HAZARDOUS AREA CLASSIFICATION & SELECTION OF ELECTRICAL

EQUIPMENT FOR FLAMMABLE ATMOSPHERES

It is clear from the fire triangle that fire/ explosion/combustion can be eliminated or avoided if any one component of the
triangle is eliminated. Electrical spark is one of major ignition source. By proper selection of electrical equipment at the
design stage, it is possible to avoid this major source of ignition. This would help in avoiding or reducing the accident due
to electrical sparks in hazardous area.

Hazardous Areas-Definitions

 Petroleum Rules, 1976

 An area shall be deemed to be a hazardous area, where:
 petroleum having FP below 65 deg C or any inflammable gas or vapour in concentration capable of ignition is
likely to be present
 petroleum or any inflammable liquid having FP above is likely to be refined, blended or stored at or above its FP

 IS 5572

 Hazardous area is an area in which an explosive gas atmosphere is present, or likely to be present, in quantities
such as to require special precautions for the construction, installation and use of electrical apparatus.

Why Area Classification?

 HAC is a method of analyzing and classifying the environment where explosive gas atmospheres may occur to allow the
proper selection of electrical apparatus to be installed in that environment.
 Ignition sources not considered
 ESD
 Sparks
 Lightning
 Flames/Fires
 Hot surfaces

 IS 5572
 HA’s are classified in zones based on the frequency of the appearance and the duration of an explosive gas
atmosphere.

Why Zoning?

 Leak Potential & Presence of Ignition Sources

 Hazardous properties of hydrocarbons
 Safe selection (& optimization) of Electrical Equipment

Zone 0 -Typical areas (Continuous grade)

 An area in which an explosive gas atmosphere is present continuously or is present for long periods.
 Vapour space above:

 closed process vessels,

 storage tanks
 closed containers,
 areas containing open tanks of volatile, flammable liquid
How to identify Zone 1 areas (IS 5572) ?

 Flammable gas or vapour concentration is likely to exist in the air under normal operating conditions
 Flammable atmospheric concentration is likely to occur frequently because of maintenance, repairs or leakage.
 Flammable liquid or vapour piping system (containing valves, meters, or screwed or flanged fittings) is in an
inadequately ventilated area
 The area below the surrounding elevation or grade is such that flammable liquids or vapours may accumulate therein

Zone 1 -Typical areas

 Imperfectly fitting peripheral seals on floating roof tanks

 Inadequately ventilated pump rooms for flammable gas or for volatile, flammable liquids
 Oily waste water sewer / basins
 Loading / unloading gantries of hazardous products
 Production blocks, Tank form areas in API units

Typical Zone 2 areas (IS 5572) ? (Secondary grade)

 An area in which an explosive gas atmosphere is not likely to occur in normal operation and if does occur it will exist
for a short period only.
 Normal Operation The situation when the plant equipment is operating within its designed parameters.
 Minor releases of flammable material may be part of normal operation. For example, releases from seals which rely on
wetting of fluid being pumped are considered to be minor release.
 Failures (such as the breakdown of pump seals, flange gaskets or spillages caused by accidents) which involve repair or
shut-down are not considered to be part of normal operation

Safe Areas -Typical areas

The following locations are considered safe from the point of view of electrical installation:

 Areas where the piping system is without valves, fittings, flanges or similar appurtenances
 Areas where flammable liquids or vapours are transported only in suitable containers or vessels
 Areas where permanent ignition sources area present like area where combustion gases are present, for example flare
pits, tips, other open flames & hot surfaces
 DG shed room / shed having adequate ventilation

For Zone – 1 & 2:

 The coverage is 8 Mtrs above the source and 16 Mtrs horizontally in all directions.
 If there is possibility of large release of volatile products, the Zone 2 area may be further extended to 32 Mtrs
with height of 0.63 Mtrs.
 In case of petroleum carrying pipelines in well ventilated area the extent of Zone 2 area is 4 Mtrs. in all
directions.
 All areas below ground level are considered as Zone 1 area.
 If source of hazard gives rise to a hazardous atmosphere under normal operating conditions then the area
described above as Zone 2 shall be considered as Zone 1.

 In the event of an enclosed premises not containing the source of hazard but situated within Zone 1 or Zone 2
area, the inside of the premises shall be classified as Zone 1 unless separated from outside hazardous area by a
fire wall.

Article by: BRL Swamy-Funder Member of CEP