Hazardous Area

Electrical Training

Hazardous Area Explosion Protected Apparatus

Installation, Maintenance & Inspection Training
Course

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EX Training
Unit 1

General Principles
Unit 01 - General Principles
 Unit 01 - General Principles

Basic Requirements for Combustion to

Occur:

• FUEL
• OXYGEN
• SOURCE OF IGNITION
Unit 01 - General Principles

• FUEL
• GAS - VAPOUR - MIST - DUST

• OXYGEN
• 21% IN AIR BY VOLUME

• SOURCE OF IGNITION
• ARC - SPARK - FLAME - HEAT
 Unit 01 - General Principles
Basic Requirements for Combustion to Occur:
GAS or VAPOUR.

FIRE
TRIANGLE.
OXYGEN SOURCE Of
(21% In Air). IGNITION.
 Unit 01 - General Principles

To prevent combustion occurring we can:

• Remove any one of the three combustion

elements.

• Isolate or Separate the Source of Ignition

from the gas/air mixture.
 Unit 01 - General Principles

• Allow the explosion to take place & contain it

within a robust enclosure.
Allow the three elements to co-exist & ensure
that the source of ignition is kept below specific
values.
Ensure that an electrical ignition source of failure
will not occur
 Unit 01 - General Principles

Flammable (Explosive) Limits:

• Combustion will only occur if the Flammable

mixture is between certain limits

• i.e. between the LEL and the UEL

 Unit 01 - General Principles

The Lower Explosive Limit - LEL

When the percentage of gas by volume is below
this limit,the mixture is too weak to burn.
i.e.
• insufficient fuel
and/or
• too much air
 Unit 01 - General Principles
The Upper Explosive Limit - UEL

When the percentage of gas by volume is above

this limit, the mixture is too rich to burn.
i.e.
• insufficient air
and/or
• too much fuel.
Unit 01 - General Principles

Upper
UpperExplosive
ExplosiveLimit
Limit Too
TooRich
Rich
(UEL)
(UEL) Insufficient
InsufficientOxygen
Oxygen

Lower Explosive Limit Too

TooWeak
Weak
(LEL) Insufficient
InsufficientFuel
Fuel
 Unit 01 - General Principles

Flammable (Explosive) Limits:

• Different gasses and vapours will have

different flammable limits.

• The greater the difference between the LEL

and the UEL.(flammable range).

The more dangerous the material.

 Unit 01 - General Principles

• We can operate safely with flammable

mixtures above the UEL

• It is more practical to operate below the

LEL.
 Unit 01 - General Principles
Flammable (Explosive) Limits:
The Flammable Limits of Some Materials are given in the table

Material LEL % by Volume UEL % (to air) by Volume

Propane. 2 9.5
Ethylene. 2.7 34
Hydrogen. 4 75.6
Acetylene. 1.5 100
Paraffin. 0.7 5
Carbon-
Disulphide. 1 60
Methane 5 15
 Unit 01 - General Principles
Sources of Ignition:
• The possible sources of ignition are many and varied.
• They include the following:
 Electrical arcs/sparks
 Frictional sparks
 Welding activities
 Static discharges
 Hot surfaces
 Cigarettes
 Batteries
Unit 01 - General Principles

Sources of ignition
• Engine exhausts

• Chemical reaction

• Lightning strikes
 Unit 01 - General Principles

Flashpoint:

Definition:
The lowest temperature at which sufficient vapour is given
off a liquid, to form a flammable mixture with air that can be
ignited by an arc, spark or naked flame.
 Unit 01 - General Principles
Flashpoint:
Some typical values are given in the table below;

Material Flashpoint oC
Propane. <-20.
Ethylene. <-20.
Hydrogen. <-20.
Acetylene. <-20.
Diethyl Ether. <-20.
Paraffin. +38.
Carbon Disulphide. <-20.
 Unit 01 - General Principles
The flashpoint of a material gives an indication of how
readily that material will ignite in normal ambient
temperatures.

Reference to tables taken from:

• The UK Code of Practice - BS 5345: Pt (1)

• The IEC Code of Practice - IEC 60079-20
 Unit 01 - General Principles

• Materials with high flashpoints should not be

overlooked as a potential hazard.

• If a flammable material is discharged under

pressure from a jet its flashpoint may be reduced.
 Unit 01 - General Principles

Ignition temperature:
Definition:
The minimum temperature at which a flammable
material will spontaneously ignite without a spark or
flame.
 Unit 01 - General Principles

Ignition temperature :

The surface temperature of equipment, indicated by its ‘T’

rating will not exceed the Ignition Temperature of the
flammable atmosphere, which may be present around the
equipment.
 Unit 01 - General Principles
Ignition temperature:
Some typical values for Ignition Temperature are given in the table below:
Ref: BS 5345 Pt (1) and IEC 60079-20 codes of practice.

Material Ignition Temperature oC

Propane. 470.
Ethylene. 425.
Hydrogen. 560.
Acetylene. 305.
Diethyl Ether. 185.
Paraffin. 210.
Carbon Disulphide. 102.
Methane 595
 Unit 01 - General Principles
Oxygen enrichment:
• The normal oxygen content in air is around 20.95%.
• Any value which exceeds this is deemed to be
oxygen enriched.

Typical examples of where Oxygen Enrichment may occur

are :

• Gas Manufacturing Plants

• Hospitals
• Oxy-Acetylene Equipment
 Unit 01 - General Principles
Oxygen enrichment has three disadvantages:
(1) It can lower the Ignition Temperature of flammable
materials as shown in the examples below:

Air Increased Oxygen

Material; Ignition Temp. 0C; Ignition Temp. 0C;

Hydrogen Sulphide. 470. 220.

Acetylene. 425. 296.
Ethane. 560. 506.
 Unit 01 - General Principles
(2) It can significantly raise the Upper
Flammable Limit of the majority of gasses and
vapours, thereby widening their Flammable Limits
.
This is illustrated in the examples below:
Air Increased Oxygen
Material; LEL %; UEL %; LEL %; UEL %;
Methane. 5. 15. 5.2 79
Propane. 2.2 9.5 2.3 55
Hydrogen. 4. 75 4.7 94
 Unit 01 - General Principles
(3) Oxygen enrichment of a flammable atmosphere
can allow it to be ignited with much lower values
of electrical energy.

Note:
• Explosion protected equipment is tested in normal
atmospheric conditions.
• Certification for equipment in an oxygen enriched
environment would be compromised.
 Unit 01 - General Principles

Density
If a flammable material is released, it is important to know
whether the material will rise or fall in the atmosphere.

Since air is the standard reference

Its relative density is 1.
 Unit 01 - General Principles

If a material is twice as heavy as air its relative density

will be 2.
Therefore:

 Materials with a relative density less than 1

will rise in the atmosphere.

 Materials with a relative density greater than 1

will fall in the atmosphere.
 Unit 01 - General Principles
Density:
• Materials which rise in the atmosphere can collect in
roof spaces.

• Those which fall can drift along at ground level and

possibly into a non hazardous location.

• May collect in locations without ever dispersing.

• Detectors must be installed at correct level and

location
 Unit 01 - General Principles
Density:
Some typical values are given in the table below:

Material Relative Vapour Density

Air 1.
Propane. 1.56.
Ethylene. 0.97.
Hydrogen. 0.07.
Acetylene. 0.9.
Diethyl Ether. 2.55.
Paraffin. 4.5.
Carbon Disulphide. 2.64.
Hydrogen Sulphide. 1.19
 Unit 01 - General Principles

Area Classification:
A hazardous area is defined as:

“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 apparatus.”
 Unit 01 - General Principles

A non-hazardous area is defined as:

“An area in which an explosive gas atmosphere is not

expected to be present, in quantities such as to require
special precautions for the construction, installation and
use of apparatus”.
 Unit 01 - General Principles
Area classification-zones:
zoning is a means of representing the following:
• the frequency of the occurrence
• the duration of an explosive gas atmosphere

It assists in proper selection and installation of

apparatus
 Unit 01 - General Principles

Evaluation of the area within each zone is based on

• The grade of release
• Presence of artificial ventilation
• Extent and volume of release

Hazardous areas are, therefore, divided into three zones.

They represent the risk in terms of:
The probability, frequency and duration of a release.
 Unit 01 - General Principles

Ref BSEN 60079-10

Classification of hazardous areas, are as follows:

Zone 0:
“In this Zone, an explosive gas atmosphere is
continuously present, or present for long periods”.
 Unit 01 - General Principles
Zone 1:
“In this zone, an explosive gas atmosphere is likely to
occur in normal operation”.

Zone 2:
“In this zone, an explosive gas atmosphere is not likely to
occur in normal operation and, if it does occur, it is likely
to do so infrequently and will exist for a short period only”.
 Unit 01 - General Principles
Although not specified in the standards, the following
figures are generally accepted in industry.
The duration of a gas release, on a normal annual basis,
for the different Zones is as follows:

• Zone 0 = over 1000 hours / year

• Zone 1 = 10 to 1000 hours / year

• Zone 2 = <10 hours / year

Unit 01 - General Principles
Zone Diagrams.

Zone ‘0’ Non- Old Zone ‘0’

Hazardous

Zone ‘1’ Zone ‘2’

 Unit 01 - General Principles

a = 3m from vent
openings.
b = 3m above the
roof.
c = 3m
horizontally from
tank.
 Unit 01 - General Principles
Sources of Release

SPACE ABOVE LIQUID

IN A CLOSED TANK PUMP GLAND
Zone ‘0’ - ZONE ‘1’
- ZONE ‘0’

FLANGED JOINT WELDED JOINT

- ZONE ‘2’ - NON HAZARDOUS
 Unit 01 - General Principles
Typical Platform Hazardous Areas

HAZARDOUS ZONE 1

HAZARDOUS ZONE 2

NON HAZARDOUS AREA

 Unit 01 - General Principles
Gas/Apparatus grouping

In the IEC (International Electrotechnical Commission)

system, the group allocation for surface and
underground (mining) industries are separate.

• Group I is reserved for the Mining industry

• Group II is for Surface industries

• This course deals with group II

 Unit 01 - General Principles
Group II is further subdivided into the following:

• Group IIA i.e. Propane

• Group IIB i.e. Ethylene

• Group IIC i.e. Hydrogen

 Unit 01 - General Principles
• Two methods have been used to ‘group’ these
flammable materials
• According to the degree of risk they represent
when ignited
• The first involved determining the Minimum
Ignition Energy for each gas
• This proved that Hydrogen and Acetylene were
the most easily ignited
• Propane was the least easily ignited
 Unit 01 - General Principles
The second, involved determination of the MESG
(Maximum Experimental Safe Gap).
• Using a flameproof bronze sphere
• The 25mm flame-path gaps could be varied
• A gas/air mixture was introduced inside and outside
• Under test, the gas inside is ignited
• The MESG is the maximum gap which prevents
ignition of the outside gas
• The more dangerous the gas the smaller the gap
 Unit 01 - General Principles
Apparatus for determination of M.E.S.G.

FLANGE
1”(25mm)

M.E.S.G.

FLAMMABLE
MIXTURE
 Unit 01 - General Principles

Gas Group Representative Gas MESG MWG MIE

(mm) (mm) (J)
I Methane (Firedamp) 1.17 0.5 280
IIA Propane 0.97 0.4 260
IIB Ethylene 0.71 0.2 95
IIC Hydrogen/Acetylene 0.5 0.1 20
 Unit 01 - General Principles
Note 1:
Apparatus marked II, i.e. with no sub-division letter A, B,
or C means that this can be used in all hazards

Note 2:
Apparatus marked II XXX.
XXX represents the chemical formulae or name of a
material and should only be used in this hazard
 Unit 01 - General Principles
Note 3:
• Apparatus marked IIA can only be used in IIA
hazards

• Apparatus marked IIB can be used in IIA and IIB

hazards

• Apparatus marked IIC can be used in IIA, IIB

and IIC hazards.
 Unit 01 - General Principles
Temperature classification:
Is based on the maximum temperature which any
relevant part of the apparatus, which may be in contact
with an explosive gas will reach when operated within its
normal design rating and ambient temperature.

Apparatus is classified into one of six temperature ranges

See following slide
 Unit 01 - General Principles
Temperature Codes are given in the table below:
Temperature Code Maximum Surface
Temperature oC
T1. 450.
T2. 300.
T3. 200.
T4. 135.
T5. 100.
T6. 85.
 Unit 01 - General Principles

Equipment T-Rating must be below the ignition

temperature of any gas / vapour surrounding it.

The T- Rating temperatures are based on a maximum

Ambient temperature rating of 40 0C, for use in the UK.

Note
Higher Ambient Temperature Ratings are available
 Unit 01 - General Principles

T-Rating and Ignition Temperature Comparison of Some

Materials are given in the table below:
Material Ignition Temperature T - Rating

Methane. 595 0C T 1 (450 0C)

Ethylene. 425 0C T 2 (300 0C)
Cyclohexane. 259 0C T 3 (200 0C)
Diethyl - Ether. 170 0C T 4 (135 0C)
Carbon - Disulphide. 102 0C T 5 (100 0C)
T 6 (85 0C)
 Unit 01 - General Principles
Temperature classification example:
If apparatus is tested in a room with an air temperature
of 20°C and the surface temperature reached 100°C
(T5), this would be an 80°C temperature rise.
However if the test had been conducted at 40°C this
would then be calculated as 80°C + 40°C = 120°C (T4).
The correct method would be to start at 40°C ambient
with a maximum 60°C temperature rise to stay within
the 100°C or T5 rating.
 Unit 01 - General Principles
In order to avoid infringement of the apparatus
certification:

• The ambient temperature rating must be

compatible with the environmental ambient
temperatures
• The temperature rise must not be exceeded.

This is demonstrated in the following example:

 Unit 01 - General Principles
TEMPERATURE CLASSIFICATION:
Ambient Air Temperature Less than Apparatus Ambient Rating;

(T 5) (T 5)

1000C 1000C

600C 800C
Temp. Rise. Temp. Rise.

400 C Ambient Rating 400 C

of Apparatus
200 C Air
200 C
Temperature
00 C 00 C
Correct Incorrect
 Unit 01 - General Principles
Ingress Protection:
Enclosures of electrical equipment are classified
according to their ability to resist:
• The ingress of solid objects
• The ingress of water
By means of a system of numbers known as the:
• Ingress of Protection (IP CODE)
• Ref BS EN 60 529.
 Unit 01 - General Principles
The Code consists of the letters IP followed by two
numbers
• For example - IP54
• The first digit is for protection from solid objects
• The second digit is for protection from water

Therefore for IP 54
5 = Dust protected
4 = Splashed water from any direction
 Unit 01 - General Principles
INGRESS PROTECTION:
SOLID OBJECTS
First
Numeral Level of Protection
0 No Protection
1 Protection against objects
greater than 50 mm
2 Protection against objects
greater than 12 mm
3 Protection against objects
greater than 2.5 mm
4 Protection against objects
greater than 1 mm
Abridged version of full table shown below;
WATER
Second
Numeral Level of Protection
0 No Protection
1 Protection against drops of
water falling vertically
2 Protection against drops of
water when tilted up to 15º
3 Protection against sprayed
water up to 60º
4 Protection against splashed
water from any direction
 Unit 01 - General Principles
INGRESS PROTECTION:
SOLID OBJECTS
First
Numeral Level of Protection
5 Dust Protected
6 Dust Tight
Abridged version of full table shown below;
WATER
Second
Numeral Level of Protection
5 Protection against jets of
water from any direction
6 Protection against heavy seas
– deck watertight
7 Protection against immersion
in water 1m in depth and for
a specific time
8 Protection against indefinite
immersion in water at a
specified depth
Unit 01 - General Principles

QUESTIONS
Answer true or false
 Unit 01 - General Principles
1. A release of flammable material under pressure may reduce its flash point ?

2. The minimum temperature at which a flammable vapour may be ignited by

a spark is known as flashpoint.

3. All electrical sparks are capable of igniting a flammable mixture ?

4. Sparks can be produced by aluminium striking rusty steel ?

 Unit 01 - General Principles
5. Any concentration of a flammable gas in air may be ignited ?

6. The glass envelope of a light bulb will prevent ignition of a flammable

mixture ?

7. A flammable mixture which has an increased percentage of oxygen in air

will require less electrical energy to cause ignition ?

8. All flammable vapours will rise in the atmosphere ?

 Unit 01 - General Principles
9. An area classified Zone 0 is less hazardous than an area classified Zone
1?

10. An area classified Zone 2 indicates that a flammable atmosphere will

occur during normal operating conditions ?

11. The duration of a gas release in Zone 2 is not expected to exceed 10 hours
per year ?

12. The probability and duration of a gas release is indicated by the Zone ?
 Unit 01 - General Principles
13. Apparatus marked gas group IIA can be used in a IIB hazard ?

14. Oxygen enrichment widens the flammable range of flammable mixtures ?

15. Group II apparatus may be used in mines, i.e. Underground ?

16. Apparatus with a T3 temperature classification may be used

instead of apparatus marked T4 ?
 Unit 01 - General Principles
17. The maximum surface temperature of equipment marked T6 is 85 °C ?

18. An enclosure marked T5, which operates in a diethyl-ether hazard, may

be replaced with an identically certified enclosure of T rating T4 ?

19. In the IEC gas group system a typical IIC gas would be Hydrogen ?

20. According to the the IEC IP code rating table an IP rating of 65 would
provide dust protection and water splashed from any direction
Unit 01 - General Principles

ANSWERS
 Unit 01 - General Principles
1. A release of flammable material under pressure may reduce its flash point ?

TRUE 

2. The minimum temperature at which a flammable vapour may be ignited

by a spark is known as flashpoint ?

TRUE 

3. All electrical sparks are capable of igniting a flammable mixture ?

FALSE 

4. Sparks can be produced by aluminium striking rusty steel ?

TRUE 
 Unit 01 - General Principles
5. Any concentration of a flammable gas in air may be ignited ?

FALSE 

6. The glass envelope of a light bulb will prevent ignition of a flammable

mixture ?
FALSE 

7. A flammable mixture which has an increased percentage of oxygen in air

will require less electrical energy to cause ignition ?

TRUE 

8. All flammable vapours will rise in the atmosphere ?

FALSE 
 Unit 01 - General Principles
9. An area classified Zone 0 is less hazardous than an area classified Zone
1?
FALSE 

10. An area classified Zone 2 indicates that a flammable atmosphere will

occur during normal operating conditions ?
FALSE 

11. The duration of a gas release in Zone 2 is not expected to exceed 10 hours
per year ?
TRUE 

12. The probability and duration of a gas release is indicated by the Zone ?

TRUE 
 Unit 01 - General Principles
13. Apparatus marked gas group IIA can be used in a IIB hazard ?

FALSE 

14. Oxygen enrichment widens the flammable range of flammable mixtures ?

TRUE 

15. Group II apparatus may be used in mines, i.e. Underground ?

FALSE 

16. Apparatus with a T3 temperature classification may be used

instead of apparatus marked T4 ?

FALSE 
 Unit 01 - General Principles
17. The maximum surface temperature of equipment marked T6 is 85 °C ?

TRUE 

18. An enclosure marked T5, which operates in a diethyl-ether hazard, may

be replaced with an identically certified enclosure with a T rating T4 ?

TRUE 

19. In the IEC gas group system a typical IIC gas would be Hydrogen ?

TRUE 

20. According to the the IEC IP code rating table an IP rating of 65 would
provide dust protection and water splashed from any direction

FALSE 
Unit 2