Hazardous area classification systems & the types of protection techniques (linkedin.

com)

Hazardous area classification systems & the

types of protection techniques
What is a hazardous area?

When electrical equipment is used in, around, or near to an atmosphere that consists of any
concentrations of flammable gases/vapors, flammable liquids, combustible dust, ignitable fibers or
flyings, there is always a possibility or risk that a fire or explosion might occur.

To understand this topic, you first need to know a little bit about fire

Fire Triangle: The sides of the triangle represent the interdependent ingredients needed for fire
which are: heat, fuel and oxygen.

-The three elements must be present at the same time in order to produce fire. If anyone out of three
elements is absent, then the fire will not occur.

Heat: A heat source is responsible for the initial ignition of a fire. Example of the source of ignition:
open flames, hot surfaces, spark etc

Fuel/Flammable substance: A fire needs a fuel source in order to burn, Fuel is any kind of
combustible material like flammable gas (acetylene, hydrogen, methane), Liquid Fuel (Petrol/Diesel),
Solid fuel (Wood) etc

Oxygen: A fire needs oxygen to start and continue, source of oxygen: Air contains about 21 percent
oxygen, and most fires require at least 16 percent oxygen content to burn.

-Electrical/Electronic equipment such as motors, switches, relays & solenoids produce

significant amounts of heat, arcing and sparking during normal and abnormal operation, which
could cause a risk of fire or explosion where the explosive atmosphere is present

 In short electrical equipment acts as a source of ignition in the fire triangle.

 Type of ignition sources may present in electrical equipment:

1. Electrical arcs/ sparks due to short circuits, Spark at the time of switching.
 2. Hot surfaces of electrical equipment: Surfaces heated by coils, resistors, lamps

3. Mechanical sparks, etc.

-A household light switch may emit a small, harmless visible spark when switching. In an
ordinary atmosphere this arc is of no concern, but in surrounding if a flammable vapor is
present then the arc acts as a source of ignition & might start an explosion.

What is a hazardous area classification?

-The process of determining the type and size of these hazardous areas is called hazardous area
classification.

Type: hazardous material in the surrounding atmosphere, Hazardous material types like flammable
gas/Vapor, combustible dust or ignitable fiber

Size: Intensity or Concentration of hazardous material present in the atmosphere, means hazardous
material is continuously, intermittently or periodically present in the atmosphere

There are currently two Hazardous area classification systems which are

1. Class/Division classification system [NEC 500]

2. Zone classification system [IEC & ATEX] & [NEC 505]

-The above two systems are based on the regions where anyone system among the above two is
accepted

-The Class/Division system is used mainly in the United States & Canada which based on NEC 500
standards

-Whereas the rest of the world generally uses the Zone system which is based on IEC standards

-However, the United States and Canada are moving towards the Zone System which is based on NEC
505 standards

Depending on where in the world you work, you are likely following one of two
standards

1. International Electrotechnical Commission (IEC)

2. National Electrical Code/Canadian Electrical Code (NEC/CEC)

-IEC & NFPA (National Fire Protection Association) are an organization which prepare and publishes
standards which are used for safety in hazardous application applicable for electrical equipment
  Note: National Electrical Code (NEC) it is part of the National Fire Code series published
by the National Fire Protection Association (NFPA)

IEC and NEC/CEC Comparison

-IEC: Follows Zone classification system

-NEC/CEC: Follows Class/Division classification system

-IEC: The International Electrotechnical Commission (IEC) is an international standards

organization that prepares and publishes international standards for all electrical, electronic and
related technologies.

 Currently, 86 countries are IEC members while another 87 participate in the Affiliate
Country Program [There are 195 countries in the world]

 Today, the IEC is the world's leading international organization in its field, and its
standards are adopted as national standards by its members

 IEC standards are also being adopted by other certifying bodies such as BSI (United
Kingdom), CSA (Canada), UL & ANSI/INCITS (United States), SABS (South
Africa), SAI (Australia), SPC/GB (China) and DIN (Germany). IEC standards adopted by
other certifying bodies may have some noted differences from the original IEC standard.

-NEC: the National Electrical Code (NEC), or NFPA 70, is a regionally adoptable standard for the
safe installation of electrical wiring and equipment in the United States

-CEC: The Canadian Electrical Code, CE code, or CSA C22.1 is a standard published by the Canadian
Standards Association (CSA) pertaining to the installation and maintenance of electrical equipment
in Canada.

 Note: Technical requirements of the Canadian Electrical Code (CEC) are very similar to
those of the U.S. National Electrical Code (NEC). Specific differences still exist and
installations acceptable under one Code may not entirely comply with the other.

What is ATEX?

-ATEX is the name of the two Directives for controlling explosive environments used by the European
Union (EU), one Directive for the manufacturer and one Directive for the user of the equipment.

 ATEX generally follows the zone classification system

What is ATEX Certification?

-ATEX certification is a certification of equipment intended for use in potentially explosive

atmospheres in the European Union.

 It is a mandatory certification for all products to be sold across Europe

What is IECEx?
-IECEx is a certification given to electrical equipment by IEC for Explosive Atmospheres

Note: ATEX & IECEx is a certification & IEC, NEC/CEN are the reference standards which governs
safety for hazardous location

ATEX and IECEx differences

 ATEX and IECEx both describe the requirements for equipment intended for use in
hazardous areas.

 ATEX is only valid in the EU (European Union) and IECEx aims for global acceptance,
hence the IECEx certification is more widely recognized and accepted compared to ATEX
certification

 ATEX is drive by law and IECEx is driven by standards

 An ATEX Certificate does not confirm compliance with any particular Standard but for
IECEx has Full compliance to IEC International Standards is mandatory

 ATEX is legally required for all non-electrical and electrical equipment that is to be
used in hazardous locations. However, IECEx is only required for electrical equipment in
hazardous locations.

 ATEX and IECEx both use the same standards (example EN-IEC 60079), so in terms of
technical content, there is basically no difference. The Only visible difference is in
many cases the marking on the device.

What is FM (Factory Mutual), UL (Underwriters Laboratories) and CSA (Canadian Standards

Association)?

-Equipment intended for use in potentially explosive atmospheres in the United States must have
the specific mark of one of the NRTLs recognized to test and certify this type of equipment.

 Nationally Recognized Testing laboratory(NRTL): FM Approvals (FM), Underwriters

Laboratories(UL)

 What does this mean for you : If you’re purchasing any electrical equipment, which
you plan to use in hazardous locations or even in non-hazardous locations in the United
States, That equipment must be certified and marked by a recognized NRTL. Even if
your equipment meets hazardous locations requirements, if it doesn’t have an NRTL
mark [Any one of testing laboratories mark like FM (Factory mutual), UL (Underwriters
Laboratories)], if it doesn’t have an NRTL mark, you may find yourself subject to
penalties.

Overall summary for classification systems & their respective applicable standards

-IEC: Prepares and publishes international standards for all electrical equipment
-IECEx: Is certification given to electrical equipment by IEC for Explosive Atmospheres

-NEC / CEC: Regionally adoptable standard by countries USA / CANADA

-FM, UL, CSA Marks: FM & UL are the marks of laboratories FM Approvals (FM), Underwriters
Laboratories(UL) respectively which are approved by Nationally Recognized Testing laboratory(NRTL)
in the region North America, FM & UL belongs to USA & CSA belongs to Canada.

-ATEX: Is the name of the two Directives for controlling explosive environments used by the European
Union (EU)

-ATEX Certification: Is a certification of equipment intended for use in potentially explosive

atmospheres in the European Union

After you have gained the above, you can submit the test data and pay the fees for regional
approvals such as:

 INMETRO (Brazil)

 KOSHA (Korea)

 TR CU (Russia, Kazakhstan, and Belarus)

 NEPSI (China)
What is the PESO certification for India?

- The PESO certification or more precisely Petroleum and Explosive Safety Organization of
India registration describes the mandatory approval program for the oil and gas industry or machines
that work with gases that are used in the oil industry or that have to withstand very corrosive
environments.

Which products are covered by PESO?

-Electrical equipment that needs to withstand highly corrosive saltwater or very hot environments, fall
under it

-Generally speaking, all products that have IECEx or ATEX certification also need PESO in India.

What does CCOE stand for?

- The PESO certification was previously called the Chief Controller of Explosives (CCOE) examination
since 2010

Area classification systems

1) Class/Division classification system [NEC 500]: Class/Division system are classified according to
the Class, Division, and Group

 Class : Class I, Class II, Class III

 Division: Division 1, Division 2

 Group: Group A, B, C, D (Class I only) & Group E, F& G (Class II or Class III)

2) Zone classification system [IEC & ATEX] & [NEC 505]: Zone system is classified according to its
Zone which can be gas or dust, for gas & dust atmospheres electrical equipment is further divided
into Groups and Subgroups

For Gas:

 Zone: Zone 0, Zone 1, Zone 2

 Group: Group I, Group II (Subgroups: IIA, IIB & IIC)

For Dust:

 Zone: Zone 20, Zone 21, Zone 22

 Group: Group III (Subgroups: IIIA, IIIB & IIIC)

Let’s discuss in detail of each term from each area classification systems
Class/Division classification system:

Class: Classes define the type of explosive or ignitable substances or flammable and combustible
materials that are present in the atmosphere.

-Class I: locations are those in which flammable liquid, vapors and gases may be present

 Examples: Acetylene, Hydrogen, Ethylene, Natural Gas

 Typical Class I Locations: Petroleum refineries, plants which handling liquefied

petroleum gas or natural gas, Petrochemical companies

-Class II: locations are those in which combustible dust may be found.

 Example: charcoal & coke dust, combustible metal dust (magnesium), Dust particles of
flour, grain, wood, plastic.

 Typical Class II Locations: Grain elevators, flour and feed mills, Coal preparation plants,
Plants that manufacture, use, or store magnesium or aluminum powders.

-Class III: locations are those in which easily ignitable fibers or flying may be present

 Example: cotton lint

 Typical Class III Locations: Textile industry, cotton gins, flax processing plants.

Division: The Division defines the probability of the hazardous material being able to produce an
explosive based upon its presence.

-Division 1: The hazardous material has a high probability to produce an explosion due to the
presence of hazardous material continuously, intermittently or periodically under normal operating
conditions.

-Division 2: The hazardous material has a low probability to produce an explosion due to the
presence of hazardous material by unusual faulty operation under abnormal operating conditions.

 Note: Abnormal operating conditions: leak does occur in the system (like a leak in the
pipeline which flows hazardous material), rupture and breakage of the cylinder which
stores dangerous hazardous material

Group:

-The Group defines the type of hazardous material in the surrounding atmosphere

-Groups A, B, C & D are for gases (Class I only) while groups E, F & G are for dust and flying (Class II or
III)

-There are four characteristics of flammable gases that are critical to the design of electrical
equipment to be used in hazardous (classified) locations, these characteristics are:
  Maximum experimental safe gap (MESG)

 Minimum igniting current ratio (MIC ratio)

 Maximum explosion pressure

 Auto ignition temperature

-Maximum experimental safe gap (MESG) is a standardized measurement of how easily a gas flame
will pass through a narrow gap bordered by heat-absorbing metal.

 MESG is defined as the maximum gap between two flat surfaces, under specified test
conditions, that prevents ignition of a flammable gas/air mixture propagating from an
inner chamber through a 25-mm long path into a secondary (outer) chamber
 Note: Smaller the gap better the safety because explosive flame gets restricted/resist
the flow path of the explosive flame
-Minimum igniting current ratio (MIC ratio): The minimum ignition energy is important in the
design of a safe apparatus, which limits the energy that can be stored and released by any part of a
circuit to less than the minimum ignition energy of the gas or vapor that will be present in use.

 Note: lesser the MIC ratio of flammable substance then the energy required for that
substance to ignite is Minimum

- Maximum explosion pressure: The maximum explosion pressure is the peak pressure produced
inside an enclosure when the designated test gas/air mixture is ignited inside of it

 Note: If the explosion chamber is not designed to sustain maximum pressure applied by
the explosion of gases inside chamber then there may get chances of breakage of an
explosion protective chamber & escaping of flame from chamber to hazardous
environment
- Auto ignition temperature:

 The substance’s auto ignition temperature is the lowest temperature at which it will
burst into flame in the air, even without an external spark or other sources. This
parameter is important for all methods of protection.

 The auto ignition temperature, however, has no correlation to MESG or the MIC ratio for
example, hydrogen has both a very low MESG and MIC ratio, but has a very high auto
ignition temperature over +500 °C

Class I Groups:

The gas groups (Class 1), from A to D, contain gases with MESG values and MIC ratios that go from
smallest to largest.

-Group A: Atmospheres containing acetylene.

-Group B: Atmospheres containing flammable gas or vapor whose MESG is less than 0.45 mm or MIC
ratio is less than 0.40

 Typical gases include hydrogen, butadiene, ethylene oxide, propylene oxide.

-Group C: Atmospheres containing flammable gas or vapor whose MESG is greater than 0.45 mm but
less than or equal to 0.75 mm or MIC ratio is greater than 0.40 but less than or equal to 0.80

 Typical gases include ethyl ether, ethylene, acetaldehyde, and cyclopropane

-Group D: Atmospheres containing flammable gas or vapor whose MESG is greater than 0.75 mm or
MIC ration is greater than 0.80

 Typical gases include acetone, ammonia, benzene, butane, ethanol, gasoline, methane,
natural gas, naphtha, and propane

Class II & Class III Group:

-Group E: Atmospheres containing combustible Conductive metal dust, including aluminum,

magnesium

-Group F: Atmospheres containing combustible electrically Non-conductive carbonaceous dust, coal,

coke dust, carbon, and charcoal are examples of carbonaceous dust

-Group G: Atmospheres containing combustible dust not included in Group E or F, including flour,
grain, wood, plastic and chemicals.

Zone classification system:

Zone for Gases:

-Zone 0: the location involves flammable gases/vapors that are present continuously or present for
long periods of time.

 Typical Zone 0 Locations: locations inside tanks in which flammable or combustible

liquids, gases, or vapors are stored

-Zone 1: location involves flammable gases/vapors which are Likely to exist under normal operating
conditions or May exist frequently because of repair, maintenance operations, or leakage

Note: A Zone 0 & Zone 1 location, similar to Class I, Division 1 location

-Zone 2: location involves flammable gases/vapors which are not likely to occur in normal operation if
occur then only for a short period of time by unusual faulty operation under abnormal operating
conditions.

 Note: A Zone 2 location, similar to Class I, Division 2 location and have similar
definitions
Groups for Gases:

-The definition is similar to the definition given in class/Division systems

- Materials have been placed in groups based on their ignition temperatures and explosion pressures

-Group I: Electrical equipment intended for use in mines (for use underground) susceptible to
firedamp, a flammable mixture of gases naturally occurring in a mine

-Group II: Electrical equipment intended for use in places (for use above ground) with a potentially
explosive atmosphere, other than mines susceptible to firedamp

 The electrical apparatus of Group II may be subdivided according to the nature of the
potentially explosive atmosphere for which it is intended.

 The subdivision is based on the maximum experimental safe gap (MESG) for flame-proof
enclosures or the minimum ignition current (MIC) for intrinsically safe electrical
apparatus

 Group IIA : acetone, ammonia, ethyl alcohol, gasoline, methane, propane; Similar to
Group C of Class/Division System

 Group IIB : acetaldehyde, ethylene; Similar to Group C of Class/Division System

 Group IIC : acetylene, hydrogen; Similar to Group A & B of Class/Division System

Zone for Dust:

-Zone 20: a place in which an explosive dust atmosphere, in the form of a cloud of dust in the air, is
present continuously, or for long periods or frequently

 Typical Zone 20 Locations: hoppers, silos, filters, blenders, mills, dryers, bagging
equipment etc
-Zone 21: a place in which an explosive dust atmosphere, in the form of a cloud of dust in the air, is
likely to occur in normal operation occasionally

-Zone 22: area in which an explosive dust atmosphere, in the form of a cloud of combustible dust in
the air, is not likely to occur in normal operation but, if it does occur, will persist for a short period
only

Groups for Dust:

Group III: Equipment in dust explosion hazardous areas (Group III) is classified according to dust type.

 Group IIIA: Combustible flying (Cotton lint); Similar to Group G of Class/Division System

 Group IIIB: Non-conductive dust (charcoal, Coal dust); Similar to Group F of

Class/Division System

 Group IIIC: Conductive dust (aluminum, magnesium); Similar to Group E of

Class/Division System.
Protection Techniques and Methods as per [IEC & ATEX] & [NEC 505]
-An electrical enclosure is a cabinet for electrical or electronic equipment to
mount switches, knobs and displays and to prevent electrical shock to equipment users and protect
the contents(electrical equipment) from the environment.

-These enclosures are specially designed and tested to ensure it does not initiate an explosion, due
to arcing contacts or high surface temperature of equipment

- Several physical methods of protection are used.

 The apparatus may be designed to prevent entry dust and water into the interior of the
enclosure that is Weather-Proof Enclosure

 The apparatus may be strong enough to contain and cool any combustion gases
produced internally that is Explosion-Proof Enclosure

 Electrical devices may be designed so that they cannot produce a spark strong enough
or temperatures high enough to ignite a specified hazardous gas that is Intrinsically
Safe Enclosure

-Various types of protective techniques are applied to an enclosure to ensure safety in hazardous area
applications.

To reduce the risk of explosion, elimination of one or more of the components of the ignition
triangle is necessary, following protective techniques helps to reduce the risk of explosion.
-Flameproof “d”: Type of protection in which the parts which can ignite an explosive atmosphere are
placed in an ENCLOSURE which can withstand the pressure developed during an internal explosion of
an explosive mixture and which prevents the transmission of the explosion to the explosive
atmospheres surrounding the enclosure
  In the Class/Division System this protective technique is called Explosion Proof

-The terms ‘explosion proof’ and ‘flameproof’ are largely interchangeable. Although there are some
subtle differences which are

 Flameproof enclosures are individually tested at the factory at 1.5 times the maximum
pressures exerted in an explosion whereas Explosion proof enclosures are tested at 4
times the maximum pressures exerted in an explosion. Because of this, explosion proof
enclosures tend to have a heavier construction

 Explosion proof enclosures are used more often as a method of protection in North
America (Class/Division System). Flameproof protection is used on projects with IEC
standards (Zone systems).

 Note: This technique applied to the enclosure which contains electrical equipment inside
it

-Intrinsic Safety “i”: Intrinsic safety (IS) is a protection technique applied to electrical equipment for
use in hazardous areas by limiting/reducing the electrical spark and thermal energy which is available
for ignition in electrical equipment in both normal & abnormal operating conditions

 Intrinsically safe equipment: equipment and wiring which is incapable of releasing

sufficient electrical or thermal energy under normal or abnormal conditions to cause
ignition of a specific hazardous atmospheric mixture in its most easily ignited
concentration

 Note: This technique is directly applies to electrical equipment which limits the
maximum amount of voltage & current by using Zener Diodes to limit voltage &
Resistors to limit current

-Increased Safety “e”: Type of protection applied to Electrical Equipment (Which place in the
enclosure) this electrical equipment does not produce arcs or sparks in normal service and under
specified abnormal conditions, in which additional measures are applied so as to give increased
security against the possibility of excessive temperatures and of the occurrence of arcs and sparks.

 Note: This technique is directly applied to electrical equipment by the electrical

equipment is assembled very carefully to ensure that arcing or sparking from part to
part or connection to connection of electrical equipment will not occur
-Encapsulation “m”: Type of protection where electrical parts that could ignite an explosive
atmosphere by either sparking or heating are enclosed in a compound (Resin) in such a way that
resin offer resistance to sparking or heating of electrical parts & separate sparking/heating from the
explosive atmosphere so that explosive atmosphere cannot be ignited.

 Note: This technique is applied around the electrical equipment by using of resin which
physically separates or isolate the electrical parts or hot surfaces from the explosive
mixture

-Oil Immersion “o”: Type of protection where electrical equipment is immersed in a protective liquid
in such a way that an explosive atmosphere that may be above the liquid or outside the enclosure
cannot be ignited.

 Note: all electrical parts are submersed in either nonflammable or low-flammability oil,
which prevents the external atmosphere from contacting the electrical components. The
oil often serves also as a coolant

-Powder Filling “q”: This protection method is similar to the oil-immersion method of protection,
except that the segregation is accomplished by filling the enclosure with powdered material so that an
arc generated inside the enclosure will not result in the ignition of the dangerous atmosphere
  Note: The filling material that is generally used is glass or quartz powder

-Pressurization “p”: Type of protection in which the protective inert gas inside the enclosure is
maintained at a higher pressure than that of the surrounding atmosphere

 Note: This method does not allow the dangerous hazardous mixture to penetrate the
enclosure containing electrical parts that can generate sparks or dangerous
temperatures

-Type of Protection “n”: Type of protection where electrical equipment, in normal operation, is not
capable of igniting a surrounding explosive gas atmosphere and a fault capable of causing ignition is
not likely to occur

 There are four categories of equipment

1. “nA” : non-Sparking

2. “nC” : enclosed break

3. “nR” : restricted breathing

4. “nL” : limited energy

 In the Class/Division System this protective technique is called Non-incendive

Non incendive and intrinsic safety protection methods are both based on the prevention concept.
However, for the non incendive approach, the device or circuit is not evaluated for safety under fault
(Abnormal) conditions. As a result, energy surges, equipment faults and static electricity are not
addressed. For this reason, non incendive devices are not approved for Division 1(Zone 0 & Zone 1)
Temperature Classification

Why Temperature Class is important:

 A mixture of hazardous gases & air may be ignited by coming into contact with the
external hot surface of the product.

 If a flammable mixture of the gas is exposed to a component above the auto-ignition

temperature of hazardous gas then the mixture will ignite

- The T code of a product denotes the maximum surface temperature that a given product will not
exceed under a specified ambient temperature

 Example : A product with a T code of T3 means that its maximum surface temperature
will not exceed 200C

 Therefore, when selecting equipment, the Temperature class must be below the auto-
ignition temperature of the potentially explosive atmosphere where it will be installed.
-As can be seen from the Temperature Classes table above; a T6 certification allows a maximum
permissible surface temperature of 85°C therefore a T6 instrument can be used in T5, T4, T3, T2 and
T1 environments.
Marking & Meaning of each classification systems
The information contained in this article is intended for general information which I tried to
cover a broad overview of the hazardous area classifications systems and the types of
protection techniques involved. The information provided is for educational purposes and
should not be used as a reference document.

Regards ,

Rahul kamlakar Patil (Email Id : rahulpatil1721@gmail.com)

Valve Application Engineer at Dembla valves Ltd. ( INDIA )