BECHTEL OIL GAS & CHEMICAL, INC (BOGCI)

ENGINEERING
ELECTRICAL

DESIGN GUIDE
PREPARATION OF HAZARDOUS AREA CLASSIFICATION DRAWINGS
3DG-E610-00001, Rev. 002, September 25, 2007
Reason for Issue: Issued as Corporate Design Guide (supersedes 3DG-E610-00001, Rev.
001)
Prepared by: F. Arias-Gavilano, D. Barlow, V. Rodionov
Approved by: M. Donati, C. King

TABLE OF CONTENTS

1.0 PURPOSE

2.0 DEFINITIONS

3.0 HAZARDOUS AREA CLASSIFICATION BASICS

3.1 Background
3.2 General
3.3 Conditions Necessary for Ignition
3.4 Behavior of Gases, Vapors and Liquids
3.5 Flammable and Combustible Liquids
3.6 Combustible Dusts
3.7 Hybrid Dusts

4.0 HAZARDOUS AREA CLASSIFICATION FOR FLAMMABLE VAPORS,

LIQUIDS & GASES (CLASS I)
4.1 Definition
4.2 Division / Zone Classification
4.3 Groups
4.4 Temperature Code
4.5 Extent of Classification
4.6 Applicable Standards
4.7 Special Considerations

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3DG-E610-00001, Rev. 002 PAGE 1 OF 36
5.0 HAZARDOUS AREA CLASSIFICATION FOR COMBUSTIBLE DUSTS
(CLASS II)
5.1 Definition
5.2 Division / Zone Classification
5.3 Groups
5.4 Ignition Temperature
5.5 Extent of Hazardous Area Classification
5.6 Applicable Standards
5.7 Special Considerations

6.0 HAZARDOUS AREA CLASSIFICATION FOR IGNITABLE FIBERS & FYINGS

(CLASS III)
6.1 Definition
6.2 Division / Zone Classification
6.3 Groups
6.4 Ignition Temperature
6.5 Extent of Hazardous Area Classification
6.6 Applicable Standards

7.0 PROCEDURE FOR HAZARDOUS AREA CLASSIFICATION

7.1 General
7.2 Assemble Data and Reference Material
7.3 List All Hazardous Materials (Work Sheet A1)
7.4 Sources of Release (API 500 – 505) / (IP 15) (Work Sheet A2 / A3)
7.5 Need for Area Classification (Work Sheet A3)
7.6 Applicable Standards
7.7 Assignment of Groups (Work Sheet A1)
7.8 Class I Assignment of Division / Zone (Work Sheet A4 / A5)
7.9 Class II Assignment of Division / Zone (Work Sheet A6 / A7)
7.10 Class III Assignment of Division (Work Sheet A8)
7.11 Extent of Hazardous Area Classification

8.0 HAZARDOUS AREA CLASSIFICATION DRAWINGS

8.1 General
8.2 Content

9.0 CLASSIFICATION ALTERNATIVES

9.1 Relocating the Process Equipment
9.2 Relocating the Electrical Equipment
9.3 Purging the Equipment/Room/Building
9.4 Pressurizing the Equipment/Room/Building

10.0 ELECTRICAL EQUIPMENT INSTALLED IN CLASSIFIED AREA

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11.0 STANDARDS AND RECOMMENDED PRACTICES

APPENDICES

APPENDIX A : WORKSHEETS
WORKSHEET A1 - FLAMMABLE / COMBUSTIBLE MATERIALS
WORKSHEET A2 - SOURCES OF RELEASE (API 500 – 505)
WORKSHEET A3 - SOURCES OF RELEASE
(Institute of Petroleum Part 15)
WORKSHEET A4 - NEED FOR CLASSIFICATION (DIVISION / ZONE)
WORKSHEET A5 - CLASS I ASSIGNMENT OF DIVISION
WORKSHEET A6 - CLASS I ASSIGNMENT OF ZONE
WORKSHEET A7 - CLASS II ASSIGNMENT OF DIVISION
WORKSHEET A8 - CLASS II ASSIGNMENT OF ZONE
WORKSHEET A9 - CLASS III ASSIGNMENT OF DIVISION
APPENDIX B : TABLES
TABLE B1 – Classification System Comparison - Class I
TABLE B2 – Gas Groups (NFPA / IEC)
TABLE B3 – Temperature Code / Class - Class I
TABLE B4 – Applicable Standards - Class I Locations
TABLE B5 – Classification System Comparison - Class II
TABLE B6 – Dust Groups (NFPA / IEC)
TABLE B7 – Applicable Standards - Class II Locations
TABLE B8 – Equipment Protection Methods
TABLE B9 – Equipment Marking

ATTACHMENT 1: Report for Hazardous Area Classification (SAMPLE)

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1.0 PURPOSE

· To establish a consistent basis for determining the appropriate hazardous area

classification for electrical installations within the areas.
· To define the boundaries of such areas, and to identify standard deliverable documents.
NOTE: The codes, standards and recommended practices are periodically revised and
must be reviewed for current definitions, practices and requirements.

2.0 DEFINITIONS

The definitions that are most frequently used have been listed below. For a complete list of
definitions, refer to NFPA 70 Articles 500-506, NFPA 496, 497, 499, API RP 500, 505, and
NMAB 353.3. For IEC definitions, refer to Institution of Petroleum Part 15, IEC 60079-10 and
61241-10.

Combustible Dusts: Any finely divided solid material that presents a fire or explosion hazard
when dispersed, and which ignites in air or other gaseous oxidizer.

Combustible Liquids: A liquid that has a flash point at or above 37.8°C (100°F).

Dust-Ignition-Proof: Enclosures that exclude ignitable amounts of dust(s) or amounts that

might affect the performance or rating of the enclosed equipment. The enclosure will
not permit arcs, sparks, or heat otherwise generated or liberated inside of the enclosure
to cause ignition of exterior dust accumulations or atmospheric suspensions of a
specified dust on, or in the vicinity of, the enclosure.

Easily Ignitable: In reference to fibers and flyings, it includes rayon, cotton, sisal or henequen,
istle, jute, hemp, tow, cocoa, fiber, oakum, baled waste kapok, Spanish moss, excelsior,
and other materials of similar nature.

Explosion-Proof Apparatus: Apparatus is an enclosure that is capable of withstanding an

internal gas or vapor explosion, and prevents the ignition of gas or vapor outside the
enclosure, and which operates at an external temperature that will not ignite the
surrounding flammable atmosphere.

Flammable (Explosive) Limits: The lower and upper percentages by volume of a

concentration of gas in a gas-air mixture that will form an ignitable mixture.

Flammable (Explosive) Range: Flammable vapor or gas and air mixture concentrations
between the upper and lower explosive limits.

Flammable Liquid: Liquids with a flash point below 37.8°C (100°F) that have a vapor pressure
not exceeding 276 kPa (40 psia) at 37.8°C (100°F).
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Flame Propagation: The spread of a flame in a combustible environment outward from the
point at which the combustion starts.

Flash Point: The minimum temperature at which a liquid gives off vapor in sufficient
concentration to form an ignitable mixture with air near the surface of the liquid.

Flyings: A fiber or group of fibers.

Hazardous: Involving highly combustible, highly flammable, or explosive products or materials

that are likely to burn with extreme rapidity.

Hybrid Dust: A mixture of a dust with one or more flammable gases or vapors (NFPA 499).

Ignitable Mixture: A mixture that is between the upper and lower limits of the flammable range
and is capable of propagating flame away from the source of ignition. (Also referred to
as flammable mixture)

Ignition Temperature: The minimum temperature required to initiate or cause self-sustaining

combustion of a solid, liquid or gas independently of the heating or heated element
(also referred to as auto-ignition temperature).

Intrinsically Safe Apparatus: Intrinsically safe apparatus refers to those electrical items that,
under normal operating conditions or in times of failure, are incapable of releasing
sufficient electrical energy to ignite a specific hazardous atmospheric mixture.

Intrinsically Safe Circuit: A circuit in which any spark or thermal effect is incapable of causing
ignition of a mixture of flammable or combustible material in air.

Non-Incendive System: A system not capable of causing ignition under normal conditions of
operation.

Pressurizing: The process of supplying an enclosure or building with clean air or inert gas at
sufficient positive pressure to prevent the entrance of hazardous vapors or dusts.

Purging: The process of supplying an enclosure with clean air or inert gas or a room/building
with clean air at a sufficient flow rate and positive pressure to reduce, to an acceptably
safe level, the concentrations of any flammable gas or vapor initially present, and to
maintain the safe level by positive pressure with or without continuous flow (Class I
classified areas).

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Temperature Identification Number (T-Rating): A number preceded by the letter "T"
designating the maximum surface temperature of a piece of equipment.
See Appendix B, Table B3, Temperature Code / Class - Class I.

Unclassified Location – Unclassified (or Non-hazardous): Areas in which there is no

likelihood that explosive or ignitable mixtures or hazardous dust layers will exist. Also
the location is not classified as Class I, Class II, or Class III.

Ventilation, Adequate: Ventilation (natural or artificial) that is sufficient to prevent the

accumulation of quantities of vapor-air mixtures in concentrations above 25 percent of
their lower flammable (explosive) limit (LFL).

Ventilation, Inadequate: Rooms, buildings or spaces that do not have a natural or a

mechanical ventilation system providing for adequate ventilation.

3.0 HAZARDOUS AREA CLASSIFICATION BASICS

3.1 BACKGROUND

Area classification is a method of analyzing and designating the locations where explosive gas
atmospheres, liquid vapors, combustible dusts and metals may occur so as to facilitate the
proper selection and installation of apparatus to be used safely in that environment, taking into
account groups and temperature classes.

Classified areas are locations where the potential for fire or explosion exists because of gases,
dust, or easily ignitable fibers or flyings in the atmosphere.

In the United States, classified hazardous areas have traditionally been identified by Classes,
Divisions and Groups to define the level of safety required for equipment installed in these
locations. Area classification is based upon three distinct classes (Classes I, II, and III) of
material that are subdivided into two divisions (Divisions 1 and 2) according to the likely
presence of a material, and categorized by group (Groups A through G) according to similar
material types.

NFPA 70 designates classified locations as Class I (flammable gases or vapor), Class II

(combustible dusts), and Class III (easily ignitable fibers).

In 1996, NFPA 70 (the NECâ) was revised to include Article 505 embracing the Zone concept
of classification which has been the traditional European method. In 1997, NFPA 497 was
aligned with the changes in NFPA 70. In quick succession, the American Petroleum Institute
introduced a new standard API RP 505. The North American equipment certifying authority,
Underwriters Laboratories (UL), also issued a new standard UL 2279 that includes IEC based
Zone certification requirements.

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In Europe and countries outside the United States, classification of hazardous areas is
accomplished differently. There are two discrete standards, IEC 60079-10 that applies for
explosive gas atmospheres and IEC 61241-10 that deal with areas where combustible dusts
are or may be present.

In IEC 60079-10 Zones 0, 1 and 2 are used to define the likelihood of a potentially explosive
atmosphere. The equipment installed in the area must be suitable for the gas Groups and
temperature classification of the substances that may be present.

IEC 61241-10 uses zones 20, 21 and 22 to define the likelihood of a potential dust hazard and
requires the installation of appropriate equipment.

In Europe there is a legal requirement to comply with the ATEX directive, which requires
employers to:

1. Prevent the formation of explosive atmospheres in the workplace

or
Avoid the ignition of the explosive atmospheres
and
Control the effects of explosions
2. Conduct risk assessments covering
· The likelihood of explosive atmospheres occurring and their persistence
· The likelihood of a source of ignition
· The effect of ignition on plant personnel and the environment
3. Classify the workplace into Zones
4. Mark areas with signs at the points of entry
5. Maintain an explosion protection document including
· Risk assessment and identification of zones
· Area classification
· Maintenance schedules
· Documentation of requirements for training staff and instituting a system of
permits to work
6. Select ATEX 100a (ATEX Equipment Directive) compliant equipment.

In the United States, “Classes”, “Zones”, and “Groups” are used to define the level of safety
required for equipment installed in these locations. “Zones” are used in place of Divisions to
define the probability of the presence of flammable materials.

3.2 GENERAL

While hazardous area classification considers some system and process failures, the
recommended practices for hazardous classified areas do not account for all situations that
might involve catastrophic failure of, or catastrophic discharge from, process vessels, pipelines,

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tanks, or systems. Such events are so rare that it is impractical to design electrical systems for
such circumstances.

The recommend practice for hazardous area classification is not intended to apply to situations
involving enriched oxygen atmospheres, pyrophoric materials, or materials above their auto-
ignition temperature. Each of these situations has particular hazards. With pyrophoric materials
and those above their auto-ignition temperature, fire is certain upon exposure to air and hence
control of potential electrical sources of ignition may be of limited benefit. In oxygen enriched
atmospheres, ignition and burning characteristics of fuels can be greatly altered - for example,
both the lower flammable limit and the auto-ignition temperature are reduced. Where such
situations are encountered, further specialist advice should be obtained. Consideration should
also be given to transient conditions and other materials that may be present. As a minimum,
area classification should be done for other materials that may be present in the location.

3.3 CONDITIONS NECESSARY FOR IGNITION

There are three basic conditions that must exist for a fire or explosion to occur:

1) The presence of flammable gas or vapor, combustible dust, fibers, or flyings.

2) The material must be mixed with air, in the proportions required to produce an
ignitable mixture or the dust must be layered on equipment in sufficient thickness,
to interfere with the dissipation of heat and allow the layer to reach the ignition
temperature of the dust.

3) There must be a release of energy intense enough to cause ignition of the mixture,
the surface temperature of equipment must be above the temperature that causes
ignition or, for conducting dusts, arc tracking sufficient to cause ignition.

The source of ignition can be any source of energy of sufficient quantity to ignite a combustible
mixture. Possible ignition sources are as follows:

1) Arcing and sparking sources including switches, circuit breakers, relays,

pushbutton stations, plugs and receptacles, lightning and static electricity.

2) Heat-producing sources and equipment include electric heaters, electric heat

tracing, lighting fixtures, motors and transformers, hot surfaces of metal.

3) Sources caused by insulation failure include wiring (particularly splices),

transformers, impedance coils, solenoids and other low-temperature devices
without make-or-break contacts.

4) Non-electrical ignition sources include open flames, fired heaters, flares, welding
machines and vehicles.
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3.4 BEHAVIOR OF GASES, VAPORS AND LIQUIDS

The flash point of a liquid is the minimum temperature at which the liquid gives off vapor in
sufficient concentration to form an ignitable mixture with air. Refer to NFPA 497 and IEC 60079-
20 for flash points of flammable liquids and gases.

A gas or vapor from a liquid will either rise or fall to grade level, depending on its relative density.
The relative density of a gas or vapor is the ratio of the weight of a volume of pure vapor or gas
to an equal volume of dry air at the same temperature and pressure. A relative density of less
than one (<1) indicates that the substance is lighter than air and will tend to rise in a relatively
calm atmosphere. A relative density greater than one (>1) indicates that the substance is
heavier than air and may travel along the ground at grade level for a considerable distance.
Heavier than air vapors and gasses will also enter pits manholes and other below grade spaces
if they exist. They will travel along any below grade ducts which can form a route into buildings
and other unexpected places if not stopped.

NFPA 497 lists the relative density of flammable vapors and gases.

IEC 60079-20 lists the relative density of flammable vapors and gases and introduces a specific
requirement that if the relative density of the gas or vapor is less than 0.8 it is regarded as
lighter than air and if more than 1.2 heavier than air. If the relative density is between 0.8 and
1.2 both possibilities should be considered.

When the mixture of air and flammable gas or vapor is between the lower explosive limit and
upper explosive limit an explosion is possible.

· The lower explosive limit (LEL) is defined as the concentration of gas or vapor in air below
which the gas atmosphere is not explosive.

· The upper explosive limit (UEL) is defined as the concentration of gas or vapor in air above
which the gas atmosphere is not explosive.

A flammable or combustible liquid must be at, or above, its flash point temperature before
combustion can be sustained. The ignition (auto-ignition) temperature is the minimum
temperature required to initiate or cause self-sustained combustion of a solid, liquid, or gas,
independent of the heating or heated element. Refer to NFPA 497 and IEC 60079-20 for a
listing of flash points.

When liquids are mixed or contaminated with another liquid, the hazardous classification is
based on the ignition temperature of the gas or vapor mixture. Special care must be taken in
such circumstances to determine if the combined gases or vapors can have a lower ignition
temperature than the individual gases or vapors. Testing may be required.

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3.5 FLAMMABLE AND COMBUSTIBLE LIQUIDS

Flammable and combustible liquids have their own classification system as described in
NFPA 321 and 497. This liquid classification system is unrelated to the system for electrically
classifying locations and there is no correlation between them.

1) Flammable liquids have a flash point below 37.8°C (100°F) and a vapor pressure
not exceeding 276 kPa (40 psia) at 37.8°C (100°F). The gases or vapors from
these liquids form an ignitable or explosive mixture with air at ambient
temperatures. Thus, suitable electrical equipment is required for the location.

2) Combustible liquids have a flash point at, or above, 38oC (100°F). In general,
combustible liquids do not form flammable mixtures with air at ambient
temperatures unless heated above their flash point. When a combustible liquid is
handled at a temperature above its flash point, the location must be classified.
Combustible liquids are further categorized as Class II, Class IIIA and Class IIIB.
For details refer to NFPA 497.

3.6 COMBUSTIBLE DUSTS

Class II locations are classified due to the presence of combustible dusts. The dust particles
burn very easily and rapidly, almost instantaneously. Within a building, a dust explosion usually
shakes other dust particles loose from the rafters and other parts of the structure, causing a
secondary, usually more violent, explosion.

Class II locations are more difficult to classify as Division 1 or Division 2 (or alternatively Zone
20, 21 & 22 as per IEC practice) because dusts do not disperse to a distance from the source to
the same extent as gases and vapors. Dust accumulates most rapidly in the vicinity of the
source equipment and is usually cleaned frequently from that area. But dust also accumulates
at a slower rate on rafters and in concealed places. Usually, these places are not cleaned as
frequently. Ventilation might not be an effective means to control dust, or it might cause the dust
to accumulate in other locations.

Combustible dusts also have flammable limits (usually called explosion concentrations),
although they are not as well defined as those for liquids and gases, particularly in the upper
limit. Refer to NMAB 353-4 for a list of minimum explosion concentrations for various dusts.

Conductive dusts in Group E are always assigned a Division 1 rating. Nonconductive dusts in
Groups F and G can be assigned either a Division 1 or 2 rating. Investigate each situation to
determine the proper division. If the Group F dust is electrically conductive (resistivity less than
105 ohm centimeter) and present in hazardous quantities then these are classified as Division I
location.

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For conductive dusts, the term "classified quantities" is not defined. Generally, this term refers to
conditions in which there is sufficient conductive dust present to form a visible film over
equipment, thus obscuring markings.

For nonconductive dusts accumulating on the major portions of horizontal surfaces in a 24-hour
period, a dust level of 1/8 inch is used to distinguish between a Division 1 and Division 2
classified location. If 1/8 inch or more of accumulated dust exists in a given area, the location
can be classified as a Class II, Division 1 location. If the dust accumulation is less than 1/8 inch,
but there is some accumulation, the location can be classified as Class II, Division 2. If the
accumulation is practically nonexistent (i.e., surface colors are readily discernible), the location
can be classified as unclassified.

NEC states that only metallic dusts are considered electrically conductive, eliminating their need
for resistivity testing to determine the division classification.

3.7 HYBRID DUSTS

A hybrid dust is a mixture of a dust with one or more flammable gases or vapors. The presence
of the flammable gas or vapor, even at concentrations less than its lower flammable limit, will not
only add to the violence of the dust-air combustion, but will drastically increase the ignition
energy. This situation is encountered in certain industrial operations; e.g., fluidized-bed driers
and pneumatic-conveying systems for plastic dusts from polymerization processes where volatile
solvents are used. In such cases, specify electrical equipment that is suitable for simultaneous
exposure to both the Class I (flammable gas) and Class II (combustible dust) locations.

4.0 HAZARDOUS AREA CLASSIFICATION FOR FLAMMABLE VAPORS, LIQUIDS &

GASES (CLASS I)

4.1 DEFINITION

Class I locations are defined for the United States as those in which flammable gases or vapors
are or may be present in the air in quantities sufficient to produce explosive or ignitable mixtures.
This type of hazard is covered by IEC 60079.

4.2 DIVISION / ZONE CLASSIFICATION

Time durations for the presence of hazardous vapors and gases are not defined for the Class /
Division method per API and NFPA except for terms such as “continuous”, “long term”,
“frequently” or “short term”.

Based on probability of presence of flammable gases or vapors, a Class I location is categorized

into:

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 1) Division 1: A location in which:
Ignitable concentrations of flammable gases or vapors exist under normal
conditions

or

Ignitable concentrations of such gases or vapors may exist frequently because of

repair or maintenance operations or because of leakage

or

Breakdown or faulty operation of equipment or processes may release ignitable

concentrations of flammable gases or vapors and may also cause simultaneous
failure of electrical equipment in such a way as to directly cause the electrical
equipment to become a source of ignition.

2) Division 2: A location in which:

Volatile flammable liquids or flammable gases are handled, processed, or used,

but in which the liquids, vapors, or gases will normally be confined within closed
containers or closed systems from which they can escape only in case of
accidental rupture or breakdown of such containers or systems or in case of
abnormal operation of equipment

or

Ignitable concentration of gases or vapors are normally prevented by positive

mechanical ventilation and which might become hazardous through failure or
abnormal operation of the ventilating equipment

or

Is adjacent to a Class I, Division 1 location, and to which ignitable concentrations

of gases or vapors might occasionally be communicated unless such
communication is prevented by adequate positive-pressure ventilation from a
source of clean air and effective safeguards against ventilation failure are
provided

Definitions of Class I, Divisions 1 & 2 refer to NFPA 70 Article 500, NFPA 497, and API - RP
500.

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Time durations for the presence of hazardous vapors and gases are defined for the Zone
method per API 505, IP 15 and CEI 31-35:

ZONE Probability (P) of explosive atmosphere Total duration of explosive

per year atmosphere in one year
(hours)

0 P > 10-1 Over 1000

1 10-1 > P >10-3 10 to 1000

2 10-3 > P >10-5 0.1 to 10

1) Zone 0: A location in which:

Ignitable concentrations of flammable gases or vapors are present continuously

or

Ignitable concentrations of flammable gases of vapors are present for long periods
of time.

2) Zone 1: A location in which:

Ignitable concentrations of flammable gases or vapors are likely to exist under

normal conditions

or

Ignitable concentrations of flammables gases or vapors may exist frequently

because of repair or maintenance or because of leakage

or

Equipment is operated or processes are carried on, of such a nature that

equipment breakdown or faulty operations could result in the release of ignitable
concentrations of flammable gases or vapors and also cause simultaneous
failure of electrical equipment in a mode to cause the electrical equipment to
become a source of ignition

or

Is adjacent to Class I, Zone 0 location, from which ignitable concentrations of

vapors could be communicated, unless communication is prevented by
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 adequate positive-pressure ventilation from a source of clean air and effective
safeguards against ventilation failure are provided.

3) Zone 2: A location in which:

Ignitable concentrations of flammable gases or vapors are not likely to occur in

normal operation, and if they do occur, it will only exist for a short period

or

Volatile flammable liquids, flammable gases, or flammable vapors are handled,

processed, or used but in which the liquids, gases, or vapors normally are
confined within closed containers of closed systems from which they can escape,
only as a result of accidental rupture or breakdown of the containers or system,
or as a result of abnormal operation of the equipment

or

Ignitable concentrations of flammable gases or vapors normally are prevented by

positive mechanical ventilation but which may become hazardous as a result of
failure or abnormal operation of the ventilation equipment

or

Is adjacent to a Class I, Zone 1 location, from which ignitable concentrations of

flammable gases or vapors could be communicated, unless such
communications is prevented by adequate positive-pressure ventilation from a
source of clean air and effective safeguards against ventilation failure are
provided.

Definitions of Zones 0, 1 & 2 refer to NFPA 70 Article 505, NFPA 497, API RP
505, and IEC 60079-10.

For a comparison of Classification systems given above, refer to Appendix B,

Table B1.

4.3 GROUPS

Gases are grouped together based on the amount of energy required to ignite the most
explosive mixture of the gases in air.

In the NFPA Division system, gases are grouped from Group D to Group A in decreasing order
of ignition energy.

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In the NFPA Zone system, which is identical to the IEC system, gases are grouped from
Group IIA to Group IIC in decreasing order of ignition energy.

See Appendix B, Table B2 for a comparison between Gas Groups in Division and Zone
classifications.

4.4 TEMPERATURE CODE

To ensure that there is no risk of ignition due to hot surfaces, equipment is classified with
regard to the maximum surface temperature of any part of the equipment under normal or fault
conditions at the marked ambient temperature or 40°C if not marked. This is known as "T" code
/ classification. T code ranges from "T6" which allows a maximum surface temperature of 85°C
(no known products have an ignition temperature as low as this), to "T1", which allows a
maximum temperature of 450°C. This is as per IEC 60079-0. In NFPA 70, the T codes are
similar to that in IEC except that codes T2, T3 & T4 have been further categorized. Refer to
Appendix B, Table B3.

As per NFPA 70 Article 500, the temperature code of the selected equipment must not exceed
the ignition temperature of the gas in which the equipment is installed.

Similarly, IEC 60079-0 states that the lowest ignition temperature of the classified atmosphere
shall be above the maximum surface temperature. However, certain exceptions are made for
components with total surface area less than 10 cm2. Refer to IEC 60079-0 for details.

4.5 EXTENT OF CLASSIFICATION

The extent of a Class I location can be broadly categorized into an overall plant classification
scheme or individual equipment classification. Various parameters like process equipment
size, flow rate, and temperature and pressure determine the approach taken to determine the
extent of classification. Refer to Table 3.6 of NFPA 497 for determining the relative
magnitudes of process equipment and piping handling combustible material.

Generally speaking, point source diagrams can be used for small or batch chemical plants and
power plants. For high-pressure plants, the API recommendations are more appropriate.
Section 5 of IP 15 identifies the factors determining the extent of the hazardous area from a
point source and the methology for obtaining the hazardous radii.

The extent of classification is determined by using sound engineering judgment and practice.
Some representative figures with references to industry standards have been provided in
Appendix C. Figures for identical sources have been arranged beside each other for sake of
comparison between the industry standards.

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4.6 APPLICABLE STANDARDS

To determine the applicable standard while classifying a Class I area, the following
characteristics of the project must be considered:

1) Geographical location (this will chiefly determine the applicable standard for the
particular project) and Client practice
2) Type of plant i.e., small or batch chemical process plant, power plant, refinery, oil
fuel handling facility.
3) Process parameters like size, pressure and flow rate. Refer to Table 3-6 of
NFPA 497 for relative magnitudes.

For a summary of the above, refer to Appendix B, Table B4.

4.7 SPECIAL CONSIDERATIONS

Gas / Vapor in an enclosed classified area can be diluted by dispersion or diffusion into the air
until its concentration is below the lower flammable limit (LFL). The degree of ventilation
(natural or artificial) can determine the Division / Zone. For further details, refer to API RP 500
Section 6.3 and IEC 60079-10 Annex B.
In vendor supplied skids handling flammable liquids / gases, welded piping is used and the
skid is categorized as general purpose. When a flanged connection is used as an interface
with such a skid, a Class I, Div 2 (alternatively Class I, Zone 2) area is created. This requires
all devices on the skid under influence of this new classified area, to be suitable for this area.
This leads to a major problem with potential costly fixes. It should also be noted that in
accordance with API RP 500 section 9.1.5, flanges may not be considered a source in a well
maintained closed piping system that includes only the pipe, fittings, flanges, meters, and
small valves. The facility owner should be consulted to determine if he will consider the facility
to be well maintained. The decision to consider the facility to be well maintained will greatly
reduce the number of sources in a petrochemical facility. In the United States where most
hydrocarbon emissions are strictly regulated by the government it would be very unusual for
facilities not to be considered well maintained.
It is recommended that welded piping be used whenever possible. Also, placing large motors /
devices with contacts in the radius zone of a potential leak source like a flange, must be
avoided.
When a mixture contains gases of different Groups, the area classification must be based on
the following conditions:
1) The ignition temperature of that gas (or vapor) having the lowest ignition
temperature must be considered. Alternatively, tests for ignition temperature may
be required.
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 2) If the vapor density of the resultant mixture is greater than 1, the gas must be
considered heavier than air. If the vapor density is less than 1, the gas must be
considered lighter than air. IEC says if the relative density is less than 0.8 it is
regarded as lighter than air and if more than 1.2 heavier than air. Between 0.8
and 1.2 both possibilities should be considered. This applies in all instances, not
just mixtures.
3) In mixtures, the Gas Group will be the most stringent gas group either A or B
(Equivalent to Group IIC) when hydrogen, acetylene or butadiene are present.
API 500 states that if the mixture contains 30% or more of hydrogen, hazardous
gas is considered as Group B (Group IIB + hydrogen or IIC). IEC 60079-20
states “…methane…is classified as Group IIA provided it does not contain more
than 15% (V/V) of hydrogen.”
4) Similarly per API 500 section 5.5.4 if natural gas contains more than 25% (by
volume) H2S, the mixture is considered Group C (or Group IIC).
Charging of non-sealed battery cells leads to the creation of a classified area since the cells
act as primary source of emission of hydrogen. Battery rooms that are adequately ventilated
as per guidelines laid down by IEEE 484 may be treated as unclassified. For the interior of an
unventilated Battery room, the hazardous area classification must be Class I, Division I (or
alternatively, Zone 1), Group B (or alternatively Group IIC). If designing to IEC 60079 the
ventilation would need to meet the requirements of IEC 60079 not IEEE 484.
Special precautions must be exercised in classifying locations associated with Crude Oil.
Crude oil contains volatile “light ends" which may be released during storage and handling or
upon heating. The flash point of crude oil can range from zero to over 150°F (-17°C to 66°C).
The volatile light ends of crude oils, such as propane, butane and pentane, upon leakage or
other release to atmosphere, may volatilize at ambient temperature. Being heavier than air,
the vaporized hydrocarbons may travel for considerable distances and accumulate in
hazardous concentrations.
Hydrogen Gas is considered an NEC Group B gas. The potential leakage of hydrogen from
flanges and meters can lead to a highly flammable or explosive environment. The application
of classification zones for hydrogen is similar to that for natural gas.

5.0 HAZARDOUS AREA CLASSIFICATION FOR COMBUSTIBLE DUSTS (CLASS II)

5.1 DEFINITION

Classified (or hazardous) locations in which combustible dusts are or may be present in the air
in quantities sufficient to produce explosive or ignitable mixtures are defined as Class II by the
API or NFPA systems.

This type of hazard is covered by IEC-61241.

5.2 DIVISION / ZONE CLASSIFICATION

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Based on probability of presence of combustible dust, a Class II location is categorized into:

1) Division I: A location in which:

Combustible dust is in the air under normal conditions in quantities sufficient to

produce explosive or ignitable mixtures.

or

Mechanical failure or abnormal operation of machinery or equipment might

cause such explosive or ignitable mixtures to be produced and might also
provide a source of ignition through simultaneous failure of electric equipment,
operation of protection devices, or from other causes.

or

Group E combustible dusts may be present in quantities sufficient to be

hazardous.

2) Division 2: A location where:

Combustibles dust due to abnormal operations may be present in the air in

quantities sufficient to produce explosive or ignitable mixtures

or

Combustible dust accumulations are present but are normally insufficient to

interfere with the normal operation of electrical equipment or other apparatus,
but could as a result of infrequent malfunctioning of handling or processing
equipment become suspended in the air

or

Combustible dust accumulations on, in, or in the vicinity of the electrical

equipment could be sufficient to interfere with the safe dissipation of heat from
electrical equipment, or could be ignitable by abnormal operation or failure of
electrical equipment

Definitions of Class II, Division 1 & 2 refer to NFPA 70 Article 500 and NFPA 499.

or

1) Zone 20: A location in which:

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 Ignitable concentrations of combustible dusts are present continuously

or

Ignitable concentrations of combustible dusts are present for long periods of

time.

2) Zone 21: A location in which:

Ignitable concentrations of combustible dusts are likely to exist occasionally

under normal conditions

or

Ignitable concentrations of combustible dusts may exist frequently because of

repair or maintenance operations or because of leakage

or

Equipment is operated or processes are carried on, of such a nature that

equipment breakdown or faulty operations could result in the release of ignitable
concentrations of combustible dusts and also cause simultaneous failure of
electrical equipment in a mode to cause the electrical equipment to become a
source of ignition

or

Is adjacent to a Zone 20 location from which ignitable concentrations of dusts

could be communicated, unless communication is prevented by adequate
positive pressure ventilation from a source of clean air and effective safeguards
against ventilation failure are provided.

3) Zone 22: A location in which:

Ignitable concentrations of combustible dusts are not likely to occur in normal

operation, and if they do occur, will only exist for a short period

or

Combustible dusts are handled, processed, or used but in which the dusts are
normally confined within closed containers of closed systems from which they
can escape only as a result of the abnormal operation of the equipment with
which the dusts are handled, processed, or used
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 or

Is adjacent to a Zone 21 location from which ignitable concentrations of dusts

could be communicated, unless such communication is prevent by adequate
positive pressure ventilation from a source of clean air and effective safeguards
against ventilation failure are provided

Definitions of Zone 20, 21 & 22 refer to IEC 61241-10.

NFPA has been revised to classify Class II locations as per Zone concept.

For comparison of the classification systems given above, refer Appendix B, Table B5.

5.3 GROUPS

Combustible dusts are grouped into three groups based on the nature of the dust.

In the NFPA Division system, combustible dusts are grouped into Group E, F, and G.

· Group E -Atmospheres containing combustible metal (i.e., conductive) dust

· Group F - Charcoal, coal, or coke dusts having more than 8 percent total volatile material
· Group G - Atmospheres containing flour, starch, or grain dust
Only Group E dusts are considered to be electrically conductive for classification purposes.
Dusts containing magnesium or aluminum are particularly hazardous, and extreme caution will
be necessary to avoid ignition and explosion. The IEC Zone system does not categorize
combustible dusts.

See Appendix B, Table B6 for Combustible Dust Groups in Division / Zone Classification.

5.4 IGNITION TEMPERATURE

Dust clouds and dust layers comprising combustible dust are both susceptible to ignition
generated from arcing and sparking parts. The ignition temperature of a dust layer is often less
than the cloud ignition temperature.

Refer to NFPA 499 Table 2-5 for the minimum ignition temperature of specific dusts. Refer to
IEC 61241-2-1 which describes the method for testing for ignition temperature.

As per IEC 60079-0, the maximum surface temperature of Group I (suitable for mines
susceptible to fire damp) shall not exceed 150°C for any surface where coal dust can form a
layer, and 450°C where coal dust is not expected to form a layer.

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5.5 EXTENT OF HAZARDOUS AREA CLASSIFICATION

In an industrial plant, storage tanks, bins & silos, piping & ductwork, ball mills, grinders,
pulverizers, conveyers, and bucket elevators handle combustible dusts. These in turn present
sources of leaks such as flanged and screwed connections, valve openings and metering and
weighing devices. While determining the extent of classification, due consideration must be
given to various factors like the combustible material involved, bulk density of particle, particle
size of material, particle density, process of storage pressure, size of leak opening, quantity of
release, dust removal system, housekeeping and presence of any hybrid mixture.

Refer to NFPA 499 for representative figures as per the United States practices. These figures
apply to operating equipment processing dusts when the specific particle density is greater
than 640.72 kg/m3 (40 lb/ft3). For lower particle densities, fine dust will have a tendency to drift
and the extent of the classified area will need to be extended using sound engineering
judgment and practice.

Refer to IEC 61241-10 for representative figures as per European practices. Based on the
Grade of Release (Continuous, Primary & Secondary), hazardous dust areas are classified
into Zones 20, 21 & 22. Typical examples of Zone 20, 21 & 22 have also been provided in this
standard. It should be noted that IEC 61241-10 does not apply to underground mining.

NFPA 499 provides the following recommendation based on a visual check of a Class II location
for a 24-hour period:

For nonconductive dusts accumulating on the major portions of horizontal surfaces in a 24-hour
period, a dust level of 1/8 inch is used to distinguish between a Division 1 and Division 2
classified location. If 1/8 inch or more of accumulated dust exists in a given area, the location
can be classified as a Class II, Division 1 location. If the dust accumulation is less than 1/8 inch,
but there is some accumulation, the location can be classified as Class II, Division 2. If the
accumulation is practically nonexistent (i.e., surface colors are readily discernible), the location
can be designated as “unclassified” or “non hazardous”.

5.6 APPLICABLE STANDARDS

The applicable standard for Class II locations shall be chiefly determined by geographical
location of the project and Client practice.

Refer to Appendix B, Table B7 for guidance to determine applicable standard for Class II
locations.

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5.7 SPECIAL CONSIDERATIONS

Certain metal dusts like that of zirconium, thorium & uranium have extremely low ignition
temperatures (as low as 20°C (68°F)) and minimum ignition temperatures lower than other
metal dusts. Safeguards for such atmosphere shall be adopted with caution.

For Class II locations, barriers, partitions and walls are very effective in reducing the degree of
classification. Class II, Div I (or alternatively, Zone 21) locations can be separated from
unclassified areas using closed doors, lightweight partitions or partial partitions.

Distinct landmarks such as curbs, dikes, walls, supports etc. shall be utilized for actual
boundaries of area classification if the source circles fall within these landmarks. This permits
easy identification of boundaries by field personnel.

In coal storage areas, the situation could exist where there is simultaneous presence of
combustible coal dust and methane gas. Methane is released from coal as it is mined,
crushed, processed, transported, and stored. About 75 percent of the methane in the coal is
dissipated within a few days of being mined. The other 25 percent dissipates at a much
slower rate. This methane release could be potentially hazardous in "mine-mouth" power
plants or in conventional fossil plants where the coal is stored in a confined space with low
ventilation.

6.0 HAZARDOUS AREA CLASSIFICATION FOR IGNITABLE FIBERS & FLYINGS

(CLASS III)

6.1 DEFINITION

Class III locations are those in which easily ignitable fibers or flyings are or may be present in
the air, but not in quantities sufficient to produce ignitable mixture.

6.2 DIVISION / ZONE CLASSIFICATION

Based on the probability of the presence of ignitable fibers or flyings, a Class III location is
categorized into:

1) Division I: A location in which:

Easily ignitable fibers or materials producing combustible flyings are handled,

manufactured or used.

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 2) Division 2: A location in which:

Easily ignitable fibers are stored or handled other than in process of

manufacture.

Definitions of Class III, Division 1 & 2 refer to NFPA 70 Article 500 and NFPA 499

Class III locations are not classified by IEC standards.

6.3 GROUPS

There is no group categorization of ignitable fibers or flyings in NFPA Article 500 or the IEC
standards.

6.4 IGNITION TEMPERATURE

NFPA 70 Article 503 limits the maximum surface temperature for Class III equipment to 165°C
(329°F) for equipment not subject to overloading and 120°C (248°C) for equipment like motors,
that may be overloaded.

6.5 EXTENT OF HAZARDOUS AREA CLASSIFICATION

The extent of classification (Division 1 or 2) must be determined based on principles as laid

down by NFPA 70 Articles 500 and 503. These have been presented in Worksheet A6. For
details, refer to Appendix A.

6.6 APPLICABLE STANDARDS

Refer to NFPA 70 Article 500 and NFPA 499.

7.0 PROCEDURE FOR HAZARDOUS AREA CLASSIFICATION

7.1 GENERAL

The work flow diagram for the preparation of hazardous area classification documents is
located in eEngineering. Area classification is a team effort comprising of:

1) Process – person who is knowledgeable about the process conditions and

flammable materials used.
2) Process Safety – person who knowledgeable in the safety aspects of the plant
design, the consequences of release of hazardous materials, including gas
dispersion behavior and the risk of explosion, and the governing codes and

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 standards. (When one person has the requisite knowledge, Process and
Process Safety roles may be combined.)
3) Mechanical - person who is knowledgeable about mechanical equipment and their
arrangements such as pumps, compressors seals, seal systems, etc.
4) Plant Design Discipline - person who is knowledgeable about the piping and
equipment utilized for hazardous liquids and gases and location of potential leak
sources like hydrogen bottles and manifolds.
5) Electrical Discipline - person who is knowledgeable of the electrical equipment and
has knowledge of what can be used in each classified area, as well as governing
codes and standards.

7.2 ASSEMBLE DATA AND REFERENCE MATERIAL

The first task is to obtain the process description, process flow diagrams (PFDs), heat and
material balance data, piping and instrumentation diagrams (P&IDs), the Material Safety Data
Sheets (MSDSs), an up-to-date plot plan (use a plot plan sometimes called equipment layout
that indicates the location of major equipment, roads, and all below-grade locations). For
classification of existing facilities, an existing hazardous area classification drawing should be
obtained if available. If none are available or there is reason to believe the drawings are not
accurate for existing areas adjacent to Bechtel's scope of work area, it is prudent to perform a
walk down of those areas (say within 100' of the scope of work boundary). This is done to
determine possible sources that could impact the area classification within the scope of work
area. Restated, verify that sources outside the battery limits do not impact the area classification
shown on the drawing.

For each project, the applicable industry recommended practices and standards must be
identified and agreed upon with the Owner. The applicable reference documents shall be
collected and reviewed before starting the classification process, such as:

• American Petroleum Institute (API) RP-500 (Class I Locations)

• NFPA 70 (Class I, II, and III Locations)

• NFPA 496 (Class I and II Locations)

• NFPA 497 (Class I Locations)

• NFPA 499 (Class II Locations)

• IEC 60079-10 Classification of Hazardous Areas

Refer to Section 11.0, for additional reference information.

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7.3 LIST ALL HAZARDOUS MATERIALS
(APPENDIX A: WORK SHEET A1)

Using the process information and with help from the Process Engineer, list all hazardous
materials (and corresponding data) in the area under study, on Work Sheet A1, "Hazardous
Materials" except for material class and group.

Material class will be determined in Section 7.5 and material group will be determined in
Section 7.6.

7.4 SOURCES OF RELEASE (API 500 – 505) / (IP-15)

(APPENDIX A: WORK SHEET A2/A3)

Using the process information, equipment arrangement plan drawings, and equipment data
sheets, list all sources of release on Work Sheet A2/A3.

7.5 NEED FOR AREA CLASSIFICATION

(APPENDIX A: WORK SHEET A4)

Complete Work Sheet A4, "Need for Classification" to determine if a location must be classified.
The completion of this work sheet will also determine the area's "Class". At this point you can
now fill in the material "Class" on Work Sheet A1.

If the answers to all of the questions on Work Sheet A4 are "NO", the area is unclassified and
you should proceed to Section 8.0. Otherwise, continue on to Section 7.6.

7.6 ASSIGNMENT OF GROUPS

(APPENDIX A: WORK SHEET A1)

For Class I and II locations, assign each hazardous material to its appropriate group (refer to
Section 4.3 for Class I locations and Section 5.3 for Class II locations). Then fill in the material
group on Work Sheet A1.

7.7 CLASS I ASSIGNMENT OF DIVISION / ZONE

(APPENDIX A: WORK SHEET A5 / A6)

The subject of adequate or inadequate ventilation is very important in establishing whether an

area is Division 1 or 2.

API RP 500 defines an inadequately ventilated area as rooms, building or spaces that do not
have a natural or a mechanical ventilation system. It is possible to have portions of buildings
adequately ventilated in some areas and inadequately in other areas. For instance a
compressor building with no walls and the roof area without ridge vents would be an example
of inadequate ventilation. API RP 500 defines adequate ventilation as ventilation (natural or
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artificial) that is sufficient to prevent the accumulation of significant quantities of vapor-air
mixtures in concentration above 25 percent of their lower flammable (explosive) limit (LFL).
Refer to NFPA 30 for additional details.

The source of air used for ventilation should be from an area classified no higher than the
desired classification: for example, air from a Division I area may not be used to ventilate a
Division 2 area. If practical, the source of air should be from an unclassified area.

Enclosed areas (rooms, buildings, or spaces) that are provided at least 1.0 cubic foot of air
volume flow per minute per square foot of floor area, but at least six (6) air changes per hour,
can be considered as adequately ventilated. This ventilation rate can be accomplished by
either natural or mechanical means.

For naturally ventilated enclosed areas (e.g., buildings), airflow due to thermal forces (stack
effect) provides adequate ventilation if the inlet and outlet ventilation openings are properly
sized and located. When determining adequate ventilation for enclosures using mathematical
analysis, a safety factor of two should be used, increasing the minimum calculated air flow rate
required to 12 air changes per hour".

To assign a Division to a Class I area, complete Work Sheet A5, "Class I Assignment of
Division" to determine if the location is Division 1 or Division 2.

To assign a Zone to a Class I area, complete Work Sheet A6, "Class I Assignment of Zone" to
determine if the location is Zone 0, 1 or 2.

A Class I, Division 1, location is described by one of the following situations:

1) Ignitable concentrations of flammable gases or vapors can exist under normal

operating conditions
2) Ignitable concentrations of flammable gases or vapors may exist frequently because
of repair or maintenance operations, because of leakage
3) Breakdown or faulty operational equipment or processes might simultaneously
release ignitable concentrations of flammable gases or vapors, and also might
cause simultaneous failure of electrical equipment

A Class I, Division 2, location is described by one of the following situations:

1) Volatile, flammable liquids or flammable gases are handled, processed or used, but
the liquids, vapors, or gases will be confined within closed containers or closed
systems from which they can escape only in case of accidental rupture or
breakdown of such containers or systems, or during abnormal operation of
equipment, as defined by NFPA 70

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 2) Ignition concentrations of gases or vapors are normally prevented by positive
mechanical ventilation, which might become hazardous through failure or abnormal
operation of the ventilation equipment, as defined by NFPA 70

3) Is adjacent to a Class I, Division 1 location from which an ignitable concentration of

gases or vapors might occasionally be communicated unless such communication is
prevented by adequate positive-pressure ventilation from a source of clean air, and
effective safeguards against ventilation failure are provided, as defined by NFPA 70

As it is uncommon for plant operations to permit ignitable concentrations of flammable gases or

vapors to exist under normal operating conditions, most process areas in the petrochemical
industry that are Class I fall into Division 2.

7.8 CLASS II ASSIGNMENT OF DIVISION /ZONE

(APPENDIX A: WORK SHEET A7 / A8)

To assign a division to a Class II area, complete Work Sheet A7, "Class II Assignment of
Division" to determine if the location is Division 1 or Division 2.

To assign a Zone to a Class II area, complete Work Sheet A8, "Class II Assignment of Zone" to
determine if the location is Zone 20, 21 or 22.

A Class II, Division 1, location is described by one of the following situations:

1) Combustible dust is in the air under normal operating conditions in quantities

sufficient to produce explosive or ignitable mixtures

2) Mechanical failure or abnormal operation of machinery or equipment might cause

explosive or ignitable mixtures to be produced, and also might provide a source of
ignition through simultaneous failure of electric equipment, operation of protective
devices, or from other causes

3) Combustible dusts of an electrically conductive nature may be present in hazardous

quantities

A Class II, Division 2 location is one where combustible dust is not normally in the air in
quantities sufficient to produce explosive or ignitable mixtures, and dust accumulations are
normally insufficient to interfere with the normal operation of electrical equipment or other
apparatus. However, combustible dust may be in suspension in the air as a result of infrequent
malfunctioning of handling or processing equipment. Also, combustible dust accumulations on,
in, or in the vicinity of, the electrical equipment may be sufficient to interfere with the safe
dissipation of heat from electrical equipment, or may be ignitable by normal operation or failure
of electrical equipment.

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7.9 CLASS III ASSIGNMENT OF DIVISION
(APPENDIX A: WORK SHEET A9)

To assign a division to a Class III area, complete Work Sheet A9, "Class III Assignment of
Division" to determine if the location is Division 1 or Division 2.

Class III locations are areas that are hazardous due to the presence of easily ignitable fibers or
flyings.

1) A Class III, Division 1 location is one in which easily ignitable fibers or materials
producing combustible flyings are manufactured, handled, or used

2) A Class III, Division 2 location is one in which easily ignitable fibers are handled or
stored, but where no manufacturing processes are performed

7.10 EXTENT OF HAZARDOUS AREA CLASSIFICATION

Based on the "Class" of hazard (Class I for flammable liquids, vapors & gases; Class II for
Combustible dusts & Class III for Fibers & Flyings), refer to the appropriate sections of this
document (Section 4.5 for Class I, Section 5.5 for Class II, Section 6.5 for Class III).

This design guide was not written as a "stand-alone" document and is intended to be used in
conjunction with the other standards referenced. Warning - this means reading and
understanding the text of the pertinent standards, not just looking at the pictures and taking off
on a classification project.

8.0 HAZARDOUS AREA CLASSIFICATION DRAWINGS

8.1 GENERAL
The development of hazardous classification drawings should follow the sequence as
explained in Section 7.0. These drawings will be produced as part of any project proposal,
final design and as-built issue of the drawings for any project that creates or changes the
extent of a classified location.
8.2 CONTENT
Prepare the area hazardous area classification drawings including all of the following
information. (The Bechtel eEngineering OG&C Electrical website includes “Benchmark”
drawings that present required minimum content.)
The drawings, must as a minimum, show the following information:
1) All equipment, roads, and below-grade locations

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 2) A note stating which standard (number and year) the area classification drawing is
based on
3) A legend with different markings for each classification
4) Special notes pertaining to the area classification
5) Elevations of equipment in order to completely define the extents of the classified
area.
6) Classification of the area of risk (i.e., Class I / II / III)
7) Demarcation of Division 1, 2 (alternatively Zone 0, 1, 2 for Class I; Zone 20, 21, 22
for Class II) via plan, elevation and section views
8) Specification of the flammable material within the zone of risk (i.e., Groups)
9) Specification of Ignition Temperature class of the flammable material within the
zone of risk
10) The topography of the area where this influences the extent of classification.

Also indicate classification of hazardous areas in the Raceway Notes, Symbols, and Details for
the project and on the corresponding raceway plans and lighting drawings. This is essential
so that the proper installation practices are followed in the field and to assist the field in
selecting fittings, pull boxes, and other field-purchased items.

9.0 HAZARDOUS AREA CLASSIFICATION ALTERNATIVES

Investigate and, if appropriate, implement alternatives to reduce extent of hazardous

classification, thus avoid classifying roadways, reducing costs for certified equipment and
associated installation. However, if these alternatives cannot be adopted, equipment protection
techniques must be implemented. Refer to Appendix B, Table B8. Consider the following
classification alternatives:

9.1 RELOCATING THE PROCESS EQUIPMENT

Consider relocating the process equipment so that the area where the electrical equipment is
located can remain non-classified. Also consider using vapor tight walls or barricades to limit the
extents of the boundaries of the classified area. This alternative applies to Class I, II, and III
locations.

9.2 RELOCATING THE ELECTRICAL EQUIPMENT

Consider relocating the electrical equipment outside the classified area, or relocating the
electrical equipment from a Division 1 to a Division 2 (or Zone 2) area. This alternative applies to
Class I, II, and III locations.

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9.3 PURGING THE ENCLOSURE / ROOM / BUILDING

Consider purging the electrical enclosure/room/building to change the classifications.

Purging applies to Class I locations only.

There are three types of purging available: X, Y, and Z as per NFPA 496 (alternatively px, py and
pz as per IEC 60079-2).

1) Type X (or px) purging reduces the classification within an enclosure/room/building

from Division 1 (or Zone 0) to unclassified.

2) Type Y (or py) purging reduces the classification within an enclosure/room/building

from Division 1 (or Zone 1) to Division 2 (or Zone 2).

3) Type Z (or pz) purging reduces the classification within an enclosure/room/building

from Division 2 (or Zone 2) to unclassified.

The requirements for purging are stringent and may require automatic de-energizing: however, in
some instances purging may be the only practical method for installing some types of electrical
equipment in Group A or Group B locations. When alarms and/or shutdowns are required for a
purged system, sufficient purge supply pressure and flow capacity should be supplied to
eliminate nuisance alarms.

Also, purging electrical enclosures with clean instrument air or inert gas helps protect against
corrosion of the internals.

Refer to NFPA 496 (or IEC 60079-2) for details on purging power sources and redundant
systems.

9.4 PRESSURIZING THE ENCLOSURE / ROOM/BUILDING

Consider pressurizing the enclosure/room/building to reduce both Division 1 and 2 locations (or
Zone 1 and 2) to an unclassified classification.

NFPA 496 covers the pressurization of control rooms, motors, instruments, switchgear, motor
controllers, and similar equipment. Requirements for pressurizing enclosures are different
depending on whether their gross internal volume is smaller or greater than 10 cubic feet. The
requirements differ also depending on whether the pressurizing is intended to reduce the
classification within the enclosure from Division 1 to unclassified (Type X Purging), from Division
1 to Division 2 (Type Y Purging), or from Division 2 to unclassified (Type Z Purging). As per IEC
60079-2, Type px is for purging to reduce Zone 0 to Zone 1; Type py is for purging to reduce
Zone 1 to Zone 2; Type pz is for purging to reduce Zone 2 to unclassified.

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As per the National Electric Safety Code (ANSI C2-1990):

The minimum acceptable requirements for adequate ventilation (pressurization) to reduce the
classification of an enclosed area or enclosure within a Class I, Division 1 area to non-
classified are:

1) The ventilation system shall maintain at least 0.1 inch (2.5 mm) of positive water
pressure in the area with all openings closed.

2) The ventilation system shall provide a minimum velocity of 60 ft per min outward
through each opening with all openings open at the same time.

3) The ventilation system shall be interlocked so that on failure of the ventilation

system, all power to the area shall be de-energized except to those devices which
meet the Class I, Division 1 requirements without the ventilation system.

4) The maximum operating temperature of any internal surface shall not exceed 80%
of the ignition temperature (°C) of the hazardous material involved.

Whether cast enclosures for classified locations or sheet metal enclosures with pressurization
are used is a question of economics if both types are available. Generally, where a large group
of devices is involved, a single pressurized sheet metal enclosure may be more economical than
individual cast enclosures. When pressurization is being considered as an alternative, the costs
of implementing interlocks, trips, and purge functions should be considered. Additional costs
may be incurred in the instrument air compressor installation so that it meets the requirements of
NFPA 496 regarding suction and discharge piping routing and design. Type X purging of
enclosures requires automatic power cutoff to the enclosure in the event of purging system
failure. The consequences of this loss of power should also be considered when making
evaluations. Type Z purging of enclosures require only alarm on event of purging system failure.

Refer to NFPA 496 for further details on pressurization.

Refer to IEC 60079-2 for pressurization of enclosures. Refer to IEC 60079-13 for pressurization
of rooms and buildings.

10.0 ELECTRICAL EQUIPMENT INSTALLED IN CLASSIFIED AREA

Various protection methods have evolved in the electrical industry to make equipment suitable
for operation in Classified areas.

Refer to Appendix B, Table B8 for different equipment protection techniques employed in

Class I location.

For Class II location, refer to NFPA 70 Article 502, NFPA 499, and IEC 61241-1-2.
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For Class III location, refer to NFPA 70 Article 503.

Equipment selection must be based on type of classified area (Class I / II / III), temperature
classification in relation to ignition temperature of the flammable material involved and Gas
Group. All equipment selected must be certified by an acceptable certifying agency viz UL,
BASEEFA, CENELEC, and PTB. Equipment marking depends on the certifying agency. The
various equipment markings are shown in Appendix B, Table B9. The summary of equipment
classification requirements as per NFPA 70 Article 500 has been furnished in Appendix B,
Table B10.

Electrical equipment approved for Class I, II, or III installations must be marked to show the
operating temperature, or temperature range, referenced to a 40°C (104°F) ambient along with
the class and group. The temperature identification number (or T-Rating) designates the
maximum surface temperature of a piece of equipment. The identification number must not
exceed the minimum auto-ignition temperature of the specific gas, vapor, or dust to be
encountered. For Class I, NFPA 70 limits the maximum operating temperature to 80 percent of
the ignition temperature in degrees Celsius. Refer to NFPA 70, Articles 500 through 503, for
additional requirements and a listing of the temperature identification numbers and their
associated maximum temperatures.

Heat-producing equipment to be used in a multiple classified area is to have the maximum

operating temperature, as determined by simultaneous exposure to the combination of the two
classes, marked on the enclosure.

11.0 STANDARDS & RECOMMENDED PRACTICES

Refer to the latest edition.

11.1 American Petroleum Institute (API). Recommended Practices. Washington, D.C.:

API-RP-500 Recommended Practice for Classification of Locations of Electrical

Installations at Petroleum Facilities Classified as Class I, Division 1 and
Division 2
API-RP-505 Recommended Practice for Classification of Locations of Electrical
Installations at Petroleum Facilities Classified as Class I, Zone 0, Zone
1, and Zone 2.
API-RP 14F Recommended Practice for Design and installation for Fixed and
Floating Offshore Petroleum Facilities for Unclassified and Class I,
Division 1 and Division 2 Locations.

11.2 National Fire Protection Association (NFPA). National Fire Codes. Batterymarch
Park, Quincy, Mass.:
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 NFPA 30 Flammable and Combustible Liquids Code
NFPA 45 Standard on Fire Protection for Laboratories Using Chemicals
NFPA 58 Liquefied Petroleum Gas Code
NFPA 70 National Electrical Code
NFPA 321 Basic Classification of Flammable and Combustible Liquids
NFPA 496 Standard for Purged and Pressurized Enclosures for Electrical
Equipment
NFPA 497 Classification of Flammable Liquids, Gases, or Vapors and of
Hazardous (Classified) Locations for Electrical Installations in
Chemical Process Areas
NFPA 499 Classification of Combustible Dusts and of Hazardous (Classified)
Locations for Electrical Installations in Chemical Process
NFPA 654 Standard for the Prevention of Fire and Dust Explosions from the
Manufacturing, Processing, and Handling of Combustible Particulate
NFPA 820 Standard for Fire Protection in Wastewater Treatment and Collection
Facilities
11.3 The Institute of Petroleum, London, 61 New Cavendish Street, London, UK

IP15 Model Code of Safe Practice in the Petroleum Industry, Part 15 -

Area Classification Code for Petroleum Installations

11.4 Institute of Electrical and Electronics Engineers, Inc (IEEE) 345 East 47th Street
New York, NY 10017 - 2394, USA

ANSI/IEEE C2 National Electrical Safety Code

IEEE 484 IEEE Recommended Practice for Installation Design and Installation
of Vented Lead Acid Batteries for Stationary Applications
IEEE-PCIC-90-7 “Risk of Ignition Due to Transition Currents in Medium-Voltage
Motors for Classified Locations," pp. 261-270. Institute of Electrical
and Electronics Engineers, Inc. (IEEE) Petroleum and Chemical
Industry Conference (PCIC).

11.5 International Electro-technical Commission (IEC), 3 Rue de Varembe, Geneva,

Switzerland
(IEC Standards are also being produced as harmonized European Norms (EN), e.g. IEC 60079-
0 is equivalent to EN 60079-0, etc.)
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 IEC 60079-0 Electrical apparatus for explosive gas atmospheres - Part 0: General
requirements
IEC 60079-2: Electrical apparatus for explosive gas atmospheres - Part 2:
Pressurized enclosures "p"
IEC 60079-5 Electrical apparatus for explosive gas atmospheres - Part 5: Powder
filling "q"
IEC 60079-6 Electrical apparatus for explosive gas atmospheres - Part 6: Oil-
immersion "o"
IEC 60079-7 Electrical apparatus for explosive gas atmospheres - Part 7:
Increased safety "e"
IEC 60079-10 Electrical apparatus for explosive gas atmospheres - Part 10:
Classification of hazardous areas
IEC 60079-11 Electrical apparatus for explosive gas atmospheres - Part 11:
Intrinsic safety "I"
IEC 60079-13 Electrical apparatus for explosive gas atmosphere – Part 13:
Construction and use of rooms or buildings protected by
pressurization
IEC 60079-15 Electrical apparatus for explosive gas atmospheres - Part 15: Type
of protection "n"
IEC 60079-18 Electrical apparatus for explosive gas atmospheres - Part 18:
Encapsulation "m"
IEC 60079-20 Electrical apparatus for explosive gas atmospheres – Part 20: Data
for flammable gases and vapors, relating to the use of electrical
apparatus.
IEC 61241-1-1 Electrical apparatus for use in the presence of combustible dust -
Part 1-1: Electrical apparatus protected by enclosures and surface
temperature limitation – Specification for apparatus
IEC 61241-1-2 Electrical apparatus for use in the presence of combustible dust -
Part 1-2: Electrical apparatus protected by enclosures and surface
temperature limitation - Selection, installation and maintenance
IEC 61241-2-1 Electrical apparatus for use in the presence of combustible dust -
Part 2: Test methods - Section 1: Methods for determining the
minimum ignition temperatures of dust
IEC 61241-2-2 Electrical apparatus for use in the presence of combustible dust -
Part 2 - Section 2: Method for determining the electrical resistivity of
dust in layers

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 IEC 61241-2-3 Electrical apparatus for use in the presence of combustible dust -
Part 2: Test methods - Section 3: Method for determining minimum
ignition energy of dust / air mixtures
IEC 61241-10 Electrical apparatus for use in the presence of combustible dust -
Part 10: Classification of areas where combustible dusts are or may
be present

11.6 U. S. Code of Federal Regulations (CFR).

Title 29: Labor, Part 1910: "Occupational Safety and Health Administration (OSHA)
Standards." National Archives and Records Administration, Office of
Federal Register. Washington, DC: GPO.

1910 Subpart H – Hazardous Materials

1910.103 - Hydrogen
1910.106 - Flammable and combustible liquids
1910.107 - Spray finishing using flammable and combustible materials
1910.108 - Dip tanks containing flammable and combustible liquids
1910.110 - Storage and handling of liquefied petroleum gases

1910 Subpart S – Electrical

1910.306 – Specific purpose equipment and locations
1910.307 – Hazardous (classified) areas

11.7 OTHER PUBLICATIONS

· Schram, Peter J. and Mark W. Earley. “Electrical Installations in Hazardous

Locations”,.Quincy, MA: National Fire Protection Association.

· ISA S12.10, Classification in Hazardous Dust Locations

· Appleton NEC Code Review, Guide for Use of Electrical Products in Hazardous
Locations

· Crouse-Hinds Code Digest

· National Materials Advisory Board (NMAB) 353-3 Classification of Combustible Dust in

Accordance with the NEC

· NMAB 353-5 Classification of Gases, Liquids, and Volatile Solids Relative to Explosion
Proof Equipment.

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· NMAB 353-4 Classification of Dusts Relative to Electrical Equipment in Class II
Hazardous Locations.

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