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IIB or not IIB? Benefits of Zone Approved Equipment For Hazardous Location
By Jason Crossman B.Sc EET, Killark Product Manager Wiring Products Hubbell Canada LP

Undoubtedly, the world is getting smaller. With each passing year more and more opportunities become available both at home and abroad. In order for Canadian companies to participate and to prosper it became necessary to consider global approvals for electrical equipment for use in hazardous locations.

Traditionally, North American regulations have been based around the Class/Division system while European authorities followed a multi-tiered Zone system. The adoption of the Zone system in North America brought substantial change to the hazardous location industry. While the purpose of each system is to the same end, they are fundamentally different in There are certain differences between the Canadian Electrical Code and the National Electrical Code when it comes to Zone approved equipment. The material contained herein is to the Canadian Electrical Code. Although the Class/Division system and the Zone system are similar in many ways there are some very distinct differences. The fundamentals of hazardous locations apply to both systems but the definition of a hazardous environment and construction of equipment differs.

One factor that is occasionally overlooked is that the fundamental laws of chemistry apply to hazardous locations. The Fire Triangle is commonly referenced since it defines the requirements for a fire to exist. According to the principles of the Fire Triangle a fire can only exist if all three sides of the triangle are present and in the proper quantities. Traditionally, North American regulations have been around the Class/Division system while European followed a multi-tiered Zone system. The adoption system in North America brought substantial change hazardous location industry. While the purpose of each is to the same end, they are fundamentally different in There are certain differences between the Canadian Code and the National Electrical Code when it comes approved equipment. The material contained herein is reference to the Canadian Electrical Code. Although the Class/Division system and the Zone system are similar in many ways there are some very distinct differences. The fundamentals of hazardous locations apply to both systems but the definition of a hazardous environment and construction of equipment differs.

One factor that is occasionally overlooked is that the fundamental laws of chemistry apply to hazardous locations. The Fire Triangle is commonly referenced since it defines the requirements for a fire to exist. According to the principles of the Fire Triangle a fire can only exist if all three sides of the triangle are present and in the proper quantities. Frequency Continuous Intermittent/Periodic Abnormal Class I, Division 2 Class/Division System Class I, Division 1 Zone System Zone 0 Zone 1 Zone 2

It can be seen that Class I, Division 1 is divided into Zone 0 and Zone 1. The implication is that an area classified as a Class I, Division 1 location can not use Zone 1 product since there is a potential that Zone 0 equipment is required. Although this may appear as a disadvantage to th

http://www.hubbell-canada.com/wiring/wphazardousloc.asp

8/2/2009

Hazardous Location White Paper

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Zone system it is actually one of the main strengths. Many facilities are over classified using Class/Division methods over concerns of liability. Under the Zone approach, the criteria that make up each zone is quite clearly defined allowing for the vast majority of applications to be Zone 1 or Zone 2. Since Class I, Division 2 and Class I, Zone 2 meet the same criteria, equivalent equipment is interchangeable following proper installation techniques. Another main difference between the two systems is the grouping of gases or vapours. The Class/Division approach uses Groups A, B, C, D and the Zone system uses Groups IIC, IIB, IIA. Group IIC incorporates both Group A and Group B under one level of protection. Therefore, Class I, Division 2, Groups A ,B, C, D and Class I, Zone 2, Groups IIC, IIB, IIA describe the same environment. The IEC Zone system distinguishes between surface and mining equipment designating the prefix I for Mining groups and II for Surface groups. The Canadian Electrical Code does not participate in mining and therefore no prefix distinction is required. The example above of Groups IIC, IIB, IIA would be referencing equipment suitable for surface use for IEC groups C, B, A. The Zone System breaks down the equipment one step further to include various forms of protection. In North America the most common methods of protection for Zone approved equipment are Ex 'd' and Ex 'e' or a combined protection method of Ex 'de'. Ex 'd' relates to equipment that is considered to be flameproof in construction. Meaning, arcing or sparking components are expected to be installed in these devices and the device or enclosure must be designed to withstand an explosion. To withstand an explosion means that high tolerance paths exist to suppress any flames and to cool the hot gases to a temperature below the ignition point of the surrounding atmosphere. North American explosion proof equipment is designed to serve the same function but the testing requirements for explosion proof and flameproof are different.

Ex 'e' is defined as equipment that encompasses increased safety. Increased safety is a method of reducing the likelihood of arcing between any live components. This is accomplished by providing additional spacing between electrical components or termination points with improved clamping to prevent terminations from becoming loose over time. Terminal boxes are an example where the terminal blocks that are used meet the requirement of an increased safety terminal and are considered a safe termination point. The Class/Division system has no equivalent. Ex 'de' compliant equipment is equipment that comprises type Ex 'd' flameproof construction with type Ex 'e' increased safety terminations. Items such as contact blocks are a good exampl of Ex 'de' devices. A flame path exists around the plunger assembly to prevent an external explosion and all wire connection points are increased safety terminals. Under this approach there is no risk of an external explosion from the contacts within the contact block or arcing of wiring at the point of termination. So what does it all mean?

There will always be a debate over which system is the best. Class/Division equipment will always offer the widest possible selection. Standard off the shelf components, such as blocks and relays, can be contained in a traditional Class/Division enclosure since the enclosure is explosion proof. The downside is that large cast enclosures are heavy and awkward. Installation is difficult with the shear bulk of the equipment often requiring several people to safely install. Installation of conduit seals and the cost of transporting all that weight can become an unnecessary expense. Being that a machined flame path is required, a lot are not Nema 4, 4X. Ex 'de' equipment is available in the form of Ex 'de' contact blocks and switches which can be housed in standard non-metallic or carbon steel enclosures easily made Nema 4X. Since the components are flameproof and the terminations are increased safety, there should not be any risk of explosion. If there is no risk of explosion, than there is no need for a cast enclosure. This also allows the user the luxury of installing lightweight equipment often manageable by one or two people. The use of approved cable and cable glands can eliminate the need for conduit and conduit seals, decreasing installation time. Why use sealing fittings in conduit or potted, barrier type glands or connectors in a non-metallic enclosure? The exception is when Zone approved explosion proof cast enclosures or flameproof enclosures are used in the same environment as non-metallic enclosures and they are interconnected. In the event of an internal explosion in the cast enclosure, the explosion could travel through the conduit system and destroy the non-metallic enclosure and ignite the surrounding atmosphere. For this reason it is required that all potentially arcing and sparking components are isolated from non-explosion proof enclosures or equipment. It is also worth noting that Ex 'e' equipmen is not considered to be flameproof or explosion proof and it should not be used where that leve of protection is required. For example, the installation of an Ex 'e' type hole plug installed in an Ex 'd' enclosure could prove fatal. Any explosion within the Ex 'd' enclosure would almost

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certainly destroy the Ex 'e' hole plug or escape through the threads, potentially igniting the surrounding atmosphere.

In summary, enclosures in a Zone application can be non-metallic, carbon steel or even stainless steel with Nema protection up to 4X. The components themselves are made out of composite materials that maintain lightweight construction. Ex 'de' approved contact blocks, relays, switches, etc. contain flame paths to suppress the flame and cool the exhaust gas maintaining increased safety terminations. The chamber where contacts are making and breaking is of such a small volume that it poses no risk of an explosion. Class/Division equipment can use everyday components inside enclosures designed to withstand an explosion but by bringing the technology down to component level protection a variety of new has been created. The modular design allows for individual control stations to be "ganged" together to form larger more elaborate panels. Components exist that allow similar stations to be mounted in direct contact with one another. Explosion proof or flameproof equipment requires connection through threaded entries. This ability to join stations together is an added bonus in instances where wall space is limited or job requirements have changed. Lightweight construction decreases installation time and can often be done by one person. Although the fundamentals of hazardous locations apply to both systems but the definition of a hazardous environment and component construction differ, both systems have the same objective. The Zone approach ultimately makes area classification and equipment selection clearer and for all those involved

http://www.hubbell-canada.com/wiring/wphazardousloc.asp

8/2/2009

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