Hazardous Area Classification

Basic Concepts
 Course Outline
Module 1 Module 2
Basic Concepts Case Study – Possible issues
Codes and Standards Dusts and Mists
Classification Methods Equipment Protection
Exercises Certification & Marking
Quiz Exercises

Reference Material
Ref 1 - Practical Hazardous Areas
Ref 2 – Overview of API 500
Ref 3 - ATEX Notes
Ref 4 – HAC Comparison IEC and NEC
 BASIC CONCEPTS
 Definitions
 Flammable and Combustible Liquids
 Combustion Properties
o Flash Point
o Ignition Temperature
o Flammable limits

 Fire Triangle
 Sources of Ignition
 Ventilation
 Hazardous Area

A Hazardous Area is “an area in which an explosive gas atmosphere is present

or may be expected to be present in quantities such as to require special
precautions for the construction, installation and use of equipment”.

Hazardous Area Classification (HAC) comprises the following steps:

• Identify and record those materials that are deemed flammable
• Identify the plant areas where materials are stored, handled or processed
• Identify where there is a possibility that an atmosphere could exist that could
cause an explosion or fire.
• Apply HAC to each separate area and / or source of release
 Definition of Flammable and Combustible
Flammable liquids are defined in NFPA 30 as :
“Any liquid that has a closed-cup flash point below 100 deg F
(37.8 deg C),
and
Its vapour pressure does not exceed an absolute pressure of
40 psi (276 kPa) at 100 deg F (37.8 deg C)”

Combustible liquids are defined as:

“Any liquid that has a closed-cup flash point at or above 100
deg F (37.8 deg C).
 Combustible v. Flammable (1/2)
Hazardous (Classified) locations are produced by the handling,
storage, or processing of flammable gases, liquids, or vapours
and combustible liquids or liquid produced vapours.

The higher the liquid vapour pressure, the more volatile the
liquid. Thus, the more likely a liquid will give off vapours.

Volatile liquids, such as propane and butane, have a high

vapour pressure at normal atmospheric conditions and have a
low boiling point.

Heating a combustible liquid above its flash point will result in

the creation of an ignitable vapour and air mixture.
 Combustible v. Flammable (2/2)

Flammable gases, liquids, or vapours require more caution than

combustible liquids when specifying electrical equipment in
locations involving handling, processing, storage or transfer.

That is because their physical characteristics, such as flash point,

vapour pressure, and boiling point occur at temperatures below
100 F (37.80 C).

Combustible liquids can be equally as dangerous as flammable

liquids, if heated above their flash point or boiling point.
 
 Flash Point and Flammable Limits
A liquid’s flash point is defined as :
“The minimum temperature of a liquid at which a sufficient
vapour is given off to form an ignitable mixture with the air.
Ignition Temperature (or auto-ignition temperature)
The minimum temperature at which a flammable vapour will
ignite by heat alone.
Flammable (Explosive) Limits are defined in NFPA 30, Paragraph
3.3.37 as:
• Lower Flammable (Explosive) Limit as the concentration of a flammable
vapour in air below which ignition will not occur.
• Upper Flammable (Explosive) Limit is defined as the concentration of a
flammable vapour in air above which ignition will not occur.
Flash Point and Ignition Temperature
Auto-Ignition Temperature
Flammability Limits
 Understanding how liquids burn

 Liquids do not burn. It is the vapour from the liquid that burns.
 So, the liquid has to produce vapour and it has to be above a
minimum concentration in the air, called the Lower Explosive
Limit (LEL), to burn or explode.
 The amount of vapour produced depends on the liquid
temperature. The Flash Point is the minimum temperature
which produces just enough vapour to reach the LEL.
 Combustion does not occur if the vapour concentration in air is
above a maximum, called the Upper Explosive Limit. This can
happen in enclosed tanks and vessels, even if they are vented.
 Flammability Class
Flammable liquids are sub-classified in NFPA 497-2012,
Section 3.3.6 as :
 
Class IA – Flash Point below 22.8 deg C and Boiling Point
below 37.8 deg C.
Class IB – Flash Point below 22.8 deg C and Boiling Point
above 37.8 deg C.
Class IC - Flash Point above 22.8 deg C but Boiling Point
below 37.8 deg C.

Some liquids are mixtures of different compounds. The

individual chemicals should be identified. The compound
with the worst properties determines the classification.
 Combustible Liquids
Combustible liquids are characterized as Class II and Class III.
Class II combustible liquids have a low vapour release at normal
ambient temperatures. Their vapours cool and condense,
limiting the dispersion area of the vapours.
Combustible liquids are typically handled or stored below their
flash point, reducing the chance for the generation of ignitable
liquid-produced vapours.
API RP500, Section 5.2.3.3 indicates that where combustible
liquids are processed, stored, or handled at or above their flash
point temperatures, those liquids should be treated as
flammable liquids.
 Class III Liquids
Class III liquids are sub-classified into Class IIIA and Class IIIB.
Class IIIA combustible liquids also require heating above their
flash point to form ignitable mixtures with air. Their vapours
have a tendency to cool and condense rapidly and their
dispersion area tends to be small to non-existent.
NFPA 497, Section 4.2.7.3 indicates that Class IIIB liquids
“…seldom evolve enough vapours to form ignitable mixtures
even when heated, and they are seldom ignited by properly
installed and maintained general purpose electrical equipment.
A Class IIIB liquid will cool below its flash point very quickly when
released. Therefore, area classification is seldom needed ”
 Vapour Ignition
API RP500, Section 5.2.3.2 indicates the chance for ignition of
Class II vapours is not as great as the ignition of Class I vapours. It
further states that the Class II liquid vapours do not travel as far
as that of Class I liquid vapours.
Section 5.2.4.1 states that Class III liquids heated above their
flash point will release flammable vapours at their surface.
For ignition (explosion) of flammable or combustible materials to
occur, there are three conditions that must simultaneously exist.
Those conditions are normally referred to as the ‘Fire Triangle’
 Fire Triangle
If any one of three conditions are inhibited or removed, a
fire or explosion cannot occur. This can be done by:
 Isolating the flammable substance
 Isolating the ignition source
 Containing the explosion

Oxidiser
Ignition
(air)
Energy

Flammable
Substance
Sources of Ignition
 Ventilation
Ventilation can play a major role in reducing the hazardous classification.

 The classification of a hazardous area may be determined to be Division 1,

Division 2, or unclassified depending upon :
o the adequacy of area ventilation,
o the flammable or combustible material present;
o the type and operating parameters for the equipment involved.

 Classification is affected by where the ventilating air source is drawn from.

An ideal ventilation air source would be from an unclassified location.
 A ventilation source from a Division 2 area could be utilized to lower the
enclosure classification from Division 1 to Division 2.
 But … generally, if the enclosure contains a potential source of fuel
release, its classification cannot be reduced from classified to unclassified.
 Enclosures

 The structure of a building, room, or enclosure

determines the adequacy of its ventilation.

 A vapour-tight wall may be used to stop migration of gas

or vapour from adjacent equipment.

 If an enclosure has openings or non-vapour tight walls

located within the extent of an adjacent hazardous
structure or equipment, it will directly affect its
classification and its ventilation requirements.
 Ventilation Design
Buildings, rooms, or enclosed spaces with at least six (6) air
changes per hour can be considered to be adequately ventilated.
Naturally ventilated enclosures have to be substantially open and
free of obstructions to air flow. They may have roofs containing
ridge vents and louvred exterior walls.
Adjustable louvres controlled by automatically closing fire
dampers can be considered to be open for ventilation purposes.
Adequate low level ventilation is required for heavier-than-air
vapours and roof or upper wall area ventilation is required for
lighter-than-air gases.
 ‘HAC-shape’ Gas Cloud vs ‘as modelled’

(ignoring wind)

Extent of HAC ‘gas cloud’ Equivalent 20% LFL

(100% LFL, 5 metre dia.) contour in CFD model
CFD model of Gas Cloud (in windy conditions)