Hazardous Area Classifcations

Ex
ELECTRICAL RISK MANAGEMENT

IN
HAZARDOUS INDUSTRIES
&
SELECTION OF ELECTRICAL EQUIPMENT
FOR FLAMMABLE ATMOSPHERES
P.G. Sreejith
pillai_sreejith@hotmail.com
Kerala, INDIA
P.G.Sreejith, Kerala
Ex
Hydrocarbon Risks
• OISD Accident compilation (1996-1999):
–Out of the total 71 accidents (5 lakh property loss/fatality/loss of

500MH/led to plant SD ), 66% were fire accidents
–47% accidents happened during operational jobs
–Causes of accidents:
- 71% human error
- 11% Failure of plant
- 18% Presence of ignition source
Is the above ‘accident cause’ grouping correct?
Ex
Hazardous Areas-Definitions
• Petroleum Rules, 1976
• An area shall be deemed to be a hazardous area, where:

– petroleum having FP below 65 deg C or any inflammable gas or
vapour in concentration capable of ignition is likely to be present
–petroleum or any inflammable liquid having FP above is likely to be
refined, blended or stored at or above its FP
• IS 5572
–Hazardous area is an area in which an explosive gas atmosphere is
present, or likely to be present, in quantities such as to require special
precautions for the construction, installation and use of electrical
apparatus.
Ex
COAL MININING SAFETY & CRUDE WAYS OF DETECTING

METHANE GAS!!
• In the 1700's, certain gases or the lack of oxygen were detected with
various hit and miss types of detection. The candles on miners caps, or
if carried by the miner, would either go out from the lack of oxygen or the
flame would get larger with a different coloring of the flame if certain
gases were in the area.
• Of course, in some instances these open flames caused fires or
explosions. By 1815, the Davy's Safety Lamp came into use in the
mines. This certainly changed the way for miners to check for certain
gases.
• They took these canaries in small cages with them down the coal mines
where they worked. The canaries were the miners alarm signal to
show them when the coal-gas levels got too high. The canary stopped
singing and was most likely to be laid feet up on the bottom of the cage,
poisoned by the mine gas.
Ex
Why Area Classification?
• HAC is a method of analyzing and classifying the environment where

explosive gas atmospheres may occur to allow the proper selection of
electrical apparatus to be installed in that environment.
• Ignition sources not considered

–ESD
–Sparks
–Lightning
–Flames/Fires
–Hot surfaces
• IS 5572
–HAs are classified in zones based on the frequency of the appearance
and the duration of an explosive gas atmosphere.
Ex
Why Zoning?
• Leak Potential & Presence of Ignition Sources
• Hazardous properties of hydrocarbons
• Safe selection (& optimization) of Electrical Equipment
Ex
AREA CLASSIFICATION
• How many Zones as per Indian standards?
• European & American classifications (Zones and Divisions)
• Why not ‘blanket’ zoning?
• Is the 4th Zone really a ‘safe’ zone?
• Who should do HAC-Electrical or Process Engineer?
Ex
HAC as per IS 5572 is not applicable for:
• Mining applications
• Explosive manufacturing
• Areas where ignitable dusts & fibers are present
• Catastrophic failures
• Ignition sources other than electrical apparatus
Ex
Zone 0 -Typical areas

(Continous grade)
• Vapour space above:
– closed process vessels,
–storage tanks
–closed containers,
–areas containing open tanks of volatile, flammable liquid
Ex
How to identify Zone 1 areas (IS 5572) ?
(Primary grade)
• Flammable gas or vapour concentration is likely to exist in the air under

normal operating conditions
• Flammable atmospheric concentration is likely to occur frequently because
of maintenance, repairs or leakage
• Flammable liquid or vapour piping system (containing valves, meters, or
screwed or flanged fittings) is in an inadequately ventilated area
• The area below the surrounding elevation or grade is such that flamamble
liquids or vapours may accumulate therein
Ex
Zone 1 -Typical areas
• Imperfectly fitting peripheral seals on floating roof tanks
• Inadequately ventilated pump rooms for flammable gas or for volatile,

flammable liquids
• Oily waste water sewer / basins
• Loading / unloading gantries of hazardous products
Ex
Typical Zone 2 areas (IS 5572) ?

(Secondary grade)
• The system handling flammable liquid or vapour is in an adequately ventilated
area and is so designed and operated that the explosive or ignitable liquids,
Vapours or gases will normally be confined within closed containers or closed
systems from which they can escape only during abnormal conditions such as
accidental release of a gasket or packing
• The flammable vapours can be conducted to the location as through trenches,

pipes or ducts
• Locations adjacent to Zone 1 areas
• Pressurized rooms where flammable gas / vapour can enter in the case of
failure of positive mechanical ventilation
Ex
Safe Areas -Typical areas
The following locations are considered safe from the point of view of
electrical installation:
• Areas where the piping system is without valves, fittings, flanges or

similar appurtenances
• Areas where flammable liquids or vapours are transported only in suitable

containers or vessels
• Areas where permanent ignition sources area present like area where
combustion gases are present, for example flare pits, tips, other open
flames 7 hot surfaces
• DG shed room / shed having adequate ventillation
• GT installation meeting the ventilation (12 ACPH) , pressurization (0.5

mbar )and flange (not more than one pair of flanges inside the turbine
room) requirements
Ex
HAC- Comparison
• North America (NFPA / API/ NFPA 70E or NEC)

–Hazardous Areas:
- Division I- Z0 + Z1
- Division II- Z2
–Hazardous Locations
- Class I-Flammable Gases / Vapour
- Class II- Combustible dust
- Class III- Combustible fibres or flyings
–Gas / vapour grouping
- A, B, C, D, E, F & G
• Japan
–Hazardous Areas
- Classes 1, 2 & 3
–Gas / vapour groups
- G1, G2, G3, G4, G5 & G6
Ex
A FEW RELEVANT DEFENITIONS
• Flash Point - A, B, C
• Ignition Temperature
• Explosive Limits (based on MIE)

–LEL
–UEL
Ex
HAZARDOUS AREA CLASSIFICATION-Guidelines
Factors to be considered (IS 5572)
• Vapour / Gas Density
• Effect of Air Current
• Identification of leak scenarios
Ex
GENERAL CONSIDERATIONS
• In the absence of walls, enclosures, etc. & air currents, vapour/gas

dispersion will depend on density & velocity. Denser gas/vapour will
disperse downward and outward, lighter gases upward & outward.HA for
a single leak source would be a circle.
• Vapours / gas released(high density releases) at or near ground level, will

be found below ground, thus altering the shape of HA.
Ex
EFFECT OF AIR CURRENT
• Winds alter the shapes of hazardous areas
• A mild breeze may extend the HA and a strong wind could dilute the
flammable concentration,making it non-hazardous
• But what are logically to be considered are the most unfavourable

conditions
Ex
HEAVIER-THAN-AIR GASES & VAPOURS
• Open -Air Situations (freely ventilated Process Areas)

–Figures 1 ,2)
–Figures 3 & 4
–In case of petroleum pipelines (where well-maintained valves, fittings,

and meters and in well-ventilated areas or in a pit), Zone 2 A/G shall
be 4m in all directions, from the potential leak source. Pit will be
considered as Zone 1.
–Zone 1
(unless Zones 1 or 2
separated by
a fire wall)
Ex
LIGHTER-THAN-AIR GASES & VAPOURS
–Vapour density of 0.75 is considered as the boundary between lighter

and heavier gases / vapours as a safety measure
HA of a leak source located in air
Source of 4.5 m
hazard
8.0 m
R 4.5 m
H<4.5m
Zone 2
Ex
How to classify areas?
• Mark in elevation and plan drawings
• Separate identification (hatching) for various zones
–Zone 0
–Zone 1
–Zone 2
• Frequency of HAC?
Ex
An experienced process engineer’s judgement

in visualizing leak scenarios and classifying
hazardous areas is the most CRUCIAL factor
in the HAC exercise
Ex
API RP 500- HAC Guidelines
• Adequacy of ventilation
• Accident record of the plant / business group / industry

sector/maintenance standard adopted in the plant
• Sound judgement & Experience of the engineer who carries out HAC
Ex
AREA CLASSIFICATION AS A TOOL FOR RISK ASSESSMENT

A LOGICAL APPROACH
• Perceived Limitations on the present HAC approach:

–Ignition sources not considered
–Reduction of zone areas & relaxation of zone designations not
considered
–Blinkers -On Approach , High cost, blanket zoning, narrow & easy
approach
or in short, the full potential of HAC is not utilized at present
Ex
• EXTENDING HAC PROCEDURE
–Additional steps
- After applying the present HAC procedure, assess all ignition
sources
- Assess the grade of release using
HAC-based risk assessment matrix
- Assessing the ventilation & evaporation aspects of the chemicals
considered
–Applying the new HAC procedure
Ex
HAC-based Risk Assessment Matrix
Gr ade of Igniti on
Gr ade of Release Continous Frequent Infre quent Very Infrequent
Continous Unacceptable Unacceptable Acceptable

unless low (e.g. Ex i
consequences apparatus)
Primary Unacceptable Unacceptable Risk Assessment Acceptable (e.g.
required-look at Ex d apparatus )
consequences
Secondary Risk Assessment Risk Assessment Acceptable Acceptable
required-look at required-look at (E.g. Ex n
consequences but consequences but apparatus)
probably
unacceptable
Non-Hazar dous Acceptable but Acceptable but Acceptable Acceptable
examine e xa mine
catastrophic catastrophic
releases releases
Ex
CONCLUSION
• A logical extension of the present HAC methodology & not a radical

approach
• New European legislation, ATEX 118a Directive will be on similar lines
• The new focussed & practical HAC approach will make HAC exercise
more cost-effective
• A SAFE APPROACH?
Ex
COMPARISON OF ZONES & DIVISIONS
Classified Time that haz. gases are Estimated % Estimated % (Z)

present in ignitable (Divisions)
area
Z0 Continuously <2%
D1 Normally present <5%
Z1
Occasionally in
normal operations
>60%
Z2 <40%
D2 Not normally present >95%
Ex
PERCENTAGE OF CLASSIFIED AREAS
C
L
A Z2
S
S
I
F
I
E Z1
D
A
Z0
R
E
A
S O 10 20 30 40 50 60
70 80 90
100
Ex
HAC- A RECAP
Ex
HAC-RELEVANT INTERNATIONAL STANDARDS
• API RP 500- Area Classification of Petroleum Installations
• IEC 79-10 :1995 -Electrical Apparatus for Explosive Gas Atmospheres,

part 10 Classification of hazardous areas
• IP Part 15, 1990- Area Classification Code for Petroleum Installations
• BS EN 60079-10, : 1996 -Electrical Apparatus for Explosive Gas

Atmospheres, part 10 Classification of hazardous areas
• BS 5345, 1983-Selection, installation and maintenance of electrical

apparatus for use in potentially explosive atmospheres (other than mining
applications or explosive manufacturing), part 2, Recommendations for
particular industrial situations
Ex
USEFUL REFERENCE BOOKS ON HAC
• Classification of Hazardous Locations,I.Chem. E. Cox, A.W., Lees, F.P.

and Ang, M.L, 1990
• IP Model Code of Safe Practice, 1990, Part 15, Area Classification Code
for Petroleum Installations
• NFPA 69, 1992, Explosion Prevention Systems
• ICI/RoSPA, 1972, ICI Electrical Installations Code
• NFPA 325M, Properties of Flammable Liquids, gases and solids
• Electrical Safety in Hazardous Locations, William Calder & Ernest C.

Magison
Ex
SELECTION OF ELECTRICAL EQUIPMENT IN HAZARDOUS AREAS
Ex
SELECTION OF ELECTRICAL EQUIPMENT IN HAZARDOUS AREAS
• How to select equipment for various zones?
• Selection Criteria
–Gas Grouping (based on ignition energy)
–Temperature Classification
–Classified Zones
Ex
TEMPERATURE CLASSIFICATION
T Class Max. Surface Temperature

(Deg. C)
T1 450
T2 300
T3 200
T4 135
T5 100
T6 85
Ex
GAS GROUP CLASSIFICATION (based on MESG & MIE)
• Gas group I
–Methane
• Gas group II A
–Ammonia, CO, Propane, Butane, Benzene, Acetone, Methanol
• Gas group II B
–Butadiene, Ethylene, Ethylene Oxide, Diethyl Ether
• Gas group II C
–Hydrogen
Which is the most hazardous group ?
Ex
GAS GROUP & TEMPERATURE CLASSIFICATION-VARIOUS

GASES/VAPOURS (IS 13408 Part I)
S No Name of the Minimum Flash point Iignition Flammable limit

chemical Ignition Deg. Cen. temperatur LEL UEL
Curre nt e
(MIC) mA (Deg C)
1 Methane I, 85 - 595 5% 15%
T1
2 Ammonia - - 630 105 mg/l 200 mg/l
II A T1
3 Ethylene 45 - 425 2.7% 34%
II B T2
4 Propane 70 - 470 2% 9.5%
II A T1
5 Acetylene 24 - 305 1.5 % 100%
II C T2
Ex
GAS GROUP & TEMPERATURE CLASSIFICATION-

VARIOUS GASES/VAPOURS
Gas Representative Gas Ignition Energy

Group (mj)
I Methane 280
II A Propane 260
IIB Ethylene 95
IIC Hydrogen 18
Ex
FLAMMABLE MIXTURE, MIG, EXPLOSION
Ex
RECOMMENDED PROTECTION METHODS FOR ZONE O
No electrical equipment should be allowed. When this is not

practicable, Ex ‘ i ‘ (ia or ib) apparatus or circuits to be used
• No transformers, motors, lights, switch gear or control gear
Ex
RECOMMENDED PROTECTION METHODS FOR ZONE 1
Motors- Ex d, Ex p
Transformers & Capacitors - Ex d
Control & Instrument Transformers - Ex i
Lighting Fitting - Ex d
Switch Gear & Control Gear - Ex d
Communication/ Telephone equipment/Meters - Ex i
Portable Hand Lamps- Ex i
*Ex o, Ex q type equipment are also allowed for use as per IS 5571
Ex
RECOMMENDED PROTECTION METHODS FOR ZONE 2
Motors- Ex d, Ex p, Ex n, Ex e,
Transformers & Capacitors - Ex d, Ex p (auxiliary devices to be

located in pressurized room/hermetically sealed / intrinsically safe)
Control & Instrument Transformers - Ex i
Lighting Fitting - Ex d, Ex e, Ex n
Switch Gear & Control Gear - Ex d, Ex o, Ex
Communication/ Telephone equipment/Meters - Ex i
Portable Hand Lamps- Ex i
* Minimum IP 55 (for UN-insulated parts) and IP 44 (for insulated parts)

if Ex e protection is used for outdoor applications
Ex
Ex
EXPLOSION-PROTECTION EQUIPMENT
Ex
EXPLOSION-PROTECTION METHODS / EQUIPMENT -Popular types
• Flameproof (EX d)
• Increased Safety (Ex e )
• Non-Sparking (Ex n )
• Pressurization (Ex p )
• Intrinsically Safe (Ex i )
Ex
OTHER TYPES OF EXPLOSION PROTECTION- Not so popular types
• Powder filled Ex ‘q’ type
• Oil immersed Ex ‘o’ type
• Special Ex ‘s’ type
Ex
Definition as per IS 2148:
EX ‘d’ Type FLAMEPROOF EQUIPMENT
US- Explosion-Proof, UK- Flame-Proof, GERMANY - Pressure-Proof
A type of protection in which the parts can ignite an

explosive atmosphere are to be placed in an
enclosure, which can withstand the pressure
developed during internal explosion of an explosive
mixture, and which prevents the transmission of the
explosion to the explosive atmosphere surrounding
the enclosure
FLAMEPROOF EQUIPMENT- A MISNOMER?
Ex
FLAMPROOF (EXPLOSION-PROOF) PROTECTION (Ex ‘d’)
Assumptions based in IS 2148 are:
• Flammable gases / vapours, if present in atmosphere will enter the enclosure
• The apparatus will be selected, installed, operated and maintained within the
acceptable ratings. The maintenance and use of FLP equipment shall be so
that its safety will not be impaired, is the responsibility of the user
• The electric circuit of the FLP equipment will have all required protection
devices
• Sparking which will ignite a flammable gas or vapour, may occur at any part of
the equipment contained in the enclosure in normal operation due to an
internal fault due to insulation failure, etc.
Ex
• FLAME PATH - Width of Joint

–Minimum
• GAP - Diametrical Clearance

–Maximum
Ex

• Maximum gaps and flame path for gas groups depends on ignition energies of
the gas / vapour and the volume of the enclosure
• For example, for IIB gas group, for 100 Cubic cm volume, for flanged joints:
–Flame Path - 6 mm
–Maximum Gap - 0.3 mm
• For II C Hydrogen, 100 cubic cm volume, for flanged joints:

–Flame path - 9.5 mm
–Maximum Gap - 0.1 mm
Ex
FLAMEPROOF EQUIPMENT- CONSTRUCTIONAL REQUIREMENTS
• USE OF APPROVED MATERIAL WITHOUT THE USE OF INCENDIVE FRICTIONAL

SPARKING
• EQUIPMENT SHOULD WITHSTAND ROUGH USAGE
• EQUIPMENT SHALL BE ADEQUATELY STRONG TO WITHSTAND ALL REQUIRED TESTS
• THE EFFECTIVE THREADED METAL TO METAL JOINTS SHALL HAVE A MINIMUM OF 5

FULL UNINTERRUPTED ENGAGED THREADS & A MINIMUM EFFECTIVE
UNINTERRUPTED DIRECT AXIAL LENGTH OF THREADED ENGAGEMENT OF 9 mm
• THERE SHALL BE NO INTENTIONAL GAP BETWEEN JOINT SURFACES
• NO PACKING MATERIAL SHALL BE USED BETWEEN OPPOSED SURFACES TO FORM A

FLAMEPROOF JOINT
• IF COMPRESSIBLE PACKING MATERIAL OR A GASKET IS NECESSARY TO SEAL A

JOINT (eg. IP) THE PACKING SHALL BE APPLIED AS A SUPPLMENT TO, BUT SHALL
NOT BE INCLUDED IN THE FLAMEPROOF JOINT
• ANY DISPLACEMENT, DAMAGE, INTEGRATION OR OMISSION OF THE PACKING SHALL

NOT RESULT IN THE FLAMPROOF NATURE OF THE JOINT BEING ADVERSELY
Ex
FLAMEPROOF EQUIPMENT- CONSTRUCTIONAL FEATURES
EX d typical marking: EEx d IIB T5
Ex
INTRINSICALLY SAFE EQUIPMENT & CIRCUITS (Ex ‘i’ )
Definition as per IS 5780
A type of protection which a circuit or part of the

circuit is intrinsically safe when any spark or
thermal effect produced normally is incapable,
under prescribed test conditions, of causing
ignition of prescribed gas or vapour
Ex
INTRINSICALLY SAFE EQUIPMENT & CIRCUITS (Ex ‘i’ )
(insert a small photo)
• Only electrical protective measure (protection technology by way of

power limitation), the other protective techniques use mechanical means
to prevent ignition from electrical faults (max. 30 volts or 50 mA)
• Ex ‘i’ apparatus is the one which has all the circuits within intrinsically
safe
• Ex ‘i’ circuit is the one which has intrinsically safe barriers with Zenner
diodes for power limitation
• Minimum IP 20 ingress protection
Ex
INTRINSICALLY SAFE EQUIPMENT- Category- Ex ib
Ex ib equipment shall be incapable of causing ignition in normal operation,

with a single fault and with the following safety factors:
–1.5 in normal operation and with one fault
–1.0 with one fault, if the equipment contains no unprotected switch

contacts in parts likely to be exposed to a potentially explosive
atmosphere and the fault is self-revealing
EX i typical marking: EEx ia IIC T5
Ex
INTRINSICALLY SAFE EQUIPMENT (Ex ‘i’ )
• Cell phone explosion accident in an offshore platform
• Fuel outlets- restricted cell phone usage?
Ex
INCREASED SAFETY EQUIPMENT (Ex ‘e’)
A type of protection by which measures are applied so

as to prevent with a minor degree of security, the
possibility of excessive temperature and the
occurrence of arcs or sparks in the interior and the
external parts of electrical apparatus which does not
produce them in normal service
Ex
INCREASED SAFETY EQUIPMENT (Ex ‘e’)
Stringiest construction methods to ensure that no sparks, excessive

temperature are produced
• Careful terminal design
• Use of good quality insulation material
• Use of special materials to protect the enclosure against impact, ingress
of dust & moisture
• Can be used for I, II A, B, C gas groups
• Permitted for us in T1, T2, T3 classes only
• Terminal with minimum IP 54 ingress protection
EX d typical marking: EEx e IIA T3

Ex
PRESSURIZATION TYPE (Ex ‘p’ )

A type of protection by which the entry of

surrounding atmosphere into the enclosure of the
electrical apparatus is prevented by maintaining
inside the said enclosure, a protective gas at a
higher than that of the surrounding atmosphere
Ex

TYPES
• Dynamic Pressurization (DP) or pressurization by continuos circulation

of protective gas (purging)
–DP is a method of maintaining pressure in an enclosure in which after

purging the protective gas is passed continously through the enclosure
at a pressure above that of the specified minimum and discharged to
the outside atmosphere
–Static Pressurization or pressurization with leakage compensation

- Air supplied & pressurized continously from a non-hazardous area to
avoid ingress of flammable gases / vapour inside the enclosure
Ex
Pressurized Equipment
• Ingress protection minimum IP 4X
• Over pressure 1.5 times or 0.2 kPa
• Material of construction should be flame retardant, self- extinguishing and

should not be affected by protective gas
Ex
Pressurized Equipment / Panels
• A minimum overpressure of 0.2 kPa (2mbar) with reference to external

atmospheric pressure
• Air intake from a safe area
• Exhaust duct outlet to be located in safe area
• Zone 1- can be used if there is no spark in normal service
• Zone 1 or 2 -if ejection of spark is prevented by effective device and rapid

suction of external atmosphere is prevented
Ex
Minimum actions of Failure of Protective Gas for Ex ‘p’
Area Enclosure does Enclosure

not contain contains I-C
Ignition-capable Apparatus
apparatus
Zone 2 No Action Alarm
required
Zone 1 Alarm Alarm with trip
Ex
NON-SPARKING TYPE EQUIPMENT (Ex ‘n’ )

–Definition as per IS 8289
A type of protection applied to electrical apparatus

such that , in normal operation it is not capable of
igniting a surrounding atmosphere and a fault
capable of causing ignition is not likely to occur
EX n typical marking: EEx n II T5
Ex
NON-SPARKING TYPE EQUIPMENT (Ex ‘n’ )
• Equipment construction in such a way that in normal operation, it is

incapable of igniting a surrounding explosive atmosphere and a fault
incapable of causing ignition
• Hermetically sealed type
• Restricted breathing type
• Careful design of terminals
- SUBSTANTIAL COST SAVING
• Applications
–Tools
–Equipment
Ex
POWDER FILLED TYPE EQUIPMENT ( Ex ‘q’)
• Equipment enclosure filled with quartz /sand so that in normal operating

condition, any arc occurring within the enclosure of electrical equipment will not
ignite the surrounding atmosphere
• No ignition shall be caused either by flame or by excessive temperature of the

surfaces of the enclosure
• Enclosure constructional features:

• High mechanical strength
• Ingress protection
• Powder filled
• Insulation of enclosed equipment
Ex
OIL IMMERSED TYPE EQUIPMENT (Ex ‘o’)
• Protection technique in which the equipment or its parts are immersed in

oil in such a way that an explosive atmosphere which, may be above the
oil or outside the enclosure cannot be ignited.
• Oil used shall be mineral oil confirming to relevant standards
• Constructional features:
– Fully enclosed, leak-proof enclosure
–Oil level indicator
• Transformers, Switch gears, Control gears
Ex
SPECIAL TYPE EQUIPMENT (Ex ‘s’)
• This is a concept that has been adopted to permit the certification of

those types of equipment which by their nature, do not comply with the
constructional or other requirements specified for equipment with
established types of protection but which, nevertheless, can be shown,
wherever necessary, by test to be suitable for use in hazardous areas in
prescribed zones
• This concept permits flexibility on the part of certifying and assessment

authorities in their approach to applications for certification of equipment
the use of which would otherwise not permitted in hazardous areas on
account of non-compliance with the requirements of standards for
established types of protection. This allows flexibility of approach to
innovative ideas and new designs, the development of which otherwise
be obstructed.
• Examples:
–Factory sealed hand lamps, Encapsulation (Ex ‘m’ type), Gas detection
apparatus
Ex
Add an appropriate photo
INGRESS PROTECTION (IP)
Ex
Insert a IP photo with gasket Ingress of Liquid
IP XY
Degree of Protection of persons
against contact with or
moving parts inside the
enclosure & Protection Of
Equipment against Solid P.G.Sreejith, Kerala
ingress
Ex
IP Types and Protection Details
FIRST NUMERAL SECOND NUMERAL

0 No protection 0 No protection
1 Objects greater than 50 mm 1 Vertically dripping
2 Objects greater than 12 mm 2 Angular dripping
3 Objects greater than 2.5 mm 3 Sprayed water
4 Objects greater than 1.0 mm 4 Splashed water
5 Dust - protected 5 Water jets
6 Dust tight 6 Heavy seas
7 Effects of immersion
8 Indefinite immersion
Ex
Indian Standards for Various Protection Techniques
• IS 5571 Guide For Selection Of Electrical Equipment For Hazardous Areas
• IS 5572 –Part I Classification of Hazardous Areas for Electrical Installations
• IS 13408 Part I, II, III Code of Selection, Installation and Maintenance of Electrical
Apparatus for Use in Explosive Atmospheres
• IS 8239 Classification of Maximum Surface Temperature of Electrical Equipment for Use

In Explosive Atmospheres
• IS 6381 Construction and testing of Electrical Apparatus with type of protection ‘e’
• IS 2148 Flameproof Enclosures of Electrical Apparatus
Ex Indian Standards for Various Protection Techniques
• IS 13346General Requirements for Electrical Apparatus for Explosive Gas Atmospheres
• IS 5780 Specification For Intrinsically Safe Electrical Apparatus and Circuits
• IS 8240 Guide for Electrical Equipment for Explosive Atmospheres
• IS 2147 Degrees of Protection Provided by Enclosures For Low Voltage Switch Gear & Control Gear
• IS 4691 Degrees of Protection Provided by Enclosures For Rotating Electrical Machinery
• IS 8241 Methods of Marking for Identifying Electrical equipment for Explosive Atmospheres
• IS 8224 Specification for Electric Lighting fitting for Explosive Atmospheres
• IS 8289 Electrical Equipment with Type of Protection ‘n’
• IS 7389 Specification for Pressurized Enclosures
• IS 2206 (PART I,III) Specification for Flame proof Electric Light Fixtures
Ex
INSTALLATION & MAINTENANCE OF

ELECTRICAL EQUIPMENT IN HAZARDOUS
AREAS
Ex
INSTALLATION GUIDELINES OF ELECTRICAL EQUIPMENT IN

HAZARDOUS AREAS (IS 5571)
• Adequate precautions to avoid ESD & Lightning to be implemented
• Use of light alloy (Mg, Al, Ti, ) material to be assessed critically in HAs
due to its incendive properties
• Where reasonably practical, electrical apparatus generally and switch &

control apparatus should be installed outside the Hazardous Areas
• Electrical apparatus may be installed in open air in a non-hazardous area
Ex

HAZARDOUS AREAS
• Equipment designed for higher gas groups can be used for less
hazardous gas groups ( for e.g., Equipment certified for II C can be used
for II A, B or I)
• Portable hand-lamps, communication equipment and other test

equipment shall be Ex i type
• All equipment shall be installed so as to avoid mechanical damage
• Earthing shall be carried out as per IS 3043
• Bonding of all pipeline flanges should be carried out so as to avoid

Electro-static discharges
• Internal earthing to be provided for all FLP equipment in addition to

external earthing
Ex

HAZARDOUS AREAS
• All circuits and apparatus in Hazardous Areas should be provided with
means to ensure quick disconnection in the event of any fault (O/C, S/C
or E/F)
• Protection & Control apparatus shall be normally located in non-HAs but if

unavoidable, they may be of the right protection type
• All electrical apparatus (for every apparatus or sub-groups) should be

provided with an effective means of isolation, including neutral
• Metal conduits, armoured cables
• Correct terminations using proper sized cable glands (double-

compression, FLP type)
• Unused cable openings of all electrical apparatus shall be closed with

plugs suitable for the type of protection
Ex

HAZARDOUS AREAS
• Copper or Aluminium (above 16 sq. mm only) conductors can be used
• FLP plugs & sockets should have preferably PUSH-IN, TWIST-ON type
to avoid ignition while insertion or removal
• Adequacy of IP equipment
• Test equipment
–Insulation Resistance megger shall be Ex i type
–Earth Megger shall be Ex i type
–Hotspot Detection equipment
Ex
MAINTENANCE RECOMMENDATIONS IN HAZARDOUS AREAS
• FLP Equipment
–All bolts in place
–All openings closed
–No site modification / alteration
– Internal & external earthing
–Double-Compression, FLP cable glands
–No physical damage
–No damage to Flame path
–All threaded connections-minimum 5/ 6 threads engagement
–Flange faces to be smooth & original (to be careful while opening stuck
covers)
Ex
• Light alloy paint even for the purpose of maintenance must not be applied
on any external surface of the equipment to prevent inscendve frictional
sparking
• Equipment shall not be tampered to open covers, etc.
• No components shall be added or removed or even replaced. This has to

be done after getting re-certified by the OEM
• A scheme of regular inspection & maintenance of the items should be

made on the basis of guidelines / standards. Any equipment which is
originally flameproof may loose its integrity if not maintained properly
• The equipment should be de-energized before attempting any repair
Ex
• Drawings /Records
–Updated SLD
–Updated HAC drawing
–Drawing with various equipment installed in various identified zones
–Certification / re-certification records
–IR / ER records
• Sufficient Spare stock of critical equipment (various Ex types)
• Solid obstruction(steel structures, walls, other electrical equipment)

effects (close to equipment flanges)
– IIC - 40 mm clearance
–IIB - 30 mm
–II A - 10 mm
–I - no clearance envisaged
Ex
• Integrity of IP equipment
–Use of gasket is permitted if certified as part of the equipment
–No sealing of flange faces (this could affect the ability of the enclosure
to withstand the maximum explosion pressure)
–Application of non-setting grease or anti-corrosive agent is permissible
–Non-hardening tape can be used in II A gas groups, II B tape is to be
avoided and no use of tape in II C gas groups
• Insulation integrity to be periodically tested and maintained
• Maintenance personnel
–Inspection, Maintenance, testing, replacement and repair in HAs shall
be carried out by trained personnel only
–Refresher training for them is essential
Ex
• Periodic examination of flange gaps and flange faces for any effects of
corrosion / damage, etc.
• Maintenance Tests (at an interval not exceeding 3 years)

– IR measurements
–Earth electrode resistance measurements
–Earth loop resistance measurements
–Operation & Setting of Protection devices
Ex
MAINTENANCE RECOMMENDATIONS FOR VARIOUS Ex Types (except
Ex d)
• Ex i - No addition / alteration of circuit components / power limitation barriers,

etc.
• Check Ex p equipment / panels / rooms for low pressure interlock operations,
periodic review of air in take stack location
• Terminations in Ex e, n types equipment
• Use of non-sparking tools
“ELECTRICAL EQUIPMENT USED IN HAZARDOUS ARAES ARE

SPECIAL AND THEY NEEDS TO BE TREATED SPECIAL”
Ex
STATUTORY REGULATIONS & APPROVAL

REQUIREMENTS
Ex
Approval / Testing Agencies
• CMRI (Central Mining Research Instituite), Dhanbad, BIHAR
• CCoE (Chief Controller of Explosives), Nagpur
• BIS (Bureau Of Indian Standards)
• DGMS (Director General Mine Safety), Dhanbad, BIHAR
• DGFASLI (Director General of Factory Advice Service and Labour

Instituites), Mumbai
Ex
Statutory Regulations For Plants Utilizing Hydrocarbons
• Petroleum Act, 1884

–Petroleum Rules, 1976
• Explosive Act, 1934

–Explosive Rules, 1983
–Gas Cylinder Rules, 1981
–Static & Mobile pressure Vessel (Unfired) Rules, 1981
CCoE, Department of Explosives is entrusted with the responsibility of

administration of the above statutory rules in India
Ex
Statutory Regulations For Plants Utilizing Hydrocarbons
• Petroleum Rules, 1976 (Chapter IV)
• Static & Mobile Pressure Vessels (U) Rules, 1981 ( Rule 31)
• Gas Cylinder Rules, 1981 (Rule 21)
Ex EXTRACTS FROM PETROLEUM ACT, 1934
• Hazardous Area- Definition

–An are shall be deemed to be an hazardous area, where:
–i) petroleum having FP below 65 deg. C or any other flammable gas or
vapour in concentration capable of ignition is likely to be present
–ii) petroleum or any inflammable liquid having FP above 65 deg
centigrade is likely to be refined, blended, handled or stored at or
above its FP
Ex EXTRACTS FROM PETROLEUM ACT, 1934
• HAC- Zones 0, 1, 2
• Earth resistance values:

–4 ohm for electrical systems
–10 ohms for non-current carrying metallic parts
–all joints in pipelines, valves, etc. shall be bonded and the earth
resistance between each joint shall be 1 ohm
• Hazardous Areas as per 4th Schedule:

–-In-line with IS 5571
• Tables 1 & 2 (as per Form XIII)

–Inter-Distances between tanks (with Classes A, B, C products)
–Distance between tanks and tankers, offices, motors
Ex
CMRI, Dhanbad -Approval Agency for Electrical Equipment for Use In

Hazardous Areas
• Equipment testing and approvals (for all gas groups- I, II A, IIB, IIC)
• Testing and approval required for modified equipment
Ex Equipment Approval Procedure
Drawing and prototype
submittal to CMRI
Tests by CMRI
Approval by CMRI
ISI Certification (Tests by

CMRI) as per applicable
Indian Standards
Approvals by:
• DGFASLI
• CCoE
Ex
ELECTRICAL SAFETY AUDITING IN HAZARDOUS

AREAS
Ex
Focus Areas
• Original HAC drawings (IS 5572)
• Plant additions / alterations
• Installation of electrical equipment in hazardous areas (IS 5571)
• Valid applicable statutory approvals (CCoE)
• Maintenance of Electrical Equipment

–FLP
–Pressurized equipment
–Earthing (internal & external)
Ex
European ATEX Directive
• Advantages include CLEAR Zone marking, stringent quality

requirements, very user-friendly
• Products will have to be re-certified as per the new harmonized ATEX

standards
• CAT 3 (Zone 2) products will not require approval from a notified body
(could be self-certified, if in-house test facilities are available)
• Use Directive ATEX137 ‘Protection of workers at Risk from Potentially

Explosive Atmospheres’
–Another directive for user industries
–Will be mandatory under EU laws in 2003
–Requirements
- Documented evidence of analysis, HAC, inspections carried out
- Use of ATEX certified (E & M) equipment & safety systems
Ex
Auditing Checklists
• OISD 145 (Section 9)
• IS 5571
• IS 5572
• IS 13408 Part I, II, III (Code of practice for selection, installation &
maintenance of Electrical equipment in potentially Explosive
atmospheres)
Ex
• Periodic examination of flange gaps and flange faces for any effects of
corrosion / damage, etc.
• Maintenance Tests (at an interval not exceeding 3 years)

– IR measurements
–Earth electrode resistance measurements
–Earth loop resistance measurements
–Operation & Setting of Protection devices
Ex
TOTAL RECAP
• HAC
• EQUIPMENT SELECTION
• VARIOUS EXPLOSION PROTECTION TECHNIQUES
• INSTALLATION , MAINTENANCE & AUDITING GUIDELINES
• STATUTORY REQUIREMENTS
Ex
European ATEX Directive
• ATEX Directive 94/9/EC is adopted by the EU members & is concerning

technical & legal requirements applicable for potentially explosive
atmospheres
• CE marking is a pre-requisite if products are to be used in EU nations
• ATEX directive 100a will become mandatory on July 1, 2003
• Equipment groups (non-mining)

–CAT 1 (Zone 0)
–CAT 2 (Zone 1)
–CAT 3 (Zone 2)
Ex
CHOLAMANDALAM AXA RISK SERVICES LTD.
COMPANY PROFILE
• JV between Cholamandalam Investment & Finance Co. Ltd. (Part of

Murugappa group) and AXA Insurance of France
• Offers customized Risk Management solutions to industrial clients in ASIA,

which include:
• Business Continuity Planning, Risk Analysis, Electrical Safety Audits,
Safety Audits as per IS 14489, Specialized safety training, Review of
Fire Protection systems, etc. (as per NFPA, BIS, OISD,API, etc.)
Ex
LET US MAKE OUR REFINERIES SAFER !!!
THANK YOU!!!
P.G.Sreejith
Product Bulletin
Hazardous Area Classifications 9.2:001
D103222X012 September 2019
Hazardous Area Classifications and

Protections
The intent of this document is to provide a broad 1. Class—The Class defines the general nature (or
overview of hazardous area classifications and the properties) of the hazardous material in the
types of protection techniques involved. The surrounding atmosphere which may or may not be in
information provided in this bulletin is for educational sufficient quantities.
purposes and should not be used in place of any other
source or governing documents. a. Class I—Locations in which flammable gases or
vapors may or may not be in sufficient quantities to
Not all approvals are covered in this bulletin. Contact produce explosive or ignitable mixtures.
your Emerson sales office for information on approvals
not covered in this bulletin. b. Class II—Locations in which combustible dusts
(either in suspension, intermittently, or
periodically) may or may not be in sufficient
Contact your Emerson sales office for product specific quantities to produce explosive or ignitable
hazardous area approval information or visit mixtures.
Fisher.com.
c. Class III—Locations in which ignitable fibers may
or may not be in sufficient quantities to produce
explosive or ignitable mixtures.
2. Division—The Division defines the probability of the

Hazardous Area hazardous material being able to produce an explosive
or ignitable mixture based upon its presence.
Classifications a. Division 1 indicates that the hazardous material
When electrical equipment is used in, around, or near has a high probability of producing an explosive or
an atmosphere that has flammable gases or vapors, ignitable mixture due to it being present
flammable liquids, combustible dusts, ignitable fibers continuously, intermittently, or periodically or from
or flyings, there is always a possibility or risk that a fire the equipment itself under normal operating
or explosion might occur. Those areas where the conditions.
possibility or risk of fire or explosion might occur due
to an explosive atmosphere and/or mixture is often b. Division 2 indicates that the hazardous material
called a hazardous (or classified) location/area. has a low probability of producing an explosive or
Currently there are two systems used to classify these ignitable mixture and is present only during
hazardous areas; the Class/Division system and the abnormal conditions for a short period of time.
Zone system. The Class/Division system is used
predominately in the United States and Canada, 3. Group—The Group defines the type of hazardous
whereas the rest of the world generally uses the Zone material in the surrounding atmosphere. Groups A, B,
system. However, the United States and Canada are C, and D are for gases (Class I only) while groups E, F,
trending more towards the Zone System. and G are for dusts and flyings (Class II or III).
a. Group A—Atmospheres containing acetylene.
Class/Division System b. Group B—Atmospheres containing a flammable

gas, flammable liquid-produced vapor, or
Hazardous locations per the Class/Division system are combustible liquid-produced vapor whose MESG is
classified according to the Class, Division, and Group. less than 0.45 mm or MIC ratio is less than 0.40.
www.Fisher.com
Product Bulletin
9.2:001 Hazardous Area Classifications
September 2019 D103222X012
Typical gases include hydrogen, butadiene, c. Zone 2—Ignitable concentrations of flammable

ethylene oxide, propylene oxide, and acrolein. gases or vapors which are not likely to occur under
normal operating conditions and do so only for a
c. Group C—Atmospheres containing a flammable short period of time.
combustible liquid-produced vapor whose MESG is 2. Dust
greater than 0.45 mm but less than or equal to
0.75 mm or MIC ratio is greater than 0.40 but less a. Zone 20—An area where combustible dusts or
than or equal to 0.80. Typical gases include ethyl ignitable fibers and flyings are present continuously
either, ethylene, acetaldehyde, and cyclopropane. or for long periods of time.
b. Zone 21—An area where combustible dusts or

d. Group D—Atmospheres containing a flammable
ignitable fibers and flyings are likely to occur under
normal operating conditions.
combustible liquid-produced vapor whose MESG is
greater than 0.75 mm or MIC ration is greater than
c. Zone 22—An area where combustible dusts or
0.80. Typical gases include acetone, ammonia,
ignitable fibers and flyings are not likely to occur
benzene, butane, ethanol, gasoline, methane,
under normal operating conditions and do so only
natural gas, naphtha, and propane.
for a short period of time.
e. Group E—Atmospheres containing combustible Group—Electrical equipment is divided into three
metal dusts such as aluminum, magnesium, and groups .
their commercial alloys.
n Group I—Equipment intended for use in mines
f. Group F—Atmospheres containing combustible susceptible to firedamp (flammable mixture of
carbonaceous dusts with 8% or more trapped gases naturally occurring in a mine).
volatiles such as carbon black, coal, or coke dust.
n Group II—Equipment intended for use in places
g. Group G—Atmospheres containing combustible with an explosive gas atmosphere other than
dusts not included in Group E or Group F. Typical mines susceptible to firedamp. Group II
dusts include flour, starch, grain, wood, plastic, and equipment is subdivided into three subgroups.
chemicals.
- Group IIA—Atmospheres containing
propane, or gases and vapors of equivalent
hazard.
Zone System
Hazardous locations per the Zone system are classified - Group IIB—Atmospheres containing
according to its Zone which can be gas or dust. For gas ethylene, or gases and vapors of equivalent
atmospheres electrical equipment is further divided hazard.
into Groups and Subgroups.
- Group IIC—Atmospheres containing
acetylene or hydrogen, or gases and vapors of
Zone—The Zone defines the probability of the
equivalent hazard.
hazardous material, gas or dust, being present in
sufficient quantities to produce explosive or ignitable
n Group III—Equipment intended for use in places
mixtures.
with an explosive dust atmosphere. Group III
equipment is subdivided into three subgroups.
1. Gas
- Group IIIA—Atmospheres containing
a. Zone 0—Ignitable concentrations of flammable combustible flyings.
gases or vapors which are present continuously or
for long periods of time. - Group IIIB—Atmospheres containing
non-conductive dust.
b. Zone 1—Ignitable concentrations of flammable
gases or vapors which are likely to occur under - Group IIIC—Atmospheres containing
normal operating conditions. conductive dust.
2
Product Bulletin
Protection Techniques and Zone system

The below concepts are high-level protection
Methods concepts. There are also sub-levels of protection that
may or not be applicable to each type. Also, some
equipment may combine multiple types of protection.
Various protection techniques and methods have been
developed and employed, thus reducing or minimizing n Flame-proof—A type of protection in which an
the potential risks of explosion or fire from electrical enclosure can withstand the pressure developed
equipment located in hazardous locations. Not all
during an internal explosion of an explosive mixture
methods are listed.
and that prevents the transmission of the explosion
to the explosive atmosphere surrounding the
enclosure and that operates at such an external
temperature that a surrounding explosive gas or
vapor will not be ignited there. This type of
protection is referred to as “Ex d”.
Class/Division system n Intrinsically Safe—A type of protection in which the
electrical equipment under normal or abnormal
n Explosion-proof—A type of protection that utilizes conditions is incapable of releasing sufficient
an enclosure that is capable of withstanding an electrical or thermal energy to cause ignition of a
explosive gas or vapor within it and or preventing specific hazardous atmospheric mixture in its most
the ignition of an explosive gas or vapor that may easily ignitable concentrations. This type of
surround it and that operates at such an external protection is referred to as “Ex i”.
vapor will not be ignited thereby. n Increased Safety—A type of protection in which
various measures are applied to reduce the
probability of excessive temperatures and the
occurrence of arcs or sparks in the interior and on
n Intrinsically Safe—A type of protection in which the the external parts of electrical apparatus that do not
electrical equipment under normal or abnormal produce them in normal service. Increased safety
conditions is incapable of releasing sufficient may be used with flame-proof type of protection.
electrical or thermal energy to cause ignition of a This type of protection is referred to as “Ex e”.
specific hazardous atmospheric mixture in its most
easily ignitable concentration. n Type n—A type of protection applied to electrical
equipment such that in normal operation it is not
capable of igniting a surrounding explosive
atmosphere. This type of protection is referred to as
n Dust Ignition-proof—A type of protection that “Ex n”.
excludes ignitable amounts of dust or amounts that
might affect performance or rating and that, when n Type t—A type of protection in which the electrical
installed and protected in accordance with the equipment is equipped with an enclosure providing
original design intent, will not allow arcs, sparks or dust ingress protection and a means to limit surface
heat otherwise generated or liberated inside the temperatures. This type of protection is referred to
enclosure to cause ignition of exterior as “Ex t”.
accumulations or atmospheric suspensions of a
specified dust. n Type h—Refers to one of three different types of
protection: (1) where constructional measures are
applied to protect against the possibility of ignition
from hot surfaces, sparks and compression
n Non-incendive—A type of protection in which the generated by moving parts; (2) ignition protection
equipment is incapable, under normal conditions, where mechanical or electrical devices are used in
of causing ignition of a specified flammable gas or conjunction with nonelectrical equipment to
vapor-in-air mixture due to arcing or thermal effect. manually or automatically reduce the likelihood of a
3
Product Bulletin
potential ignition source from becoming an

effective ignition source; or (3) protection where Nomenclature
potential ignition sources are made ineffective or
separated from the explosive atmosphere by either
totally immersing them in a protective liquid, or by
Class/Division system
partially immersing and continuously coating their Approved equipment is marked according to which
active surfaces with a protective liquid in such a way Class (I, II, or III), Division (1 or 2), Group (A, B, C, D, E,
that an explosive atmosphere which may be above F, or G), and temperature code (T1 through T6) that it
the liquid, or outside the equipment enclosure, is rated for. For intrinsically safe equipment the words
cannot be ignited. Non-electrical equipment often “Intrinsically Safe” or “IS” will precede the actual
apply “Ex h” protection methods. approval marking to indicate it as being intrinsically
safe. Examples are listed below:
Class I Division 1 Group B,C,D T5

CL I Div 2 GP ABCD T5
IS CL I,II,III Div 1 GP ABCDEFG
CL II,III Div 1,2 GP EFG T4
Equipment Protection
Level (EPL) Markings Zone system
The EPL marking indicates the level of protection that Approved equipment is marked according to the
is given to equipment based on the likelihood of its protection concept for which it has been designed
becoming a source of ignition and distinguishing the (Ex i, Ex d, Ex n, and etc.), the group (I, IIA, IIB, IIC, IIIA,
difference between explosive gas atmospheres, IIIB, or IIIC), and temperature code (T1 through T6)
explosive dust atmospheres, and the explosive that it is rated for. For the United States it will be
atmospheres in mines susceptible to firedamp. preceded by which Class and Zone it is approved for.
Examples are listed below:
Ex ia IIC T5
Ex d IIB+H2 T6
Ex nA IIC T6
Temperature Code Class I Zone 2 AEx nC IIC T5
(T Code)
A mixture of hazardous gases and air may be ignited by
Additional Terminology
coming into contact with a hot surface. The conditions Although the following terminology is not permitted
under which a hot surface will ignite a gas depends on for markings it is commonly used to describe the
surface area, temperature, and the concentration of various types of approvals or when speaking of them.
the gas. The same can be said about combustible
dusts. The T code of a product denotes the maximum XP—Flameproof approval for Class I Division 1
surface temperature that a given product will not EXP—Flameproof approval for Class I Division 1
exceed under a specified ambient temperature. For NI—Non-incendive approval for Class I Division 2
example, a product with a T code of T3 means that its DIP—Dust Ignition Proof approval for Class II
maximum surface temperature will not exceed 200_C Division 1
provided it is operated in a ambient temperature S—“Suitable For” for Class II Division 2
defined by the manufacturer. IS—Intrinsically Safe
4
Product Bulletin
Approval Agencies country within the union, known as CENELEC

certifications/approvals. CENELEC is the acronym for
Generally speaking, most countries require that European Committee for Electrotechnical
products intended for installation in a hazardous Standardization. A product which has been CENELEC
location be approved by a recognized authority or certified or approved by any of the Notified Bodies is
approval agency (governmental or independent) automatically accepted for use within all of the
which that country has established by various laws, participating union countries. In July 2003 a European
regulations, or codes. See table 1 for an overview of Directive, called the ATEX Directive, which pertains to
approvals and approval agencies. equipment for explosive atmospheres, was adopted.
All equipment intended for use in explosive
atmospheres must comply with the ATEX Directive in
order to be sold into the European Union.
North American Approvals
Of the 15 national testing laboratories (NRTL's) in the
United States, only a few are qualified to approve International Approvals
products for use in hazardous locations. Two such
agencies are; Factory Mutual (FM) and Underwriters Countries participating in the IECEx Scheme
Laboratories (UL). In Canada, products are approved by (International Electrotechnical Commission on
the Canadian Standards Association (CSA). explosion protected equipment, known as “Ex”) can
issue either an international certification or a national
certification of explosion protected equipment. Each
European Approvals country within the IECEx scheme establishes an ExCB
(Ex Certification Body) which can approve products.
Each country belonging to the European Union has ExCB's can issue the national certification for their
established one or more “Notified Bodies” for product country based upon the IECEx standards (including any
approval. Notified Bodies not only approve products national deviations) and the international certification.
for use within their own country, commonly called Currently, Australia is the only country accepting
national certifications/approvals, but also for any other international certifications for use in their country.
Table 1. Approval Agencies

Approvals(1) Approval Agencies Used(2) Approvals Accepted
FM FM—Factory Mutual North America
CML CML—Certification Management Limited Japan
CSA CSA—Canadian Standards Association North America
Baseefa—British Approvals Service for Electrical Equipment in Flammable Atmospheres
ATEX KEMA—NV tot Keuring van Elektrotechnische Materialen European Union
LCIE—Laboratorie Central des Industries Electriques
CSA—Canadian Standards Association
IECEx International
SAA SAA—Standards Association of Australia Australia
NEPSI—National Supervision and Inspection Centre for Explosion Protection and Safety of
NEPSI China
Instrumentation
TIIS TIIS—Technology Institution of Industrial Safety Japan
INMETRO INMETRO—National Institute of Metrology, Quality and Technology Brazil
FGUP Certification Centre: SC VSI VNIIFTRI Russia, Belarus,
CUTR
Certification Body: OS VSI VNIFFTRI Kazakhstan, and Armenia
1. Fisher™ products may carry additional approvals. Contact your Emerson sales office for additional approval information.
2. Fisher product approvals may be certified by other agencies. Contact your Emerson sales office for additional information.
5
Product Bulletin
Figure 1. Typical I.S Installation

HAZARDOUS AREA NON-HAZARDOUS AREA
DVC6200 I.S. BARRIER

Vmax = 30 VDC Voc = ?
Imax = 226 mA Isc = ?
Pi = 1.4 W Ca = ?
Ci = 5 nF La = ?
Li = 0.55 mH
DEVICE COMMUNICATOR
Vmax = 30 VDC Voc = 1.9 VDC
Imax = 200 mA Isc = 32 μA
Pi = 1 W Po = 61 μW
Ci = 0 μF Ca = 100 μF
Li = 0 mH La = 5600 mH
Guidelines for Selecting The values Voc, Ioc, Ca, and La are specified by the
barrier manufacturer for any given barrier. The values
Intrinsic Safety Barriers of Ccable and Lcable for the signal cable must be
determined for the specific cable used.
Using Entity Ratings Example barrier entity ratings calculation.
Selecting an intrinsic safety barrier with the required A system is comprised of a FIELDVUE™ DVC6200 digital
entity ratings depends upon the combined effects of valve controller (FM approved), a Device
the instrument, its cabling, and any instrument Communicator (FM approved), and 1000 feet of cable
accessories such as the AMS Trex™ Device with 60 pF/ft capacitance and 0.2 μH/ft inductance.
Communicator. Determine the barrier entity ratings Calculate the barrier entity ratings.
using the following guidelines:
Figure 1 shows a typical I.S. installation.
Voc ≤ Vmax
Isc ≤ Imax Calculate Ccable and Lcable
Ca ≥ Ci + Ccable Ccable = 60 pF/ft x 1000 ft
La ≥ Li + Lcable
= 60 nF
where: Lcable = 0.2 μH/ft x 1000 ft
Voc = Barrier open circuit voltage = 0.2 mH
Vmax = Instrument Vmax Determine Ca and La for the barrier
Ca w Ci(DVC6200)+ Ci(Trex) + Ccable
Isc= Barrier short circuit current
w 5 nF + 0 nF + 60 nF
Imax = Instrument Imax
Ca w 65 nF
Ca = Barrier acceptable connected capacitance
Ci = Instrument total unprotected internal capacitance
La w Li(DVC6200)+Li(Trex) + Lcable
Ccable = Signal cable total capacitance w 0.55 mH + 0 mH + 0.2 mH
La = Barrier acceptable connected inductance La w 0.75 mH
Li = Instrument total unprotected internal inductance
Determine Voc and Isc of the barrier. Note that in this
Lcable = Signal cable total inductance example the output of the Trex (Voc(Trex) and Isc(Trex))
6
Product Bulletin
must also be considered because it can also add Isc of the barrier must meet all of the following
energy to the loop besides just the barrier itself. Voc of conditional requirements.
the barrier plus any additional voltage that could be
added to the loop from each device must be
subtracted from Vmax for each device. Isc of the barrier 1) Isc v Imax(DVC6200) + Isc(Trex) 226 mA +
plus any additional current that could be added to the 0.032 mA 226.032 mA
loop from each device must not exceed Imax for each
device. 2) Isc v Imax(DVC6200) 226 mA
Voc of the barrier must meet all of the following 3) Isc v Imax(Trex) 200 mA
conditional requirements.
1) Voc v Vmax(DVC6200) - Voc(Trex) 30 VDC - 1.9 VDC Isc v 200 mA
28.1 VDC
2) Voc v Vmax(DVC6200) 30 VDC
3) Voc v Vmax(Trex) 30 VDC
Voc v 28.1 VDC
7
Product Bulletin
Neither Emerson, Emerson Automation Solutions, nor any of their affiliated entities assumes responsibility for the selection, use or maintenance
of any product. Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user.
Fisher, Trex and FIELDVUE are marks owned by one of the companies in the Emerson Automation Solutions business unit of Emerson Electric Co. Emerson
Automation Solutions, Emerson, and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property of their
respective owners.
The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not
to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are
governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such
products at any time without notice.
Emerson Automation Solutions
Marshalltown, Iowa 50158 USA
Sorocaba, 18087 Brazil
Cernay, 68700 France
Dubai, United Arab Emirates
Singapore 128461 Singapore
www.Fisher.com
E
8 2006, 2019 Fisher Controls International LLC. All rights reserved.
Product Bulletin
Hazardous Area Classifications and

Protections
The intent of this document is to provide a broad 1. Class—The Class defines the general nature (or
overview of hazardous area classifications and the properties) of the hazardous material in the
types of protection techniques involved. The surrounding atmosphere which may or may not be in
information provided in this bulletin is for educational sufficient quantities.
purposes and should not be used in place of any other
source or governing documents. a. Class I—Locations in which flammable gases or
vapors may or may not be in sufficient quantities to
Not all approvals are covered in this bulletin. Contact produce explosive or ignitable mixtures.
your Emerson sales office for information on approvals
not covered in this bulletin. b. Class II—Locations in which combustible dusts
(either in suspension, intermittently, or
periodically) may or may not be in sufficient
Contact your Emerson sales office for product specific quantities to produce explosive or ignitable
hazardous area approval information or visit mixtures.
Fisher.com.
c. Class III—Locations in which ignitable fibers may
or may not be in sufficient quantities to produce
explosive or ignitable mixtures.
2. Division—The Division defines the probability of the

Hazardous Area hazardous material being able to produce an explosive
or ignitable mixture based upon its presence.
Classifications a. Division 1 indicates that the hazardous material
When electrical equipment is used in, around, or near has a high probability of producing an explosive or
an atmosphere that has flammable gases or vapors, ignitable mixture due to it being present
flammable liquids, combustible dusts, ignitable fibers continuously, intermittently, or periodically or from
or flyings, there is always a possibility or risk that a fire the equipment itself under normal operating
or explosion might occur. Those areas where the conditions.
possibility or risk of fire or explosion might occur due
to an explosive atmosphere and/or mixture is often b. Division 2 indicates that the hazardous material
called a hazardous (or classified) location/area. has a low probability of producing an explosive or
Currently there are two systems used to classify these ignitable mixture and is present only during
hazardous areas; the Class/Division system and the abnormal conditions for a short period of time.
Zone system. The Class/Division system is used
predominately in the United States and Canada, 3. Group—The Group defines the type of hazardous
whereas the rest of the world generally uses the Zone material in the surrounding atmosphere. Groups A, B,
system. However, the United States and Canada are C, and D are for gases (Class I only) while groups E, F,
trending more towards the Zone System. and G are for dusts and flyings (Class II or III).
a. Group A—Atmospheres containing acetylene.
Class/Division System b. Group B—Atmospheres containing a flammable

Hazardous locations per the Class/Division system are combustible liquid-produced vapor whose MESG is
classified according to the Class, Division, and Group. less than 0.45 mm or MIC ratio is less than 0.40.
www.Fisher.com
Product Bulletin
Typical gases include hydrogen, butadiene, c. Zone 2—Ignitable concentrations of flammable

ethylene oxide, propylene oxide, and acrolein. gases or vapors which are not likely to occur under
normal operating conditions and do so only for a
c. Group C—Atmospheres containing a flammable short period of time.
combustible liquid-produced vapor whose MESG is 2. Dust
greater than 0.45 mm but less than or equal to
0.75 mm or MIC ratio is greater than 0.40 but less a. Zone 20—An area where combustible dusts or
than or equal to 0.80. Typical gases include ethyl ignitable fibers and flyings are present continuously
either, ethylene, acetaldehyde, and cyclopropane. or for long periods of time.
b. Zone 21—An area where combustible dusts or

d. Group D—Atmospheres containing a flammable
ignitable fibers and flyings are likely to occur under
normal operating conditions.
combustible liquid-produced vapor whose MESG is
greater than 0.75 mm or MIC ration is greater than
c. Zone 22—An area where combustible dusts or
0.80. Typical gases include acetone, ammonia,
ignitable fibers and flyings are not likely to occur
benzene, butane, ethanol, gasoline, methane,
under normal operating conditions and do so only
natural gas, naphtha, and propane.
for a short period of time.
e. Group E—Atmospheres containing combustible Group—Electrical equipment is divided into three
metal dusts such as aluminum, magnesium, and groups .
their commercial alloys.
n Group I—Equipment intended for use in mines
f. Group F—Atmospheres containing combustible susceptible to firedamp (flammable mixture of
carbonaceous dusts with 8% or more trapped gases naturally occurring in a mine).
volatiles such as carbon black, coal, or coke dust.
n Group II—Equipment intended for use in places
g. Group G—Atmospheres containing combustible with an explosive gas atmosphere other than
dusts not included in Group E or Group F. Typical mines susceptible to firedamp. Group II
dusts include flour, starch, grain, wood, plastic, and equipment is subdivided into three subgroups.
chemicals.
- Group IIA—Atmospheres containing
propane, or gases and vapors of equivalent
hazard.
Zone System
Hazardous locations per the Zone system are classified - Group IIB—Atmospheres containing
according to its Zone which can be gas or dust. For gas ethylene, or gases and vapors of equivalent
atmospheres electrical equipment is further divided hazard.
into Groups and Subgroups.
- Group IIC—Atmospheres containing
acetylene or hydrogen, or gases and vapors of
Zone—The Zone defines the probability of the
equivalent hazard.
hazardous material, gas or dust, being present in
sufficient quantities to produce explosive or ignitable
n Group III—Equipment intended for use in places
mixtures.
with an explosive dust atmosphere. Group III
equipment is subdivided into three subgroups.
1. Gas
- Group IIIA—Atmospheres containing
a. Zone 0—Ignitable concentrations of flammable combustible flyings.
gases or vapors which are present continuously or
for long periods of time. - Group IIIB—Atmospheres containing
non-conductive dust.
b. Zone 1—Ignitable concentrations of flammable
gases or vapors which are likely to occur under - Group IIIC—Atmospheres containing
normal operating conditions. conductive dust.
2
Product Bulletin
Protection Techniques and Zone system

The below concepts are high-level protection
Methods concepts. There are also sub-levels of protection that
may or not be applicable to each type. Also, some
equipment may combine multiple types of protection.
Various protection techniques and methods have been
developed and employed, thus reducing or minimizing n Flame-proof—A type of protection in which an
the potential risks of explosion or fire from electrical enclosure can withstand the pressure developed
equipment located in hazardous locations. Not all
during an internal explosion of an explosive mixture
methods are listed.
and that prevents the transmission of the explosion
to the explosive atmosphere surrounding the
enclosure and that operates at such an external
vapor will not be ignited there. This type of
protection is referred to as “Ex d”.
Class/Division system n Intrinsically Safe—A type of protection in which the
electrical equipment under normal or abnormal
n Explosion-proof—A type of protection that utilizes conditions is incapable of releasing sufficient
an enclosure that is capable of withstanding an electrical or thermal energy to cause ignition of a
explosive gas or vapor within it and or preventing specific hazardous atmospheric mixture in its most
the ignition of an explosive gas or vapor that may easily ignitable concentrations. This type of
surround it and that operates at such an external protection is referred to as “Ex i”.
vapor will not be ignited thereby. n Increased Safety—A type of protection in which
various measures are applied to reduce the
probability of excessive temperatures and the
occurrence of arcs or sparks in the interior and on
n Intrinsically Safe—A type of protection in which the the external parts of electrical apparatus that do not
electrical equipment under normal or abnormal produce them in normal service. Increased safety
conditions is incapable of releasing sufficient may be used with flame-proof type of protection.
electrical or thermal energy to cause ignition of a This type of protection is referred to as “Ex e”.
specific hazardous atmospheric mixture in its most
easily ignitable concentration. n Type n—A type of protection applied to electrical
equipment such that in normal operation it is not
capable of igniting a surrounding explosive
atmosphere. This type of protection is referred to as
n Dust Ignition-proof—A type of protection that “Ex n”.
excludes ignitable amounts of dust or amounts that
might affect performance or rating and that, when n Type t—A type of protection in which the electrical
installed and protected in accordance with the equipment is equipped with an enclosure providing
original design intent, will not allow arcs, sparks or dust ingress protection and a means to limit surface
heat otherwise generated or liberated inside the temperatures. This type of protection is referred to
enclosure to cause ignition of exterior as “Ex t”.
accumulations or atmospheric suspensions of a
specified dust. n Type h—Refers to one of three different types of
protection: (1) where constructional measures are
applied to protect against the possibility of ignition
from hot surfaces, sparks and compression
n Non-incendive—A type of protection in which the generated by moving parts; (2) ignition protection
equipment is incapable, under normal conditions, where mechanical or electrical devices are used in
of causing ignition of a specified flammable gas or conjunction with nonelectrical equipment to
vapor-in-air mixture due to arcing or thermal effect. manually or automatically reduce the likelihood of a
3
Product Bulletin
potential ignition source from becoming an

effective ignition source; or (3) protection where Nomenclature
potential ignition sources are made ineffective or
separated from the explosive atmosphere by either
totally immersing them in a protective liquid, or by
Class/Division system
partially immersing and continuously coating their Approved equipment is marked according to which
active surfaces with a protective liquid in such a way Class (I, II, or III), Division (1 or 2), Group (A, B, C, D, E,
that an explosive atmosphere which may be above F, or G), and temperature code (T1 through T6) that it
the liquid, or outside the equipment enclosure, is rated for. For intrinsically safe equipment the words
cannot be ignited. Non-electrical equipment often “Intrinsically Safe” or “IS” will precede the actual
apply “Ex h” protection methods. approval marking to indicate it as being intrinsically
safe. Examples are listed below:
Class I Division 1 Group B,C,D T5

CL I Div 2 GP ABCD T5
IS CL I,II,III Div 1 GP ABCDEFG
CL II,III Div 1,2 GP EFG T4
Equipment Protection
Level (EPL) Markings Zone system
The EPL marking indicates the level of protection that Approved equipment is marked according to the
is given to equipment based on the likelihood of its protection concept for which it has been designed
becoming a source of ignition and distinguishing the (Ex i, Ex d, Ex n, and etc.), the group (I, IIA, IIB, IIC, IIIA,
difference between explosive gas atmospheres, IIIB, or IIIC), and temperature code (T1 through T6)
explosive dust atmospheres, and the explosive that it is rated for. For the United States it will be
atmospheres in mines susceptible to firedamp. preceded by which Class and Zone it is approved for.
Examples are listed below:
Ex ia IIC T5
Ex d IIB+H2 T6
Ex nA IIC T6
Temperature Code Class I Zone 2 AEx nC IIC T5
(T Code)
A mixture of hazardous gases and air may be ignited by
Additional Terminology
coming into contact with a hot surface. The conditions Although the following terminology is not permitted
under which a hot surface will ignite a gas depends on for markings it is commonly used to describe the
surface area, temperature, and the concentration of various types of approvals or when speaking of them.
the gas. The same can be said about combustible
dusts. The T code of a product denotes the maximum XP—Flameproof approval for Class I Division 1
surface temperature that a given product will not EXP—Flameproof approval for Class I Division 1
exceed under a specified ambient temperature. For NI—Non-incendive approval for Class I Division 2
example, a product with a T code of T3 means that its DIP—Dust Ignition Proof approval for Class II
maximum surface temperature will not exceed 200_C Division 1
provided it is operated in a ambient temperature S—“Suitable For” for Class II Division 2
defined by the manufacturer. IS—Intrinsically Safe
4
Product Bulletin
Approval Agencies country within the union, known as CENELEC

certifications/approvals. CENELEC is the acronym for
Generally speaking, most countries require that European Committee for Electrotechnical
products intended for installation in a hazardous Standardization. A product which has been CENELEC
location be approved by a recognized authority or certified or approved by any of the Notified Bodies is
approval agency (governmental or independent) automatically accepted for use within all of the
which that country has established by various laws, participating union countries. In July 2003 a European
regulations, or codes. See table 1 for an overview of Directive, called the ATEX Directive, which pertains to
approvals and approval agencies. equipment for explosive atmospheres, was adopted.
All equipment intended for use in explosive
atmospheres must comply with the ATEX Directive in
order to be sold into the European Union.
North American Approvals
Of the 15 national testing laboratories (NRTL's) in the
United States, only a few are qualified to approve International Approvals
products for use in hazardous locations. Two such
agencies are; Factory Mutual (FM) and Underwriters Countries participating in the IECEx Scheme
Laboratories (UL). In Canada, products are approved by (International Electrotechnical Commission on
the Canadian Standards Association (CSA). explosion protected equipment, known as “Ex”) can
issue either an international certification or a national
certification of explosion protected equipment. Each
European Approvals country within the IECEx scheme establishes an ExCB
(Ex Certification Body) which can approve products.
Each country belonging to the European Union has ExCB's can issue the national certification for their
established one or more “Notified Bodies” for product country based upon the IECEx standards (including any
approval. Notified Bodies not only approve products national deviations) and the international certification.
for use within their own country, commonly called Currently, Australia is the only country accepting
national certifications/approvals, but also for any other international certifications for use in their country.
Table 1. Approval Agencies

Approvals(1) Approval Agencies Used(2) Approvals Accepted
FM FM—Factory Mutual North America
CML CML—Certification Management Limited Japan
CSA CSA—Canadian Standards Association North America
ATEX KEMA—NV tot Keuring van Elektrotechnische Materialen European Union
LCIE—Laboratorie Central des Industries Electriques
CSA—Canadian Standards Association
IECEx International
SAA SAA—Standards Association of Australia Australia
NEPSI—National Supervision and Inspection Centre for Explosion Protection and Safety of
NEPSI China
Instrumentation
TIIS TIIS—Technology Institution of Industrial Safety Japan
INMETRO INMETRO—National Institute of Metrology, Quality and Technology Brazil
FGUP Certification Centre: SC VSI VNIIFTRI Russia, Belarus,
CUTR
Certification Body: OS VSI VNIFFTRI Kazakhstan, and Armenia
1. Fisher™ products may carry additional approvals. Contact your Emerson sales office for additional approval information.
2. Fisher product approvals may be certified by other agencies. Contact your Emerson sales office for additional information.
5
Product Bulletin
Figure 1. Typical I.S Installation

HAZARDOUS AREA NON-HAZARDOUS AREA
DVC6200 I.S. BARRIER

Vmax = 30 VDC Voc = ?
Imax = 226 mA Isc = ?
Pi = 1.4 W Ca = ?
Ci = 5 nF La = ?
Li = 0.55 mH
DEVICE COMMUNICATOR
Vmax = 30 VDC Voc = 1.9 VDC
Imax = 200 mA Isc = 32 μA
Pi = 1 W Po = 61 μW
Ci = 0 μF Ca = 100 μF
Li = 0 mH La = 5600 mH
Guidelines for Selecting The values Voc, Ioc, Ca, and La are specified by the
barrier manufacturer for any given barrier. The values
Intrinsic Safety Barriers of Ccable and Lcable for the signal cable must be
determined for the specific cable used.
Using Entity Ratings Example barrier entity ratings calculation.
Selecting an intrinsic safety barrier with the required A system is comprised of a FIELDVUE™ DVC6200 digital
entity ratings depends upon the combined effects of valve controller (FM approved), a Device
the instrument, its cabling, and any instrument Communicator (FM approved), and 1000 feet of cable
accessories such as the AMS Trex™ Device with 60 pF/ft capacitance and 0.2 μH/ft inductance.
Communicator. Determine the barrier entity ratings Calculate the barrier entity ratings.
using the following guidelines:
Figure 1 shows a typical I.S. installation.
Voc ≤ Vmax
Isc ≤ Imax Calculate Ccable and Lcable
Ca ≥ Ci + Ccable Ccable = 60 pF/ft x 1000 ft
La ≥ Li + Lcable
= 60 nF
where: Lcable = 0.2 μH/ft x 1000 ft
Voc = Barrier open circuit voltage = 0.2 mH
Vmax = Instrument Vmax Determine Ca and La for the barrier
Ca w Ci(DVC6200)+ Ci(Trex) + Ccable
Isc= Barrier short circuit current
w 5 nF + 0 nF + 60 nF
Imax = Instrument Imax
Ca w 65 nF
Ca = Barrier acceptable connected capacitance
Ci = Instrument total unprotected internal capacitance
La w Li(DVC6200)+Li(Trex) + Lcable
Ccable = Signal cable total capacitance w 0.55 mH + 0 mH + 0.2 mH
La = Barrier acceptable connected inductance La w 0.75 mH
Li = Instrument total unprotected internal inductance
Determine Voc and Isc of the barrier. Note that in this
Lcable = Signal cable total inductance example the output of the Trex (Voc(Trex) and Isc(Trex))
6
Product Bulletin
must also be considered because it can also add Isc of the barrier must meet all of the following
energy to the loop besides just the barrier itself. Voc of conditional requirements.
the barrier plus any additional voltage that could be
added to the loop from each device must be
subtracted from Vmax for each device. Isc of the barrier 1) Isc v Imax(DVC6200) + Isc(Trex) 226 mA +
plus any additional current that could be added to the 0.032 mA 226.032 mA
loop from each device must not exceed Imax for each
device. 2) Isc v Imax(DVC6200) 226 mA
Voc of the barrier must meet all of the following 3) Isc v Imax(Trex) 200 mA
conditional requirements.
1) Voc v Vmax(DVC6200) - Voc(Trex) 30 VDC - 1.9 VDC Isc v 200 mA
28.1 VDC
2) Voc v Vmax(DVC6200) 30 VDC
3) Voc v Vmax(Trex) 30 VDC
Voc v 28.1 VDC
7
Product Bulletin
Neither Emerson, Emerson Automation Solutions, nor any of their affiliated entities assumes responsibility for the selection, use or maintenance
of any product. Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user.
Fisher, Trex and FIELDVUE are marks owned by one of the companies in the Emerson Automation Solutions business unit of Emerson Electric Co. Emerson
Automation Solutions, Emerson, and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property of their
respective owners.
The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not
to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are
governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such
products at any time without notice.
Emerson Automation Solutions
Marshalltown, Iowa 50158 USA
Sorocaba, 18087 Brazil
Cernay, 68700 France
Dubai, United Arab Emirates
Singapore 128461 Singapore
www.Fisher.com
E
8 2006, 2019 Fisher Controls International LLC. All rights reserved.
Hazardous Area Classification and Control of Ignition
Sources
hse.gov.uk/comah/sragtech/techmeasareaclas.htm
Beta This is a new way of showing guidance - your feedback will help us improve it.
This Technical Measures Document refers to the classification of plant into hazardous
areas, and the systematic identification and control of ignition sources
The relevant Level 2 Criteria are 5.2.1.3(29)c, 5.2.1.11(63)f, 5.2.1.13 and 5.2.4.2(93)a.
Design of plant, pipework and general plant layout is considered in Technical Measures
Documents on Plant Layout, Design Codes - Plant, Design Codes - Pipework, Plant
Modification / Change Procedures, Maintenance Procedures.
The Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR)

provide for the first time a specific legal requirement to carry out a hazardous area study,
and document the conclusions, in the form of zones.
General Principles
Hazardous Area Classification for Flammable Gases and Vapours

Area classification may be carried out by direct analogy with typical installations described
in established codes, or by more quantitative methods that require a more detailed
knowledge of the plant. The starting point is to identify sources of release of flammable gas
or vapour. These may arise from constant activities; from time to time in normal operation;
or as the result of some unplanned event. In addition, inside process equipment may be a
hazardous area, if both gas/vapour and air are present, though there is no actual release.
Catastrophic failures, such as vessel or line rupture are not considered by an area
classification study. A hazard identification process such as a Preliminary Hazard Analysis
(PHA) or a Hazard and Operability Study (HAZOP) should consider these abnormal
events.
The most commonly used standard in the UK for determining area extent and classification
is BS EN 60079 part 101, which has broad applicability. The current version makes clear
the direct link between the amounts of flammable vapour that may be released, the
ventilation at that location, and the zone number. It contains a simplistic calculation
relating the size of zone to a rate of release of gas or vapour, but it is not helpful for liquid
releases, where the rate of vaporisation controls the size of the hazardous area.
1/14
Other sources of advice, which describe more sophisticated approaches, are the Institute of
Petroleum Model Code of Practice (Area Classification Code for Petroleum Installations,
2002), and the Institution of Gas Engineers Safety Recommendations SR25, (2001). The
IP code is for use by refinery and petrochemical type operations. The IGE code addresses
specifically transmission, distribution and storage facilities for natural gas, rather than gas
utilisation plant, but some of the information will be relevant to larger scale users.
Zoning
Hazardous areas are defined in DSEAR as "any place in which an explosive atmosphere
may occur in quantities such as to require special precautions to protect the safety of
workers". In this context, 'special precautions' is best taken as relating to the construction,
installation and use of apparatus, as given in BS EN 60079 -10 1.
Area classification is a method of analysing and classifying the environment where

explosive gas atmospheres may occur. The main purpose is to facilitate the proper selection
and installation of apparatus to be used safely in that environment, taking into account the
properties of the flammable materials that will be present. DSEAR specifically extends the
original scope of this analysis, to take into account non-electrical sources of ignition, and
mobile equipment that creates an ignition risk.
Hazardous areas are classified into zones based on an assessment of the frequency of the
occurrence and duration of an explosive gas atmosphere, as follows:
Zone 0: An area in which an explosive gas atmosphere is present continuously or for

long periods;
Zone 1: An area in which an explosive gas atmosphere is likely to occur in normal
operation;
Zone 2: An area in which an explosive gas atmosphere is not likely to occur in normal
operation and, if it occurs, will only exist for a short time.
Various sources have tried to place time limits on to these zones, but none have been
officially adopted. The most common values used are:
Zone 0: Explosive atmosphere for more than 1000h/yr

Zone 1: Explosive atmosphere for more than 10, but less than 1000 h/yr
Zone 2: Explosive atmosphere for less than 10h/yr, but still sufficiently likely as to
require controls over ignition sources.
Where people wish to quantify the zone definitions, these values are the most appropriate,
but for the majority of situations a purely qualitative approach is adequate.
When the hazardous areas of a plant have been classified, the remainder will be defined as
non-hazardous, sometimes referred to as 'safe areas'.
2/14
The zone definitions take no account of the consequences of a release. If this aspect is
important, it may be addressed by upgrading the specification of equipment or controls
over activities allowed within the zone. The alternative of specifying the extent of zones
more conservatively is not generally recommended, as it leads to more difficulties with
equipment selection, and illogicalities in respect of control over health effects from vapours
assumed to be present. Where occupiers choose to define extensive areas as Zone 1, the
practical consequences could usefully be discussed during site inspection.
As an example:
A proposal was made to zone an aircraft hanger as Zone 1, although the use of fuels
handled above their flash point would be a rare event. It proved difficult to obtain a floor-
cleaning machine certified for Zone 1 areas, though the floor needed sweeping regularly.
The option of writing out an exception to normal instructions to allow a non Ex-protected
machine to be used regularly is not recommended. Instead, a more realistic assessment of
the zones is needed, and special instructions issued for the rare event of using more volatile
fuels.
A hazardous area extent and classification study involves due consideration and
documentation of the following:
The flammable materials that may be present;

The physical properties and characteristics of each of the flammable materials;
The source of potential releases and how they can form explosive atmospheres;
Prevailing operating temperatures and pressures;
Presence, degree and availability of ventilation (forced and natural);
Dispersion of released vapours to below flammable limits;
The probability of each release scenario.
These factors enable appropriate selection of zone type and zone extent, and also of
equipment. The IP code gives a methodology for estimating release rates from small
diameter holes with pressurised sources, and shows how both the buoyancy and
momentum of the release influence the extent of a zone. It tabulates values for an LPG
mixture, gasoline, natural gas, and refinery hydrogen for pressures up to 100barg. Similarly
the IGE code gives a methodology for natural gas, relating the leak rate to the hole-size and
the operating pressure. The tables of dispersion distances to the zone boundary address in
the main quite large diameter deliberate vents. There is in practice little overlap between
the codes.
The results of this work should be documented in Hazardous Area Classification data
sheets, supported by appropriate reference drawings showing the extent of the zones
around (including above and below where appropriate) the plant item.
3/14
Selection of Equipment
DSEAR sets out the link between zones, and the equipment that may be installed in that
zone. This applies to new or newly modified installations. The equipment categories are
defined by the ATEX equipment directive, set out in UK law as the Equipment and
Protective Systems for Use in Potentially Explosive Atmospheres Regulations 1996.
Standards set out different protection concepts, with further subdivisions for some types of
equipment according to gas group and temperature classification. Most of the electrical
standards have been developed over many years and are now set at international level,
while standards for non-electrical equipment are only just becoming available from CEN.
The DSEAR ACOP describes the provisions concerning existing equipment.
There are different technical means (protection concepts) of building equipment to the
different categories. These, the standard current in mid 2003, and the letter giving the type
of protection are listed below.
Zone 0 Zone 1 Zone 2
Category 1 Category 2 Category 3
'ia' intrinsically safe 'd' - Flameproof Electrical

EN 50020, 2002 enclosure Type 'n' - EN 50021
EN 50018 2000 1999
Non electrical
EN 13463-1, 2001
Ex s - Special protection if specifically certified for 'p' - Pressurised

Zone 0 EN 50016 2002
'q' - Powder filling

EN 50017, 1998
'o' - Oil immersion

EN 50015, 1998
'e' - Increased safety

EN 50019, 2000
'ib' - Intrinsic safety

EN 50020, 2002
'm' - Encapsulation
EN 50028, 1987
's' - Special protection
Correct selection of electrical equipment for hazardous areas requires the following
information:
4/14
Classification of the hazardous area (as in zones shown in the table above);
Temperature class or ignition temperature of the gas or vapour involved according to
the table below:
Temperature Maximum Surface Ignition Temperature of gas or

Classification Temperature, °C vapour, °C
T1 450 >450
T2 300 >300
T3 200 >200
T4 135 >135
T5 100 >100
T6 85 >85
If several different flammable materials may be present within a particular area, the
material that gives the highest classification dictates the overall area classification. The IP
code considers specifically the issue of hydrogen containing process streams as commonly
found on refinery plants. Consideration should be shown for flammable material that may
be generated due to interaction between chemical species.
Ignition Sources - Identification and Control

Ignition sources may be:
Flames;
Direct fired space and process heating;
Use of cigarettes/matches etc;
Cutting and welding flames;
Hot surfaces;
Heated process vessels such as dryers and furnaces;
Hot process vessels;
Space heating equipment;
Mechanical machinery;
Electrical equipment and lights
Spontaneous heating;
Friction heating or sparks;
Impact sparks;
Sparks from electrical equipment;
Stray currents from electrical equipment
Electrostatic discharge sparks:
5/14
Lightning strikes.
Electromagnetic radiation of different wavelengths
Vehicles, unless specially designed or modified are likely to contain a range of
potential ignition sources
Sources of ignition should be effectively controlled in all hazardous areas by a combination

of design measures, and systems of work:
Using electrical equipment and instrumentation classified for the zone in which it is
located. New mechanical equipment will need to be selected in the same way. (See
above);
Earthing of all plant/ equipment (see Technical Measures Document on Earthing)
Elimination of surfaces above auto-ignition temperatures of flammable materials
being handled/stored (see above);
Provision of lightning protection
Correct selection of vehicles/internal combustion engines that have to work in the
zoned areas (see Technical Measures Document on Permit to Work Systems);
Correct selection of equipment to avoid high intensity electromagnetic radiation
sources, e.g. limitations on the power input to fibre optic systems, avoidance of high
intensity lasers or sources of infrared radiation
Prohibition of smoking/use of matches/lighters
Controls over the use of normal vehicles
Controls over activities that create intermittent hazardous areas, e.g. tanker
loading/unloading
Control of maintenance activities that may cause sparks/hot surfaces/naked flames
through a Permit to Work System
Precautions to control the risk from pyrophoric scale, usually associated with
formation of ferrous sulphide inside process equipment
Direct Fired Heaters, Hot Oil Systems and Processes Operating

Above Auto-Ignition Temperatures
A range of petrochemical and refinery processes use direct fired heaters, e.g. steam
crackers for ethylene production. Clearly, if the fuel supply to the heater or the pipework
carrying the process fluid leaks close to the furnace, any leak must be expected to find a
source of ignition, either directly at the flames, or by a surface heated by a flame. In these
circumstances, hazardous area classification, and appropriate selection of ATEX
equipment is not suitable as a basis of safety for preventing fire and explosion risks.
Instead, safety should be achieved by a combination of a high standard of integrity of fuel

and process pipelines, together with a means of rapid detection and isolation of any pipes
that do fail. The consequences of the failure of a pipe carrying process materials within the
6/14
furnace should be considered in any HAZOP study.
Other processes (such as hot oil heating circuits) may handle products above their auto-
ignition temperature. Any such processes should be specifically identified in a safety case.
Again, area classification is not a suitable means of controlling the ignition risks, and the
same considerations apply, as with fired heaters.
Lightning Protection
Protection against lightning involves installation of a surge protection device between each
non-earth bonded core of the cable and the local structure. Further guidance can be found
in BS 6651:19991 - (Code of practice for protection of structures against lightning).
Ignitions caused by lightning cannot be eliminated entirely, particularly with floating roof
tanks, where vapour is usually present around the rim seal. In these circumstances,
measures to mitigate the consequences of a fire should be provided.
Vehicles
Most normal vehicles contain a wide range of ignition sources. These will include electrical
circuits; the inlet and exhaust of any internal combustion engine; electrostatic build up;
overheating brakes, and other moving parts. Site rules should be clear where normal road
vehicles may be taken, and areas where they must be excluded.
Standard EN 1755 1 sets out the requirements for diesel powdered ATEX category 2 or 3 lift
trucks. Electric powered vehicles can also be built using a combination of this standard and
the normal electrical standards. No specification is available for vehicles with spark
ignition engines, and it is unlikely that such an engine could be built economically.
Vehicles certified to ATEX requirements are however expensive, and for many applications
an unprotected type has to be extensively rebuilt. Consequently, many employers are likely
to try and justify not zoning storage compounds, where lift trucks handle flammable liquids
or gases in containers. In some stores, perhaps with limited use of a vehicle, this may be
acceptable. Discussions have been held with the British Chemical Distributors and Traders
Association, with the objective of clarifying when storage areas should be classified as zone
2. The conclusions from this exercise will be made available in due course. Discussions are
also ongoing, about vehicles with gas detection systems, designed to shut the engine and
isolate other sources of ignition in the event of a gas release. At present these are sold
without any claim for ATEX compliance, but with the suggestion they may be useful in
cases of remote risk.
For the purposes of COMAH, an assessment is needed of the risk that an ignition within a
storage compound will produce a major accident, either directly or because a fire or
explosion spreads to involve other materials. If this is possible, it is more appropriate to
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provide controls to prevent the spread, rather than simply apply more conservative zoning,
and more restrictive rules on the equipment used in the store.
Where specialist vehicles (e.g. cranes) are needed during maintenance operations, proper
controls and plant isolation may allow the normal zones to be suspended. Typically these
will involve written instructions, as specified in DSEAR schedule 1, or a formal permit to
work system.
Many sites will have operations of filling and emptying road tankers with flammable
materials. Controls will be needed to prevent or minimise the release of gas or vapour but
controls over ignition sources are also needed. Hazardous areas may be considered to exist
during the transfer operation, but should not be present once the transfer is complete. Safe
systems of work are needed to ensure safety where such 'transient' zones exist.
Factors for Assessor of a Safety Case to Consider

Is a full set of plans identifying hazardous areas available? For a large site they need
not all be provided in the report, but those examples relevant to the representative set
of major accidents upon which the ALARP demonstration is based must be included.
Have all flammable substances present have been considered during area
classification, including raw materials, intermediates and by products, final product
and effluents? Commonly these will be grouped for the purposes of any area
classification study.
Locations where a large release is possible and the extent of hazardous areas has been
minimised by the use of mechanical ventilation should be identified, e.g. gas turbine
power generation units, compressor houses. Some reference to design codes, and
commissioning checks to ensure the ventilation achieves the design aim, should be
provided. The consequences of a loss of power to the system should be included in
any section looking at other consequences of power loss.
Have appropriate standards been used for selection of equipment in hazardous
areas? Existing plant will not meet the formula in DSEAR, but older standards
distinguished between electrical equipment suitable for zones 0, 1 and 2. Does the
report identify old electrical equipment still in service in a hazardous area, and what
assessment has been made to ensure it remains safe for use?
Is there a reference to the impact upon extent and classification of hazardous areas in
the section describing plant modification (see Technical Measures Document on
Plant Modification / Change Procedures); passive items like new walls and buildings
can influence this if they obstruct natural ventilation of adjacent plant
Have all ignition sources been considered? A check list is provided in the DSEAR
ACOP on control and mitigation measures, and BS EN 1127 part 11 (Explosive
atmospheres. Explosion prevention and protection. Basic concepts and
methodology).
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Factors that could be considered during an on site inspection
If there are any large areas of zone 1 on the drawings, is there evidence that by design
and operation controls, the sources of release and consequently the location and
extent of hazardous areas have been minimised?
Do any zone 2 areas extend to places where the occupier has inadequate control over
activities that could create an ignition source, or is there any suggestion that the zone
boundaries have been arbitrarily adjusted to avoid this?
Has ignition protected electrical equipment been installed and maintained by
suitably trained staff.
Are the risks from static discharges controlled properly? Earthing of plant, drums
and tankers is the most basic requirement; other precautions are described in the
references
What control measures over ignition sources are adopted in hazardous areas during
maintenance; where ignition sources must be introduced, typical precautions include
the use of supplementary ventilation, portable gas detectors, and inerting of sections
of plant. A local project on Electrical Equipment in Flammable Atmospheres (PDF)
was undertaken and a report of the project's conclusions completed.
Dust Explosions
The COMAH Regulations do not apply to any material if the only risk created is that of a
dust explosion. However, many toxic materials are handled in fine powder form, and a
serious dust explosion could cause a major accident. A dust explosion involving a non-toxic
dust like polyethylene would not result in a major accident as defined in the regulations,
unless it also led to loss of containment of a COMAH substance. A dust explosion could
then be an initiator of a major accident. Measures to prevent major accidents should
address all potential initiators.
DSEAR requires that hazardous area classification for flammable dusts should be
undertaken in the same manner as that for flammable gases and vapours. Zoning as
described above may be applied, replacing 'gas atmosphere' with 'dust/air mixtures'. The
zone numbers used are 20, 21 and 22, corresponding to 0,1 and 2 used for gases/vapours
The only relevant standard to help people zone their plant is BS EN 50281 part 3, 20021,
which is an adaptation of the IEC equivalent.
Where toxic dusts are processed, releases into the general atmosphere should be
prevented, and the extent of any zone 21 or 22 outside the containment system should be
minimal or non-existent. The inside of different parts of the plant may need to be zoned as
20, 21 or 22, depending on the conditions at particular locations.
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Classification of dusts relating to autoignition and minimum ignition current is undertaken
similarly to gases/vapours, but involves additional complications.
The explosibility of dusts is dependent upon a number of factors:
chemical composition;
particle size;
oxygen concentration;
Where toxic dusts are handled, in most cases occupiers will need to carry out testing of the
product for its explosion properties. Companies able to undertaken such testing are listed
in the IChemE's book on the prevention of dust explosions. There is no legally defined test
for an explosible dust. However, for many years we have used a small-scale screening test,
the vertical tube test, described in HSG 1032. The issues about representative samples of
dust, and other factors that might cause the results to vary are also discussed in this
guidance. In general, dusts with a particle size greater than 500 µm are unlikely to cause an
explosion. For most chemical products it is preferable to test dust taken from the process,
but if the particle size distribution varies, it is common to test material that passes a 63-
micron sieve, and take this as the worst case.
Ignition due to a hot surface is possible, but the temperature needed to ignite a dust layer
depends on layer thickness and contact time. For COMAH sites with toxic dusts, the most
likely hazard would arise in drying processes, if substantial quantities were held for
extended periods hot enough to start self heating or smouldering combustion.
Status of Guidance
Existing codes of practice provide information with respect to good practice for hazardous
area classification. The standards detailing selection of appropriate electrical apparatus
have been updated to take into consideration ventilation effects.
European equipment standards may become 'harmonised' when a reference to them is

published in the Official Journal of the European Community. A list of ATEX harmonised
standards can be checked on the EU web site:
Equipment built to such a harmonised standard may assume automatic conformity with
those essential safety requirements of relevant directives that are covered by the standard.
The EPS regulations describe the conformity assessment procedures that apply to different
types of equipment.
Reference Documents
2 10/14
HS(G)512 Storage of flammable liquids in containers, HSE, 1998.
Appendix 3 describes the requirements for hazardous area classification. The use of
BS EN 60079-10: 2003 1, and the Institute of Petroleum Code 'Area Classification
Code for Petroleum Installations: Model Code of practice in the Petroleum Industry'
Part 15 are recommended. It suggests all drum stores should be zone 2, to a height
1m above the stack. The same advice appears in HSG 166 and HSG 113 on ignition
protected lift trucks. Discussions with industry on the relaxation of this in particular
circumstances are ongoing.
HS(G)71 2 Chemical warehousing: the storage of packaged dangerous substances,
HSE, 1998.
This contains very limited information on hazardous area classification or control of
ignition sources
HS(G)1032 Safe handling of combustible dusts: precautions against explosions, HSE,
2nd Edition, 2003
HS(G)1132 Lift trucks in potentially flammable atmospheres. The contents of this
have been overtaken to some degree by DSEAR, and the EPS regulations.
HS(G)1402 Safe use and handling of flammable liquids, HSE, 1996.
BS EN 60079-14 1 and the Institute of Petroleum Code 'Area Classification Code for
Petroleum Installations: Model Code of practice in the Petroleum Industry' Part 15
are recommended. This is aimed mainly at small scale handling, with containers of
200 litres or less.
HS(G)166 2 Formula for health and safety: guidance for small and medium sized
firms in the chemical industry, HSE, 1997.
The guidance describes the requirements for hazardous area classification, and gives
some typical examples. These should now be seen as rather conservative. The use of
BS EN 60079-14, BS EN 50281 and BS EN 605291 are recommended. This is basic
level guidance, and COMAH reports should normally reference more specific
publications, such as the other HSG series books listed, and other items in this list.
HS(G)176 2 The storage of flammable liquids in tanks, HSE, 1998.
Paragraphs 35 to 39 describe the requirements for hazardous area classification. This
cross references BS EN 60079-10: 20031, and the Institute of Petroleum Code 'Area
Classification Code for Petroleum Installations: Institute of Petroleum Model Code of
Safe Practice, part 15, area classification for installations handling flammable fluids,
2nd edition 2002.
2 11/14
HS(G)1862 The bulk transfer of dangerous liquids and gases between ship and shore,
HSE, 1999.
BS EN 60079-101 and the Institute of Petroleum Code 'Area Classification Code for
Petroleum Installations: Model Code of practice in the Petroleum Industry' Part 15
are recommended. Contains useful information about electrostatic hazards during
unloading.
LPGA COP 1 Bulk LPG storage at fixed installations. Part 1: Design, installation and
operation of vessels located above ground, LP Gas Association, 1998.
LPGA codes have not previously drawn a clear distinction between hazardous areas,
and separation distances required for other reasons. These are currently under
revision, and will specify hazardous areas, that in most cases will be smaller than the
separation distance. Current codes are listed on the UKLPG website.
Model Code of practice in the Petroleum Industry' Part 15 is recommended. The
guidance also recommends that zones be recorded in a plan to prevent sources of
ignition being brought in.
Electrical Equipment
Standards produced by Europe in the BS EN 50014 range are gradually being
superseded by international standards produced in the range BS IEC 600791.
Equipment built to older standards, including purely national standards may remain
in service, provided it is properly maintained. The IEC range of standards also
includes documents on selection, installation and maintenance of equipment for use
in explosive atmospheres.
Non-electrical equipment
The first standard for explosion protected non-electrical equipment is BS EN 13463
part 11. It describes requirements for "Category 3" equipment. Further parts of this
standard are well advanced and will appear during 2004.
BS EN 1127-1: 1998 1 Explosive atmospheres - Explosion prevention and protection -
Part 1: Basic concepts and methodology, British Standards Institution.
This gives additional general advice on the many of the issues covered in this TMD.
Electrostatic ignition risks
The most recent general source of advice was drafted by a European standards working
group, but was published in the UK as BS PD R044-001 and not as a full standard. It
contains much useful advice about limiting pumping speeds, electrostatic risks from
clothing, and many detailed operations. The two parts of the older BS 5958: 19911 Code of
Practice for the control of undesirable static electricity remain current, because they
contain some useful information not duplicated by the PD. The two parts are:
12/14
Part 1: 1991 General considerations;
Part 2: 1991 Recommendations for particular industrial situations
BS EN 50281 1. The different parts of this standard set out requirements for
construction of equipment for use in atmospheres containing explosive dusts;
information about selection and maintenance; and
BS EN 50281-3: 2002 1 covers the classification of areas where combustible dusts are
or may be present.
BS 6651:19991. Code of practice for protection of structures against lightning, British
Standards Institution.
Section 9 provides guidance on lightning protection of structures with inherent
explosive risks.
BS 7430:19981 Code of practice for earthing, British Standards Institution.
Lightning protection. Section 23 provides guidance on lightning protection.
Further Reading Material

Cox, A.W., Lees, F.P. and Ang, M.L., 'Classification of Hazardous Locations', 1993.
This was a study led by a consortium of the chemical, electrical and mechanical
engineering institutes, and showed how the subject spanned the traditional divides. It was
important in the development of ideas, but provides no new methodology for users.
A Guide to Safety in Aerosol Manufacture, BAMA, Third Edition, 1999.
Dust Explosion Prevention and Protection: A Practical Guide, IChemE, ISBN 0852954107
A practitioner's handbook - Electrical installation and maintenance in potentially explosive

atmospheres, Publication No. 186, The Engineering Equipment and Materials Users
Association.
References
1. For further information on the relevant British Standards, please access the British
Standards web site and use the search facility.
Page last updated: 22nd September 2004
See also
COMAH Strategic Forum
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ELECTRICAL RISK MANAGEMENT

• OISD Accident compilation (1996-1999):

–Out of the total 71 accidents (5 lakh property loss/fatality/loss of

–47% accidents happened during operational jobs

Is the above ‘accident cause’ grouping correct?

• Petroleum Rules, 1976

• An area shall be deemed to be a hazardous area, where:

COAL MININING SAFETY & CRUDE WAYS OF DETECTING

Why Area Classification?

• HAC is a method of analyzing and classifying the environment where

• Ignition sources not considered

• Leak Potential & Presence of Ignition Sources

• Hazardous properties of hydrocarbons

• Safe selection (& optimization) of Electrical Equipment

• How many Zones as per Indian standards?

• European & American classifications (Zones and Divisions)

• Why not ‘blanket’ zoning?

• Is the 4th Zone really a ‘safe’ zone?

• Who should do HAC-Electrical or Process Engineer?

HAC as per IS 5572 is not applicable for:

• Areas where ignitable dusts & fibers are present

• Ignition sources other than electrical apparatus

Zone 0 -Typical areas

– closed process vessels,

–areas containing open tanks of volatile, flammable liquid

How to identify Zone 1 areas (IS 5572) ?

• Flammable gas or vapour concentration is likely to exist in the air under

Zone 1 -Typical areas

• Imperfectly fitting peripheral seals on floating roof tanks

• Inadequately ventilated pump rooms for flammable gas or for volatile,

• Oily waste water sewer / basins

• Loading / unloading gantries of hazardous products

Typical Zone 2 areas (IS 5572) ?

• The flammable vapours can be conducted to the location as through trenches,

• Locations adjacent to Zone 1 areas

Safe Areas -Typical areas

• Areas where the piping system is without valves, fittings, flanges or

• Areas where flammable liquids or vapours are transported only in suitable

• DG shed room / shed having adequate ventillation

• GT installation meeting the ventilation (12 ACPH) , pressurization (0.5

• North America (NFPA / API/ NFPA 70E or NEC)

A FEW RELEVANT DEFENITIONS

• Explosive Limits (based on MIE)

HAZARDOUS AREA CLASSIFICATION-Guidelines

Factors to be considered (IS 5572)

• Vapour / Gas Density

• Effect of Air Current

• Identification of leak scenarios

• In the absence of walls, enclosures, etc. & air currents, vapour/gas

• Vapours / gas released(high density releases) at or near ground level, will

EFFECT OF AIR CURRENT

• Winds alter the shapes of hazardous areas

• But what are logically to be considered are the most unfavourable

HEAVIER-THAN-AIR GASES & VAPOURS

• Open -Air Situations (freely ventilated Process Areas)

–In case of petroleum pipelines (where well-maintained valves, fittings,

LIGHTER-THAN-AIR GASES & VAPOURS

–Vapour density of 0.75 is considered as the boundary between lighter

HA of a leak source located in air

How to classify areas?

• Mark in elevation and plan drawings

• Separate identification (hatching) for various zones

An experienced process engineer’s judgement