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Area Classification

CHAPTER 3 There is a large opportunity for additional, lower

AREA CLASSIFICATION cost Zone 2 equipment as companies classify more
areas as Zone 2 outside of North America.
Many North American facilities using the Zone
concept in the future will classify Hazardous Locations 3.2 PRESENT DAY HAZARDOUS AREA
as Zone 2, which is equivalent to Division 2. CLASSIFICATIONS AND PRODUCT MIX
It is estimated that less than 5% of hazardous areas in North
America are classified as Division 1. The split of hazardous
3.1 COMPARISON BETWEEN DIVISIONS &
areas in Europe is just the opposite, with over 60%
ZONES of the areas classified as Zone 1. See Table 3.2. Because of
Outside of the USA many countries are migrating to the use of
this, the percentage of products offered for Hazardous
the Zone classification system, which gives them greater
Locations also varies from North America to Europe. The
flexibility for choices of equipment and wiring methods. Except
majority of hazardous area products in North America are for
for Switzerland and the United Kingdom, many of these facilities
Division 2 while in Europe they are for Zone 1 applications.
using the Zone concept outside of North America are classified
One reason is that the product standards for Zone 2 apparatus
as Zone 1. This is in direct conflict to areas in North America
have only recently been written.
where over 90% of hazardous areas are classified as Zone 2 or
Division 2. There were 3 primary catalysts for reclassifying Table 3.2
areas as Division 2 from Division 1: Comparison of Zones and Divisions
Time that Estimated Estimated
• Reduced cost—Division 2 installations are less expensive. hazardous gases % of Division % of Zone
Classified are present in areas in areas in
• Air pollution laws—These required the drastic reduction of Area ignitable concentrations North America Europe
fugitive emissions, which would normally escape in Division 1
Zone 0 Continuously <2%
areas.
• Safety—Most companies reduced emissions to create safer Div. 1 Normally Present <5%
working environments.
Zone 1 Occasionally in normal >60%
operations
It is logical to expect that most North American facilities using
the Zone concept in the future will classify Hazardous Locations Zone 2 Div. 2 Not normally present >95% <40%
as Zone 2, which is equivalent to Division 2.
Area classification is the determination of the
A comparison of the Division and Zone classification system is probable frequency and duration of the presence of
shown in Table 3.1. Division 2 is equivalent to Zone 2 while
gas, vapor or mist in excess of 100% of the LEL.
Division 1 is either Zone 0 or 1. Zone 0 is reserved for those
areas continuously hazardous (e.g., inside a vented fuel tank),
so other Division 1 areas would be classified as Zone 1.
3.3 AREA CLASSIFICATION—A PRACTICAL
Table 3.1 APPROACH
Classification System Comparison Area classification is the most important aspect of electrical
design in Hazardous Locations. Historically, the process of
1996 NEC classifying Hazardous Locations has not been well understood
(Article 505)
by many designers. As a consequence, the approach to “over-
Division & 1998 CEC
classify” to err on the side of safety has been the industry
Class I System Description Zone System Comments
standard.
Division 1 Hazardous Zone 0 Division 1 is split
under into Zone 0 and 1.
normal Zone 0 is a small
operations percentage of
Gases & Zone 1 locations usually
Vapors confined to inside
vented tanks.

Division 2 Not Zone 2 Zone 2 and

normally Division 2 are
hazardous essentially the
same.

Most hazardous areas located indoors were classified as Division 1.

(Old-style motor starters have been replaced by EBMs.)
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Area Classification

While it was common practice prior to the early 1990s to classify While past practices achieved Zone 2 (Division 2) area
most indoor Class I Hazardous Locations as Zone 1 (Division classification by providing six air changes per hour by
1), many users now believe that most buildings function in mechanical means, recent experience has shown that in many
accordance with the definition for Class I, Zone 2. It is important Class I buildings, “adequate ventilation” often requires less than
to remember that the Hazardous Location definitions in the one air change per hour, and can be provided by the naturally
NEC and CEC are the basic requirements. There are many occurring ventilation. Often the reduced ventilation requirement
other industry documents such as the API Recommended eliminates the need for complicated and expensive ventilation
Practice for Area Classification which are only recommended systems and reduces the energy required to heat the building.
means of meeting the Code definitions and are not Code (Calculation formulas are also given in IEC 60079-10) However,
requirements. Any method that demonstrates compliance with there are many instances where buildings such as pumping
the area classification definitions meets the requirements of the stations are remotely located and not manned on a 24-hour
respective Code. basis. The buildings are designed as Zone 1 to accommodate
any unforeseen problems.
In most buildings the area classification choice is between Zone
1 and Zone 2. In making that choice there are a number of tools
that may be used. If it can be demonstrated that a building is
“adequately ventilated,” it meets one of the main requirements
of a Zone 2 classification. The other requirement for a Zone 2
classification is that in the event of an abnormal gas release
approaching or exceeding explosive levels, action must be
taken to correct the problem within a “short time.” Many
industrial users accept a 10-hour/per year “rule of thumb” limit
on exposure to “explosive gas atmospheres” for Zone 2
Hazardous Locations. If the building is on a site that is
continuously manned, or it is monitored by gas detection to shut
down the process, or alarmed to allow operating personnel to
correct the problem, the requirements for a Zone 2 classification
are often effectively met. Many skid platforms are not manned and are classified as Zone 1.

3.4 ADEQUATE VENTILATION 3.5 WHO CLASSIFIES HAZARDOUS

API RP505 — Recommended Practice for Classification of LOCATIONS?
Locations for Electrical Installations at Petroleum Facilities There is considerable debate around the world as to who is
Classified as Class I, Zone 0, Zone 1, and Zone 2 outlines a responsible for the classification of Hazardous Locations. The
number of methods for demonstrating or meeting the general consensus of opinion is that it is a task for chemical
requirement for “adequate ventilation.” One method that has and/or process engineers, but should include the advice of
been used for many years is to provide a minimum of six electrical and mechanical engineers in the analysis.
continuous air changes per hour. Another method is to carry out
a fugitive emissions study as outlined in Appendix B of the API If the North American Division method of area classification has
standard. For existing buildings a third method would be to been used on an existing plant then reference can be made to
measure the gas concentration in various areas of the building Appendix J of the Canadian Code, the National Electric Code
to determine if the requirement for “adequate ventilation” is Article 500-503 and the American Petroleum Institute
actually met. Permanently installed gas detection system Publications RP 500B and RP 500C. Articles 500-505 of the
records are often available to provide historical data. In recent NEC, Section 18 of the Canadian Code and the IEC Standard
years a combination of fugitive emission studies and 79-10 publication provide guidance on classifying Hazardous
measurement have been used to demonstrate a building is Locations for the Zone system. In any case a thorough analysis
adequately ventilated. should be undertaken by the responsible designers, chemical
or electrical engineers to determine the correct Hazardous
Locations classification. The following portions in this section
define the classifications and provide insight on how the rest of
the world classifies Hazardous Locations.

Gas detectors in process plants detect the presence of volatile vapors.

12 Cooper Crouse-Hinds Ex Digest
Area Classification

Article 501.1 of the NEC permits properly marked operation of equipment. A storage room which houses 55-
Class I, Zone 0,1 or 2 equipment to be installed in gallon drums of volatile solvents would be a typical example of
Division 2. a Division 2 location. This classification approximates Zone 2 in
IEC Standards.

3.6 CLASS I HAZARDOUS LOCATIONS 3.8 DEFINITION OF ZONES

The classification of Hazardous Locations is a complex subject. Class I locations can be further divided into three Zones based
It would be ideal if all electrical equipment could be installed in upon frequency of occurrence and duration of an explosive gas
safe areas so that no danger from electrical ignition was atmosphere as follows:
possible in the process plant, but this situation is seldom likely.
Therefore the classification of areas is an essential design 3.8.1 ZONE 0
consideration. (a) Zone 0, comprising Class I locations in which explosive gas
atmospheres are present continuously or are present for long
Area classification in Class I locations is the determination of periods;
the probable frequency and duration of the presence of an
explosive gas atmosphere in a Hazardous Location. Zone 0 locations are typically locations such as the vapor
space above the liquid in a tank. In Zone 0 locations it is
An explosive gas atmosphere is defined as: probable that the gas concentration will exceed 100% of LEL
“A mixture with air, under atmospheric conditions, of flammable for very long periods. Table 3 in paragraph 6.5.8.3 of API-
substances in the form of gas, vapor, or mist in which, after RP505—Recommended Practice for Classification of
ignition, combustion spreads throughout the unconsumed Locations for Electrical Installations at Petroleum Facilities
mixture.” Classified as Class I, Zone 0, Zone 1, and Zone 2, suggests
Zone 0 locations are those where there is a flammable
In other words, area classification is the determination of the mixture typically more than 1,000 hours per year. Zone 0
probable frequency and duration of the presence of gas, vapor locations typically do not exist outside of enclosed spaces
or mist in excess of 100% of the LEL. Areas where an explosive except for the area immediately around vents which are
gas atmosphere is likely to be present more frequently or for venting from a Zone 0 location.
longer periods will have “higher” area classification than areas
where explosive gas atmospheres occur less frequently or for
shorter periods.

3.7 DEFINITION OF DIVISIONS

North American Hazardous Locations are divided into Class
and Divisions:

A Class I, Division 1 location is one where an explosive

atmosphere is presumed to be present in normal operation
either all or part of the time. These are typically manufacturing
areas such as a pharmaceutical plant where volatile gases
escape from vessels during fermentation. In theory, Division 1
locations encompass both Zones 0 and 1 as designated in IEC
Standards.

The inside of a vented storage tank is typically Zone 0.

3.8.2 ZONE 1
(b) Zone 1, comprising Class I locations in which:
(i) Explosive gas atmospheres are likely to occur in normal
operation; or
Division 1 areas
encompass
Table 3 in paragraph 6.5.8.3 of API-RP505—Recommended
Zones 0, 1 & 2.
Practice for Classification of Locations for Electrical Installations
at Petroleum Facilities Classified as Class I, Zone 0, Zone 1,
and Zone 2, suggests Zone 1 locations are those where there
A Class I, Division 2 location is one where volatile flammable is a flammable mixture more than 10 hours per year and less
liquids or flammable gases are handled, processed or used, but than 1,000 hours per year. Zone 1 locations normally occur
which are normally enclosed in containers from which they can around vents or in enclosed areas where there are
only escape in the case of accidental rupturing or abnormal intermittent or continuously open processes (for example, a
 Cooper Crouse-Hinds Ex Digest 13
Area Classification

paint spray booth). When classifying indoor locations it is 3.8.3 ZONE 2

common to treat them as Zone 1 if it cannot be demonstrated (c) Zone 2, comprising Class I locations in which:
the conditions for a Zone 2 location exist. An example of this (i) Explosive gas atmospheres are not likely to occur in normal
situation would be a remote unattended gas compressor operation and, if they do occur, they will exist for a short time
building where there is no gas monitoring. An abnormal leak only; or
resulting in gas concentration exceeding 100% of LEL could
conceivably persist for well above the 10-hour threshold for Explosive gas atmospheres will not occur in the air except as
Zone 1 locations. the result of an abnormal situation such as a failed pump
packing, flange leak, etc. Also when an abnormal situation does
occur it will be corrected within a short time. API-RP505—
Recommended Practice for Classification of Locations for
Electrical Installations at Petroleum Facilities Classified as
Class I, Zone 0, Zone 1, and Zone 2 suggests Zone 2 locations
are those where explosive gas atmospheres will exist for less
than 10 hours per year. Most Inspection Authorities require that
indoor locations be classified as Zone 1 unless it can be
demonstrated the conditions for Zone 2 exist. Indoor locations
Remote pumping stations should have gas monitors installed to detect gas in remote unattended and unmonitored facilities most often
leaks. cannot meet the 10-hour per year rule of thumb. The most
(ii) Explosive gas atmospheres may exist frequently because of common means of meeting the 10-hour rule of thumb in remote
repair or maintenance operations or because of leakage; facilities is to install gas detection to shut down and
depressurize the facility or to send an alarm to alert personnel
Examples of Zone 1 locations that exist as the result of repair to take corrective action.
or maintenance are the areas around a pig trap where gas or
vapor is released each time the trap is opened or the area It is important that means to ensure the limited exposure time
around a filter where gas is released each time the filter is is met in Zone 2 locations as the design requirements for
changed. These areas are typically limited to the immediate equipment acceptable in Zone 2 locations are based on
area of the equipment as the amount of gas released is limited exposure time.
relatively small and is diluted to safe concentrations a short
distance from the equipment. (ii) Flammable volatile liquids, flammable gases, or vapors are
handled, processed, or used, but in which liquids, gases, or
vapors are normally confined within closed containers or closed
systems from which they can escape only as a result of
accidental rupture or breakdown of the containers or systems or
the abnormal operation of the equipment by which the liquids or
gases are handled, processed, or used; or

This is the original wording for Class I, Division 2 locations prior

Wellhead and gas detector. to the addition of the IEC definition above in the 1998 Code. It
has similar meaning to (i) except it does not clearly outline the
limited exposure time.
(iii) The location is adjacent to a Class I, Zone 0 location, from
which explosive gas atmospheres could be communicated.

Typically these areas would exist around a vent from a Zone

0 location. The size of the Zone 1 area around the Zone 0
area will depend upon the rate of release of the gas or vapor,
the vapor density of the material released and the conditions
in the area where it is released.

Areas where volatile liquids

are stored are normally
Outside the classified as Zone 2
Zone 0 area is or Division 2.
a Zone 1 area.
14 Cooper Crouse-Hinds Ex Digest
Area Classification

(iii) Explosive gas atmospheres are normally prevented by Similar to (b)(iii), there will normally be a Zone 2 area
adequate ventilation but which may occur as a result of failure classified around a Zone 1 area surrounding a vent. It is also
or abnormal operation of the ventilation system; or common for there to be a Zone 2 location around enclosed
areas classified as Zone 1 unless there is a “vapor-tight
Adequate ventilation is defined as “natural or artificial barrier” around the Zone 1 area. For example, a process
ventilation that is sufficient to prevent the accumulation of building with doors windows and other openings in the walls
significant quantities of vapor-air or gas-air mixtures in will typically have a Zone 2 area around all or portions of the
concentrations above 25% of their lower explosive limit.” building.
During “normal operation” there are small gas and vapor
releases from various components of the piping system such
as pump seals, valve packing and flange gaskets. These
releases are relatively small in comparison to abnormal
releases due to equipment failures. These releases are
referred to as “fugitive emissions.” Adequate ventilation for an
enclosed area is therefore the amount of ventilation required
to continuously dilute the fugitive emissions in that enclosed
area to concentrations below 25% of their LEL. (In practice it
is uncommon to encounter gas concentrations above 1 or 2%
of LEL.)

Appendix B of API-RP505—Recommended Practice for

Classification of Locations for Electrical Installations at
Petroleum Facilities Classified as Class I, Zone 0, Zone 1, and Outside the Zone 1 area is a Zone 2 area.
Zone 2 outlines a procedure for determining the fugitive
emissions in an enclosed area and calculating the amount of As outlined above, area classification is based on the probable
ventilation required to achieve “adequate ventilation.” For frequency and duration of the occurrence of “explosive gas
existing facilities it is also possible to determine whether an atmospheres at a location.” It is done primarily to determine the
enclosed area is adequately ventilated by measurement of the type of equipment that is suitable for use in the area. The design
emissions in the area during “normal operation.” of Hazardous Location equipment is based on the likely
exposure time to “explosive gas atmospheres” as defined
Adequate ventilation deals only with the ventilation required above.
to dilute the normal or fugitive emissions. It is not intended to
ensure that gas concentrations during an abnormal release 3.9 ZONE CLASSIFICATION SUMMARY
will not reach concentrations above 100% of the LEL. In an The primary activity for Area Classification is to list the process
“adequately ventilated area,” explosive gas atmospheres equipment in the area under consideration and identify all
may be experienced as the result of a loss of ventilation or an potential sources of flammable material. An estimate must be
abnormal gas or vapor release. In addition to “adequate made of the duration and frequency of each release in order to
ventilation,” it is also important to ensure that measures are classify the emission as Continuous, Primary or Secondary and
in place to ensure that explosive concentrations of gas exist the rate of potentially explosive atmosphere into the
for “a short time only.” As outlined above, API RP500 surrounding area.
suggests a short time to be less than 10 hours per year in
total. For unattended facilities, it is usually necessary to install • Continuous Grade (1000 hours/year) leads to a Zone 0.
gas detection systems to either shut down the facilities or to • Primary Grade (100 hours/year) leads to a Zone 1.
send an alarm to alert personnel to take corrective action • Secondary Grade (10 hour/year in total) leads to a Zone 2.
when an abnormal release of gas or vapor occurs. Typical
industry practice is to alarm and initiate additional ventilation
when the LEL in a building reaches 20% and to shut down
3.10 EXAMPLES OF HAZARDOUS AREA ZONE
the process in the building if the LEL reaches 40%. CLASSIFICATION

(iv) The location is adjacent to a Class I, Zone 1 location from ZONE 0

which explosive gas atmospheres could be communicated, • Areas within process equipment developing flammable gas
unless such communication is prevented by adequate positive- or vapors.
pressure ventilation from a source of clean air, and effective • Areas within enclosed pressure vessels or storage tanks.
safeguards against ventilation failure are provided. • Areas around vent pipes which discharge continually or for
long periods.
• Areas over or near the surface of flammable materials.
 Cooper Crouse-Hinds Ex Digest 15
Area Classification

ZONE 1
• Areas above roofs outside storage tanks.
• Areas above floating storage tanks.
• Areas within a specified radius around the outlet pipes and
safety valves.
• Rooms without ventilation openings from a Zone 1 area.
• Areas around flexible pipelines and hoses.
• Areas around sample taking points.
• Areas around seals of pumps, compressors and similar
primary sources.

ZONE 2
• Areas around flanges and connecting valves.
• Areas outside Zone 1 around outlet pipes and safety valves.
• Areas around vent openings from Zone 2.

– ZONE 0

– ZONE 1

ZONE 2 –

Typical Zone designation.

Zone 0 is inside the vented tank and near the vent.

Zone 1 is a perimeter around the vent.
Zone 2 is the area outside the tank.

For questions or comments, please contact the author at

[email protected]