Hazardous Area

Classification
 Introduction
Fire, Explosions and Environmental Pollution are the most serious
“unpredictable "issues affecting life and business losses in the hydrocarbon
and chemical industries today.
Fire and Explosion Fundamentals

• What is Fire?

• Flammable Hazardous Material

• Fire Triangle and Fire Tetrahedron

• What is an Explosion?

• Properties of Hazardous Materials

 What is Fire?

Fire
Is a rapid oxidation process which is a
chemical reaction resulting in the evolution of
heat and light.
 Flammable or hazardous material
• Flammable Material can be gas , vapor , liquid or solid that can react
continuously with oxygen and may result in fire or explosion.

• This reaction can be initiated by Spark or Hot Surfaces

Flammable
Vapor
• Flammable Materials can be:
• Flammable vapors generated by liquid
• Flammable Mists
• Flammable Gases Paint

• Combustible Dusts
 Fire Triangle

 Fuel

 Heat

 Oxygen

All three elements must be

present to initiate a fire.
 Fire Tetrahedron

 Fuel

 Heat

 Oxygen

 Chemical reaction
 Fire Tetrahedron
CHEMICAL CHAIN
FUEL OXIDIZING AGENT (O2) HEAT
REACTION

May be the combustible Those materials that yield Heat is the energy The chemical chain reaction
material. Can be solid ,liquid oxygen or other Oxidizing component needed to known as fire occurs when
or gas gases during the course of increase the fuel’s fuel, oxygen and heat are
a chemical reaction. temperature to the point present in the right
where sufficient vapors are conditions and amount.
produced for ignition to
occur.
 What is an Explosion?

Explosion
is an uncontrolled release of energy
accompanied by a sudden and
violent expansion of gases and
possibly rapid combustion of any
flammable materials present.
Explosion
 Properties of Hazardous Materials
Flammability Range
The minimum or maximum concentration
of gas in air that will ignite.
Lower Flammability Limit
The lowest concentration at which a
fuel/air mixture will burn. Below this there
is too little fuel (the mixture is too lean)
Upper Flammability Limit
The highest concentration at which a
fuel/air mixture will burn. Above this there
is not enough oxygen (the mixture is too
rich)
 Properties of Hazardous Materials
Flash Point
The minimum temperature to which a liquid fuel gives off sufficient vapor that
can be ignited momentarily by a flame.

Fire Point
The minimum temperature to which a liquid fuel gives off sufficient vapor to
support continuous combustion.

Auto Ignition Temperature

The minimum temperature at which a liquid fuel will ignite without the presence
of a pilot flame or spark.
 What is Hazardous Area?
The area in which an explosive gas
atmosphere present or likely to be
present in quantities such as to
require specific precautions for
construction, installation and use of
electrical apparatus.
 What is Hazardous Area?
HAC is Defined by three main criteria:

Type of the hazard ( gas , vapor, dust, fibers)

Likelihood of the hazard being present in

flammable concentrations

The Auto Ignition Temperature of the

hazardous temperature.
 Why do we classify Hazardous Areas?
• If proper area classification and safety engineering practices are followed
while working in those areas we can greatly reduce the risk of fire and
explosions hazards in these places.

• All electrical equipment produce energy in the form of sparks which can
ignite these hazardous materials and or cause explosions causing
catastrophic damage .

• In hazardous area we use special purpose explosion protected electrical

equipment and instruments.
 Concept of Classification
• Hazardous Area Classification is to be done for the areas of the plant that
would have instances of flammable mixtures of vapors ,gases or dusts in
normal day to day operations.

• Under unusual conditions like a catastrophic accidental release of large

quantity of inflammable which are not easily predictable.

• Under usual day to day operational conditions in the plant or facility there
are some areas which would have the presence of flammable mixtures of
vapors and gases e.g.. Vapor space in the storage tank, around a
mechanical seal of a pump , the area around surrounding the breathing
valve on the storage tank.
 Basic concepts
• What is Hazard?
• What is Risk?
• Can we avoid the risk altogether?
• Area classification – a measure of the risk
• Area classification benefits.
• How does Area Classification work?
• How can area classification reduce the costs?
 HAZARD & RISK
Hazard

is the source of potential damage, harm or

adverse health effects. A hazard can exist
without incurring any harm.

NO EXPOSURE: NO RISK

21
 What is the risk?
• Is the measure of likelihood that the undesired event or accident
will actually occur
 Can we avoid the risk altogether?
• It is not possible in the world without some amount of risk
Hierarchy of Control
 Can we avoid the risk altogether?
• Since we cannot avoid the risk we can manage it in a logical way.

• Since we have no control over the severity of the consequence , we

reduce the other factor in the risk equation which is the probability of
the occurrence.

• In the same way we manage the risk of handling and storing large
amounts of flammable and explosive materials by area classification
which reduce the probability of the materials catching fire or
explosion.
Area classification - A Measure of the Risk
• Hazardous Area Classification provides a
profile of the risk of explosion in these areas.

• It Cannot predict definitively that an explosion

will or will not take place in that area.

• It only segregates the plant areas into areas

where the likelihood of an explosion is high and
areas where the likelihood is low or improbable.

• The classification provides us a tool to mitigate

the risk of explosion in such areas.
 How Does Area Classification Works ?
• Identify which areas of the plant are more hazardous and need
special attention or equipment.

• Identify areas of the plant carry more risks than others.

• Area classification allows the operations managers to

mitigate these risks by taking appropriate safety measures in
each identified areas and reduce the overall risk of the facility

• Design operations , material and staff movement to restrict

access to these areas and have special work procedures for
these areas.
 Area Classification Benefits
• Give us a risk profile of the plant or facility to enable us to operate it
safer

• Enables top management to really understand the real risk of the facility
and then come up with appropriate strategies to mitigate the risk.

• Enable us to design and install electrical instrumentation and control

system equipment that will not cause fires or explosions at the optimum cost

• Reduce the costs of compliance to regulations and standards without

compromising on the safety

• Make the overall operations safer and more profitable

 How Area Classification Reduce Costs?
• It tells us what kind of equipment can be used in the area and
what type cannot be used.

• Put explosion protected electrical equipment designed for

use only in certain area.
• The equipment carry marking which tells weather it can
How be used or not.
• Based on this it will be safely use the equipment in that area
without any worry.
• There would be some electrical equipment and instruments
that are suitable for use only in zone 2 whereas certain
other types can be used safely in zone 1
 Standards for Area Classification
• European System /IEC System ( Zones & Groups )

• North American System (NEC) ( Classes & Divisions )

IEC : International Electrotechnical Committee.

NEC : National Electric Code.
 Standards for Area Classification

European System /IEC System

• The European System is based on zones

• Every Hazardous Area is broken up into different zones

based on the likelihood of a hazardous gas/vapor mixture
being present.
European System /IEC
European System /IEC
Examples
Examples
European System (ZONES)
ZONES(CONT.)
ZONES(CONT.)
ZONES(CONT)
ZONES(CONT.)
ZONES(CONT.)
ZONES(CONT.)
ZONES(CONT.)
ZONES(CONT.)
ZONES(CONT.)
ZONES(CONT.)
ZONES(CONT.)
ZONES(CONT.)
ZONES(CONT.)
ZONES(CONT.)
Floating roof tank
 Openings classification

• Openings are classified as A, B, C, D with the following characteristics:

• Type A – Openings not conforming to the characteristics specified for types B, C or D

• Examples:

• open passages for access or utilities, for example, ducts, pipes through walls, ceilings and
floors;

• fixed ventilation outlets in rooms, buildings and similar openings of types B, C and D which
are opened frequently or for long periods.
 Openings classification(cont.)

• Openings are classified as A, B, C, D with the following characteristics:

• Type B – Openings which are normally closed (for example, automatic closing)
and infrequently opened, and which are close-fitting.
 Openings classification(cont.)

• Type C – Openings normally closed and infrequently opened, conforming to type B,

which are also fitted with sealing devices (for example, a gasket) along the whole
perimeter; or two type B openings in series, having independent automatic closing
devices.
 Openings classification(cont.)

• Openings are classified as A, B, C, D with the following characteristics:

• Type D – Openings normally closed conforming to type C which can only be opened
by special means or in an emergency.
 IEC Gas Grouping
Under IEC system Materials are classified under various Groups as
follows :

DANGER
Group I : Mining applications
(underground mines containing firedamp the
mine gas that compromised mainly of
Methane)

II A II B II C
Group II :: ( surface industry)
Flammable Gases like hydrogen
propane ..etc. flammable vapors
like acetone ,benzene etc. Group
II is subdivided into A,B,C
IEC Gas Grouping
 North American System/ NEC
• This system consists of Classes , Divisions & Groups:
Class I :locations in which flammable gases,
flammable liquids-produced vapors are or may be
present in the air in quantities sufficient to produce
explosive or ignitable mixtures ,

Class II :locations that are hazardous

because of present of combustible dust.

Class III :locations that are hazardous

because of the presence of easily ignitable
fibers.
 North American System/NEC
• The NEC System is based on Divisions
• In which ignitable concentrations of hazard
Division 1 exists under normal operation conditions
and/or where hazard is caused by frequent
maintenance or repair work or frequent
equipment failure.
Division 2 • In which ignitable concentrations of hazard are
handled, processed or used, but which are
normally in closed containers or closed
systems from which they can only escape
through accidental rupture or breakdown of
such containers or systems.
 North American System
• In the North American System each Class has several
Groups under it.
Material Classification under the two systems
 Temperature Classification
Why This Is Necessary ?
As a hot surface can provide sufficient energy to ignite flammable mixtures
of vapors , gases or dusts in the hazardous area.
IEC North America /NEC
 Protection Techniques

Popular Types Not - Popular Types

Exd: Flame/Explosion Proof Exq: Powder Filled
Exi: Intrinsically safe Exo: Oil Immersed
Exe: Increased safety
Exn: No-sparking
Exp: Pressurization
 Protection Techniques
Flameproof enclosure “ d ”
• is totally enclosed construction.
• When gas or vapor get into the enclosure and an
explosion take place,
• the enclosure withstands the pressure of explosion
and,
• preventing the ignition of a specified gas or vapor
surrounding the enclosure by sparks, flashes, or
explosion of the gas or vapor within, and which
operates at such an external temperature that a
surrounding flammable atmosphere will not be
ignited thereby.
Application:
switchgear, motors, Machine Control Systems
 Protection Techniques
Increased Safety “ e ”
• IN case of INCREASED SAFETY CONCEPT
additional measures are applied to increase the level
of safety,
• thus preventing the possibility of high temperatures
and the occurrence of sparks or electric arcs within the
enclosure or on exposed parts of electrical equipment
• “Increased safety” increases the insulation
performance

Application :
Junction boxes/terminal boxes - Lighting - Measuring
instruments - Transformers - Squirrel cage motors
 Protection Techniques

The “e” Principal

insulated enclosure,
minimum IP 54

Ex certified electrical components

(with electrical connections that
cannot loosen by themselves)

Methods of protection
 Protection Techniques
“de” protection

• Mainly junction boxes have 100% increased safety “e”

• Sparking equipment often incorporates “d ” components
• Most products commonly referred to as “e” combine the 2 types of
protection “e+d”

Methods of protection
 Protection Techniques
“de” products “e” enclosure

also called «ed»

16A plug and socket flameproof “d” chambers

Methods of protection
 Protection Techniques
“de” products
also called «ed»

Control stations
Methods of protection
 Protection Techniques
“de” products
also called «ed»
fluorescent luminaire

Methods of protection
 Protection Techniques
“de” products
also called «ed»

stainless steel - “e” (junction box)

cabinet - “de” (control station)

Methods of protection
 Protection Techniques
Intrinsically safe “ i ”
• Electrical system /apparatus and its wiring is not capable of realizing sufficient
electrical or thermal energy under normal or abnormal conditions to cause ignition
of a specific flammable or combustible mixture in its most ignitable concentrations.
Ex ia
Equipment that incapable of causing
ignition in normal operation with two
faults
Intrinsically
safe “ i ” Ex ib
Equipment incapable of causing
ignition in normal operation with a
single fault
e.g. switch amplifier
 Protection Techniques
Pressurization type “ p ”
• is a type of protection by which the entry of a
surrounding atmosphere into the enclosure of the
electrical apparatus is prevented by maintaining,
• inside the said enclosure, a protective gas at a
higher pressure than that of the surrounding
atmosphere.
• The over pressure is maintained with or without
continuous flow of the protective gas.
• The protective gas can be either air, inert gas or an
other suitable gas.
 Protection Techniques
Pressurization type “ p ”

Application:
• Large machines
• Switching and M&C panels
• Switch rooms & control centers
• Analysis & monitoring apparatus
• Special application solutions
 Protection Techniques
No – sparking “n”
It is applicable to electric equipment which is not capable of igniting potentially
explosive atmospheres under normal operation.
is the special explosion protection construction for Zone 2 or Division 2.
 Protection Techniques
Powder Filled “q”
is a type of protection in which the enclosure of the electrical
apparatus is filled with a material in a finely granulated
state so that, in the intended conditions of service, any arc
occurring within the enclosure of the electrical apparatus
will not ignite the surrounding atmosphere.
No ignition shall be caused either by flame or by excessive
temperature of the surfaces of the enclosure.

Application :
• Fuses
• Capacitors
• Electronic circuit boards - EVG
 Protection Techniques
Oil immersion “o”
• is a type of protection in which the electrical
apparatus or parts of the electrical apparatus are
immersed in oil
• in such a way that an explosive atmosphere which
may be above the oil or outside the enclosure
cannot be ignited.

Application :
• Switching units
• Circuit breakers
• Transformers
 Protection Techniques
Encapsulation “m”
• is a type of protection, in which the parts that could
ignite an explosive atmosphere,
• are enclosed in a resin sufficiently resistant to
environmental influences,
• in such a way that this explosive atmosphere cannot be
ignited either by sparking or heating which may
occur within the encapsulation.

Application :
• Valves
• Electronic circuit boards
• Miniature motors
 Methods of classifying Hazardous area

 API 500 (American Petroleum Institute) using Division method

only for petroleum industries.

 European Standards IEC using ZONING method for general

industries .

 API 505 For Petroleum industry using zoning method.

 North America using classes and divisions, Class I for Gas,

Class 2 for Dust and Class 3 for Fiberd.
 Ex Marking

CENELEC: European committee for electrotechnical standardization

 Ex Marking
ATEX MARKING SYSTEM

ATEX: Explosive Atmosphere

Methods of installation throughout the world
• conductors placed inside a
rigid threaded conduit
• connection using a seal

• wire, braid or steel-tape

armoured cable.
• connection using an earth
continuity cable gland

• unarmoured cable
• connection using a cable gland
Installation rules
Methods of installation throughout the world
Multicore cables
Protection against mechanical shocks
• armoured cables
Or • cable ducting + installation clamps

Protection against chemical attack

• most industrial cables are suitable

Protection against fire

• minimum : cable which does not propagate flames
• ideal : cable capable of withstanding fire
Installation rules
 Methods of installation throughout the world
Selecting cable inlets
The cable gland must:
• be adapted to the type of thread of the product on which it is
mounted
• be Exe or Exd certified
• have at least the same index of protection as the product on
which it is mounted
• be adapted to the cable diameter and type
• sometimes clamp the cable
Installation rules
Methods of installation throughout the world

Selecting cable glands

The cable gland must be certified:

• Exe if the enclosure is Exe or Exed

• Exd if the enclosure is Exd

IP of the cable gland ≥ IP of the product ( later will be explained)

Installation rules
Methods of installation throughout the world
Selecting cable glands
The cable gland must be matched to the cable type

• Cable diameter

• Cable .armoured
or .unarmoured
or .MICC
Mineral-insulated copper-clad cable

Installation rules
Methods of installation throughout the world

Selecting cable glands

The cable must be correctly clamped by means of the
cable gland

• Internal clamping system

• External clamping system

or by means of an installation clamp

 Methods of installation throughout the world

Selecting
cable glands

“e” cable gland

• polycarbonate
• IP 67
cable clamp
• for unarmoured cable
 Methods of installation throughout the world

“e” plastic cable gland

Selecting
cable glands
“ed” 16A 230V socket

unarmoured cable
Methods of installation throughout the world
Selecting cable glands

“ed” rotary switch

armoured cable

“e” cable gland for

an armoured cable
Methods of installation throughout the world

Selecting cable glands

cable clamping
rings

“e” cable gland for an armoured cable

and earth continuity
NB: this type of gland ensures the earth continuity of the armoured cable

Installation rules
Methods of installation throughout the world

Selecting cable glands

“d” cable gland

Installation rules
Methods of installation throughout the world

Selecting cable glands

• The connection between the

conduit and the electrical
Compound device is achieved using a
seal
• The connector is filled with a
sealing compound (to prevent
an explosion from spreading
through the conduits)
seal

Installation rules
Methods of installation throughout the world

Advantages of an installation with cable glands

compared to a conduit installation
• More competitive prices
• No need to thread the conduits on site
• No generalized seals
• Easier maintenance, inspection and extensions
• Far fewer problems with corrosion

Installation rules
Conduit installation
Installation with cable gland
What do you think?

EX !!!
What do you think?

EX !!!
 Ingress Protection
• IP classification system designates the
degree of protection provided by an
enclosure against impact and water or
dust penetration (ingress).

• It has two numbers;

• First: Protection against solid objects,

• second: Protection against water.
 Ingres Protection

EXAMPLE: IP 54
IP Rating
IP Rating
IP ratings
What if hazardous area is wrongly classified ?

Unnecessarily pay more money

More Maintenance Costs

Facility will incur more costs over its lifecycle.

Cost could be high as they may result in unwanted

explosion leading to loss of life and property
 Methods of classifying Hazardous area

 API 500 (American Petroleum Institute) using Division method

only for petroleum industries.

 European Standards IEC using ZONING method for general

industries .

 API 505 For Petroleum industry using zoning method.

 North America using classes and divisions, Class I for Gas,

Class 2 for Dust and Class 3 for Fiberd.
 SUMMEERY
European System /IEC
 North American System/ NEC
• This system consists of Classes , Divisions & Groups:
Class I :locations in which flammable gases,
flammable liquids-produced vapors are or may be
present in the air in quantities sufficient to produce
explosive or ignitable mixtures ,

Class II :locations that are hazardous

because of present of combustible dust.

Class III :locations that are hazardous

because of the presence of easily ignitable
fibers.
 North American System
• In the North American System each Class has several
Groups under it.
 Temperature Classification
Why This Is Necessary ?
As a hot surface can provide sufficient energy to ignite flammable mixtures
of vapors , gases or dusts in the hazardous area.
IEC North America /NEC
 Ex Marking

CENELEC: European committee for electrotechnical standardization

 Ex Marking
ATEX MARKING SYSTEM

ATEX: Explosive Atmosphere

NEC Marking
 Ingres Protection

EXAMPLE: IP 54
 How to carry out area classification?
Step by step
STEP 1 :
Decide on the standard that would be followed (IEC- NEC)
STEP 2 :
Check out the lay out of the facility or the plant, the quantities that are
handled in the process plant

STEP 3 :
what is the material temperature classification of these materials ?flash points,
auto ignition temperature, density of vapor/ gas (lighter or heavier than air)
How to carry out Area Classification?
Step by step
STEP 4 :
• Divide the plant into different units
• Start to evaluate the sources of release of unit
• Classify them as continuous grade, primary grade or secondary grade
• Tabulate them findings in a worksheet and mark these on the general
arrangement drawing of the unit
STEP 5 :
Evaluate ventilation in the area (closed or open) how does the wind go? Does the
wind direction remain the same or changed if the vapor cloud formed , how far it
will travel along with the wind ? Are there are any places where escaped vapors
may accumulate
Sources of
release
How to carry out Area Classification?
Step by step

STEP 6 :
based on the findings on step 4&5 and the standard you are following
mark the hazardous area on the drawings these extents will be
surrounding the release points that have been marked in step4

STEP 7 :
Divide the hazardous area into divisions or zones ( depending on the standard
you are using)
 Consequence of Poor area classification

• Over Classification – White Elephant

• Under Classification – Playing with Fire

• Proper Area Classification is the virtuous in between

 Over classification- A White Elephant
• Increase capital expenditure on new projects due to more
expensive equipment being specified
• Increase operations and maintenance expenditure of an
existing facility as replacement parts will become more expensive
maintenance work permits will be stringent and time consuming
leading to higher costs
• Unnecessary label your facility dangerous in the local
community

• Increase your insurance premiums

 Under classification – Playing With Fire

• Increase The Risks of your plant or facility without anybody

knowing it, especially the top management.

• In case of an unfortunate accident expose you and your

company to lawsuits.

• Give lot of bad press to your company and even threaten its
existence
 So now what do we do?
• Conduct an Audit of your Facility.

• Marking Hazardous Areas with reference to the current

standards.

• Training personnel on the basics of HAC.