Area Classification and Related Electrical IP 16-1-1

INTERNATIONAL Design for Flammable Liquids, Gases or Vapors Page 1 of 7

PRACTICE
Rev. 0 March 1998

Changes shown by 

SCOPE
I  1.1 This practice covers the classification of areas where flammable liquids, gases, or vapors are handled,
processed, or stored.
I  1.2 The requirements of this practice are intended for application to petroleum refineries and similar
petrochemical facilities.
I 1.3 An asterisk () indicates that additional information is required. If a job is contracted, this additional
information is furnished in the Job Specification.

SUMMARY OF ADDITIONAL REQUIREMENTS

I  2.1 Table 1 lists the standards (including recommended practice) which shall be used with this practice.
TABLE 1

STANDARDS

ANSI / NFPA Standards

70 National Electrical Code (NEC)
496 Purged and Pressurized Enclosures for Electrical Equipment
497A Recommended Practice for Classification of Class 1 Hazardous (Classified) Locations
for Electrical Installations in Chemical Process Areas (1)
497M Manual on Classification of Gases, Vapors and Dusts for Electrical Equipment in
Hazardous (Classified) Locations
API Recommended Practice
RP 500 Classification of Locations for Electrical Installations at Petroleum Facilities
IEC Standard
79-14 Electrical Apparatus for Explosive Gas Atmospheres - Part 14: Electrical Installations in
Hazardous Areas (Other Than Mines)
OTHER REGIONAL OR NATIONAL STANDARDS
Appropriate Regional or National Standard Applicable to the specific location.

Note:
(1) The application of NFPA 497A shall be limited to small or batch type plants in accordance with NFPA 497A.
Continuous process or large batch type plants shall comply with API RP 500 and this practice.
I 2.2 Where compliance with any code or standard specified by an authority having jurisdiction is mandatory, the
prescribed regulation shall be met.

DOCUMENTATION
S  3.1 Area classification drawings shall be prepared by the contractor as follows:
a. The classification and extent of each area shall be shown with major structures and equipment
indicated.
Drawings shall provide plan views and those sectional views required to supplement API RP 500 and
Figures 1 through 2A of this practice.
b. All equipment which is considered a source of flammable liquid, gas or vapor shall be shown on the
drawings. Each source shall be identified by equipment number, flammable material(s) handled,
flash point(s) and ignition temperature(s), and atmosphere group(s) according to the standard(s) to
which electrical equipment is to be purchased.
c. Drawing shall specify the edition date of the standard used for the classification and note exceptions
which have been taken.

DEFINITIONS
I 4.1 Flammable liquids, for purposes of area classification, are those having:
a. Flash points below 100F (37.8C).
b. Temperatures above or within 15F (8C) of their flash points.

THIS INFORMATION FOR AUTHORIZED COMPANY USE ONLY

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.
 IP 16-1-1 Area Classification and Related Electrical
Page 2 of 7 Design for Flammable Liquids, Gases or Vapors INTERNATIONAL
PRACTICE
Rev. 0 March 1998

I 4.2 Area classification is not required for liquids which do not meet Par 4.1 criteria. Note, however, that area
classification is required for equipment or storage facilities which under normal or abnormal conditions can
be contaminated by flammable liquids.
a. NEC Class I Divisions correlation with International Electrotechnical Commission (IEC) Zones and
Zone definitions are provided in Pars. 7.1 and 7.2.
b. NEC Class I atmosphere groups correlation with IEC groups is provided in Par 7.3.

AREA CLASSIFICATION
S 5.1 All areas shall be classified in accordance with API RP 500 as modified in the following paragraphs.
S  5.2 Figures A1 through A14 of API RP 500 shall be applied with the following modifications:
API RP 500 MODIFYING FIGURE
TITLE REFERENCE OF THIS PRACTICE

Adequately Ventilated Process Area. Buildings with None Figure 1

Heavier-than-Air Gas Source

Mechanical Induced Draft Cooling Tower Handling Figure A - 9 Figures 2, 2A

Process Cooling Water

I  
5.3 Where the release source which determines classification does not have the capability of producing a
large quantity of flammable liquid, gas, or vapor, the “Additional” 50’ x 2’ high classified zone may be
waived subject to approval of the Owner’s Engineer.
S 5.4 Areas above Division 2 locations, in order to be designated as “unclassified," must be either of the
following:
a. An outdoor location without restricted ventilation, or,
b. Within a closed building (such as substation or control house) or outdoor switchgear or control center,
whose floor level is above the Division 2 area and with the space beneath the floor either solid filled
or open on at least 3 sides. If lighter-than-air gas is involved, the floor must be without openings and
non skirted.
S 5.5 Mixtures of gases of different groups may be involved, or sources of both heavier-than-air and lighter-
than-air gases may exist within an area. In classifying such areas, all the following shall apply:
a. Upon release, gas mixtures shall be considered to separate immediately into their separate gases. If
the separate gases are of different groups, electrical equipment used within each classified area shall
be suitable for all the groups involved.
b. In mixtures of Group C and D gases per NEC (or the equivalent gases designations per the
applicable standard) the Group C gases shall be disregarded if they constitute 30% or less by volume
of the mixture.
c. If the separate gases in a gas mixture are both lighter-than-air and heavier-than-air, the extent of the
separate area classifications shall be as specified in this practice (for lighter-than-air and heavier-
than-air gases). Overlapping of classified areas involving different atmosphere groups will usually
result.
d. In areas which are adequately ventilated from the standpoint of lighter-than-air vapor, the hydrogen in
a gas mixture shall be disregarded if it constitutes 30% or less by volume of the gas mixture.
e. Mixtures of Group B, C and D gases per NEC (or the equivalent gases designations per the
applicable standard) with sufficient inert or non-flammable gases to prevent a flammable mixture do
not require area classification.
S 5.6
All piping systems are considered to be well-maintained, closed systems, including systems which
contain valves, fittings, meters, or flanged and threaded connections. Therefore, adequately ventilated
areas through which piping is routed need not be classified.
While leakage or small releases from the piping system components may occur infrequently the effect of
ventilation (natural or artificial as appropriate to the location) which permits judging the location to be
adequately ventilated, prevents the formation of flammable atmospheres.
Recent testing for emissions from control valves has shown that the normal leakage was far below the
lower flammable limit required for a flammable atmosphere. Therefore, well-maintained control valves in
adequately ventilated areas do not require classification.

THIS INFORMATION FOR AUTHORIZED COMPANY USE ONLY

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 Area Classification and Related Electrical IP 16-1-1
INTERNATIONAL Design for Flammable Liquids, Gases or Vapors Page 3 of 7
PRACTICE
Rev. 0 March 1998

Fuel gas and pilot gas knockout drums adjacent to fired equipment and drained into closed systems shall
be considered part of the piping system.
S  5.7 The following equipment and facilities shall be classified to the extent indicated:

UNIT OR FACILITY CLASSIFIED AREA

a. Boiler Plant, Gas Turbine Power Plant Areas around: gas compressors, flammable liquid fuel storage tanks
(with or without supplementary fired and vessels, vaporizers, and pumps.
waste heat boilers)

b. Marine Loading Arms handling Electrical devices shall be suitable for Class I Division 1 locations.
flammable liquids

c. Tank Truck and Rail 1. Classify per API RP 500 Figure A-4 for heavier-than-air release
Loading/Unloading facilities handling sources other than loading/unloading positions. The “Additional"
flammable liquids (50 ft x 2 ft high) Division 2 area can be waived providing the area
is freely ventilated and spills are contained with the classified area.
2. Classify the loading/unloading positions per API RP 500 Figure
A-11 through A-14 and C-21 providing the areas is freely
ventilated and oil spills are contained within the classified area.

ELECTRICAL DESIGN FOR CLASSIFIED AREAS

S 6.1 Electrical equipment selection and installation for classified areas shall be in accordance with
ANSI/NFPA 70 Article 501 (or the appropriate articles of the applicable standard), except where covered
by this and other practices.
S 
6.2 Ventilating Air. For buildings or enclosures whose area classification is improved by means of artificial or
pressure ventilation, ventilating or pressurizing air shall be obtained from a point at least 10 ft (3 m) above
grade, 10 ft from the nearest Division 1 area, and 10 ft above the roof of the building restricting free air
movement. Particular attention must be given to location relative to pressure relief valves and other vents.
If the classification improvement is to “unclassified," the point at which air is obtained shall be in a
unclassified area, not above a lighter-than-air classified area. Design basis for ventilating systems for
buildings or rooms shall be approved by the Owner's Engineer.
I 
6.3 Specific enclosed Division 1 locations containing a release source, such as a compressor shelter, or
an analyzer enclosure artificially ventilated or pressurized by air taken from Division 2 or unclassified
locations. Design basis shall be approved by the Owner's Engineer.
EQUIPMENT FOR CLASSIFIED AREAS
S 6.4 Approved equipment, which is required for classified locations, shall be labeled, listed, or certified by a
nationally recognized testing organization such as the Underwriters Laboratory (USA), BASEEFA (Great
Britain), or PTB (Germany). Where such equipment is not available, its design shall conform to the
standards of a nationally recognized testing organization. Note particularly that designs using oil
immersion for reasons of insulation or corrosion protection are not acceptable as satisfying the intent of
this requirement unless so labeled, listed, certified, or conforming.
S 
6.5 Arcing and sparking equipment shall be as follows for the specified area classification:

AREAS CLASSIFICATION EQUIPMENT TYPE

Division 1 Intrinsically safe or explosion proof, approved for the gas group
NEC Groups involved, or
B, C, D or equivalent Equipment approved by the applicable code or standard

Division 2 1. Same as Division 1, or

NEC Groups 2. Oil-immersed approved for the gas group involved, or
B, C, D, or equivalent 3. Hermetically sealed with enclosure providing suitable
mechanical protection

Division 1 and 2 If equipment meeting the above requirement is not available,

NEC Groups pressurized equipment shall be used. Design of equipment shall
be approved by the Owner's Engineer.
B, C, D, or equivalent

S 6.6 Motor enclosure selection shall conform to Table 1 of IP 16-7-1.

THIS INFORMATION FOR AUTHORIZED COMPANY USE ONLY

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.
 IP 16-1-1 Area Classification and Related Electrical
Page 4 of 7 Design for Flammable Liquids, Gases or Vapors INTERNATIONAL
PRACTICE
Rev. 0 March 1998

CLASS I DIVISIONS AND GROUPS CORRELATION WITH

IEC ZONE AND GROUP DESIGNATION BASES
I 7.1 The following table is a guide for correlating the class and division designations per NEC, with the zone
designation system for classified areas used by IEC and other regional and national standards.

PRESENCE OF IGNITABLE
CONCENTRATIONS ZONE
NEC CLASS 1 DIVISION OF FLAMMABLE GASES AND VAPORS DESIGNATION

Division 1 Continuously or for long periods Zone 0(1)

Division 1 Under normal operating conditions Zone 1

Division 1 Frequently because of repair, maintenance or Zone 1

leakage

Division 1 Equipment breakdown or faulty operation Zone 1

might release ignitable concentration and
might also cause simultaneous failure of
electrical equipment that could become a
source of ignition

Division 2 In case of abnormal equipment operation or Zone 2

breakdown or rupture of closed containers or
closed systems

Division 2 Normally prevented by positive ventilation and Zone 2

might become ignitable through failure or
abnormal operation of the ventilating
equipment

Division 2 Adjacent to a Division 1 location (and not Zone 2

separated by a vapor tight barrier) and to
which ignitable concentrations of gases or
vapors might occasionally be communicated

Note:
(1) For this condition, IEC 79-14 requires installation of intrinsically safe apparatus and systems.
I 7.2 The zone definitions in IEC 79-10 “Classification of Hazardous Areas and Installation Requirements" are:
Zone 0 - An area in which an explosive gas atmosphere is present continuously or for a long period.
Zone 1 - An area in which an explosive gas atmosphere is likely to occur in normal operation.
Zone 2 - An area in which an explosive gas atmosphere is not likely to occur in normal operation and if it
does occur, is likely to do so only infrequently and will exist for a short period only.
I 7.3 The following table is a guide for correlating the NEC Class I flammable groups with the equivalent group
designations used by IEC and other regional and national standards.

FLAMMABLE WITH
CHARACTERISTICS NEC CLASS I IEC
TYPICAL OF THE GROUP GROUP GROUP

Acetylene A IIC

Hydrogen B IIC

Ethylene C IIB

Propane D IIA

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 Area Classification and Related Electrical IP 16-1-1
INTERNATIONAL Design for Flammable Liquids, Gases or Vapors Page 5 of 7
PRACTICE
Rev. 0 March 1998

Revision Memo
9/68 Original Issue of Basic Practice 1/83 Revision 3
6/72 Revision. 1 12/93 Revision 4
1/75 Revision 2
3/98 Revision 0 - Original Issue of International Practices
Complete editorial revision to rationalize this practice with the referenced standards and other IPs. Significant changes include: the
following paragraphs of BP 16-1-1 Revision 4 have been deleted: 1.1b, 4.1-4.3, 5.2 table (4 rows) & note, 5.6 table (row b.),
Figures 1 and 2. Par. 1.1 reworded after Subpar. deletion. Par. 1.2 note was deleted. Par. 2.1 added IEC Standard. Pars. 3.1 &
Par. 5.2 revised reference to API RP 500 figures. Par. 5.3 provides guidance on additional Div. 2 areas. Par. 5.7 revised to match
API RP 500.
Old Par. No. New Par. No.
4.2d 6.3
4.4, 4.5 4.1, 4.2
4.1d 5.3
5.3 - 5.6 5.4 - 5.7
6.3, 6.4a 6.4, 6.5
6.4b 6.6
Fig. 3, Fig. 4 Fig. 1, Fig. 2
Fig. 4a Fig. 2a

© Exxon Research and Engineering Company, 1993, 1998

FIGURE 1
ADEQUATELY VENTILATED PROCESS AREA BUILDINGS WITH HEAVIER-THAN-AIR GAS SOURCE

Continuous Ridge Ventilation

10'

Source of
"Additional"
Release
Division 2
2'
10'
25'

Grade
8' Min 50' 50'
Open Sides

Acceptable Metric Equivalents

Division
Legend: ft 2 8 10 25 50
2
m 0.6 2.4 3 7.5 15
160101f1

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EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.
 IP 16-1-1 Area Classification and Related Electrical
Page 6 of 7 Design for Flammable Liquids, Gases or Vapors INTERNATIONAL
PRACTICE
Rev. 0 March 1998

FIGURE 2
MECHANICAL INDUCED DRAFT TYPE COOLING TOWER HANDLING PROCESS COOLING WATER
(MODIFICATION OF API RP 500 FIGURE A-9)

10'

10'
10'

10'
1

2 2

Return
Header

3 10'

Legend: Division 2

1 Fan Stack

2 Water Distribution Basins (Crossflow towers only)

3 Pump Basin

1. Division 2 classification for tower and external based on:

A. Hydrocarbons disengaged from cooling water are flammable liquids.

B. Probability of tower having to disengage hydrocarbons meets Division 2 location criteria.
C. Fans operate at all times when cooling water flows through tower and fans do not operate
in reverse mode.

2. If frequency of disengaging hydrocarbons exceeds Division 2 criteria or fan operation does

not conform to 1-C, use Figure 2-A to determine the classified areas.

Acceptable Metric Equivalents

ft 5 10 25 50
m 1.5 3 7.5 15
160101f2

THIS INFORMATION FOR AUTHORIZED COMPANY USE ONLY

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.
 Area Classification and Related Electrical IP 16-1-1
INTERNATIONAL Design for Flammable Liquids, Gases or Vapors Page 7 of 7
PRACTICE
Rev. 0 March 1998

* FIGURE 2-A
MECHANICAL INDUCED DRAFT TYPE COOLING TOWER HANDLING PROCESS COOLING WATER
(USE WHEN REQUIRED BY NOTE 2 OF FIG. 2)

10'

10'

10'
10'
5' 5' Radius

10'
5'
1

10'
5'

2 2

25' 25'

50' 50'

25'
25'

Note (1) Note (1)

Return
Header

Note:
(1) 50' dimension to be measured from outside edge of cooling tower basin

Legend: Division 1 Division 2

1 Fan Stack

2 Water Distribution Basins (Crossflow towers only)

3 Pump Basin

Acceptable Metric Equivalents

ft 5 10 25 50
m 1.5 3 7.5 15
1601012a

THIS INFORMATION FOR AUTHORIZED COMPANY USE ONLY

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.