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Wiring Methods for Hazardous Locations White Papers

NEC guidelines for electrical contractors working in hazardous locations
David Herres | Electrical Construction and Maintenance Aug. 19, 2011 Choosing the Right LED Product for Industrial
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The math is easy. If you’re using HID (high-intensity

NEC guidelines for electrical contractors working in hazardous locations
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residential and commercial spaces. Many of these areas
are hazardous in varying degrees, requiring exceptional
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wiring methods and materials.

Take a flammable liquid or gas facility as an example.

Volatile fuel may mix with air in a critical proportion so that an overheated surface or a
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NEC Guidance
Never
The Code and associated documents deal with these hazards in a highly competent Daily
manner. People enter these hazardous areas every day with much less risk than they
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encounter driving on a public road or engaging in other everyday activities. However, it is
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possible for electrical professionals to accomplish this task while minimizing the cost
without cutting corners or compromising safety. The preferred strategy is to mitigate risk Monthly

as opposed to reducing protection. Before examining the methods for doing so, however,
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let’s review some of the ways the Code delineates and organizes hazardous locations. The
NEC recognizes three classes of hazardous areas:

Class I locations are characterized by the presence of flammable gases, flammable liquid- EC&M Books
produced vapors, or combustible liquid-produced vapors. If any of these are or may be
present in the air (in quantities sufficient to produce explosive or ignitable mixtures), the
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location is considered Class I. As such, it requires specialized wiring techniques (see Art.
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Class II locations are characterized by the presence of combustible dust. These locations also up to speed very quickly on the most
require specialized wiring techniques (see Art. 502); however, they are generally less extreme essential 2011 NEC changes...
than those needed in Class I locations. Nevertheless, huge explosions are possible due to
combustible dust suspended in air in critical proportions; therefore, electricians must take Conduit Bending Manual
great care when wiring these locations. Additional hazards accompany the presence of Now in its tenth printing, author Jack
electrically conductive dusts, notably aluminum and magnesium. Zirconium and thorium Benfield explains the art of conduit
dusts suspended in air are subject to spontaneous ignition. Conductive dusts may settle on bending in clear non technical language.
circuit boards, bridging adjacent traces and resulting in short circuits. Another hazard The...
associated with Group II locations occurs when dusts settle on motor housings and the like,

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resulting in heat buildup. 2011 National Electrical Code

Class III locations are characterized by the presence of easily ignitable fibers or flyings. Chapter-by-Chapter

These may be the same materials as found in Class II, but they're less finely divided. David Herres, owner and operator of a

Although explosion is not a possibility, ignition may result in a rapidly spreading fire. The residential and commercial construction

hazard is less than in Class II locations, but nonetheless is substantially greater than within company, obtained a Journeyman

unclassified locations. Specialized wiring techniques are also needed (see Art. 503) in these Electrician's...

locations.
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Each of the three classes contains two divisions, based on the immediacy of the hazard.
Within Class I, Div. 1, for example, ignitable concentrations of flammable gases (or Advertisement

flammable/combustible liquid-produced vapors) can exist under normal operating

conditions or because of repair/maintenance operations or leakage. Another possibility is
breakdown or faulty operation of equipment or processes, resulting in the release of these
substances into the air and allowing electrical equipment to become a source of ignition.

Within Class I, Div. 2 locations, the hazard, while still substantial, is somewhat less
immediate. Volatile flammable gases or flammable/combustible liquid-produced vapors
may be handled, produced, or used, but they will normally be confined within closed
containers or closed systems. If they escape, it’s typically because of accidental rupture or
breakdown of the containers or systems or abnormal operation of equipment. Division 2
conditions also exist when ignitable concentrations of flammable gases or
flammable/combustible liquid-produced vapors are normally prevented by positive
mechanical ventilation. These could become hazardous through failure or abnormal
operation of the ventilating equipment. Webinars

Another possibility is that the area in question is adjacent to a Class I, Div. 1 location - On-Demand: A Better Understanding of Arc
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Class II and Class III locations may also be Div. 1 or Div. 2, depending upon the
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immediacy of the hazard. Typically, in Div. 2 areas, the substances are present in ignitable
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periods of time.

The zone classification system is a viable alternative to conventional hazardous location

delineation, and its use is appropriate under certain circumstances. Traditionally, division
classifications were used in North America while zone classifications were used
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elsewhere. In recent years, the NEC added Art. 505, permitting optional use of Zones 0, 1,
and 2 within Class I areas and Zones 20, 21, and 22 within Class II and III areas. Use of
the zone method allows designers to specify offshore equipment. The resulting Advertisement

installation may or may not be less expensive. Decisions should be made on a

case-by-case basis.

Material Groups

Article 500 also introduces the topic of material groups, stating explicitly that various air
mixtures are to be grouped for testing, approval, and area classification. This means that
equipment must be approved not only for the class of location, but also for the material
involved.

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NEC Handbook contains an extensive multi-page list of hazardous materials with group
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designation and other properties, as part of its commentary, but the requirements don’t
end there.
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Surface temperature
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An additional condition is placed upon equipment contemplated for use within a
hazardous area. The equipment temperature marking in Class I locations is not to exceed COUNTRY:
the ignition temperature of the specific gas or vapor to be encountered. In Class II
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locations, the temperature marking must not exceed the lower of either the ignition
temperature of the dust encountered or 165°C (329°F). One of the problems with dust is
that it may settle on potentially hot surfaces, such as motor housings. Repeated exposure Connect With Us
to heat may cause partial carbonization, which lowers the ignition temperature.

To facilitate compliance with this Code mandate, Table 500.8(C) provides temperature
class (T Code) categories for various maximum surface temperatures of heat-producing
equipment, ranging from T1, with a maximum surface temperature of 450°C (842°F), to
T6, with a maximum surface temperature of 85°C (185°F).

Protection Techniques

Whenever electrical equipment is installed within a hazardous area, one or more

protection techniques must be employed to ensure that life and property are not
endangered. The principal protection techniques include:

Explosionproof equipment - permitted for equipment in Class I, Div. 1 or 2 locations.

Dust ignitionproof equipment - permitted for equipment in Class II, Div. 1 or 2 locations.
Dusttight equipment - permitted for equipment in Class II, Div. 2 or Class III, Div. 1 or 2
locations.
Purged and pressurized equipment - permitted for equipment in any hazardous location for
which it is identified.
Intrinsic safety - permitted for equipment in any hazardous location.
Nonincendive circuit, nonincendive equipment, nonincendive component, and hermetically
sealed - permitted for equipment in Class I, Div. 2, Class II, Div. 2, or Class III, Div. 1 or 2
locations.
Oil immersion - permitted for current-interrupting contacts in Class I, Div. 2 locations.
Combustible gas detection system - permitted as a means of protection only in industrial
establishments with restricted public access and where conditions of maintenance and
supervision ensure that only qualified persons service the installation.

Any protection technique that is permitted for a Div. 1 location is also good for Div. 2
within the same class, because the hazards are the same - although not as immediate - as
in a Div. 1 location. However, the same relation is not applicable among classes. A
protection technique permitted for Class I, for example, is not necessarily relevant for
Class II, and explosionproof enclosures permitted for Class I locations are not meaningful
in Class II locations.

It is possible for a location to be simultaneously Class I and Class II or III, so care must be
taken in complying with all requirements. Dual-rated equipment is useful, but it’s
necessary to observe material and temperature parameters in all cases.

We have seen how hazardous areas are delineated and have listed applicable protection
techniques. Additionally, many other Code mandates are in place. It is necessary to
consider NEC requirements on a case-by-case basis to ensure that a safe environment is
maintained. Particular attention must be focused on raceway sealing so that hazardous
area gases or liquids do not infiltrate non-classified areas where protection techniques are
not in place. Enhanced grounding and bonding techniques are essential as well.
Redundant bonding, using grounding lugs designed for the purpose, ensures that there
will be no interruption in the low-impedance ground path. This technique must be
continued outside the hazardous location all the way back to the service, load center, or
other grounding electrode conductor connection.

Obviously, materials and labor involved in any hazardous location installation will be
much more costly than the same work within a non-hazardous industrial location. There
are, however, ways of greatly reducing these costs without compromising safety.

Taking Action

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The first and most effective strategy is to take a hard look at the overall installation to see
if it is possible to relocate part or all of the electrical equipment and circuitry that powers
it outside of the hazardous area - or perhaps moving it from a Div. 1 to a Div. 2 location. It
may be possible to do pre-assembly outside a hazardous area so that less equipment is
required within it.

A second hazard mitigation technique is ventilation, which may be used to good effect. In
a commercial garage, for example, where floor areas include pits, below-grade work areas,
or subfloor work areas in lubrication or service rooms, differing classification rules apply,
depending on whether ventilation is provided. The entire floor area is unclassified where
there is mechanical ventilation, providing a minimum of four air changes per hour.
Ventilation must provide for air exchange across the entire floor area, and exhaust air is
to be taken at a point within 12 inches of the floor.

In contrast, where ventilation is not provided, the floor area up to a level of 18 inches
above any unventilated pit, below-grade work area, or subfloor work area, and extending
a distance of 3 feet horizontally from its edge, is Class I, Div. 2.

Similarly, areas adjacent to classified areas within commercial garages in which

flammable vapors aren’t likely to be released, such as stock rooms, switchboard rooms,
and other similar locations, are unclassified where mechanically ventilated at a rate of
four or more air changes per hour, designed with positive air pressure, or effectively cut
off by walls or partitions.

A third hazard mitigation technique is to use intrinsically safe systems within a hazardous
location wherever possible. To see how this works, let’s look at a more conventional but
far more expensive protection technique.

Explosionproof enclosures, in conjunction with properly sealed rigid or intermediate

metal raceway, are acceptable as a protection technique for use in Class I, Div. 1 locations
(see Photo 2). These enclosures have wide bolted flanges, threaded covers, and entries
that preclude the transmission of flame or heat. The idea is that, over a period of time,
flammable gas or liquid-produced vapors will infiltrate the enclosure. An arcing switch or
relay will cause ignition if the flammable material exists in critical mix with air. The
explosionproof enclosure ensures the resulting explosion will be contained so that
ignition will not occur outside the enclosure. A system of explosionproof enclosures is
highly effective if installed and maintained correctly, with proper raceway sealing and
protection from physical damage.

A much less expensive and every bit as effective protection technique is available for use
in all classes and divisions. Rather than relying on the brute-force approach of the
explosionproof enclosure, intrinsically safe systems depend upon an entirely different
approach (click here to see Fig. 1).

For fire or explosion to occur, three elements must be present simultaneously. There must
be a source of ignition (such as an electrical spark), a supply of fuel (such as gasoline),
and an oxidizing agent (such as the oxygen) available in the earth’s atmosphere.
Intrinsically safe systems protect against hazard by limiting the amount of power to a
level where any spark or thermal effect is incapable of igniting the mixture of flammable
or combustible material. Intrinsically safe apparatus is permitted to be installed in any
hazardous location for which it is listed. General-purpose (non-explosionproof)
enclosures are permitted.

Because of the low power levels necessary to ensure that ignition will not occur, it is not
feasible to use intrinsically safe systems to power motors and other heavy equipment.
Intrinsically safe systems are used for instrumentation, controls, and power-limited fire

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alarm systems. Because these items comprise a large proportion of the wiring within
hazardous locations, significant cost savings are possible.

Power transfer is a function of the connected load and applied voltage. By choosing these
values, it is possible for an intrinsically safe system to work as intended. However, the
possibility remains that higher voltage and current levels would infiltrate the hazardous
location if a power surge, misconnection, or arcing from adjacent wiring outside the
hazardous location boundary should occur. One technique for preventing this eventuality
is to observe required separations of intrinsically safe conductors, as outlined in Sec.
504.30.

These and other requirements are laid out within the control drawings supplied by the
manufacturer, which documents, among other things, allowed interconnections between
intrinsically safe apparatus and associated field wiring. These control drawings must be
scrupulously followed.

An essential component is the Zener, or shunt diode barrier, which is installed on the
nonhazardous location side adjacent to the boundary. This barrier provides secure
isolation to ensure that unsafe current does not flow into the hazardous area, making
possible ignition of the gas, vapor, dust, or other material within.

This barrier works by shunting excess voltage to ground. A Zener diode, with a specified
reverse-bias breakdown voltage, is wired across the input terminals. Because this type of
diode could become subject to an open-circuit fault, a second diode is provided for
redundant protection. A fuse in series with one line is provided with a rating such that it
will open if the power rating of the Zener diodes is exceeded. A resistor (plus a second one
for redundancy) is provided so that in the event that the Zener diode enters the
conduction mode, the source within the unclassified area will not be subject to a direct
short circuit.

This type of barrier depends for its effectiveness upon a totally reliable ground
connection. Two separate ground connections are desirable, each with a resistance of less
than 1 ohm. Ground cables must be insulated and protected from physical damage. The
ground electrode should be as near to the barrier as possible, preferably directly adjacent.

Because of the resistors, it is possible that the output of the barrier would not be sufficient
for the application contemplated. The protection would be in place, but the barrier would
not permit the system to function. Therefore, this aspect has to be considered.

Where it is not feasible to create a suitable ground, another type of barrier is available.
This is the so-called “active barrier.” It does not work by diverting the fault current to
ground, so the dedicated ground is not required, just (as always) the required equipment
grounding means.

Now that we've discussed some of the NEC 2011 hazardous location requirements, it’s
easy to see that there are ways to comply while reducing labor and materials costs without
compromising safety. Careful planning, compliant design work, and flawless installation
will ensure a safe electrical infrastructure for those whose lives depend upon it.

Herres is a licensed master electrician in Stewartstown, N.H. He can be reached at

[email protected].

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