Hazardous Area Classification

& Method of Protections

Aasif Vindhani

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Hazardous Area Classification 1/26/2018
Topics:
 Introduction
 Define the Hazardous Area
 How it’s classified?
 Peculiarity of each Area
 Different International Standards
 Comparison of Standards
 Methods of Protection
 Classification of Protection methods
 IP Protection
 Ruggedness Standards
This will take about 2 hrs
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Hazardous Area Classification 1/26/2018
Introduction
 From Chemical point of view, Oxidation,
Combustion, Explosion are all exothermic
reaction with different reaction speeds.
 For such reaction to take place it’s essential that
following three components, in due proportion,
be present simultaneously:
A. Fuel: gas, vapors or powder form
B. Oxidizer: Generally air or Oxygen
C. Ignition Energy : Thermal or electrical
 These three
components are identified
in the Ignition Triangle

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Introduction: (Contd.)
 Explosive mixture is appropriate ratio of Air & combustible
materials which can ignite at any time & sustain subsequent
combustion

 It’s possible to draw an ignition characteristic of each fuel as

shown in above figure. A Minimum Ignition Energy (MIE) exists
for every fuel below which ignition of the mixture is impossible.
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Introduction (Contd.)
 For concentration lower than the one corresponding to MIE,
the quantity of energy required to ignite the mixture rapidly
increases until concentration value reached below which the
mixture can not be ignited because of loss of fuel. This value
is called Lower Explosive Limit (LEL)
 In the same way when increasing the concentration the
energy required increases and concentration value is
identified above which ignition cannot occur because of loss
of oxidizer , this value is called Upper Explosive Limit (UEL)
 For H2 MIE/LEL/UEL are 20 mJ/4%/75% & for Propane it is
180 mJ/2%/9.5%
 LEL data is important while classifying Hazardous area.
 IGNITION TEMPERATURE: The minimum ignition
temperature of air/gas mixture at which the mixture ignites
itself without supply of electric energy.
 Important for allowing maximum surface temperature for the
device located in Hazardous locations, both in normal & fault
condition
 FLASH POINT: It’s lowest temperature at which the liquid
releases sufficient vapors ignitable by an energy source.
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 Hazardous Area:
 Hazardous area is the place where there is chance of
presence of explosive mixture in sufficient quantity which
can lead fire or explosion.
 The explosive mixture can be present in normal operation
or due to malfunction of equipment
 The identification of HAZARDOUS LOCATION in a plant is
normally carried out by expert or highly qualified process
engineers.
 They must establish where there is hazardous atmosphere
being present, in which condition & how long.
 The most common dangerous area are where the
possibility of a leakage of flammable gas is present.
 The leakage can occur during normal function, due to a
fault, or due to the deterioration of components operating
in the process.
 E.g. top area of flammable liquid storage tank, pump seal,
gland joints etc.

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Hazardous Area Classification 1/26/2018
How it’s classified?
 Depending on the type of leakage, continuous (e.g.
Inside tank), intermittent (e.g. pump gland packing), & if
intermittent with which frequency, the classification of
HAZARDOUS LOCATION is determined.
 The area surrounding the location identified as
HAZARDOUS is extended to such a distance as to
where the flammable substance becomes so diluted
with air that ignition no longer is possible.
 This distance is related to the nature & quantity of the
gas, degree of ventilation etc.
 There are different standards for defining Hazardous
area. Some of them are-
 Italian Standard CEI 64.2
 European Standard or IEC 60079
 USA & Canada standard based on ISA-12.01
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Hazardous Area Classification 1/26/2018
Area Classification as per Italian
standard CEI 64.2 (Presently merged with CENLEC)
 Combustible material type
1. Class-0: Hazardous for presence of Explosive
2. Class-1: Hazardous for presence of flammable
substance as gas or vapors
3. Class-2: Hazardous due to presence of
Flammable powder
4. Hazardous due to presence of flammable
substance at liquid state, fiber or dust state or
solid state.

 Probability of Hazards in a year (For Class-0 & 1)

1. Division-0: Hazards for more than 100 hrs
2. Division-1: Hazards between 1 hr to 100 hrs
3. Division-2: Hazards between 0.01hr to 1 hr
4. Respected: Hazards less than 0.01 hr
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Area Classification as per
European standard IEC 79-10
 Probability of Hazards
1. Zone-0: An area in which explosive air/gas
mixture is continuously present or present for
long time.
2. Zone-1: An area in which explosive air/gas
mixture is likely present in normal operation
3. Zone-2: An area in which explosive air/gas
mixture is unlikely to occur, but, if it does, only
for short period.
 Combustible material type
1. Class-1: Gas & Vapors
2. Class-2: Dust
3. Class-3: Fibers
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Area Classification as per
US/Canada standard ISA-12.01
 Probability of Hazards
1. Division-1: An area in which explosive air/gas
mixture can be present during normal operation.
2. Division-2: An area in which explosive air/gas
mixture can be present during abnormal
condition.
 Combustible material type
1. Class-1: Gas & Vapors
 Group-A, B, C & D
2. Class-2: Dust
 Group E, F & G
3. Class-3: Fibers 11
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Comparisons of Standards

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Surface Temperature Classification
 An apparatus directly located in Hazardous location
must also be classified for maximum surface
temperature that can be generated by the equipment
either in Normal functioning or Fault condition.
 The maximum surface temperature must be lower
than the Minimum Ignition Temp. (MIT) of gas present

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Relevant International Standards
 API RP 500- Area Classification of Petroleum
Installations
 IEC 79-10 :1995 -Electrical Apparatus for Explosive
Gas Atmospheres, part 10 Classification of hazardous
areas
 IP Part 15, 1990- Area Classification Code for
Petroleum Installations
 BS EN 60079-10, : 1996 -Electrical Apparatus for
Explosive Gas Atmospheres, part 10 Classification of
hazardous areas
 BS 5345, 1983-Selection, installation and
maintenance of electrical apparatus for use in
potentially explosive atmospheres (other than mining
applications or explosive manufacturing), part 2,
Recommendations for particular industrial situations
 IS-5572 Indian Standard

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 Methods of Protection

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Methods of Protection
 As explained earlier, to reduce the risk of
explosion, elimination of one or more
component of Ignition Triangle is necessary.
 Based on this, there are three methods of
Protection:
A. Explosion Containment: Explosion is allowed
to occur but confines it in well defined place &
avoid propagation to surrounding atmosphere.
B. Segregation: Attempts to physically separate
electrical part or hot surface from explosive
mixture.
C. Prevention: Both thermic & electric Energy is
limited to safe level in unfavorable condition
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Selection of Protection Method
 It depends on the degree of Safety needed for
the type of Hazardous Location in a way to
have the lowest probable degree of an
eventual simultaneous presence of an
adequate energy source & explosive mixture.
 All the protection methods don’t give 100%
certainty of avoiding Explosion, but statistically
it proved 100% reliable.
 First precaution is to avoid Electrical
apparatus in Hazardous area.
 Secondary factors are size of apparatus,
maintenance approach, installation cost,
flexibility of the system etc.
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Different Protection Method
1. EXPLOSION PROOF ENCLOUSER EX”d”
Explosion is allowed to happen but in
confined enclosure.
It should be strong enough to
withstand.
 Large opening are not allowed
Not necessary to be tight shut-off
Very heavy & bulky, difficult to install
Not suitable for humid atmosphere
Difficulty in maintenance

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2. PRESSURIZATION EX”p”
It’s based on Segregation Method
Doesn’t allow explosive mixture to
penetrate the enclosure.
 Electrical parts are kept under
pressure by protective gas (Air or N2) at
slightly positive pressure
Requires certain degree of tightness
Initial circulation is required
 It’s allowed to used in both divisions
 Pressure loss will automatically cut-
off power
Used for large electrical machine,
control panel

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3. ENCAPSULATION EX”m”
It’s based on Segregation Method
Electrical parts are segregated by
means of potting in resin resistant to
specific ambient condition
 Assures good mechanical protection,
very efficient in not allowing the input of
the explosive mixture
Normally used for modest dimension
electric circuit having no moving
components
It’s also referred as Hermetically
Sealed device.
 Relatively cheap
 Repairing will not be possible at site

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4. OIL IMMERSION METHODS EX”o”
It’s based on Segregation Method
All or part of electrical apparatus are
immersed in oil in a way that the
explosive atmosphere, above the oil
level or outside the enclosure can not
be ignited.
 Useful for large electrical apparatus
like Transformer where there is no
moving part
Not suitable for the apparatus that
requires frequent maintenance or have
moving components
Not used for Instrumentation

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5. POWDER FILLING PROTECTION EX”q”
It’s based on Segregation Method
Similar to previous one but instead of
oil or resin, powder is used
Normally Quartz is used as filling
powder
Allowed for Division 1 & 2
Difficulty with maintenance & check
Not suitable where there is moving
parts
 Not suitable for Instrumentation

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6. INCREASED SAFETY PROTECTION EX”e”
It’s based on Prevention Method
An elevated Safety Coefficient
Electrical components are used so that
possibility of having excessive or
temperature generation of arches or
sparks inside and outside apparatus do
not generated in normal functioning
Applicable for Class-1 & 2
Normally used for the protection of
terminals, electrical connections, lamp
sockets, squirrel cage motors and in
combination with other protecting
methods.
 Ease in maintenance

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 7. INTRINSIC SAFETY PROTECTION EX”i”
It’s based on Prevention Method
In this method energy to the Apparatus is limited so that No spark / arch
over heating can occur in normal or fault conditions.
It’s the only method that not only protects the apparatus in hazardous
location but also its relative wiring, expecting the breaking, short circuiting,
or accidental grounding of the connecting cable.
Installation is simplified.
Suitable for the device which requires less than 30 V & 100 ma
Very widely used for Instrumentation
 Ease in maintenance, checking is possible even when circuit is powered.
Most effective, Reliable & Economical Protection method

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 8. SIMPLIFIED PROTECTION EX”n”
It’s based on Prevention Method
In this, electrical apparatus are incapable of igniting a surrounding
atmosphere in normal function.
Allowed only for Division-2 only
Similar to Intrinsic, only difference is that only normal function of
apparatus is considered.
Normally used with combination of other methods

9. SPECIAL PROTECTION EX”s”

It’s based on some testing of apparatus
Not recognized by IEC
It was developed to allow certification of apparatus that, even if not
according to any of the protection methods, can be considered safe, for
specific Hazardous Location, by means of appropriate tests or detailed
analysis of the design

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Summary of Protection Methods

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Summary of Protection Methods

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IP (Ingress) Protection
IP Ratings

A global standard
established by the IEC
(International Electro-
technical Commission)
that lets you know how
well equipment is sealed
against dust & liquids
Different International
standards are DIN-40050,
IEC-1464, BS(S420) etc.
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 IP Rating – first digit
IP LEVEL DESCRIPTION

IP0X No protection
IP1X Hands & large tools
IP2X Fingers & smaller tools
IP3X Tools & wire
IP4X Tools & small wires
IP5X Limited dust
IP6X Dust proof

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 IP Rating – Second digit
IP Level Description
IPX0 No protection
IPX1 Condensation
IPX2 15 direct spray
IPX3 60 direct spray
IPX4 All directions, limited ingress
IPX5 Low pressure, limited ingress
IPX6 High pressure, limited ingress
IPX7 Immersion, 15 cm to 1 m
IPX8 Immersion under pressure
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IP Standard Summary
 IP-22 = Drip Proof, IP-23 = Rain Proof,
IP-34 = Splash Proof, IP-55 = Weather Proof,
IP-57 = Water Tight, IP-54 = Dust Proof,
IP-65 = Dust Tight
 Anything less than IP6X will allow dust into equipment
 Anything less than IPX7 will allow liquids into
equipment
 The minimum to accept is IP65 as this eliminates dust
ingress and limits liquid ingress under all weather
conditions
 Insist on IP67 if you want to remove any danger of
liquid ingress
 Make sure equipment is tested to this standard rather
than “designed to meet” and ask for a certificate of
compliance
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Ruggedness Standard

MIL STD 810F

► A set of test procedures that measure the

ability of equipment to withstand the rigors of
everyday use in field applications.

► Originally developed by the

US military

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 MIL STD 810F (Contd.)
Test # Description Test Standard
810F 502.4 Cold temperature Storage at -40oF (-40oC) then tested at room
storage & temperature. Unit stored for 3 hrs at -20oC then
operation tested at -20oC
810F 501.4 High temperature Storage at 70oC without battery or 60oC with
storage & battery then tested at room temperature. Unit
operation stored at 50oC & then tested at 50oC
810F 503.4 Thermal shock 3 temperature cycles from -40oC to 70oC, then 3
cycles from -40oC to 70oC performed in less than 1
minute per cycle
810F 506.4 Rain 4” per hour with a wind speed of 66 kmph for 30
minutes. Water temperature between 5oC & 25oC
810F 512.4 Immersion 30 minutes immersion to a depth of 3 ft

810F 507.4 Humidity 95% (+/- 5%) non-condensing humidity at 75oF for
48 hrs
810F 516.5 Free-fall drop 26 drops from 4 ft on 2” of plywood using up to 5
units. No temperature is stated
810F 514.5 Vibration 0 - 500 Hz, 0.5 octave/min on 3 axis. 65 minutes/axis
duration
810F 500.4 Low pressure Equipment is tested comparable to that of an aircraft
operation luggage hold at 15,000 ft altitude
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 MIL STD 810F Summery (Contd.)
► Testing to MIL STD 810F can give you confidence that equipment will
survive in the field
► Check which sub-sections the equipment is tested against
► Make sure it is actually tested & ask for a certificate of compliance
Why is this important?
► Testing to these standards proves a product is rugged
► Rugged products are more reliable
► Less lost time
► Reduced internal support costs
► No “lost” data
► Longer project life cycle
In other words, “a reduced annualized cost”

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 Any Question????

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 Thank You….!!!

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