HAZARDOUS AREA CLASSIFICATION

Objectives: The objectives of this chapter are to:

 Identify the different hazardous areas and classifying

 Learning about the different classification of the hazardous areas

 Learning about the precautions and prevention that should be taken in different

hazardous areas

Definitions: Hazardous Area is defined as:

 “Any area in which the explosive/flammable/combustible materials

(gases/vapours) are present, most likely to be present or may present during normal

condition/ repair/maintenance/leak of the equipment/system & which needs to require

special precautions for the construction, installation and use of electrical apparatus”.

-As per IS 5572-2209

OR

 “An area in which an explosive gas atmosphere is or may be expected to be

present, in quantities such as to require special precautions for the construction,

installation and use of equipment”.

-As per IEC 60079-10-1

Explosive gas atmosphere: “Mixture with air, under atmospheric conditions, of

flammable substances in the form of gas or vapor, which, after ignition, permits self-

sustaining flame propagation”.

Lower explosive limit (LEL): “The concentration of flammable gas, vapor or mist in air

below which an explosive gas atmosphere will not be formed”.

 -As per IEC-60050 – 426

Upper explosive limit (UEL): “The concentration of flammable gas, vapor or mist in air

above which an explosive gas atmosphere will not be formed”.

-As per IEC-60050 – 426

Flashpoint: “Lowest liquid temperature at which, under certain standardized conditions,

a liquid gives off vapours in a quantity such as to be capable of forming an ignitable

vapour/air mixture”.

Auto Ignition Temperature: “The Lowest temperature at which a substance

Spontaneously ignites at normal temperature without any External source of Ignition like

Spark or Flame”.

Classification of Hazardous Area: Classification of Hazardous area consists of three

elements.

a) Area Classification

b) Classification of equipment based on

a. Type of material present in the atmosphere

b. Maximum surface temperature of Equipment.

c) Type of protection applied

 As the O&G/Petroleum sector always associated with such kinds of atmospheres,

it’s obvious to consider these special considerations. However, the level of protection

will be based on quantum of hazardous content being handled/stored/processed in a

particular area.

 Along with this, determination of probability and severity of occurrence such

atmospheres is necessary in an area is vital, because it’s infeasible to provide higher

degree of protection in area where it is not necessary. Similarly, inferior protection in

potential risk areas will leads to devastating results.

 Hence, in a particular area where a specific material is being handled the risk of

explosion will be decided by probability of occurrence of such flammable/explosive

atmosphere.

 By considering above said as criterion, a particular area containing specific

hazardous material, is classified into sub divisions/zones (acc. to IEC 60079-10-part-1,

IS 5572:2009, NEC chapter V: zonal classification) as under:

 Zone-0: (Gas and Vapours) “an area in which an explosive gas atmosphere is

present continuously or for long periods or frequently”.

Examples for Zone 0 locations:

1. Space inside a tank containing volatile flammable Liquid.

2. Pits or hatches near to storage or process areas of heavier than air gases. Eg:

LPG

 No electrical equipment should be installed in Zone 0 locations unless it is mandate

for the process. Only intrinsically safe equipment should be used only after the system

is purged with inert gases.

 Zone-1(Gas and Vapours): “an area in which an explosive gas atmosphere is

likely to occur in normal operation occasionally”.

Examples for Zone 1 Locations:

1) Locations where liquefied flammable gases transferred between two containers, in

areas the vicinity of spraying and painting operations

2) Locations which are ventilated adequately and contains oil and Fat extraction

machines using flammable solvents.

3) Compartments or Drying rooms which are ventilated adequately used for the

evaporation of flammable solvents.

 Zone-2(Gas and Vapours): “an area in which an explosive gas atmosphere is not

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

 “The Zone 2 classification usually includes locations where flammable liquids or

flammable gases or vapours are used, but which would become hazardous only in case

of an accident or of some unusual operating condition”.

* Ref.IS 5572 :2009, IEC 60079-10 : part-1, NFPA 497 :2008 &

NFPA70(NEC) :2011

Note: some companies follow the standardized frequency rate, which supposes as

under:

 Zone-0: Area where chance of occurrence of explosive atmosphere >

1000hrs./year

 Zone-1: Area where chance of occurrence of explosive atmosphere > 100hrs./year

and < 1000 hrs./year

 Zone-2: Area where chance of occurrence of explosive atmosphere < 100hrs./year

For Dust: For the areas prone to combustible dust/fibers the following classification is

followed:
Zone 20: “A place in which Explosive atmosphere is in the form of combustible dust in

air is present continuously for a long period of time and frequently”

Zone 21: “A place in which explosive atmosphere (combustible dust) in air is likely to

occur in normal operation occasionally”.

Zone 22: “A place in which explosive atmosphere (Combustible dust) in air is not likely

to occur in normal operation but if occur it persists for small duration only”.

* Ref.IS 5572 :2009, IEC 60079-10 : part-1

According to NFPA 70 the hazardous area Is classified in to Divisions.

Class I : Gas and Vapors

Class II : Dust

Class III : Fibre and Flyings.

Now for Every class the Will be two divisions.

Division 1 : ‘Explosive atmosphère Is présent or likely to be present in Normal

Operations’.

Division 2 : ‘Explosive atmosphere is not likely to bé présent in normal Operations but

could be présent in abnormal Operations’. Ref. NFPA 497 :2008 &

NFPA70(NEC) :2011

Classification of Groups based on Flammability:

 For this purpose, IEC 60079-20-part-1 gives the guidance to group/classify the

equipment based on gases/vapours flammable properties, which follows as below:

 Group I: Equipment used in underground installations, example mines where

dusty atmosphere is present

 Group II: equipment’s used in above ground locations where explosive gas

atmosphere is present and is classified based on MSEG (Maximum Experimental Safe

Gap) and MIC (Minimum Ignition Current Ratio) (even tough other classifications are

there solely based on MSEG or MIC ratio this classification is in common with NEC &

CEC too)

 Group IIA: Materials having “MESG ≥ 0.9 mm, or MIC ratio> 0.9”.

 Group IIB: Materials having “0.55 mm <MESG <0.9” mm, or “0.5 < MIC ratio <

0.8”;

 Group IIC: Materials having “MESG <0.5 mm, or MIC ratio < 0.45mm”.

Hence, above classification is to be determined before deciding the level of

protection.

NFPA 70 IEC Some Examples of Hazardous

material in surroundings

Group A IIC “(C2H2) or Equivalent Hazard”

Group B IIB + H2 Hydrogen(H2),and its equivalent.

Group C IIB Diethyl oxide((C2H5)2O),

Ethene(C2H4) or Gases of Equivalent

Hazard
 Group D IIA* Gasoline(C4–C12), Acetone(C3H6O),

Ammonia(NH3), Methane, Natural

gas, Naphtha(C6–C13),

Propane((C3H8) Etc.

Group E -- “Metal Conductive dusts including

(Al), (Mg) and their Alloys or other

Combustible Dusts”.

Group F -- “Carbon black and coal dust and its

equivalent hazards”.

Group G -- Flour, Sugar, Starch grain, Wood

and Plastic Dusts.

TABLE 5.1: GAS AND DUST GROUPS

Maximum Experimental Safe Gap (MESG): “The maximum of the joint between two

parts of interior chamber of a test apparatus that, when the internal mixture is ignited and

under specific conditions, prevents the ignition of external gas mixture by propagating

through a 25mm long joint, for all concentrations of tested gas or vapour in air”. * Ref.

(API 505-3.2.39)

Minimum Ignition Current Ratio (MIC Ratio): “The minimum energy required from a

captive spark discharge to ignite the most easily ignitable mixture of gas or vapour divided

by the minimum current required from and inductive spark discharge to ignite methane

under the same test conditions”.

* Ref. NFPA 497 :2008

Temperature Classes: Based on their ignitibility Explosive gas atmosphere is divided in

to Temperature Classes. Gas – Air mixture can be ignited by coming in contact with hot

surfaces also.so based on their maximum surface temperature all electrical equipment
used in hazardous areas are classified.

“Maximum surface temperature is the highest temperature attained by any part of

electrical equipment in its service under the specified conditions described in standards,

which can ignite the surrounding Explosive atmosphere”.

Maximum Permissible Surface Class

TABLE
Temperature of Electrical Equipment (0C)
5.2:
“450” “T1”

“300” “T2”

“200” “T3”

“135” “T4”

“100” “T5”

“85” “T6”

TEMPERATURE CLASSIFICATION OF ELECTRIC EQUIPMENT

*As per NEC 500 – 5(d)

Protection Methods: There should be some specific type of electrical Equipment to be

used in Hazardous areas according to their Zones. An Explosion occurs when:

1. If explosive atmosphere is present.

2. There is presence of any ignition source

3. There is transmission of explosion.

Following are the protection schemes for eliminating any of these conditions which

prevents Explosion in Hazardous Area.

There are seven types of Protection Schemes.

1) Intrinsically safe (i)

2) Flame Proof (d)

3) Increased Safety(e)

4) Pressurized Equipment(p)

5) Non – Sparking (n)

6) Oil Immersed (o)

7) Sand Filled (s)

Intrinsically Safe (i): This type of protection will eliminate any source of ignition such

as Sparks, Over heating etc. The Spark’s thermal energy in electrical equipment is

incapable under test conditions to cause ignition of explosive atmosphere.

The Principle of intrinsic safety applicable to electric equipment’s in which output Energy

or consumption of Energy is so small than Ignition Energy of Explosive atmosphere.

FIG 5.1 SCHEMATIC OF INTRINSICALLY SAFE APPARATUS

Increased Safety (e): This is based on German concept. This is used to motors used

both in coal mining and chemical / petro chemical industries. “Increasing safety means

of additional mechanical, electrical and thermal protection methods. Increased security

against temperature, arcs and sparks during normal service of life of the machine”.
Flame Proof(d): It is recognized explosion may occur inside the enclosure, but the

enclosure is sufficiently strong to withstand an interval and is so constructed that flame

passing from inside to the outside is cooled. This is achieved by controlling the length of

the possible flame paths.

Pressurized Equipment(p): Pressurization is, the dangerous parts are enclosed in

housing purged with fresh air or inert gas. The gas is then prevented reentering, the

enclosures by maintaining its internal pressure slightly above atmosphere.

The normal safety devices are

a) Pressure measuring device: - “These devices should be provided for the operation

alarm or trip devices”.

Safe Starting Devices: - “These devices should be provided to ensure that no apparatus

with in the enclosure”.

Non Sparking (n): The ‘N’ motors are similar in basic concept to type ‘e’ motors, but

with some relaxation in requirement. Mechanical clearances are similar to type ‘e’ but

clearance, temperature are less than ‘e’ type. High quality installation system is required

for motor winding. Frame sizes of type ‘N’ motors are generally the same as for general

purpose motors.

Oil Immersed (O): In this type of electrical apparatus, all parts on which arcs may occur

in normal service are immersed in oil to prevent ignition of an explosive gas mixture.

This type of protection is commonly used in the case of transformer, switch gear and

control gears. While designing the oil immersed electrical apparatus, case is taken that

the temperature rises and the temperature of the oil at the surface as well as the
temperature of any part of the enclosure.

Sand Filled(s): Electrical apparatus all live parts filled with mass of powder material. If

an arc occurs within the enclosures this arc will not be liable to ignite the outer explosive

atmosphere. The following material should be 100% noncombustible and should meet

requirements for its electrical strength, degree of purity and processing. Quartz is used

as a common filling material.

Ingress Protection (IP) Rating of Electrical Equipment:

These developed by European committee for electro technical standardizations

(NEMAIEC 60529) degrees of protection provide by enclosure- IP code.

The IP rating normally has either 2 or 3 numbers;

1 Protection from solid object

2 Protect from liquids

3 Protections against mechanical impacts. (not a part of IEC 60529)

Example (IP rating 54 means, 5 describe the protection from solid object and 4 describe

level of protection from liquids)

“0” “No special protection needed”

“1” “Protection against solid object more than

50mm”

“2” “Protection against solid object more than 12

mm”

“3” “Protection against solid object more than 2.5

mm”

“4” “Protection against solid object more than 1

mm”

“5” “Protection against dust”

“6” “Totally against dust” TABLE 5.3

 PROTECTIONS AGAINST SOLIDS. INGRESS PROTECTION (IP) 1ST NUMBER *As per (NEMA

IEC60529)
“0” “No protection”
TABLE 5.4
“1” “Protection against falling drops of water or

condensation”

“2” “Protection against direct spray of water up to

150 from vertical”

“3” “Protection against direct spray of water up to

600 from vertical”

“4” “Protection against water spray from all

directions – limited ingress permitted”

“5” “Protection against low pressure jets of water

spray from all directions- limited ingress”

“6” “Protection against temporary flooding of water

– limited ingress protection”

“7” “Protected against the effect of immersion b/w

15cm and 1m”.

“8” “Protection against long periods of immersion

under pressure”

PROTECTION AGAINST LIQUIDS, IP 2ND NUMBER *As per (NEMA IEC60529)

0 No protection

1 Protects against impacts of 0.225 joule TABLE 5.5

2 Protects against impacts of 0.375 joule
IP 3’RD
3 Protects against impacts of 0.5 joule
NUMBER
4 Protects against impacts of 2 joule

5 Protects against impacts of 6.0 joule (NOT AS A

6 Protects against impacts of 20.0 joule PART IEC

60529)

Summary: “An area in which an explosive gas atmosphere is or may be expected to be

present, in quantities such as to require special precautions for the construction,

installation and use of equipment”.

Classification of Hazardous area consists of three elements.

1. Area Classification – based on frequency of occurrence of flammable/combustible

atmosphere

2. Material Group of equipment- based on nature of material present in atmosphere

3. Temperature classification - based on maximum surface temperature of equipment

4. Type of protection applied- based on type of protection scheme applied

All these details must be given on name plate of equipment, along with the certifying

standards. NFPA and IEC are the two mostly accepted and adopted international

standards and hence, classifications as per both of them are to be understood. However,

India adapted IEC standards. Apart from these, name plate details also represent the

type of ingress protection given to equipment. Based on all these ratings/specifications

equipment must be selected, installed, operated and maintained in hazardous areas.

Review Questions:

1. What is hazardous area?

2. What is the classification of hazardous area based on NFPA and IS standards?

3. What are the different classes and zones of hazardous areas in NFPA and IS

respectively?

4. What are the different ingress protection of an equipment?

5. What is the standard of hazardous area classification in NFPA and IS?

6. What is MESG and MIC Ratio and the classification based on these?

7. What are the temperature classification as per NFPA and IS?

References:

1. Electrical Safety, Fire Safety Engineering and Safety Management Author S.

Rao, R.K. Jain and H.L. Saluja

2. DS/EN 60079-10-1 & UK

3. DS/EN 60079-10-2 & UK

4. IP15

5. IES 5572

6. NFPA70