RIZAL TECHNOLOGICAL UNIVERISTY

COLLEGE OF ENGINEERING ARCHITECTURE AND TECHNOLOGY

INSTRUMENTATIO AND CONTROL ENGINEERING

TOPIC NO.3

INSTRUMENTATION ENGINEERING

CALMA, NORIELLE

HAZARDOUS CAÑAS, CHARLIE JACK F.

AREA
CLASSIFICATION

MARIBAO, ALLYZA

NAZARIO, RYNDEL RAPHAEL

PADRIGON, WILFREDO D.

VERGARA, BRYAN

ENGR. JOHN YASAY

 Contents

Title page

I. INTRODUCTION ------------------------------------------------------------------------------- 1
II. HAZARDOUS AREA CLASSIFICATION ------------------------------------------------- 4
A. HAZARDOUS LOCATION STANDARDS
B. ZONE SYSTEM
C. CLASS/DIVISION SYSTEM
III. HAZARDOUS AREA CLASSFICATION MAPPING ------------------------------------12
IV. HAZARDOUS AREA CLASSIFICATION MARKINGS---------------------------------16
V. REFERENCES -----------------------------------------------------------------------------------20
I. Introduction

To prevent any risk of explosion or fire and improve safety of the process and employees, all
potentially hazardous areas must be classified according to the processes conducted in these
areas. It is in responsibility of the end user to define the Hazardous Areas Within the
operations.

Hazardous Area Classifications is the method of analyzing and classifying the environments
that may contain explosive gas atmospheres, as well as assisting in the right selection of
electrical equipment. The concept of analyzing potentially explosive locations is critical for
reducing the risk of electrical equipment installation in potentially explosive environments.

Appropriate areas classification allows preparation of safety procedures for plant operation and
maintenance. Classification varies across the world.
II. Hazardous Area Classification

A. Hazardous Location Standards

Electrical equipment installed in hazardous locationsare subject to regulations and standard.

Different Standards Depending on Installation Location

International Electrotechnical Commission

Global standard outside

Atmosphere Explosive

Adopts IEC standards into series of directives

Law in European Union

North America and European Union

North America

Regulations established by NEC, CEC, OSHA and NFPA NEC 500 is most common and use
d for decades
 Explosive Atmospheres Standards

• International - IEC 60 079 series

IEC 60079 Series Explosive Atmosphere Standards

The International Electrotechnical Commission (IEC) 60079 series of explosive atmosphere

standards covers a wide array of important considerations when it comes to potentially
explosive atmospheres. Dealing with general equipment requirements, gas detectors,
intrinsically safe equipment, a variety of different methods of equipment protection, and
moving on to the classification of areas, material characteristics, and some industry specific
standards, the IEC 60079 series is truly expansive.

• European - CENELEC 60 079 series

• National - USA: ANSI/API RP 505 (zone system)
• Russia - Gost R 51330-X-99 series

Classification of Hazardous Areas according to IEC 60079

The International Electrotechnical Commission has been adopted by countries around the
world (IEC) zoning is the name for this ideology, which is used throughout North America.

To determine the level of safety required, it is divided into Classes, Divisions, and Groups.
The boundaries of a particular hazardous zone are primarily defined by zone classification,
such as the release rate of gas or vapour and duration of release in normal condition.

There are 3 types of zone:

zone 0, zone 1, and zone 2 can be present in any explosive atmosphere according to

IS 5572:2009 (concentration of flammable gas, vapour or mist in air) and IEC 60079-10
 Hazardous Area Classification according to IEC 60097 and ATEX

Areas where there is the likelihood of the presence of gases, vapors, dust, and fibers are referred
to as zones. The higher the number in this ‘zonal classification’ the smaller is the risk of an
explosion.
Zones are classified as per IEC 60097 and ATEX shown below

Zones classified as per IEC 60079 and ATEX

Gasses and Vapours Dust and Fibers

Zone 0 Zone 1 Zone 2 Zone 20 Zone 21 Zone 22

B. Zone System

Hazardous areas are defined in DSEAR as "anywhere where explosive atmospheres are likely
to occur in such quantities that special precautions are required to protect worker safety. ". In
this context, it is better to take "special precautions" for the equipment's construction,
installation, and use, as indicated in BS EN 60079 101.

Zone classification is a method of analyzing and classifying environments where

explosive gases may occur. The primary purpose is to facilitate the proper selection and
installation of apparatus to be used safely in that environment, considering the properties of
the flammable materials present. DSEAR expands the initial scope of this scan explicitly to
see whether non-electrical ignition sources and portable equipment pose a fire hazard.

Hazardous areas are classified into zones based on an assessment of frequency and
duration of explosive gas atmospheres, as follows:

• Zone 0: An area in which an explosive gas atmosphere is present continuously or for long
periods;
• Zone 1: An area in which an explosive gas atmosphere is likely to occur in regular
operation;
• Zone 2: An area in which an explosive gas atmosphere is not likely to occur in regular
operation and, if it happens, will only exist for a short time.

Various sources have attempted to establish time limits for these regions, but none have
been officially approved. The most commonly used values are:

• Zone 0: Explosive atmosphere for more than 1000h/yr

• Zone 1: Explosive atmosphere for more than 10, but less than 1000 h/yr
• Zone 2: Explosive atmosphere for less than ten h/yr, but still sufficiently likely to require
controls over ignition sources.

A study of the extent and classification of a hazardous area involves reviewing and
documenting the following:

• Have any flammable materials;

• Physical properties and characteristics of each type of combustible material;
• Potential sources of releases and how they can form explosive atmospheres;
• Superior operating temperature and pressure;
• The presence, extent, and capacity of ventilation (forced and natural);
• Dispersion of vapors released below the flammability limit;
• Probability of each release scenario.

These factors allow the appropriate selection of the zone type, extent of the zone, and
as well as the equipment. The IP code provides a method for estimating the release rate of
small diameter holes with a pressurized source. It shows how the buoyancy and momentum of
a drop affect the extent of an area. Otherwise, it sums the values of a mixture of LPG, gasoline,
natural gas, and hydrogen from a refinery for pressures up to 100 bar.
Selection of Equipment:

The DSEAR ACOP describes the provisions concerning existing equipment. There are
different technical means (protection concepts) of building equipment to the other categories.
These, the standard current in mid-2003, and the letter giving the type of protection are listed
below.

Zone 0 Zone 1 Zone 2

Category 1 Category 2 Category 3

Electrical
Type 'n' - EN
50021 1999
'd' - Flameproof Non-electrical
'ia' intrinsically safe enclosure EN 13463-1,
EN 50020, 2002 EN 50018 2000 2001

Ex s - Special protection if
specifically certified for Zone 'p' - Pressurized
0 EN 50016 2002

'q' - Powder
filling
EN 50017,
1998

'o' - Oil
immersion
 EN 50015,
1998

'e' - Increased
safety
EN 50019,
2000

'ib' - Intrinsic
safety
EN 50020,
2002

'm' -
Encapsulation
EN 50028,
1987

's' - Special
protection

The correct selection of electrical equipment for hazardous areas requires the following
information:

• Hazardous area classification (as in the areas indicated in the table above);
• The temperature class or ignition temperature of the gas or vapor is mentioned
in the table below:
 Maximum
Surface
Temperature Temperature, Ignition Temperature
Classification °C of gas or vapour, °C

T1 450 >450

T2 300 >300

T3 200 >200

T4 135 >135

T5 100 >100

T6 85 >85

Although several different combustible materials may be present in a particular area, the
material that gives the highest classification determines the overall type of the area. The IP
code specifically looks at the problem of hydrogen-containing process flows as commonly
found in refineries. Consideration should be given to combustible materials that may be
generated by chemical interactions.

C. CLASS/DIVISION SYSTEM

Hazardous locations per the Class/Division system are classified according to the
Class, Division, and Group.
▪ CLASS – The Class explains the general nature (or characteristics) of hazardous
substances that may or may not be present in sufficient quantities.

Class I – Locations where flammable gases or vapors are present in sufficient

amounts to develop explosive or ignitable combinations.

Class II – Locations where combustible dusts (in suspension, intermittently, or on

a regular basis) may or may not be present in sufficient amounts to generate
explosive or ignitable combinations.

Class III – Locations where ignitable fibers may or may not be present in sufficient
amounts to form explosive or ignitable mixes.

HAZARDOUS MATERIAL CLASSES AND DIVISION

CLASS DIVISION

I. Flammable gases or vapors may 1 – Ignitable concentrations of hazards

be present. exist under normal operation conditions
and/or where the hazard is caused by
frequent maintenance or repair work or
frequent equipment failure.
2 – Ignitable concentrations of hazards
exist under abnormal operation conditions.

II. Combustible dust may be 1 – Ignitable concentrations of hazards

present. exist under normal operation conditions
and/or where the hazard is caused by
frequent maintenance or repair work or
frequent equipment failure.
2 – Ignitable concentrations of hazards
exist under abnormal operation conditions.
 III. Easily ignitable fibers or flyings 1 – Ignitable concentrations of hazards
may be present exist under normal operation conditions
and/or where the hazard is caused by
frequent maintenance or repair work or
frequent equipment failure.
2 – Ignitable concentrations of hazards
exist under abnormal operation conditions.

Group definition

Group - define the type of hazardous material and (partly) the location of the surrounding
atmosphere. Group is divided in three groups where Group I is reserved for mining locations.
Group II is for explosive gases (Zone 0, 1 and 2) and Group III is for explosive dusts (Zone
20, 21 and 22).

Group Mines
I susceptible to firedamp (flammable mixture of gases naturally occurring
in a mine).

Group Explosive gas

II atmosphere other than mines susceptible to firedamp. Group II
equipment is subdivided into three subgroups.

A Atmospheres containing propane, acetone, benzene, butane, methane,

petrol, hexane, paint solvents or gases and vapors of equivalent hazard.

B Atmospheres containing ethylene, propylene oxide, ethylene oxide,

butadiene, cyclopropane, ethyl ether, or gases and vapors of equivalent
hazard.
 C Atmospheres containing acetylene, hydrogen, carbon disulfide or gases
and vapors of equivalent hazard.

Group Explosive dust

III atmosphere. Group III equipment is subdivided into three subgroups.

A Atmospheres containing combustible flying.

B Atmospheres containing non-conductive dust.

C Atmospheres containing conductive dust.

III. Hazardous Area Classification Mapping

A potentially explosive atmospheres exist where there is a risk of explosion due to mixtures of
gas/air, vapor/air, dust/air or other flammable combinations. Any area that could have a
potentially explosive atmosphere is known as a Hazardous Area. The purpose of area
classification is to identify the extent of the area made hazardous as a result of the presence of
explosive atmosphere and to classify the identified hazardous area on the premise of likelihood
and kind of flammable release expected to be present.
Fig. 1 Area classification example according to International Electrotechnical Committee
(IEC)

Fig. 2 Area classification for storage tanks, by a particular code

Fig. 3 Tank with floating roof with or without protective cone roof
Fig. 4 Area Classification Diagram for a Class I Area (Flammable Liquid)

Fig. 5 Area Classification Diagram for a Class II Area (Combustible Dust)

Determination of hazard radius

3 methods can be used:

• Direct examples limited to common facilities

• A point source approach for all situations

• A risk-based approach.

Hazard radius depend on the following parameters:

Grade of release - Fluid category- Release pressure- Hole release size

Grades of release

3 basic grades of release in order of decreasing frequency and likelihood of the explosive gas
atmosphere:

• Continuous grade of release

Release which is continuous or is expected to occur frequently or for long periods.

• Primary grade of release

Release which can be expected to occur periodically or occasionally during normal

operation.

• Secondary grade of release

Release which is not expected to occur in normal operation and, if it does occur, is likely
to do so only infrequently and for short periods.
Release rate

The greater the release rate, the larger the extent of the zone.

• Geometry

• Release Velocity

• Concentration

• Volatility of flammable liquid

• Liquid Temperature

Openness

An area can be classified in three categories with respect to confinement:

• An open area (basically no roof/ceiling, no walls and floor made of grating)

• A sheltered, partially enclosed, partially confined area (various combinations of solid

floor, ceiling and walls or equivalent obstructions to natural draft).

• An enclosed area.

• The extent of confinement governs the determination of the level of ventilation.

Ventilation

Natural or artificial movement of air and its replacement with “fresh air”.

Degree of ventilation (natural / artificial

• High ventilation (VH)

• Medium ventilation (VM)

• Low ventilation (VL)

Availability of ventilation

• Good: “present continuously”

• Fair: “Present at normal operation. Discontinuities are permitted for short period.”

• Poor: “Discontinuities are not expected to occur for long period.”

IV. Hazardous Area Classification Markings

Marking

The marking criteria for electrical equipment are uniformly given forth in general technical
requirements standards. The equipment must be clearly labeled in accordance with the
classified area in which it is permitted to be installed.

The minimal marking must indicate the following:

• Class
• Division
• Group
• The maximum safe operating temperature or temperature range, based on a 40°C
ambient.
• Any special conditions that have to be observed (such as NEC section 500-5(d))

And according to these Regulation for marking:

• ATEX - European directive 2014/34/EU covers equipment and protective

systems for use in hazardous areas. Directive 99/92/EC (ATEX137)
defines employers’ responsibilities to hazardous area safety.
• IECEx - International Standards on equipment and installations in
potentially explosive areas published by IEC (International
Electrotechnical Commission).
• NEC / CEC - National Electric Code (USA) and Canadian Electric Code
define the standards by which all electrical wiring and equipment must be
installed.
Markings:

EUROPEAN COMFORMITY MARKING

NOTIFIED BODY INDETIFICATION
UROPEAN COMMISION MARK
EQUIPMENT GROUP
EX:
• I - For use in underground mines
• II - For use in all other places
EQUIPMENT CATEGORY
EX:

• 1- Equipment that is intended for use in ATEX Marking (Europe) – 2014/34/EU

areas where an explosive atmosphere is
present continuously, for long periods or 0344 II 3 G Ex d IIB T5 Gc
frequently
• 2- Equipment that is intended for use in
areas where an explosive atmosphere is
likely to occur in normal operation and
must ensure a high level of protection.
• 3- Equipment that is intended for use in
areas where an explosive atmosphere is
unlikely to occur in normal operation
and must ensure a normal level of
protection.

SURROUNDING ATMOSPHERE
EX:

• G- Equipment certified for use in

flammable gases
• D- Equipment certified for use where TEMPERATURE
dust is present in the atmosphere
CLASSIFICATION
EX:
EXPLOSION PROTECTED
• T1- 450ºC
PROTECTION TYPE • T2- 300ºC
• T3- 200ºC
EX: • T4- 135ºC
• T5- 100ºC
• d- Flameproof • T6- 85ºC
• Ia- Intrinsically Safe
• e- Increased safety
MATERIAL GROUP EQUIPMENT PROTECTION LEVEL
EX: EX:
First letter:
• I - Mines
• II - Surface above ground industries • G- Gas
• D - Dust
Second letter:
SUB GROUP:
• a – normal
EX:
• b – expected malfunction
• A - Less easily ignited gases e.g. propane
• c – rare malfunction
• B- Easily ignited gases e.g. ethylene
• C- Most easily ignited e.g. hydrogen or acetylene
 IECEx Marking (Global) – IEC60079-0 6th edition

EX ic IIB T5 Gc

EXPLOSION PROTECTED

PROTECTION TYPE
EX:

• d- Flameproof
• Ia- Intrinsically Safe
• e- Increased safety

MATERIAL GROUP
EX:

• I - Mines
• II - Surface above
ground industries

SUB GROUP:
EX:

• A - Less easily ignited gases e.g. propane

• B- Easily ignited gases e.g. ethylene
• C- Most easily ignited e.g. hydrogen or acetylene

TEMPERATURE
CLASSIFICATION
EX:
• T1- 450ºC
• T2- 300ºC
• T3- 200ºC
• T4- 135ºC
• T5- 100ºC
• T6- 85ºC

EQUIPMENT PROTECTION LEVEL

EX:
First letter:
• G- Gas
• D - Dust
Second letter:
• a – normal
• b – expected malfunction
• c – rare malfunction
 NEC / CEC Marking (North America)

Class l Division 2 AEx Group C, D T5

TYPE OF FLAMMABLE SUBSTANCE

EX:
• Class I-Flammable gas, vapors, and liquids
• Class II-Combustible dusts
• Class Ill-Ignitable fibers and flyings

AREA CLASSIFICATION
EX:

• Division 1-Flammable substances are

continually present or are likely to exist
under normal operating conditions
• Division 2-Flammable substances are not
likely to exist under normal operating
conditions

AMERICAN STANDARD MARKING

GROUP CLASSIFICATION
EX:

Gas :

• GROUP A- Acetylene
• GROUP B- Hydrogen Ethylene,
acrylonitrile, propylene oxide, ethyl oxide
• GROUP C- Cyclopropane, ethyl ether
• GROUP D - Acetone, methane, hexane,
propane

Dust, fibers, flyings:

• GROUP E - Conductive dust,

• metal dust TEMPERATURE
• GROUP F - Coal dust
• GROUP G - Non-conductive dust, grain CLASSIFICATION
dust
EX:
• T1- 450ºC
• T2- 300ºC
• T3- 200ºC
• T4- 135ºC
• T5- 100ºC
• T6- 85ºC
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hazardous-locations-124-qt

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