CHAPTER?

ELECTRICAL EQUIPMENT FOR NEC CLASS I LOCATIONS

A. General

Maximum safety can be obtained in a Div. 1 and Div. 2 hazardous area when
enclosures of electrical equipment for the areas are purged, pressurized or are
explosion proofed.
Without these types of enclosures, safety in a Div. 1 area is nonexistent. In
a Div. 2 area safety will exist, but only at a reduced level. The basis for the
reduced safety level in the Div. 2 hazardous area is the remote possibility of a
simultaneous failure of electrical equipment and process equipment. The risk that
both equipment will breakdown at the same time is sufficiently remote to consider
the Div. 2 area as an "acceptably safe" environment.
The question, however, is why bother with nonpurged, nonpressurized and
nonexplosion-proof electrical equipment when the application of the purged,
pressurized and explosion-proof electrical equipment provides the location with
greater safety? The reason for this is the high cost of the equipment.
Explosion-proof electrical equipment, for example, can cost 2 to 4 times
more than nonexplosion-proof electrical equipment. It is, therefore, more
economical to accept for the Div. 2 area a lower level of safety with electrical
equipment at low cost.

B. Electrical Equipment Required for A Div. 1 Location

Electrical equipment for a Div. 1 hazardous location must be approved for

NEC Class I, Div. 1. This means that the enclosures for the electrical equipment
must either be explosion proof, purged, or pressurized. For a great number of
electrical equipment it is far more practical and economical when individual
components of the electrical system be of the explosion-proof type rather than
having the enclosures purged or pressurized.
Approved for NEC Class I, Div. 1 also means that the electrical equipment
is not permitted to have a temperature exceeding the ignition temperature of the
involved flammable product. Nonarcing type devices of the heat producing type
such as transformers, relay coils, resistors, electric motors, etc. must also be ap-
proved for NEC Class I and also have a surface temperature that does not exceed
the ignition temperature of the flammable product. Temperatures not exceeding
the ignition temperature of a flammable product include temperatures from over-
load and locked rotor conditions from electrical motors in a NEC Class I, Div. 1
location.
 There are four different types of electrical motors that may be used in a NEC
Class I, Div. 1 location:
(1) An explosion-proof electrical motor approved for the
location with temperatures as indicated above.
(2) TEFC electric motors with positive pressure ventilation and
a surface temperature not exceeding 80% of the ignition
temperature of the flammable product involved.
(3) A TE inert gas filled motor also with a surface temperature
not exceeding 80% of the ignition temperature.
(4) A nonexplosion-proof electric motor designed to be
submerged in oil in which the oil is flammable only when
vaporized and mixed with air, or in a gas with a pressure
greater than the atmospheric pressure and which is
flammable when mixed with air..

The electric motors of items 2 and 3 must be provided with safeguards that
automatically shut down the motors or with a suitable alarm system if temper-
atures are exceeding the temperature limits as designed for the electric motors.

C. Electrical Equipment Required for A Div. 2 Location

If the location is classified Div. 2, the electrical equipment for the location
does not have to be approved for NEC Class I.
For example, arcing devices such as fuses, switches, circuit breakers,
controllers, push button stations, etc., do not have to be approved for an NEC
Class I location if their contacts are immersed in oil or enclosed in a hermetically
sealed chamber.
The current interrupting contacts of nonexplosion-proof electrical equipment
which are within hermetically sealed chambers do no allow flammable gases or
vapors to enter the sealed chambers. If the current interrupting contacts are
immersed in oil the oil level must be 2" minimum above the contacts for power
and 1" for control. The design of these types of equipment is such that under
normal operating conditions, both the hermetically sealed and oil immersed con-
tacts are not capable of igniting a flammable gas or vapor in the air. These types
of electrical equipment are permitted to use general purpose enclosures.
Nonarcing type devices, also devices of the heat producing type such as re-
sistors, control transformers, fixed lighting fixtures, etc., are also permitted in
general purpose enclosures or can be of the general purpose type if their temper-
atures do not exceed 80% of the ignition temperature of the flammable product
involved.
Arcing devices such as circuit breakers and fuses for protection of lighting
circuits and isolating switches may also be installed in general purpose enclosures
if they are not intended to interrupt currents by manual operation. The probability
that the fuses and circuit breakers will operate as a result of a fault current at the
same time that a hazardous condition exists must be considered remote. Because
of this, these types of arcing devices do not have to be explosion proof or have
their contacts immersed in oil or hermetically sealed.
Rotating electrical machinery in Div. 2 locations do not have to be approved
for Class I locations, unless they do contain arcing devices. Nonexplosion-proof
electric motors, and even open type motors, are permitted in a Div. 2 location as
long as they are not capable of igniting a flammable gas or vapor in the
atmosphere under normal operating conditions.
The application of nonexplosion-proof electrical motors without arcing
devices in a Div. 2 location is generally considered safe. The safety is based on
the fact that the motor, when it fails, may not fail at the same time as the failure
of process equipment, and vice versa. The chance that a nonexplosion-proof
electrical motor will fail simultaneously with the process equipment is considered
remote.
However, there are conditions in which the nonexplosion-proof electrical
motors in a Div. 2 location may become unsafe without its failure. For example,
if the motor under normal operating conditions should operate at a too high
temperature, the motor may become a source of ignition. The majority of electric
motors are provided with Class B insulation. However, electric motors may also
be provided with Class F or Class H insulation, allowing the motor to operate at
a higher temperature. If these motors with Class F or Class H insulation are
operating at a higher temperature and should be overloaded for too long a period
of time because the overload relays are set too high, or when these motors have
a long starting time or are started a number of times in quick succession,
excessive heat will develop in the motor. The temperature may rise considerably
and approach or exceed the ignition temperature of the flammable product. If the
electric motor should reach these elevated temperatures when a flammable gas or
vapor is in the air, and the ignition temperature of the flammable product is below
the elevated temperature of the motor, an explosion may result.
To avoid these possible conditions, it is necessary that during the purchase
of the electric motor, the motor manufacturer be informed about the involved
flammable products. It is vital that the motor manufacturer knows the explosion
features of the flammable product if he is to furnish a trouble-free motor. A
trouble-free motor is designed to produce a motor starting time, which includes
at least a safety margin of 20% in temperature and time. For example, if the
electric motor is used for pumping jet fuel JP-5 which has an ignition temperature
of 2040C and requires 6.0 seconds to accelerate from standstill to full speed at
rated voltage, the temperature in the motor under locked-rotor condition shall not
exceed 0.8 x 204 = 163.20C in not less that 1.25 x 6.0 = 7.5 seconds. Generally,
the time for the motor under locked-rotor conditions to reach 80% of the ignition
temperature is much longer than is required by the 20% margin. However, if the
actual time should be close to the 20% margin, the permitted temperature in the
motor should also be checked against this locked-rotor condition at reduced
voltage.
Unfortunately, not all overcurrent relays can be used for protection of electric
motors in a Div. 2 location. The induction disk-type overcurrent relays, for
example, do not provide adequate protection for electric motors in hazardous
locations. Frequent starting of a motor, for example, will not produce a
temperature rise in the induction disk-type relay. Therefore, only thermal type
overcurrent relays with a characteristic similar to that of the motor heating curve
are recommended for motors in hazardous locations. Care must be taken in
setting the overcurrent relay so that it does not operate prematurely under the
manufacturers allowable starts.
Nonexplosion-proof motors which are selected on the basis of temperature
restrictions will guarantee a higher degree of safety in the location than without
temperature restrictions, provided proper overload relays with proper settings are
used for motor protection.

D. Intrinsically Safe Electrical Equipment

Intrinsically safe electrical equipment and wiring may be used in a Div. 1

and Div. 2 hazardous location as long as they are approved for the location.
An approved intrinsically safe system is not capable of igniting a flammable
gas or vapor mixed with air.
In view of this, enclosures for intrinsically safe equipment and wiring do not
have to be explosion proof, purged or pressurized.

E. Marking of Electrical Equipment

Electrical equipment approved for a Class I, Div. 1 location shall be marked

to show the NEC Class (Class I, Class II, etc.), the grouping of the flammable
product (Group A, B, C, D) and the operating temperature of the electrical
equipment based on a 1040F ambient temperature. The temperature shall be
shown as an identification number which is listed in Table 500-3(b) of the NEC.
Electrical equipment does not have to have temperature markings if they are:
(1) Of the nonheat producing type such as conduits, boxes,
fittings, etc., or
(2) Of the heat producing type but with temperatures not
exceeding 2120F, or
(3) Of the general purpose type but approved for a Class I, Div.
2 location and do not constitute a source of ignition under
normal operating conditions.
 These types of electrical equipment do not have to be marked with a
"grouping" either. For example, an induction motor not being equipped with
arcing or heat producing devices does not have to be marked when located in a
Div. 2 area. Locked-rotor and overload conditions are not considered as heat
producing features that require temperature or group markings as long as the
electric motor is only used and designed for the Div. 2 location.

F. Construction of Explosion-Proof Enclosures

The construction of explosion-proof enclosures will prevent the flame of an

explosion within the enclosure from propagating to the outside of the enclosure.
This unique feature makes the hazardous location equipped with explosion-proof
electrical equipment completely safe. The explosion-proof enclosures must also
withstand the pressure of the internal explosion. Most manufacturers will follow
the UL Standards for explosion-proof electrical equipment which have been
developed on the basis of extensive laboratory tests. The UL is a non-profit
organization sponsored by the American Insurance Association. Its purpose is to
determine the safety of equipment and materials for use in hazardous locations and
to establish standards for the industry. The UL will subject the explosion-proof
electrical equipment and its materials to a series of tests with specific gas or vapor
mixtures over a range of flammable or explosive concentrations from which the
maximum explosion pressure that may occur in the enclosure is determined. The
clearance and the width of the points of the equipment are tested to make sure that
the flame or sparks in the enclosure are prevented from passing through to ignite
the surrounding atmosphere as shown in Fig. 1-23. The explosion-proof
electrical equipment must also operate at a low enough temperature so that the
atmosphere around it will not be ignited.
Explosion-proof enclosures are not supposed to be gas tight, nor are gaskets
permitted between the joints to make the enclosure watertight since this would
ruin its explosion-proof properties (except for ring-type gaskets which will be
blown out under explosion pressure). Because of this, the enclosures cannot be
prevented from breathing and when installed in an atmosphere saturated with a
flammable vapor mixture, this vapor mixture may, in time, enter the enclosure.
For this reason, the gas clearance and the width are of critical importance. Larger
clearances would require a larger joint width. A threaded joint shall be made up
with at least five threads, fully engaged, and the threads shall not exceed 20
threads per inch. The strength of the explosion-proof equipment depends upon
the group in which the enclosure is to be located.

G. Grouping of Electrical Equipment

Grouping of electrical equipment is only required when the equipment needs

to be explosion proof. Equipment that is not required to be explosion proof needs
no grouping. The basis for grouping of electrical equipment is the explosion
pressure that is created by the flammable product. Each flammable product has
its own specific explosion pressure. For example, acetylene can produce a
maximum pressure of 1140 lbs. per square inch (psi), hydrogen — 845 lbs. psi,
diethyl ether — 200 lbs. psi, and gasoline — 160 lbs. psi. By grouping the
various flammable products according to their explosion characteristics, the
maximum explosion pressure can be grouped also.
The NEC recognizes four groups of explosion pressures for Class I
flammable products as shown in Table 1-1A. The strength of the explosion-proof
equipment depends upon the group in which the enclosure is located. This means
that an enclosure must be designed to withstand the maximum pressure of an
internal explosion of a particular group without bursting and without loosening the
joints in the enclosure. The enclosure shall also withstand, without rupture or
permanent distortion, a hydrostatic test of four times the maximum internal
explosion pressure developed during the explosion test. Such hydrostatic tests
may be omitted where acceptable calculations indicate a safety factor of five for
the enclosing parts and bolts, based on the maximum pressure and the tensile
strength of the materials. In addition, joints must be wide enough and clearances
small enough so that flames will be quenched and will not propagate from the
interior of the enclosure to the atmosphere surrounding it. As a result of these
requirements, an explosion-proof enclosure that is designed for a particular group
may not be capable of withstanding the explosion pressure of another group. For
example, suppose an explosion-proof enclosure designed for Group D will be
used for a Group B atmosphere. The maximum explosion pressure that can occur
in a Group D enclosure is from gasoline which can develop 160 lbs. psi. The
enclosures for Group D must withstand 4 x 160 = 640 lbs. psi. If the B
atmosphere should contain hydrogen, the enclosure is subject to an explosion
pressure of 845 psi when the hydrogen entering the enclosure would be ignited.
The enclosure, then functioning as a hand grenade, could do considerable damage.
In view of the above, it is not recommended that an explosion-proof enclosure for
a given group be used in an atmosphere of another group, unless the explosion
pressure of the group in the atmosphere is less than that of the enclosure, or an
explosive mixture is not capable of entering an explosion-proof enclosure. If
group "B" enclosures are not commercially available, group "C" enclosures may
be used for gases or vapors of equivalent hazard to hydrogen such as ethylene
oxide, propylene oxide and acrylene and group "D" enclosures may be used for
butylene provided both ends of the enclosures are sealed by sealing fittings of a
size 1/2" or larger. Whether an explosive mixture is capable of entering an
enclosure depends mainly on the operating conditions of the flammable substance.
These operating conditions must be established when an area classification is
required.
 Much careful research has been done in various countries on the relationship
of turbulence and pressure buildup in electrical equipment. The explosion
pressure is greatly influenced by turbulence of the explosive mixture, resulting in
a higher explosion pressure. The speed at which the pressure is developed tends
to increase with the increase of turbulence. The internal explosion pressure of
motors when they are running is often more than twice as great as when they are
stationary because of the turbulence created by the moving rotor and internal fan.
Ignition of the flammable gas at one end of the motor, i.e., the fan end, forces
unexploded gas to the opposite end, causing an increase in pressure prior to
ignition. A similar condition would occur if two explosion-proof boxes connected
by a short piece of conduit are considered. If the gases in one box are ignited,
there is a rise in pressure in the other box caused by the compression of these
gases.
Excessively high explosion pressure can develop in long conduit runs and,
therefore, it is good practice to place a seal in the conduit run every 50 feet to
limit the explosion pressure.
 DOTTED LINES INDICATE THE SHAPE THAT
A RECTANGULAR ENCLOSURE STRIVES TO
ATTAIN DURING INTERNAL PRESSURE.

INTERNAL
PRESSURE

ONLY COOL GAS

COMES OUT
ONLY COOL GAS JOINT
COMES OUT CLEARANCE

HOT GAS IS
COOLING IN
HOT PASSING
FLAMMABLE THROUGH
GAS THREADS

HOT FLAMMABLE
WIDTH OF METAL GAS
TO METAL JOINT
THREADED JOINT

1. DURING AN EXPLOSION, THE ENCLOSURE SHALL PREVENT THE PASSAGE OF FLAME OR

SPARKS WHICH MAY IGNITE THE SURROUNDING ATMOSPHERE.

2. CONDUIT BOXES AND FITTINGS USED IN HAZARDOUS LOCATIONS, CLASS I, GROUPS A,

B, C AND D SHALL BE CAPABLE OF WITHSTANDING THE INTERNAL PRESSURE
RESULTING FROM EXPLOSION WITH A FACTOR OF SAFETY WITHOUT BURSTING AND
LOOSENING OF THE JOINTS IN THE CONDUIT BOX AND FITTINGS.

3. THE CONDUIT BOXES AND FITTINGS SHALL ALSO WITHSTAND RUPTURE OR

PERMANENT DISTORTION, A HYDROSTATIC TEST OF FOUR TIMES THE MAXIMUM
INTERIOR EXPLOSION PRESSURE DEVELOPED DURING EXPLOSION.

FIG. 1-23. DESIGN CRITERIA FOR CONSTRUCTING EXPLOSION-PROOF ENCLOSURES