmosphere

Where different zones are created by different sources of release and they
overlap the higher risk of zone will apply in the area.

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Explosive Atmosphere

Zone 0 An area in which an explosive gas-air

mixture is present continuously, for long
periods or frequently.
Zone 1 An area in which an explosive gas-air mixture
is likely to occur for short periods or
occasionally in normal operation.

Zone 2 An area in which an explosive gas-air mixture

is not likely to occur, and if it occurs it will
only exist for a very short time due to an
abnormal condition.

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Zone Classifications

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RELATIVE DENSITY

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Relative Density

A gas with a density

lighter than air will
H2
rise when released
into the atmosphere
and a gas with a
density heavier than H2S
air will fall.

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Relative Density

Relative vapour
Material
density
Air 1
Acetylene 0.9
Butane 2.05
Ethylene 0.9
Hydrogen 0.07
Hydrogen
1.19
Sulphide
Methanol 1.11
Petroleum 2.8

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Relative Density

▰ Lighter than air gases will rise and disperse into the air quickly.
▰ Heavier than air gases will fall and could collect at ground level, or in
sumps or drains, and remain there for long periods.

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VENTILATION

Zone 1 due to low ventilation

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Natural Ventilation

▰ Natural ventilation is described as the movement of air caused by the wind or

temperature gradients
▰ In open air areas, natural ventilation can assist in the dispersal of an explosive
gas atmosphere.

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Artificial Ventilation

▰ Artificial ventilation is provided by the use of fans or extractors.

▰ Although artificial ventilation is mainly used inside a room or enclosed
space, it can also be applied to outside situations as well.

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Ventilation

The more ventilation there is, the faster the substance will be dispersed into
the air (below the LEL) and therefore the extent of the zone will be smaller.

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Degrees of ventilation: 3 Types

▰ (VH) High Degree of Ventilation

▰ (VM) Medium Degree of Ventilation
▰ (VL) Low Degree of Ventilation

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Availability of Ventilation: 3 Types

▰ Good: Ventilation is present continuously

▰ Fair: Ventilation is expected to be present during normal operations.
▰ Poor: This is where there is no continuous ventilation and breaks
happen often.

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Ventilation can alter the zone.

▰ Ventilation: Type: Natural

Degree: Medium
Availability: Good

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Ventilation can alter the zone.

▰ Ventilation: Type: Artificial (Natural)

Degree: Low (Medium)
Availability: Fair (Good)

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36
 GRADING OF GAS RELEASE

▰ Sources of Release:
The point from which a flammable gas, vapour or mist can be released into
the atmosphere.

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Grading of Gas Release

Every item of process equipment should be considered as a potential source

of gas release.

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Continuous Grade of Release

Zone 0
▰ The surface of a flammable liquid contained in a storage tank.
▰ The surface of an open reservoir.

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Primary Grade of Release

Zone 1
Seals of pumps, compressor or valves which would normally emit
flammable materials at particular stages of the start up cycle.

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Primary Grade of Release

▰ Water drainage points on vessels which contain flammable liquid

▰ Outlets from which samples are drawn for analysis.
▰ Relief vents and valves which are expected to release during normal
operations

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Secondary Grade of Release

Zone 2
Flanges, connections and pipe fittings not expected to release
Flammable materials during normal Operations.

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Secondary Grade of Release

Seals of pumps, compressor or valves which would not be expected to emit

flammable materials during normal operations.

Relief vents and valves which are not expected to release flammable
materials during normal operations.

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Secondary Grade of Release

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Normal Operation

Situation when the equipment is operating within its design parameters.

Minor releases of flammable material may be part of normal operation.

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Catastrophic Failure !

Catastrophic failure is, for example, the unforeseen rupture of a process

vessel or pipeline that in normal operation cannot be predicted.

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Catastrophic Failure !

Once a plant has been classified and all necessary records made, it is
important that no modification to equipment or operating procedures are
made.

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Catastrophic Failure !

Changes can be made but only after discussion with those responsible for
the area classification or a management of change (MOC) is in effect.

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 GAS GROUPS

Gases are grouped for mining and surface applications based on the amount
of energy necessary to ignite the most explosive mixture of gas with air.

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Group I

Below ground where methane firedamp is present.

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Group II

Above ground where explosive gas atmospheres exist.

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Group III

Above ground where explosive dust atmospheres exist.

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Gas Groups

Ignition
Gas Type Temperature
Group Energy
(Representation) Classification
(Approx)

Methane
I ----- 280 μJ
(Firedamp)

II Propane T1 260 μJ

II Ethylene T2 95 μJ

II Hydrogen T1 20 μJ

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Group II is further divided into 3 Sub Divisions.

Ignition
Gas Type Temperature
Group Energy mA
(Representation) Classification
(Approx)

IIA Propane T1 260 μJ 70

IIB Ethylene T2 95 μJ 45

IIC Hydrogen T1 20 μJ 21

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Gas Groups

IIA IIB IIC

Methane Ethylene Acetylene

Propane
Butadine Hydrogen
Petroleum

Butane Hydrogen Carbon

Sulphide Disulphide
Kerosine

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 EXPLOSIVE LIMITS

Oxygen is a key factor in making gases and vapours flammable.

If too much or too little oxygen is present, the gas/oxygen mixture will
not ignite.
The exception to this rule is Acetylene which does not require oxygen to
ignite.

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Explosive Limits

Lower Explosive
LEL Limit

The percentage concentration of

gas in air below which the
gas atmosphere is not
explosive.

Mixture is too lean

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Explosive Limits

Upper Explosive
UEL
Limit

The percentage concentration of

gas in air above which the
gas atmosphere is
not explosive.

Mixture is too rich 58

Explosive Limits

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Explosive Limits

Gas Type Gas Group LEL UEL

(%) (%)
Acetylene IIC 1.5 100

Ethylene IIB 2.7 34

Hydrogen IIC 4.0 75

Methanol IIA 6.7 36

Propane IIA 2.0 9.5

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Explosive Limits

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Flashpoint (Definition)

Flashpoint is:
‘the minimum temperature at which sufficient vapour is given off from a
liquid, to form a flammable mixture with air that can be ignited by an arc,
spark or naked flame’.

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Flashpoint (Definition)

Gas Type Flashpoint LEL (%) UEL

(%)
Acetylene 1.5 100

Butane -60˚C gas 1.4 9.3

Hydrogen 4.0 75

Methanol 11˚C 6.7 36

Propane -104˚C gas 2.0 9.5

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Flashpoint (Definition)

Methanol will ignite at

11˚C

Insufficient vapour to cause

an ignition at
10˚C
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Ignition Temperature

The minimum uniform temperature required to initiate or cause:

▰ Self-sustained combustion of a solid, liquid, or gaseous substance
(independent of any other ignition source).
▰ Sometimes called auto ignition.

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Ignition Temperature

Gas Type Flashpoint Ignition

Temperature
Acetylene 305˚C

Butane -60˚C gas 372˚C

Hydrogen 560˚C

Methanol 11˚C 386˚C

Propane -104˚C gas 470˚C

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Ignition Temperature

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 TEMPERATURE CLASSIFICATION

When selecting electrical apparatus for use in hazardous areas it is important to

ensure that the maximum surface temperature of the apparatus will not be greater
than the ignition temperature of the gas in the surrounding atmosphere.

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Temperature Classification

Ignition Temperature
Typical Gas Temperature Class

Methane 595˚C T1

Ethylene 425˚C T2

Cyclohexane 259˚C T3

Diethyl Ether 170˚C T4

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Temperature Classification

Maximum Surface
Temperature Class
Temperature
T1 450°C

T2 300°C

T3 200°C
T4 135°C
T5 100°C
T6 85°C

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Maximum Surface Temperature

▰ This is the maximum temperature a piece of equipment will reach in

normal operation.
▰ Equipment with a T3 rating could reach a temperature of 200°c in
normal operation, but will not get any hotter.

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Temperature Classification

Ignition Temperature
Typical Gas
Temperature Class
Butane 372˚C T2

Hydrogen 560˚C T1

Hydrogen Sulphide 270˚C T3

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Temperature Classification

Typical Gas Ignition

Temperature
Diethyl Ether 170˚C

Typical Gas Maximum

Temperature
Surface
Class
Temperature

Diethyl Ether T4 135°C

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74
Ambient Temperatures

▰ Temperatures are based on an ambient temperature of -20˚C to +40˚C

▰ The maximum surface temperature of an item of apparatus depends on
the temperature rise above 40˚C

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The maximum permissible RISE in temperature is 45˚C

Ignition Temp Ambient Temp

Gas
Temp Class Temp Class

Methane 595˚C T1 40˚C T1

Ethylene 425˚C T2 45˚C T2

Diethyl Ether 170˚C T4 > 45˚C T5

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 EQUIPMENT PROTECTION LEVELS

▰ Where only zones are indentified in the area

classification documentation, then the
relationship between EPL's and zones shall
be followed.
▰ EPLs may be determined on the basis of
risk, i.e. taking into account the
consequences of an ignition.

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EPL

Equipment Protection Suitable Zones

Level (EPL) of Use
Ga Zones 0, 1 and 2

Gb Zones 1 and 2

Gc Zone 2

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EPL

If, the risk is considered especially severe, then the required EPL for the
zone may be increased

Normal Low
Zone High Risk
Risk Risk

1 Ga Gb Gc

2 Gb Gc Gc

The required EPL for the zone can also be decreased

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 CATEGORIES OF EQUIPMENT

Gas Group II is designated for explosive atmospheres relating to the oil and
gas industry, (Surface Industrial Applications)

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Group it has been designed/tested for

Location
Flammable
Group Location Suitable for
Material
Use
Methane
I Below ground Group I
(Firedamp)

II Above ground Gases/Vapours Group II

III Above ground Dusts/Fibres Group III

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The Categories of Group II equipment

Where the equipment is to be used:

Zone Zone Zone
The period of time over which the 0 1 2
potentially explosive atmosphere is
likely to be present:

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The Categories of Group equipment

▰ Category 1G: Very high level of protection. Suitable for Zone 0

▰ Category 2G: High level of protection. Suitable for Zone 1
▰ Category 3G: Normal level of protection. Suitable for Zone 2

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84
Test Yourself

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Test Yourself

Which of the three zones has the highest risk of gas explosion?

Zone 0

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Test Yourself

In relation to gas release, what is meant by the terms Continuous?

Continuous release relates to Zone 0 where the release

is expected to be continuous over a lengthy period of
time.

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Test Yourself

In relation to gas release, what is meant by the terms Primary?

Primary release relates to Zone 1 where the release is

expected during normal operations occasionally.

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Test Yourself

In relation to gas release, what is meant by the terms Secondary?

Secondary release relates to Zone 2 where the release is

not expected to occur in normal operations and, if it
does, then it will be of short duration only

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Test Yourself

What does the term ‘explosive limits’ mean in relation to hazardous

atmospheres?

Upper and lower percentage concentrations of gas in

air above and below which explosion will not occur

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Test Yourself

How should the T classification of an item of apparatus relate to the

ignition temperature of gas in which it is operated?

The maximum surface temperature at which

equipment will operate without igniting gas in the
atmosphere.

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Test Yourself

How do the three categories of the hazardous equipment relate to their

level of hazard protection and gas zone?

Category 1: Equipment has a very high level of

protection.
Suitable for use in Zones 0, 1 and 2

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Test Yourself

Category 2: Equipment has a high level of protection.

Suitable for use in Zones 1 & 2
Category 3: Equipment has a normal level of protection.
Suitable for use in Zone 2 only

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Training Targets

• Identify hazardous area classified

Number 4 zones and gas groups

• Describe the factors relating to the

Number 5 ignition of explosive atmospheres

• Know the categories of equipment

Number 6 for use in explosive atmospheres

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Activity

▰ For the fixed-roof storage tank shown,identify the hazardous areas zone
0, zone 1 and zone 2

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Activity

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Activity Define Zone 0

▰ Zone 0 is an area in which an explosive gas-air mixture is present

continuously.

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Activity Define Zone 1

▰ Zone 1 is an area in which an explosive gas-air mixture is likely to

occur for short periods or occasionally in normal operation

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Activity Define Zone 2

▰ Zone 2 is an area in which an explosive gas-air mixture is not likely to

occur, and if it does occur it will only exist for a very short time due to
an abnormal condition.

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Thank You