Introduction to Electrical Area Classification

Written by: Rebecca Johnson, PE

Introduction
Zones and Divisions for Area Classification

There are several documents that can be used to aide in the decision to classify an area.
How an area is classified determines the type of equipment that can be used in it. Most
engineers are familiar with the terms hazardous, non-hazardous, classified, unclassified
and Class I, Division 1, Class I, Division 2. Less familiar are the Class II, Divisions 1
and 2, Class III, Divisions 1 and 2, and the Class I, Zone 0, Class I, Zone 1, and Class I,
Zone 2 designations. The designations are also further defined by groups which further
breakdown the type of hazardous material.

An area is classified based on the properties of the flammable vapors, liquids, gases, or
combustible dust or fiber that may be present and the chance that a flammable or
combustible concentration would be present. The class designations tell you what type of
flammable or combustible material is present. Class designations use Roman numerals.
The division designation tells you to what degree the hazard is present. Division
designations and Zone designations use Arabic numbers.

When flammable gases or combustible dusts are mixed in the proper proportion with air,
a source of energy is all that is needed to create an explosion. This source could be from
electricity - equipment that can produce arcs or sparks under normal operation when
contacts are opened or closed (such as switches, circuit breakers, motor starters, or plugs
and receptacles). Another source could be from heat. Lights (luminaries) and motors
could have a surface temperature that may exceed the safe limits of a flammable
atmosphere. Sometimes there could be a non-electrical source of ignition, such as a
hammering on masonry or dropping a tool on a ferrous surface if the tool is not made of
non-sparking material (such as aluminum).

The Fire Triangle (also for explosions)

The “fire triangle” refers to the three elements below that must be present for a fire (or
explosion) to occur and sustain itself.

1. A flammable liquid or vapor or combustible dust must be present in

sufficient quantity.
2. There must be the proper mixture of oxygen
3. There must be an ignition source.

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Each element above comprises one side of the triangle. If any side of the triangle is
broken, then a fire cannot start or sustain itself.

Article 500 of the NEC

Article 500 of the NEC covers Class and Division designations.

Class I

Class I locations are those in which flammable gases or vapors exist or may be present in
the air in enough of a quantity to produce explosive or ignitable mixture.

Class I, Division 1

A Class I, Division 1 location is a location in which:

1. Ignitable concentrations of flammable gases or vapors can exist under

normal operating conditions;

2. Ignitable concentrations of such gases or vapors may exist frequently

because of repair or maintenance operations or because of leakage;

3. Breakdown of the equipment or a failure of the process might release

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

Examples include:

• Places where volatile flammable liquids or liquefied flammable gases are

transferred from one container to another
• Locations containing open tanks or vats of volatile flammable liquids
• Interiors of spray booths and areas in the vicinity of spraying and painting
operations where volatile flammable solvents are used
• Gas generator rooms and other portions of gas manufacturing plants where
flammable gas may escape.

In some Division 1 locations, ignitable concentrations of flammable gases or vapors may

be present continuously or for long periods of time, such as in the inside of inadequately
vented enclosures containing instruments normally venting flammable gases or vapors to
the interior of the enclosure or the inside of vented tanks containing volatile flammable
liquids.

Class I, Division 2

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A Class I Division 2 location is a location in which:

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

but which will normally be kept within closed containers or systems from
where they can escape only in the case of accidental rupture or breakdown of
the containers (abnormal operation);

b. Ignitable concentrations of gases or vapors are normally prevented by positive

mechanical ventilation. The ignitable concentrations of the gases or vapors
may become hazardous if the ventilation system fails;

c. Any location that is adjacent to a Class I, Division 1 location where ignitable

concentrations of gases or vapors might be communicated unless prevented by
adequate positive-pressure ventilation from a clean source of air and
safeguards against ventilation failure.

Class I Groups

Class I Group classifications are listed as Groups A, B, C, and D:

Group A is acetylene.

Group B is typically hydrogen, but is a flammable gas, flammable liquid produced vapor
or combustible liquid produced vapor mixed with air that may burn or explode that has a
maximum experimental safe gap (MESG) value less than or equal to .45 mm or a
minimum igniting current ratio (MIC ratio) less than or equal to .40.

Group C is typically ethylene, but is a flammable gas, flammable liquid produced vapor
or combustible liquid produced vapor mixed with air that may burn or explode that has a
maximum experimental safe gap (MESG) value greater than .45 mm and less than or
equal to .75 mm or a minimum igniting current ratio (MIC ratio) greater than .40 and less
than or equal to .80.

Group D is typically propane, but is a flammable gas, flammable liquid produced vapor
or combustible liquid produced vapor mixed with air that may burn or explode that has a
maximum experimental safe gap (MESG) value greater than .75 or a minimum igniting
current ratio (MIC ratio) greater than .80.

MESG is the maximum experimental safe gap in millimeters. It is the maximum gap
between mating surfaces of explosion proof enclosures that will prevent the flames or hot
gases resulting from an explosion inside the enclosure from causing ignition of the
surrounding external atmosphere. This can only be determined experimentally and is
dependent on several factors.

MIC is the minimum igniting current ratio. It is the ratio of the minimum current
required from an inductive spark discharge to ignite the most easily ignitable mixture of a

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gas or vapor divided by the minimum current required from an inductive spark discharge
to ignite methane under the same test conditions.

Class II

Class II locations are those in which there is the presence of combustible dust. There are
three groups of combustible dusts based on the type of material – metallic, carbonaceous,
or organic.

Class II, Division 1

A Class II Division 1 location is a location:

a. In which combustible dust is in the air under normal operating conditions in

quantities sufficient to produce explosive or ignitable mixtures;

b. Where 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, through operation of protection devices, or from other causes;

c. In which combustible dusts of an electrically conductive nature may be

present in hazardous quantities.

Combustible dusts that are electrically nonconductive include dusts produced in the
handling and processing of grain, pulverized sugar, pulverized spices, dried hay and other
organic materials that may produce combustible dusts when processed or handled.

Only Group E dusts are considered to be electrically conductive for classification

purposes. Dusts containing magnesium or aluminum are particularly hazardous and
extreme precaution must be used with them.

Class II, Division 2

A Class II, Division 2 location is a location where:

a. Combustible dust is not normally in the air in enough quantity to produce an

explosive or ignitable mixture and dust accumulations are normally not
enough to interfere with the normal operation of electrical equipment.
Combustible dust may be in suspension in the air as a result of infrequent
malfunctioning of handling or processing equipment;

b. Combustible dust accumulations around the vicinity of the electrical

equipment may be enough to interfere with the dissipation of heat from
electrical equipment or may be ignited by abnormal operation or failure of
electrical equipment.

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The quantity of combustible dust that may be present and the adequacy of dust removal
systems are factors in determining if the area should be classified or unclassified. Where
products such as seed are handled such that there is a low quantity of dust, the amount of
dust may be a factor in determining if the area should be classified.

Class II Groups

Class II Groups are listed as Groups E, F, and G:

Group E is an atmosphere containing combustible metal dusts including aluminum,

magnesium and their commercial alloys or other combustible dusts whose particle size,
abrasiveness, and conductivity present similar hazards in the use of electrical equipment.

Group F is an atmosphere containing combustible carbonaceous dust that have more than
8 percent total entrapped volatiles or that have been sensitized by other materials so that
they present an explosion hazard. Coal, carbon black and charcoal are examples of
carbonaceous dusts.

Group G is an atmosphere that contains combustible dusts not included in Group E or F

such as flour, grain, wood or plastic. Certain dusts may require additional precautions
due to chemical phenomena that can result in the generation of ignitable gases.

Class III

Class III locations are those where there are easily ignitable fibers or where materials that
produce combustible flyings are handled, manufactured or used.

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

For example, textile mills and fiber manufacturing and processing plants, cotton gins and
cotton seed mills, clothing manufacturing plants. Easily ignitable fibers and flyings
include rayon, cotton, and Spanish moss.

A Class III, Division 2 location is a location in which easily ignitable fibers are stored or
handled.

Article 505 of the NEC

Article 505 of the NEC covers Class and Zone designations.

Class I

Class I, Zone 0

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A Class I, Zone 0 is a location where:

a. Ignitable concentrations of flammable gases or vapors are present

continuously;
b. Ignitable concentrations of flammable gases or vapors are present for
long periods of time.

This includes inside vented tanks or vessels that contain volatile flammable liquids and
inside inadequately vented spraying or coating enclosures where volatile flammable
solvents are used. It is not good practice to install electrical equipment in Zone 0
locations except when the equipment is essential to the process or when other locations
are not feasible. If it is necessary to install the equipment, it is good practice to use an
intrinsically safe system. In Class I, Zone 0 locations only intrinsically safe wiring
methods may be used.

Class I, Zone 1

A Class I, Zone 1 location is a location where:

a. Ignitable concentrations of flammable gases or vapors are likely to

exist under normal operating conditions;
b. Ignitable concentrations of flammable gases or vapors may exist
frequently because of repair or maintenance operations or leakage;
c. Equipment is operated or processes are carried on such 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;
d. That is adjacent to a Class I, Zone 0 location from which ignitable
concentrations of vapors 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.

This includes locations where volatile flammable liquids or liquefied flammable gases are
transferred from one container to another.

Class I, Zone 2

A Class I, Zone 2 location is a location where:

a. Ignitable concentration of flammable gases or vapors are not likely

to occur in normal operation and if they do occur, will exist only
for a short period;

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 b. 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 with which the liquids or
gases are handled, processed or used;
c. 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;
d. That is adjacent to a Class I, Zone 1 location from where ignitable
concentrations of flammable gases or vapors could 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.

This includes locations where volatile flammable liquids or flammable gases or vapors
are used but which would become hazardous only in case of an accident or unusual
operating condition.

Groups

Groups are listed as Group I, IIC, IIB, and IIA. Group I is for atmospheres that contain a
mixture of gases composed mostly of methane found underground.

Group IIC is for atmospheres containing acetylene, hydrogen, or flammable gas or vapor
mixed with air that may burn or explode, having either a maximum experimental safe gap
(MESG) less than or equal to .5 mm or minimum igniting current ratio (MIC ratio) less
than or equal to .45. Group IIC is equivalent to a combination of Class I, Group A and B.

Group IIB is an atmosphere containing acetaldehyde, ethylene or flammable gas or vapor

mixed with air that may burn or explode having either a maximum experimental safe gap
(MESG) greater than .5 mm and less than or equal to .9 mm or minimum igniting current
ratio (MIC ratio) greater than .45 and less than or equal to .80. Group IIB is equivalent to
Class I, Group C.

Group IIA is an atmosphere containing acetone, ammonia having either a maximum

experimental safe gap (MESG) greater than .9 or minimum igniting current ratio (MIC
ratio) greater than .80. Group IIA is equivalent to Class I, Group D.

Unclassified
Unclassified locations are locations that are not Class I, Division 1 or 2, Class II, Division
1 or 2, Class III, Division 2 or 2, Class I, Zone 0, 1 or 2.

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 Dual Classification
In cases of areas within the same facility classified separately, Class I, Zone 2 locations
shall be permitted to abut, but not overlap Class I Div. 2 locations. Class I, Zone 0 or
Zone 1 locations shall not abut Class I, Division 1 or 2 locations.

Reclassification
A Class I, Division 1 or Division 2 location shall be permitted to be reclassified as a
Class I, Zone 0, Zone 1 or Zone 2 location, provided all of the space that is classified
because of a single flammable gas or vapor is reclassified under the proper requirements.

Equipment
Equipment that is listed for a Zone 0 location can be used in a Zone 1 or Zone 2 location
of the same gas or vapor. Equipment that is listed for a Zone 1 location can be used in a
Zone 2 location of the same gas or vapor. The equipment may be listed for a specific gas
or vapor or a combination of gases or vapors, such as IIB +H2 (hydrogen – hydrogen
being more common than acetylene).

Equipment listed for Classes and divisions shall be marked to show the class, group and
operating temperature or temperature class referenced to a 40 degree C ambient
temperature.

Equipment identified for Class I, Division 1 or 2 shall be marked accordingly, and may
also be marked for Class I, Zone 1 or 2 as applicable, or with the gas classification group
or with temperature classification from the Zone section.

Equipment that is approved for Division 1 may be used in Zone 1 or Zone 2 areas.
Division 2 equipment may be used in Zone 2 areas. However, the reverse is not
necessarily permitted. Zone 0, Zone 1 and Zone 2 equipment may be used in a Division
2 location for the same gas and a suitable temperature rating. No Zone rated equipment
can be used in a Division 1 location because a Division 1 location includes areas that
could be considered Zone 0.

Protection Techniques
When an area is classified in accordance with zones, electrical and electronic equipment
may be protected by the following techniques.

“d” Flameproof, for Class I, Zone 1 or 2. Similar to explosion proof.

“p” Purged and Pressurized, for Class I, Zone 1 or 2 for which it is listed
“i” Intrinisic Safety, for Class I, Zone 0, 1 or 2

ia = Zone 0

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 ib = Zone 1

“n” for Class I, Zone 2 locations which under normal operation are not capable of
igniting a surrounding explosive gas atmosphere and not likely to create a fault
that is capable of causing ignition.

nA non sparking equipment

nC Sparking equipment where the contacts are suitably protected other than by
restricted breathing enclosure
nR Restricted breathing enclosure

“o” Oil Immersion, for Class I, Zone 1 or 2, immersion in a protective liquid

“e” Increased Safety, for Class I, Zone 1 or 2, commonly used for motors, generators,
and fluorescent luminaries

“m” Encapsulation, for Class I, Zone 1 or 2, arcing parts are completely surrounded in
a compound in such a way that an explosive gas or vapor cannot be ignited in a
Class I, Zone 1 area

“q” Powder filling, arcing parts are surrounded by glass or quartz powder to prevent
ignition of an external explosive atmosphere in a Class I, Zone 1 area

Electrical equipment of types of protection “e,” “m,” “p,” or “q” shall be marked Group
II. Electrical equipment of types of protection “d,” “ia,” or “ib” shall be marked Group
IIA, IIB, or IIC, or for a specific gas or vapor. Electrical equipment of types of
protection “n” shall be marked Group II unless it contains nonincendiary components in
which case it shall be marked Group IIA, IIB, or IIC, or for a specific gas or vapor.
Electrical equipment of other types of protection shall be marked Group II unless the type
of protection utilized by the equipment requires that it be marked Group IIA, IIB, or IIC,
or for a specific gas or vapor.

Temperature Class
Temperature class is referenced to a 40 degree C ambient temperature. The temperature
class, if provided, shall be indicated using the temperature class codes, also known as the
T Codes. There are tables to refer to for these numbers. The lower the T Code, the
higher the temperature rating.

Class I temperature shall not exceed the ignition temperature of the specific gas or vapor
to be encountered. The ignition temperature is the minimum temperature required to
initiate or cause self-sustained combustion independent of the heating or heated element.

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Class II temperature shall be less than the ignition temperature of the specific dust to be
encountered. For organic dusts that may dehydrate or carbonize, the temperature
marking shall not exceed the lower of either the ignition temperature or 165 degrees C.

There are exceptions for temperature marking, both for Division rated equipment and
Zone rated equipment. Refer to the appropriate guiding document for further
information.

Equipment Marking
Example:

Class I, Zone 1, Aex, ia, IIC, T6

Class I: Class
Zone 1: Zone
Aex: American Standard (European Common Markets are Eex)
ia: Protection Technique
IIC: Group
T6: Temperature Class

References

National Electric Code Articles 500 – 504 (Divisions)

National Electric Code Article 505 (Zones)

API/RP 500, 501, 505 Recommended Practice for the Classification of Locations for
Electrical Installations at Petroleum Facilities Classified as ClassI, Division 1 and
Division 2 (or Class I, Zone 0, Zone 1 or Zone 2)

NFPA 497 Recommended Practice for the Classification of Flammable Liquids, Gases,
or Vapors and of Hazardous (Classified) locations for Electrical Installations in
Chemical Process Areas

NFPA 499 Recommended Practice for the Classification of Combustible Dusts and of
Hazardous (Classified) Locations for Electrical Installations in Chemical Process
Areas.

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