Source of

Ignition

Hazardous Area Classification

Spark
Spark

Heat

Hazardous
location

Air

Gas

Presented by:
Amila Abeywickrama, B.Sc. (Engineering), AMIESL
Instrument Engineer
Introduction

Introduction

Explosion Triangle

A1

Plant and Installations

A2

Equipment

are classified according to:-

is classified according to:The nature of the Hazardous Atmosphere

The maximum spark energy it can produce
- Gas Classification
- Ignition Temperature

- Apparatus Group

The probability that the Hazardous Atmosphere

will be present

Its maximum surface temperature

- Temperature Classification

- Area Classification
Introduction

Requirement for plant classification

Requirement for equipment classification

A3

Propane-air (1 atmos.)
1.0

Introduction

Gas/air mixtures are ignitable over a range of concentrations called the

Ethylene-air
(1 atmos.)

Flammable Range

Ignition Energy
(milli Joules)
Hydrogen-air
(1 atmos.)

0.1

Material

Flammable Range
0

10

Lower Explosive Limit (LEL)

20
30
40
50
60
Volume concentration (%)

70

80

90

Lower explosive limit Upper explosive limit

LEL

Minimum Ignition
Energy (MIE)
0.01

A4

100

UEL

Minimum *
ignition energy

propane

2%

9.5 %

180J

ethylene

2.7 %

34 %

60J

hydrogen

4%

76 %

20J
* of most easily ignitable mixture

(UEL) Upper Explosive Limit

Introduction

Spark Ignition Characteristic

A5

Introduction

Explosive limits for materials

A6

Gas classification
Representative
(test) gas

EXPLOSIVE LIMITS (% gas in air by volume)

GAS

10

20

30

40

50

60

70

80

90

IEC countries
(including Europe)

Ignitability
USA & Canada

100

Methane
Propane
Ethylene
Hydrogen

Acetylene
Hydrogen
Ethylene
Propane

Group IIC
Group IIC
Group IIB
Group IIA

Class I, Group A
Class I, Group B
Class I, Group C
Class I, Group D

Methane

Group I (mining)

(No classification)

Metal dust
Carbon dust
Flour, starch,
grain

(Dusts not
classified)

Class II, Group E

Class II, Group F
Class II, Group G

More
easily
ignited

Class III

Fibres & flyings

Introduction

Flammable Range

A7

Flammable materials have a temperature at which ignition

will take place, even in the absence of an external source

Introduction

Gas classification: the two main systems

Temperature
classification

Maximum
surface
temperature

of that material

Apparatus must be selected such that it will not expose the

gas-air mixture to a temperature exceeding the ignition
temperature

T1

450 C

T2

300 C

T3

200 C

T4

135 C

T5

100 oC

Tamb = 40oC

unless otherwise
stated
Operation above
stated Tamb will
require re-assessment

This temperature is called the

Ignition Temperature

o
o

Better
Apparatus

T6

85 C

Introduction

Temperature classification

T class

A9

Introduction

Temperature classification (IEC/European)

T1

450

T2

300

T2A

280

T2B

260

T2C

230

T2D

215

T3

200

T3A

180

T3B

165

T3C

160

T4

135

T4A

120

T5

100

T6

85

700

Gas Ignition
Temperature
Apparatus is marked with either T rating
or maximum surface temperature
User has responsibility to ensure that the
T-rating is below the Spontaneous
Ignition Temperature ( SIT )

Ammonia 630
Hydrogen 560
Methane 537
Propane 470
Ethylene 425

600

A10

Apparatus
Temperature
Classification

500
T1
400

Butane 365
300

T2

200

T3

Cyclohexane 259
Diethyl Ether 170

T4
Carbon Disulphide 95

Tamb =

A8

100

T6

T5

40oC
Introduction

Temperature classification in North America

A11

Introduction

Gas/equipment compatibility

A12

T4 for apparatus is usually OK

Flashpoint

Exception:

The flashpoint of a flammable liquid

is defined as the temperature at which the free
surface of the liquid emits sufficient vapour
to be ignited by a small flame

Carbon Disulphide,CS2 requiring T6

Don't confuse T Class with maximum operating

temperature!

Note: Dont confuse Flashpoint with Ignition Temperature

(eg for kerosene, Flashpoint = 38C; Ignition Temp. = 210C)

Introduction

Gas Ignition Temperature

Compound

Vapour
Density

Acetone
Ammonia
Butane
Carbon Disulphide
Cyclohexane
Diethyl Ether
Ethylene
Hydrogen
Kerosene
Methane
Propane

2.00
0.59
2.05
2.64
2.90
2.55
0.97
0.07
0.55
1.56

LFL UFL
2.0
15
1.5
1.0
1.2
1.7
2.7
4.0
0.7
5.0
2.0

13
28
8.5
60
7.8
36
34
75.6
5
15
9.5

Ignition
Temp C
535
630
372
95
259
160
425
560
210
537
470

Introduction

Flashpoint Definition

A13

A14

T
Apparatus
Class
Group
T1
T1
T2
T6
T3
T4
T2
T1
T3
T1
T1

IIA
IIA
IIA
IIC
IIA
IIB
IIB
IIC
IIA
I / IIA
IIA

Probability of
Gas/Air Mixture
being present

Probability of

Source of
Ignition

Acceptable
Risk

Reasoning : The higher the probability of the gas/air mixture being present demands a lower
probability of having a source of ignition and vice versa. Hence in Zone 0 we use IS;
in Zone 2 we perhaps use Type N or Exq,Exo,Exm, etc

Takenfrom
from BS.5345
IEC 79-10:1995
Extract
Part 1
Introduction

Properties of Gases

A15

Introduction

Why Area Classify?

A16

Areas are classified with regard to the probability of a potentially

Division 1

explosive atmosphere being present and the length of time

for which it is likely to exist

Zone 0:

in which an explosive gas-air mixture is continuously

present or present for long periods

Zone 1:

in which an explosive gas-air mixture is likely to occur

in normal operation

Zone 2:

in which an explosive gas-air mixture is not likely occur

in normal operation, and if it occurs it will exist only
for a short time

Hazardous atmosphere is likely to be present in normal operation

Division 2
Hazardous atmosphere is unlikely to be present in normal operation

Introduction

Area classification in IEC/European countries

A17

Introduction

Area classification in North America

A18

For Hydrogen Sulphide, H2S:

Why area Classify ?

a very common danger when dealing with oil products

Why go to all the trouble with areas & equipment?

If we know the probability of hazardous area & probability
of source of ignition , we know whether we are taking an
acceptable risk.
Eg. Probability of flammable atmosphere = high
If apparatus insures never sparks = acceptable risk

Introduction

Property

Volume
Concentration

Smell detection level

Safe working level
Serious health danger level
Lower Flammable Limit
Upper Flammable Limit

0.1 ppm
10
50
40,000 (4%)
460,000 (46%)

Note! Figures for safe working levels vary, the above are from a
Middle East location.

Personnel Hazards

A19

Zone 2

Zone 0

Zone 1

Zone 1

Zone 0
Inside of pipe or
process vessel

Zone 2

Liquid surface

A20

Outside of pipe

Key

Tank vents

Area Classification
for a fixed-roof tank
with heavier than air
vapour

Introduction

Division 1
Division 2
Bund wall
Introduction

Area Classification Example

Equipment
Code

A21

Description

Suitable for zones

Equipment
Category

Ex ia

Intrinsic safety 'ia'

0, 1, 2

1G

Ex ib

Intrinsic safety 'ib'

1,2

2G

Ex d

Flameproof protection

1,2

2G

Ex p

Purge/pressurized protection

1,2

2G

Ex e

Increased safety

1,2

2G

Ex m

Encapsulation

1,2

2G

Ex o

Oil immersion

1,2

2G

Ex q

powder filling

1,2

2G

Ex n

Type - n protection

3G

Introduction

Thermocouple in a hazardous area

A technique whereby electrical energy is limited

such that any sparks or heat generated by
electrical equipment is sufficiently low as to not
ignite an explosive atmosphere

Ex ia Zone 0,1,2
Ex ib Zone 1,2

Introduction

Types of Protection for Gas/Vapour Hazard

A22

A23

Introduction

Intrinsic Safety Type - Ex i

A24

A type of protection in which the parts can ignite

an explosive atmosphere are to be placed in an
enclosure, which can withstand the pressure
developed during internal explosion of an
explosive mixture, and which prevents the
transmission of the explosion to the explosive
atmosphere surrounding the enclosure

Electrical equipment is housed in an

enclosure which is initially purged to remove
any explosive mixture, then pressurized to
prevent
ingress
of
the
surrounding
atmosphere prior to energizing.

Introduction

Introduction

Flame Proof Type - Exd

A25

Pressurization Type - Exp

A method of exclusion of the

explosive
atmosphere
by
fully
encapsulating
the
electrical
components in an approved material

This equipment is so designed as to eliminate

sparks and hot surfaces capable of igniting an
explosive atmosphere

Introduction

Introduction

Increased Safety Type - Exe

A27

The electrical components are

immersed in oil, thus excluding the
explosive atmosphere from any
sparks or hot surfaces

EncapsulationType - Exm

A28

Equipment is surrounded with a fine

powder, such as quartz, which does not
allow the surrounding atmosphere to
come into contact with any sparks or
hot surfaces

Introduction

Oil Immersion Type - Exo

A26

A29

Introduction

Powder FillingType - Exq

A30

Sparking
contacts
are
sealed
against ingress of the surrounding
atmosphere, hot surfaces are
eliminated

Introduction

Non Sparking Type - Exn

A31

Introduction

IEC Marking

Adequate precautions to avoid ESD & Lightning to be implemented

Use of light alloy (Mg, Al, Ti, ) material to be assessed critically in
HAs due to its incendive properties
Where reasonably practical, electrical apparatus generally and
switch & control apparatus should be installed outside the
Hazardous Areas
Electrical apparatus may be installed in open air in a non-hazardous
area
Equipment designed for higher gas groups can be used for less
hazardous gas groups ( for e.g., Equipment certified for II C can be
used for II A, B or I)
Portable hand-lamps, communication equipment and other test
equipment shall be Ex i type
All equipment shall be installed so as to avoid mechanical damage
Earthing shall be carried out where necessary

Example:
IP 54

Introduction

Introduction

Ingress Protection (IP Class)

A33

Bonding of all pipeline flanges should be carried out so as to avoid

Electro-static discharges
Internal earthing to be provided for all Flame Proof equipment in
addition to external earthing
All circuits and apparatus in Hazardous Areas should be provided
with means to ensure quick disconnection in the event of any fault
(O/C, S/C or E/F)
Protection & Control apparatus shall be normally located in non-HAs
but if unavoidable, they may be of the right protection type
All electrical apparatus (for every apparatus or sub-groups) should
be provided with an effective means of isolation, including neutral
Metal conduits, armoured cables
Correct terminations using proper sized cable glands (doublecompression, Flame Proof type)
Unused cable openings of all electrical apparatus shall be closed
with plugs suitable for the type of protection
Introduction
INSTALLATION GUIDELINES OF ELECTRICAL EQUIPMENT IN
HAZARDOUS AREAS

A32

A35

INSTALLATION GUIDELINES OF ELECTRICAL EQUIPMENT IN

HAZARDOUS AREAS

A34

Flame Proof Equipment

All bolts in place
All openings closed
No site modification / alteration
Internal & external earthing
Double-Compression, Flame Proof cable glands
No physical damage
All threaded connections-minimum 5/ 6 threads
engagement
Flange faces to be smooth & original
Introduction

MAINTENANCE RECOMMENDATIONS IN HAZARDOUS AREAS A36

 Light alloy paint even for the purpose of maintenance must

not be applied on any external surface of the equipment to
prevent incendive frictional sparking
Equipment shall not be tampered to open covers, etc.
No components shall be added or removed or even
replaced. This has to be done after getting re-certified by
the OEM
A scheme of regular inspection & maintenance of the items
should be made on the basis of guidelines / standards. Any
equipment which is originally flameproof may loose its
integrity if not maintained properly
The equipment should be de-energized before attempting
any repair
Insulation integrity to be periodically tested and
maintained
Introduction

MAINTENANCE RECOMMENDATIONS IN HAZARDOUS AREAS A37

Ex i - No addition / alteration of circuit components / power

limitation barriers, etc.
Check Ex p equipment / panels / rooms for low pressure
interlock operations, periodic review of air in take stack
location
Terminations in Ex e, n types equipment
Use of non-sparking tools
ELECTRICAL EQUIPMENT USED IN HAZARDOUS ARAES ARE
SPECIAL AND THEY NEED TO BE TREATED SPECIAL
Introduction

MAINTENANCE RECOMMENDATIONS IN HAZARDOUS AREAS A38