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Electrical Equipment in Hazardous Areas
Electrical Equipment in Hazardous Areas
Overview
A light switch may cause a small, harmless spark when switched on
or off. In an ordinary household this is of no concern, but if a
flammable atmosphere is present, the arc might start an explosion.
In many industrial, commercial, and scientific settings, the presence
of such an atmosphere is a common, or at least commonly possible, This inspection lamp is constructed
occurrence. Protecting against fire and explosion is of interest for so that it cannot set off an explosion
both personnel safety as well as reliability reasons. when surrounded by specified
flammable gases or dust.
Several protection strategies exist. The simplest is to minimize the
amount of electrical equipment installed in a hazardous location,
either by keeping the equipment out of the area altogether, or by making the area less hazardous (for
example, by process changes, or ventilation with clean air).
When equipment must be placed in a hazardous location, it can be designed to reduce the risk of fire or
explosion. Intrinsic safety designs equipment to operate using minimal energy, insufficient to cause ignition.
Explosion-proofing designs equipment to contain ignition hazards, prevent entry of hazardous substances,
and, contain any fire or explosion that could occur.
Different countries have approached the standardization and testing of equipment for hazardous areas in
different ways. Terminology for both hazards and protective measures can vary. Documentation
requirements likewise vary. As world trade becomes more globalized, international standards are slowly
converging, so that a wider range of acceptable techniques can be approved by national regulatory
agencies.
The process of determining the type and size of hazardous locations is called classification. Classification of
locations, testing and listing of equipment, and inspection of installation, is typically overseen by
governmental bodies. For example, in the US by the Occupational Safety and Health Administration.
Standards
North America
In the US, the independent National Fire Protection Association (NFPA) publishes several relevant
standards, and they are often adopted by government agencies. Guidance on assessment of hazards is given
in NFPA 497 (explosive gas) and NFPA 499 (dust). The American Petroleum Institute publishes analogous
standards in RP 500 and RP505.
NFPA 70, the National Electrical Code (NEC), defines area classification and installation principles.[1]
NEC article 500 describes the NEC Division classification system, while articles 505 and 506 describe the
NEC Zone classification system. The NEC Zone system was created to harmonize with IEC classification
system, and therefore reduce the complexity of management.
Canada has a similar system with CSA Group standard C22.1, the Canadian Electrical Code, which defines
area classification and installation principles. Two possible classifications are described, in Section 18
(Zones), and Appendix J (Divisions).
Often an area classification plan view is provided to identify equipment ratings and installation techniques
to be used for each classified area. The plan may contain the list of chemicals with their group and
temperature rating. The classification process requires the participation of operations, maintenance, safety,
electrical and instrumentation professionals; and the use of process diagrams, material flows, safety data
sheets, and other pertinent documents. Area classification documentations are reviewed and updated to
reflect process changes.
Explosive gas
Typical gas hazards are from hydrocarbon compounds, but hydrogen and ammonia are also common
industrial gases that are flammable.
Unclassified locations
Also known as non-hazardous or ordinary locations, these locations are determined to be
neither Class I, Division 1 or Division 2; Zone 0, Zone 1 or Zone 2; or any combination
thereof. Such areas include a residence or office where the only risk of a release of
explosive or flammable gas would be such things as the propellant in an aerosol spray.
The only explosive or flammable liquids are paint and brush cleaner. These are
designated as very low risk of causing an explosion and are more of a fire risk (although
gas explosions in residential buildings do occur). Unclassified locations on chemical and
other plant are present where it is absolutely certain that the hazardous gas is diluted to a
concentration below 25% of its lower flammability limit (or lower explosive limit (LEL)).
Explosive dust
Dust or other small particles suspended in air can explode.
NEC
Zone Description
Zone 20 ignitable concentrations of dust, fibers, or flyings are present for long periods of time
Zone 21 ignitable concentrations of dust, fibers, or flyings are likely to exist under normal conditions
Zone 22 ignitable concentrations of dust, fibers, or flyings unlikely to exist under normal conditions
Different explosive atmospheres have chemical properties that affect the likelihood and severity of an
explosion. Such properties include flame temperature, minimum ignition energy, upper and lower explosive
limits, and molecular weight. Empirical testing is done to determine parameters such as the maximum
experimental safe gap (MESG), minimum igniting current (MIC) ratio, explosion pressure and time to peak
pressure, spontaneous ignition temperature, and maximum rate of pressure rise. Every substance has a
differing combination of properties but it is found that they can be ranked into similar ranges, simplifying
the selection of equipment for hazardous areas.[4]
Flammability of combustible liquids are defined by their flash-point. The flash-point is the temperature at
which the material will generate sufficient quantity of vapor to form an ignitable mixture. The flash point
determines if an area needs to be classified. A material may have a relatively low autoignition temperature
yet if its flash-point is above the ambient temperature, then the area may not need to be classified.
Conversely if the same material is heated and handled above its flash-point, the area must be classified for
proper electrical system design, as it will then form an ignitable mixture.[5]
Each chemical gas or vapour used in industry is classified into a gas group.
NEC Division System gas & dust groups
A Acetylene
B Hydrogen
Class I, Divisions 1 & 2
C Ethylene
D Propane, methane
E (Division 1 only) Metal dusts, such as magnesium (Division 1 only)
Class II, Divisions 1 & 2 F Carbonaceous dusts, such as carbon & charcoal
Hydrogen
IIB+H2
(equivalent to NEC Class I, Group B)
Zone 0, 1 & 2
Ethylene
IIB
(equivalent to NEC Class I, Group C)
Propane
IIA
(equivalent to NEC Class I, Group D)
Group IIC is the most severe zone system gas group. Hazards in this group gas can be ignited very easily
indeed. Equipment marked as suitable for Group IIC is also suitable for IIB and IIA. Equipment marked as
suitable for IIB is also suitable for IIA but NOT for IIC. If equipment is marked, for example, Ex e II T4
then it is suitable for all subgroups IIA, IIB and IIC
A list must be drawn up of every explosive material that is on the refinery or chemical complex and
included in the site plan of the classified areas. The above groups are formed in order of how explosive the
material would be if it was ignited, with IIC being the most explosive zone system gas group and IIA being
the least. The groups also indicate how much energy is required to ignite the material by energy or thermal
effects, with IIA requiring the most energy and IIC the least for zone system gas groups.
Temperature
Equipment should be tested to ensure that it does not exceed 80% of the autoignition temperature of the
hazardous atmosphere. Both external and internal temperatures are taken into consideration. The
autoignition temperature is the lowest temperature at which the substance will ignite without an additional
heat or ignition source (at atmospheric pressure). This temperature is used for classification for industry and
technology applications.[6]
The temperature classification on the electrical equipment label will be one of the following (in degree
Celsius):
International Germany °C
USA °C
(IEC) °C Continuous - Short time
T1 - 450 T3A - 180 T1 - 450 G1: 360 - 400
The above table shows that the surface temperature of a piece of electrical equipment with a temperature
classification of T3 will not rise above 200 °C. The surface of a high pressure steam pipe may be above the
autoignition temperature of some fuel-air mixtures.
Equipment
Equipment can be designed or modified for safe operation in hazardous locations. The two general
approaches are:
Intrinsic safety
Intrinsic safety, also called non-incendive, limits the energy present in a system, such that
it is insufficient to ignite a hazardous atmosphere under any conditions. This includes low
both power levels, and low stored energy. Common with instrumentation.
Explosion proof
Explosion-proof or flame-proof equipment is sealed and rugged, such that it will not ignite
a hazardous atmosphere, despite any sparks or explosion within.[7][8]
Several techniques of flame-proofing exist, and they are often used in combination:
The equipment housing may be sealed to prevent entry of flammable gas or dust into the
interior.
The housing may be strong enough to contain and cool any combustion gases produced
internally.
Enclosures can be pressurized with clean air or inert gas, displacing any hazardous
substance.
Arc-producing elements can be isolated from the atmosphere, by encapsulation in resin,
immersion in oil, or similar.
Heat-producing elements can be designed to limit their maximum temperature below the
autoignition temperature of the material involved.
Controls can be fitted to detect dangerous concentrations of hazardous gas, or failure of
countermeasures. Upon detection, appropriate action is automatically taken, such as
removing power, or providing notification.
IEC 60079
Types of protection
Ex
Description Standard Location Use
code
Equipment construction is
such that it can withstand
an internal explosion and
provide relief of the
external pressure via
flamegap(s) such as the
labyrinth created by
threaded fittings or
machined flanges. The
escaping (hot) gases must
sufficiently cool down along
the escape path that by the
time they reach the outside Zone 1 if gas Motors, lighting,
IEC/EN
Flame proof d of the enclosure not to be a group & temp. junction boxes,
60079-1
source of ignition of the class correct electronics
outside, potentially
ignitable surroundings.
Equipment has
flameproof gaps (max
0.006" (150 μm)
propane/ethylene,
0.004" (100 μm)
acetylene/hydrogen)
Equipment components of
Zone 1 (Ex
the equipment are usually IEC/EN Electronics (no
Encapsulated m mb) or Zone 0
encased in a resin type 60079-18 heat)
(Ex ma)
material
Equipment can be
installed in ANY
housing provided to
IP54.
A 'Zener Barrier', opto-
isolator or galvanic
unit may be used to
assist with
certification.
A special standard for
IEC/EN
instrumentation is 60079-25
'ia': Zone 0 & Instrumentation,
Intrinsically safe i
IEC/EN 60079–27, IEC/EN
'ib': Zone 1 measurement,
describing 60079-11
'ic: zone 2 control
IEC/EN60079-
requirements for 27
Fieldbus Intrinsically
Safe Concept (FISCO)
(zone 0, 1 or 2) (This
special standard has
been withdrawn, and
has been partially
replaced by:
IEC/EN60079-
11:2011 and
IEC/EN60079-
25:2010)[1] (https://we
bstore.iec.ch/publicati
on/12946)
The types of protection are subdivided into several sub classes, linked to EPL: ma and mb, px, py and pz,
ia, ib and ic. The a subdivisions have the most stringent safety requirements, taking into account more than
one independent component faults simultaneously.
Many items of EEx rated equipment will employ more than one method of protection in different
components of the apparatus. These would be then labeled with each of the individual methods. For
example, a socket outlet labeled EEx'de' might have a case made to EEx 'e' and switches that are made to
EEx 'd'.
In recent years also the EPL is specified for several kinds of protection. The required protection level is
linked to the intended use in the zones described below:
Group Ex risk Zone EPL Minimum type of protection
I (mines) energized Ma
Equipment category
The equipment category indicates the level of protection offered by the equipment.
In the US, the National Electrical Manufacturers Association (NEMA) defines standards for enclosure
types for a variety of applications.[10][11] Some of these are specifically for hazardous locations:
NEMA
Definition
Type
7 Certified and labeled for use in indoor locations rated NEC Class I, Groups A, B, C, and D
Certified and labeled for use in locations rated NEC Class I, Groups A, B, C, and D; both indoors
8
and outdoors
9 Certified and labeled for use in locations rated NEC Class II, Groups E, F, or G
Meets the requirements of the Mine Safety and Health Administration (MSHA), 30 CFR Part 18
10
(1978)
Labeling
All equipment certified for use in hazardous areas must be labelled to show the type and level of protection
applied.
Europe
In Europe the label must show the CE mark and the code number of the certifying/notified body). The CE
mark is complemented with the Ex mark: A yellow-filled hexagon with the Greek letters εχ (epsilon chi),
followed by the Group, Category, and, if Group II, G or D (gas or dust). Specific types of protection being
used will also be marked.
Example markings
Mark Meaning
Australia and New Zealand use the same IEC-60079 standards (adopted as AS/NZS 60079), however the
CE mark is not required.
North America
In North America the suitability of equipment for the specific hazardous area must be tested by a Nationally
Recognized Testing Laboratory, such as UL, FM Global, CSA Group, or Intertek (ETL).
The label will always list the class, division and may list the group and temperature code. Directly adjacent
on the label one will find the mark of the listing agency.
Some manufacturers claim "suitability" or "built-to" hazardous areas in their technical literature, but in
effect lack the testing agency's certification and thus unacceptable for the AHJ (Authority Having
Jurisdiction) to permit operation of the electrical installation/system.
All equipment in Division 1 areas must have an approval label, but certain materials, such as rigid metallic
conduit, does not have a specific label indicating the Cl./Div.1 suitability and their listing as approved
method of installation in the NEC serves as the permission. Some equipment in Division 2 areas do not
require a specific label, such as standard 3 phase induction motors that do not contain normally arcing
components.
Also included in the marking are the manufacturers name or trademark and address, the apparatus type,
name and serial number, year of manufacture and any special conditions of use. The NEMA enclosure
rating or IP code may also be indicated, but it is usually independent of the Classified Area suitability.
History
With the advent of electric power, electricity was introduced into coal mines for signaling, illumination, and
motors. This was accompanied by electrically initiated explosions of flammable gas such as fire damp
(methane) and suspended coal dust.
At least two British mine explosions were attributed to an electric bell signal system. In this system, two
bare wires were run along the length of a drift, and any miner desiring to signal the surface would
momentarily touch the wires to each other or bridge the wires with a metal tool. The inductance of the
signal bell coils, combined with breaking of contacts by exposed metal surfaces, resulted in sparks, causing
an explosion.[12]
See also
Arc flash
ATEX directive
CompEx competency standard
Electrical conduit
Grounding kit
Intrinsic safety
Mineral-insulated copper-clad cable
Notified Body
Pressure piling
References
"Hazardous Location Motors" (https://www.dietzelectric.com/hazard-loc/). Dietz Electric.
Retrieved 2018-04-04.
1. "NFPA 70, National Electric Code" (https://www.nfpa.org/codes-and-standards/all-codes-and
-standards/list-of-codes-and-standards/detail?code=70). National Fire Protection
Association. Retrieved 2020-07-31.
2. IEC 60079:2020 SER Series - Explosive atmospheres - ALL PARTS (https://webstore.iec.c
h/publication/62417), International Electrotechnical Commission, 2020-06-26, retrieved
2020-07-31
3. "Hazardous Area Classification and Control of Ignition Sources" (https://www.hse.gov.uk/co
mah/sragtech/techmeasareaclas.htm). UK Health and Safety Executive. 22 September
2004. Retrieved 2020-08-01.
4. Bossert, John; Hurst, Randolph (1986). Hazardous Locations: A Guide for the Design,
Construction and Installation of Electrical Equipment. Toronto: Canadian Standards
Association. Chapter 9. ISBN 0-9690124-5-4.
5. Keith Lofland (2014-11-10), "Hazardous (Classified) Locations — NEC Articles 500 through
517" (https://web.archive.org/web/20170705001128/https://iaeimagazine.org/magazine/201
4/11/10/hazardous-classified-locations-nec-articles-500-through-517/), IAEI Magazine,
International Association of Electrical Inspectors, archived from the original (https://iaeimaga
zine.org/magazine/2014/11/10/hazardous-classified-locations-nec-articles-500-through-51
7/) on 2017-07-05, retrieved 2018-04-04
6. Autoignition temperature of liquid (https://web.archive.org/web/20160618030406/http://www.
ozm.cz/en/autoignition-temperature-of-liquid-ait-551/), OZM Research, archived from the
original (http://www.ozm.cz/en/autoignition-temperature-of-liquid-ait-551/) on 2016-06-18,
retrieved 2018-04-04
7. Explosion Proof & Flame Proof (https://www.intertek.com/hazardous-locations/protection-me
thods/flame-explosion-proof/), Intertek Group, retrieved 2020-07-31
8. "Explosionproof Equipment" (https://www.nfpa.org/codes-and-standards/all-codes-and-stand
ards/list-of-codes-and-standards/detail?code=70), National Electrical Code (2020 ed.),
National Fire Protection Association, chapter 1, article 100, part III, page 70-43, 2019-08-05,
retrieved 2020-07-31
9. "IEC 60079-27:2008 | IEC Webstore" (https://webstore.iec.ch/publication/12946).
10. NEMA Enclosure Types (https://www.nema.org/docs/default-source/products-document-libra
ry/nema-enclosure-types.pdf) (PDF), National Electrical Manufacturers Association,
November 2005, retrieved 2020-07-31
11. NEMA/IEC Enclosure Ratings (https://www.coleparmer.com/tech-article/nema-iec-enclosure
-ratings), Cole-Parmer, 2018-10-15, retrieved 2020-07-31
12. Bossert 86 page 17
Further reading
Alan McMillan, Electrical Installations in Hazardous Areas, Butterworth-Heineman 1998,
ISBN 0-7506-3768-4
Peter Schram Electrical Installations in Hazardous Locations, Jones and Bartlett, 1997,
ISBN 0-87765-423-9
EEMUA, A Practitioner's Handbook for potentially explosive atmospheres, The Engineering
Equipment and Materials Users Association, 2017, ISBN 978-0-85931-222-6