TRAINING WORKSHOP

ON
SELECTION OF ELECTRICAL EQUIPMENT IN
CLASSIFIED HAZARDOUS AREA

BY
ENGINEERS INDIA LTD.

DATE : 2nd SEPTEMBER, 2021

VENUE : Virtual through WebEx

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 SELECTION OF ELECTRICAL EQUIPMENT
IN
CLASSIFIED HAZARDOUS AREA

1.0 Introduction

Many liquids, gases and vapours which are generated, processed, handled and stored
in industry are combustible when mixed with air in the appropriate proportions, and
when suitably ignited, these may burn readily and generate considerable explosive
force. With regard to electrical installations, potential ignition sources include arcs,
sparks or hot surfaces produced either in normal operation or under specified fault
conditions.

Electrical technology plays a decisive role in the rational, reliable and safe operation of
the industrial plants. In oil & gas industry, there is a major responsibility for safe
operation & safe shutdown of plant in view of the fact that certain Electrical equipment
produce sparks during normal/ abnormal operation and also the failure of any Electrical
equipment can be a source of ignition which may ignite the flammable liquids, gases or
vapours. Accordingly, it is essential that appropriate measures are taken in order to
eliminate/ reduce the likelihood of an explosive gas atmosphere occurring around the
source of ignition along with the measures aimed at eliminating / reducing the source of
ignition so that the probability of co-incidence is so small as to be acceptable.

It is recognized that when electrical equipment is to be installed in or around hazardous

areas, it is possible by taking suitable care in the layout of the installation to locate
much of the electrical equipment in less hazardous or non-hazardous areas, and thus
reduce the quantum of special equipment required.

Several Indian standards for electrical equipment for explosive atmospheres have been
published. Some of these standards deal with particular construction techniques while
others with aspects of standardisation which are relevant to more than one technique.

2.0 Selection of Electrical Equipment for Hazardous Atmospheres

The selection of electrical apparatus for explosive gas atmospheres is based on the
general principle that the likelihood of the simultaneous presence of a hazardous
atmosphere and a source of ignition is reduced to an acceptably low level.

When the electrical apparatus does not have an internal release of flammable material,
the classification of the hazardous area surrounding the electrical equipment allows the
selection of an adequate type of protection.

When the electrical apparatus has an internal release of flammable material, the actual
hazard is a combination of the external and internal hazards and both must be taken
into account when selecting an adequate type of protection.

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 The selected apparatus will normally have a recognised type of protection and should
also be selected for the appropriate temperature class and the appropriate apparatus
group wherever applicable. Where gases of different degrees of hazard exist in the
same area, the type of protection appropriate for the highest degree of hazard shall be
applied.

The selected electrical apparatus shall be adequately protected against corrosive and
solvent agents and against water ingress and thermal and mechanical stresses as
determined by the environmental conditions. These construction requirements should
ensure that the protection against explosion is not reduced when the apparatus is used
in the specified conditions of service.

As electrical apparatus for flammable gas atmospheres require special safety

maintenance after they are installed, the selection of electrical apparatus shall be made
with full consideration to the facility and frequency of inspection and maintenance
facilities, provision for spares and repairing materials and the extent of interruption of
power supply during maintenance work.

It is advisable that the selection of electrical apparatus be made after giving full
consideration to not only the initial cost of installation but also the expected life and
expenses for operation and maintenance of the apparatus.

Electrical equipment for use in hazardous areas, including imported equipment, shall
be approved by statutory bodies, i.e. PESO or DGMS as applicable.

The increasing number of types of protection which are becoming available to ensure
the safe operation of apparatus and the principles of apparatus grouping and
temperature classification have all resulted in proper marking requirements which are
covered in the published standards for electrical equipment for hazardous areas.

All electrical equipment intended for use in hazardous areas shall be certified by a
recognized testing agency and shall be approved by the concerned statutory authority
for use in flammable atmospheres under its jurisdiction. Imported equipment for such
use shall also be approved by the concerned statutory authority in India. All indigenous
flameproof electrical equipment require BIS License as per statutory requirements.

3.0 Electrical Equipment Selection Procedure

In order to select the appropriate electrical equipment for hazardous areas, the
following information is required:

Classification of the hazardous area according to Zone

- Temperature class or ignition temperature of the Gas or Vapour or Combustible Dust

involved

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 - Where applicable, Gas or Vapour or Combustible Dust classification in relation to the
Group or Subgroup of the Electrical equipment and

- External influences and ambient temperature.

Apparatus certified to the constructional and design requirements for a particular group
may also be used with compounds of lesser risk which correspond to a lesser group,
subject again to consideration of temperature classification and chemical compatibility.
Similarly, electrical apparatus which is designed so that it may be used with certain
flammable materials in a particular zone may also be used with flammable materials in
a zone of lesser risk without restriction provided it is determined that the flammable
materials likely to be present are compatible with the following characteristics of the
apparatus:

- Apparatus grouping (where this is applicable)

- Temperature classification, and

- Chemical compatibility

4.0 Equipment Protection level (EPL)

Level of protection assigned to equipment based on its likelihood of becoming a source

of ignition and distinguishing the differences between explosive gas atmospheres,
explosive dust atmospheres, and the explosive atmospheres in mines susceptible to
firedamp.

4.1 EPL a:

Equipment has very high level of protection and thus a very high degree of safety. Such
equipment is not a source of ignition in normal operation, expected malfunction or when
subject to rare malfunction. Such equipment will have a form of protection which will
remain effective even in the presence of two potential faults (for example, intrinsic
safety level of protection ia) or will have two independent means of protection (for
example Ex’e’ & Ex’d’ acting independently of each other.

4.2 EPL b:

Equipment has high level of protection and therefore a high degree of safety. Such
equipment is not a source of ignition in normal operation or when subject to faults that
may be expected, though not necessarily on a regular basis.

4.3 EPL c:

Equipment has normal level of protection and therefore a conventional degree of

safety. Such equipment is not a source of ignition in normal operation and which may
have some additional protection to ensure that it remains inactive as an ignition source
in the case of regular expected occurrences.

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5.0 Selection According to Zones

Hazardous Gas / Vapor

Zone Default EPL Permitted Equipment EPL

0 Ga Ga

1 Gb Ga or Gb

2 Gc Ga or Gb or Gc

Combustible Dust

Zone Default EPL Permitted Equipment EPL

20 Da Da

21 Db Da or Db

22 Dc Da or Db or Dc

5.1 Equipment for Use in Zone 0

Electrical equipment and circuits can be used in Zone 0 if they are constructed in
accordance with following:

EPL ‘Ga’

(i) Intrinsic safety (category ‘ia’) according to IS/ IEC 60079-11

(ii) Encapsulation (category ‘im’) according to IS/ IEC 60079-18
(iii) Two independent type of protection each meeting ‘Gb’ according to IS/ IEC
60079-26
(iv) Special Protection (category ‘sa’) according to IS/ IEC 60079-33

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5.2 Equipment for Use in Zone 1

Electrical equipment can be used in Zone 1 if it is constructed in accordance with the

requirements for zone 0 or one or more of the following types of protection:

EPL ‘Gb’

i) Flameproof enclosures ‘d’ according to IS/ IEC 60079-1

ii) Pressurised enclosures ‘p’, ‘px’, ‘py’ according to IS/ IEC 60079-2
iii) Increased Safety ‘e’ according to IS/ IEC 60079-7
iv) Powder filling ‘q’ according to IS/ IEC 60079-5
v) Oil immersion ‘o’ according to IS/ IEC 60079-6
vi) Intrinsic safety ‘ib’ according to IS/ IEC 60079-11
vii) Encapsulation ‘m’, ‘mb’ according to IS/ IEC 60079-18
viii) Special Protection ‘sb’ according to IS/ IEC 60079-33

5.3 Equipment for Use in Zone 2

Electrical equipment can be used in Zone 2 if it is constructed in accordance with the

requirements for Zone 0 / Zone 1 or one or more of the following types of protection:

EPL ‘Gc’

i) Non sparking ‘n’ or ‘nA’ according to IS/ IEC 60079-15

ii) Restricted Breathing ‘nR’ according to IS/ IEC 60079-15
iii) Energy Limitation ‘nL’ according to IS/ IEC 60079-15
iv) Sparking Equipment ‘nC’ according to IS/ IEC 60079-15
v) Pressurised Enclosure ‘pz’ according to IS/ IEC 60079-2
vi) Special Protection ‘sc’ according to IS/ IEC 60079-33
vii) Intrinsic safety ‘ic’ according to IS/ IEC 60079-11
viii) Encapsulation ‘m’, ‘mc’ according to IS/ IEC 60079-18
ix) Electrical heat tracers and equipment, which are certified for use in zone 2 areas
according to IS/ IEC 60079-30

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5.4 Equipment for Use in Combustible Dust Atmosphere

EPL Type of Protection Code

Encapsulation “ma”

“Da” Protection by enclosure “ta”

Intrinsically Safe “ia” or “iaD”

Encapsulation “mb”

Protection by enclosure “tb” or “tD”

“Db”
Pressurized enclosures “pD”

Intrinsically Safe “ib” or “ibD”

Encapsulation “mc”

Protection by enclosure “tc” or “tD”

“Dc”
Pressurized enclosures “pD”

Intrinsically Safe “ic”

6.0 Selection According to the Ignition Temperature of the Gas or Vapour or

Combustible Dust and Ambient Temperature

The electrical equipment shall be so selected that its maximum surface temperature will
not reach the ignition temperature of any gas or vapour of Combustible Dust which may
be present. Symbols for the temperature classes which may be marked on the
electrical equipment have the meaning indicated in Table below:

Relationship between Gas or Vapour or Combustible Dust, Ignition Temp. & Temp.
Class of Equipment

Sl. Temperature Class Ignition Temperature Allowable

No. Required by the Area of Gas or Vapour or Temperature Class
Classification Combustible Dust (°C) of Equipment
i. T1 >450 T1-T6
ii. T2 >300 T2-T6
iii. T3 >200 T3-T6
iv. T4 >135 T4-T6
v T5 >100 T5-T6
vi T6 >85 T6

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 The electrical apparatus shall be used within the limits of ambient temperature for
which it is designed. If the marking of the apparatus does not include an ambient
temperature range, the apparatus shall be used only within the ambient temperature
range from -20°C to +40°C.

If the marking of the apparatus includes an ambient temperature range, this apparatus
shall be used only within the specified range.

Temperature limitations for DUST CLOUDS

The maximum surface temperature of equipment shall not exceed two-third of the
minimum ignition temperature of the dust/air mixture:

Tmax ≤ 2/3 TCL

where TCL is the minimum ignition temperature of the cloud of dust.

Temperature limitations for DUST LAYERS

The maximum surface temperature of equipment shall not exceed a value of 75º C
below the minimum ignition temperature for the 5 mm thick layer of the dust:

Tmax ≤ T5 mm – 75º C

where T5 mm is the minimum ignition temperature of the 5 mm layer of dust.

7.0 Selection According to Apparatus Grouping

Electrical equipment of types of protection ‘e’, ‘m’, ‘p’ and ‘q’ shall be of equipment
group II.

Electrical equipment of types of protection ‘d’ and ‘i’ shall be of equipment group IIA,
IIB or IIC and selected in accordance with Table below.

Electrical equipment of type of protection ‘n’ shall normally be of equipment group II

but, if it contains enclosed break devices, non-incendive components or energy limited
apparatus or circuits, then the equipment shall be group IIA, IIB or IIC and selected in
accordance with Table below.

Electrical equipment of type of protection ‘o’ shall be of equipment group IIA, IIB or IIC
for certain equipment and selected in accordance with Table below:

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 Relationship between Gas/ Vapour Subdivision & Apparatus Subgroup

Sl No. Location Gas/ Vapour Permitted Apparatus Group or

Subdivision Subgroup

i. IIA II, IIA, IIB or IIC

ii. IIB II, IIB or IIC
iii. IIC II or IIC

Relationship between Combustible Dust & Typical Substance

Sl No. Combustible Dust Group Typical Substance

i. IIIA Combustible Fibers & Flyings

ii. IIIB Combustible Dust – Non Conductive
iii. IIIC Combustible Dust – Conductive

8.0 External Influences

Electrical equipment shall be selected and installed so that it is protected against

external influences (for example, chemical, mechanical, vibrational, thermal, electrical
and humidity), which could adversely affect the explosion protection. Precautions shall
be taken, without affecting designed ventilation conditions, to prevent foreign bodies
falling vertically into the ventilation openings of vertical rotating electrical machines.
The integrity of electrical equipment may be affected, if it is operated under
temperature or pressure conditions outside those for which the equipment has been
constructed.

9.0 Codes & Standards:

Following Indian Standards are in vogue for Hazardous Area Classification and
Selection of Electrical Equipment in Hazardous Area

IS No. Title
IS 16724 Explosive Atmospheres – Electrical Installations
Design, Selection & Erection
IEC 60079-14
IS 5572 Classification of hazardous areas (other than mines)
having flammable gases and vapours for electrical

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 IS No. Title
installation
IS/ IEC 60079-0 Explosive Atmospheres – General Requirements
IS/ IEC 60079-1 Explosive Atmospheres - Equipment Protection by
Flameproof Enclosures "d"
IS/ IEC 60079-2 Explosive Atmospheres- Equipment Protection by
Pressurized Enclosure "p"
IS/ IEC 60079-26 Explosive Atmospheres - Equipment With Equipment
Protection Level (EPL) "Ga"
IS/ IEC 60079-27 Explosive Atmospheres - Fieldbus Intrinsically Safe
Concept (FISCO)
IS/ IEC 60079-5 Explosive Atmospheres - Equipment Protection by
Powder Filling "q"
IS/ IEC 60079-6 Explosive Atmospheres - Equipment Protection by Oil
Immersion "o"
IS/ IEC 60079-7 Explosive Atmospheres - Equipment Protection by
Increased Safety "e"
IS/ IEC 60079-11 Explosive Atmospheres - Equipment Protection by
Intrinsic Safety "i"
IS/ IEC 60079-15 Explosive Atmospheres - Equipment Protection by type
of Protection "N"
IS/ IEC 60079-17 Explosive Atmospheres - Part 17 Electrical Installations
Inspection and Maintenance
IS/ IEC 60079-18 Explosive Atmospheres - Equipment Protection By
Encapsulation "m"
IS/ IEC 60079-19 Explosive atmospheres – Equipment Repair, Overhaul
and Reclamation
IS/ IEC60079-20 Explosive Atmospheres - Equipment Protection by
Intrinsic Safety "i"
IS/ IEC 60079-25 Explosive Atmospheres - Intrinsically Safe Electrical
Systems
IS/ IEC 60079-28 Explosive Atmospheres - Protection of Equipment and
Transmission Systems Using Optical Radiation
IS/ IEC 60079-29 Explosive Atmospheres - Gas Detectors
IS/ IEC 60079-30 Explosive Atmospheres – Electrical Resistance Trace
Heating
IS/ IEC 60079-31 Explosives Atmospheres - Equipment Dust Ignition
Protection By Enclosure "t"
IS/ IEC 61241-11 Electrical apparatus for use in the presence of
combustible dust – Protection by Intrinsic Safety “ID”
IS/ IEC 61241-14 Electrical apparatus for use in the presence of
combustible dust – Selection and Installation

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 Oil Industry Safety Directorate (OISD) has published following standards on the
subject:

OISD-STD-113 Classification of areas for electrical installations at

hydrocarbon processing and handling facilities
OISD-RP-149 Design aspects for safety in electrical systems

10.0 Certification and Approval

All hazardous area classification drawings and electrical equipment for installation in
hazardous area require approval from statutory authorities for the area under their
jurisdiction. The statutory authorities at present are:

a) Chief Controller of Explosives, Petroleum and Explosives Safety Organisation

(PESO), Nagpur.

b) The Directorate General of Mines Safety (DGMS), Dhanbad. (For mining areas)

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Typical Ex Marking of Equipment

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