-

HAZARDOUS AREA CLASIFFICATION & PROTECTION

Compiled By: B.Venugopal

Manager (Inst.), HOCL
DEFINITIONS
1. Explosive atmosphere. A mixture with air, under atmospheric conditions, of flammable substances in the
form of gas, vapour or mist in such proportions that it can be exploded by excessive temperatures, arcs or
sparks
2. Potentially explosive atmosphere. An atmosphere that could become explosive.
3. Flammable mist: A free suspension in air of droplets of liquid whose vapour is flammable.
4. Hazardous area: An area in which explosive atmospheres are, or may be expected to be present in
quantities such as to require special precautions for the construction and use of electrical apparatus.
5. Non-Hazardous area: An area in which explosive atmospheres are not expected to be present in quantities
such as to require special precautions for the construction and use of electrical apparatus are necessary.
6. Flash point: The minimum temperature at which a material gives off sufficient vapour to form an explosive
atmosphere within the apparatus used for flash point determination.
7. Ignition temperature: The lowest temperature of a flammable gas or vapour at which ignition occurs when
tested as described in International Electromechanical Commission (IEC) publication.
8. Flammable material : A gas, vapour, liquid or solid that can react continuously with atmospheric Oxygen
and that may therefore sustain fire or explosion when such reaction is initiated by a suitable spark, flame or
hot surface.
9. Apparatus Certification: A formal attestation by a recognized testing station that a prototype or sample of
apparatus ( or system) constructed to the certification documents, complies with standard.
10. Temperature Class (T class): One of the six values of temperature allocated to electrical apparatus derived
from a system of classification according to the maximum surface temperature of the apparatus.
11. Apparatus group : The group assigned to electrical apparatus to indicate its suitability for use in mines or
surface industry
12. Type of protection: The measures applied in the construction of electrical apparatus to prevent ignition of
surrounding explosive atmosphere by such apparatus.
13. Lower Explosive limit: the lowest concentration of combustible gas in air, which, if ignited, is capable of
sustaining the propagation of flame and therefore explosion. The LEL is normally expressed in terms of the
percentage of the particular combustible gas in air, by volume.

Note:
There is no precise method of calculation of the LEL for any gas but an approximate formula is as follows
LEL = 100/ (4.85N – 1.425) % V/V
Where N = the number of Oxygen atoms necessary for complete combustion of one molecule
of gas.
E.g.: In the case of Methane (CH4) complete combustion equation is

CH4 + (2O2) = CO2 + 2H2O where N = 2O2 = 4

LEL = 100/ (4.85x 4) – 1.425 = 5.56 % V/V
14. Upper Explosive Limit : The highest concentration of combustible gas in air which, if ignited, would cause
an explosion
15. Explosive Range of a gas: mixtures of gas in air between the LEL and UEL. The most explosive mixture of
gas in air (the stoichiometric mixture) is within the explosive range.
16. Vapour Density : A comparison of a gas or vapour density with that of air will indicate whether the gas or
vapour is lighter or heavier than air
17. Auto ignition temperature: The lowest temperature at which an explosive/flammable mixture can be
ignited.

Classification Of hazardous areas

The standard practice is based on the concept, which is accepted internationally, of dealing with the risk of fire
and explosion by area classification This concept recognizes the differing degrees of probality with which
concentrations of flammable gas or vapour may arise in installations in terms of both the frequency of occurrence
and the probable duration of existence of on each occasion. The area is classified in to three Zones as given
below.

Zone 0 In which an explosive gas air mixture is continuously present, or

present for long periods.
Zone 1 In which an explosive gas air mixture is likely to occur in normal
operation
Zone 2 In which an explosive gas air mixture is not likely to occur in
normal operation, and if it occurs it will exist only for a short
time.

It is important to note that we are concerned with the presence of explosive gas mixture and not just gas air
mixtures. The gas air mixture must be in the flammable range, i.e. between the LEL and UEL, inorder to become
an “ explosive gas-air mixture”.
Zone 0 is the most hazardous area of any plant and it is usually restricted to very small area of the plant, e.g.,
within tanks of volatile flammable liquids – in the volume filled with vapour. In most cases, only a small
percentage of a plant is designated zone 0
Zone 1 is the next most hazardous area of a plant and it, too, is restricted in area according to the nature of the
plant. Zone 1 may, for example, be associated with parts of a plant where gas may, as a matter of routine, be
vented to atmosphere in an enclosed area or where tankers are loaded or unloaded, etc.
It is important to note that Zone 1 applies only to those areas of a plant where explosive gas- air mixture are
likely to occur in normal operation.
Zone 2 covers the remainder of the plant – where an explosive gas – air mixture is not likely to occur in normal
operation- and even if it does, then only for a short duration.

It is the responsibility of the user to define the zones in his plant using such expert advice as he needs from those
especially trained and experienced in such work.
ELECTRICAL APPARATUS FOR USE IN POTENTIALLY EXPLOSIVE ATMOSPHERES

There are two philosophies regarding the protection of plant from explosion hazards due to electrical apparatus in
potentially explosive atmospheres.

(1) To design and make the electrical apparatus in such a manner that it is “ unlikely “ to ignite a flammable
atmosphere in the zone of use.
(2) To automatically shut down conventional (non-explosion protected) electrical apparatus if and when an
explosive atmosphere develops in the zone of use. For this an efficient gas detection system is required.

The conclusion is option 1 is the first line of defence while option 2 is the second line of defence.

Types of protection

The various techniques for making electrical apparatus suitable for use in potentially explosive atmospheres are
generally called “ types of protection”
There are nine recognized types of protection

Flameproof Ex ‘d’
Increased safety Ex ‘e’
Pressurized Ex ‘p’
Non-sparking Ex ‘N’
Oil filled ex ‘o’
Power filled ex ‘q’
Intrinsic safety Ex ‘I’
Special protection Ex ‘s’
Encapsulation Ex ‘m’

The different types of protection are given in the figures

Flameproof enclosure:
A method of protection where the enclosure for electrical apparatus will withstand an internal explosion of the
flammable gas or vapour (for which it is designed) that may enter it, without suffering damage and without
communicating the internal flammation to the explosive atmosphere for which it is designed, through any joints
or structural openings in the enclosure.
The strength of the enclosure are calculated and evaluated by actual ignition tests
Increased Safety:
A Method of protection by which additional measures are applied to an electrical apparatus to give increased
security against the possibility of excessive temperatures and of the occurrence of arcs and sparks during service
life of the apparatus. It applies only to an electrical apparatus, no parts of which produce sparks or arcs or
exceeds the limiting temperature in normal life.

Pressurized
A method of protection using the pressure of a protective gas to prevent the ingress of an explosive atmosphere
to a space that may contain a source of ignition and, where necessary, using continuous dilution of an atmosphere
within a space that contains a source of emission of gas, which may form an explosive mixture.
Non sparking
A type of protection applied to electrical apparatus such that, in normal operation, it is not capable of igniting a
surrounding explosive atmosphere, and a fault capable of causing ignition is not likely to occur.
Oil filled
A method of protection where electrical apparatus is made safe by oil-immersion in the sense that an explosive
atmosphere above the oil or outside the enclosure will not be ignited.
Power filled.
A method of protection where the enclosure of electrical apparatus is filled with a mass of granular material such
that, if an arc occurs, the arc will not be liable to ignite the outer flammable atmosphere.
Intrinsic safe
A protection technique based upon the restriction of electrical energy within apparatus and in the inter connecting
wiring, exposed to a potentially explosive atmosphere, to a level below that which can cause ignition by sparking
or heating effects. Because of the method by which intrinsic safety is achieved it is necessary that not only the
electrical apparatus exposed to the potentially explosive atmosphere, but also other (associated) electrical
apparatus with which it is interconnected, is suitably constructed.
Special protection
A concept for those types of electrical apparatus that, by their nature, do not comply with the constructional or
other requirements specified for apparatus with established types of protection, but that nevertheless can be
shown, where necessary by test, to be suitable for use in hazardous areas in prescribed zones.
Encapsulation
A type of protection in which parts that could ignite an explosive atmosphere by either sparking or heating are
enclosed in a compound in such a way that this explosive atmosphere cannot be ignited.

Procedure for selecting electrical apparatus

Apparatus for use in hazardous areas should be selected in accordance with each of the following criteria:
(a) classification of area;
(b) temperature classification;
(c) apparatus group;
(d) Environmental conditions.
Selection according to classification of area
Hazardous areas are to be classified in to different zones as explained earlier. Having established the zones, the
types of protection to be applied to the electrical apparatus should be selected with table given below

Selection of apparatus and systems according to zone of risk

Zone Type of protection

Zone 0 ‘ia’ intrinsically –safe apparatus or systems

‘s’ special protection ( specifically certified for use in zones 0)

Zone 1 Any explosion protection suitable for Zone 0 and

‘d’ Flammable enclosure
‘ib’ Intrinsically safe apparatus or systems
‘p’ pressurization, continuous dilution and pressurized rooms
‘e’ increased safety
‘s’ special protection

Zone 2 Any explosion protection suitable for zones 0 or 1 and

‘n’ type of protection
‘o’ oil-immersion
‘q’ sand filling

Selection according to temperature classification

When selecting according to temperature classification, maximum surface temperature of the T class of the
apparatus should not exceed the ignition temperature of the gas or vapours present. The relationship between T
class and maximum surface temperature is given in table below.

Relationship between T class and maximum surface temperature

T class Maximum surface temperature in C

T1 450
T2 300
T3 200
T4 135
T5 100
T6 80
Selection according to apparatus group
Apparatus are divided into two basic groups
(a) Group I : Electrical apparatus for mines susceptible to firedom
(b) Group II : Electrical apparatus for places with a potentially explosive atmosphere, other than mines
susceptible to firedom
The apparatus group and the representative gas is given below (BS 5501 standard)

Representative gas Apparatus Group North American

BS 5501 NEC classification
Methane I Class I Group D

Propane II A Class I Group D

Ethylene II B Class I Group C

Hydrogen II C Class I Group B

Acetylene II C Class I Group A

Selection according to environmental conditions

Apparatus and its component parts should be constructed so as to guard against electrical and mechanical failure
in the intended conditions of use. Particular attention should be given to the need for protection against the
weather, the ingress of liquids and particular matter, corrosion, the effect of solvents and the effect of heat from
adjacent plant.
Marking of flameproof enclosure

The marking on an apparatus with the type of protection ‘d’ will normally include the following details to
comply with the standards
(a) the symbol of the type of protection ‘d’
(b) the apparatus group and subdivision
(c) the temperature classification
Data for flammable material for use with electrical apparatus
Compound LEL V % UEL V % Ignition T class Apparatus
temperature group
Acetone 2.15 13 535 T1 II A

Acetylene 1.5 100 305 T2 II C

Ammonia 15 28 630 T1 II A

Aniline 1.2 8.3 617 T1 II A

Benzene 1.2 8 560 T1 II A

Butane 1.5 8.5 365 T2 II A

Cumene 0.88 6.5 420 T2 II A

Methane 5 15 595 T1 II A
Naphtha 0.9 6 290 T3 II A
Phenol 605 T1 II A
Propane 2 9.5 470 T1 II A
Propylene 2 11.7 II A
Toluene 1.2 7 535 T1 II A