Sales Bulletin No.

06/2005 Hazardous Area Classifications

Hazardous Areas are locations where the potential for fire or explosion exists because of gases, dust, or easily ignitable fibers or flyings in the atmosphere. In North America, hazardous areas are separated by classes, divisions, and groups to define the level of safety required for equipment installed in these locations. Classes define the general form of the flammable materials in the atmosphere. Divisions define the probability of the presence of flammable materials. Groups classify the exact flammable nature of the material. In Europe and countries outside of North America, classification of hazardous areas is accomplished differently. Zones are used to define the probability of the presence of flammable materials. Protection Types denote the level of safety for the device. Groups classify the exact flammable nature of the material. These groups are separated differently than North American Groups. Temperature Identifications convey the maximum surface temperature of the apparatus based on 104 F (40 C) ambient. These temperature codes are selected carefully not to exceed the ignition temperature of the specific gas or vapor to be encountered in the application. Some classifications are not shown here. For further detailed information, see specific standards published by approval organizations.

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Dated: 09.06.2005

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Classifications Inside North America Classes Class I Class II Class III Flammable gases or vapors are present in the air in quantities sufficient to produce explosive or ignitable mixtures. Combustible or conductive dusts are present. Ignitable fibers or flyings are present, but not likely to be in suspension in sufficient quantities to produce ignitable mixtures. (Group classifications are not applied to this class.)

Division Division 1 Division 2 The substance referred to by class is present during normal conditions. The substance referred to by class is present only in abnormal conditions, such as a container failure or system breakdown.

Groups Group A Group B Group C Group D Group E Group F Group G Acetylene Hydrogen (or gases of equivalent hazard) Ethylene (or gases of equivalent hazard) Gasoline (or gases of equivalent hazard) Metal Dust Coal Dust Grain Dust

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Classifications Outside North America Zones Zone 0 Zone 1 Zone 2 Area in which an explosive gas-air mixture is continuously present or present for long periods. Area in which an explosive gas-air mixture is likely to occur in normal operation. Area in which an explosive gas-air mixture is not likely to occur, and if it occurs it will only exist for a short time.

Protection Types Zone d e ia ib o p q m n Flameproof (Explosion proof) Enclosure Increased Safety Intrinsic Safety Intrinsic Safety Oil Immersion Pressurized Apparatus (Purged Apparatus) Powder Filling (Sand Filling) Encapsulation Normally Nonsparking and/or Nonincendive Circuits) 1,2 1,2 0,1,2 1,2 2 1,2 2 1,2 2

Temperature Codes F T1 T2 T3 T4 T5 T6 842 572 392 275 212 185 C 450 300 200 135 100 85
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Groups Group I For application in below ground installations (mines) where methane (firedamp) and coal dust may be present. For application in above ground installation where hazards due to propane may exist. This group most closely matches the North American Group D. For application in above ground installations where hazards due to ethylene may exist. This group most closely matches the North American Group C. For application in above ground installations where hazards due to hydrogen or acetylene may exist. This group most closely matches the North American Groups A and B.

Group IIA

Group IIB

Group IIC

Hazardous-Area Classification and equipment The term hazardous location once meant a place within a petrochemical or some other equally volatile plant. Today, hazardous manufacturing processes include coatings, adhesives and flammable liquids in parts-cleaning tanks and dry-cleaning plants. Even flood processing and other agricultural-related industries are becoming familiar with hazardous designations by the nature of the processes involved, such as grain elevators or flour and feed mills. Textile mills and any plant that creates sawdust also fall into the hazardous category. Selecting equipment that may be used in such locations requires an understanding of how hazards are classified. The NEMA, Underwriters Laboratories , and the National Fire Protection Association have categorized hazardous environments by the following classes with divisions similar to European zones. The division defines the probability of an explosive mixture being present: Division 1 locations are areas where the hazardous concentration exists continuously, intermittently or periodically under normal operating conditions. Division 2 locations are those where the hazardous vapors are present only in case of accidental rupture or breakdown of equipment. Classification of hazardous areas varies slightly between the United States and other countries. The European classification of hazardous areas generally follows that of the International Electrotechnical Commission (IEC) and is affiliated with the International Organisation for Standardisation (ISO), as its electrotechnical division. The IEC classifications are as follows. A hazardous area is divided into zones: Zone 0: Where an explosive gas-air mixture is continuously present for long periods Zone 1: Where an explosive gas-air mixture is likely to occur in normal operation Zone2: Where an explosive gas-air mixture is not likely to occur, and if it occurs, it will only exist for a short time.

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The following table shows the zone and division cross reference used in IEC countries and North America.

IEC
United States

Zone 0
Division 1

Zone 1

Zone 2
Division 2

The responsibility for the area classification of a plant rests jointly with the engineering, process, safety, and any other departments involved in its design and operation. Factors to be considered include: 1. The probability that the hazardous gas is present 2. The quantity of hazardous gas 3. The nature of the gas (e.g. is it heavier than air?) 4. The extent of ventilation 5. The consequences of an explosion Product Classification Two other safety aspects are commonly included in the classification of devices for use in hazardous areas-gas groupings and temperature classification. The gas grouping takes account of the maximum amount of energy which can be released under operating or fault conditions, whereas the temperature classification is concerned with the maximum temperature which can be attained by the external surface of the device. Temperature classification Gasair mixtures can be ignited by contact with a hot surface, and consequently all electrical equipment used in hazardous atmospheres must be classified according to its maximum surface temperature: Table 11.2 shows the ignition temperature to be taken into consideration in Europe (IEC) and the United States (NEC) for the gases and vapors stipulated there. All temperature classifications, unless otherwise specified, are assessed with reference to a maximum ambient temperature of 400C (1040F). If the equipment is used in a temperature higher than this, then its temperature classification should be reassessed.

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Table 11.2 Temperature Classes IEC Temperature class Max. surface temperature C NEC Temperature identification number Max surface temperature Ignition temp. of gases or vapors, C

C T1 T2 450 300 T1 T2 T2A T2B T2C T2D T3 200 T3 T3A T3B T3C T4 135 T4 T4A T5 T6 100 85 T5 T6 45 0 30 0 28 0 26 0 23 0 21 5 20 0 18 0 16 5 16 0 13 5 12 0 10 0 85

F 842 573 536 500 446 419 392 356 329 320 275 248 212 185 >450 >300 >280 >260 >230 >215 >200 >180 >165 >160 >135 >120 >100 >85

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Table 11.3 Gas Groupings for IEC* Example of gases IEC North America (group) D

Hydrocarbons such as alkenes, including propane, benzenoids, alkenes, gasoline Oxygen compounds such as carbon monoxide, alcohols and phenols, some aldehydes, ketones, esters Halogens Nitrogen compounds such as ammonia, amines, amides Natural Gas Hydrocarbons such as ethylene propylene Oxygen compounds such as ethyl, ether, aldehydes Hydrogen sulfide Hydrogen Carbon disulfide Acetylene (with special material limitations) *NOTE: These are approximate correlations.

IIA

IIB

IIC IIC

B A

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Gas or Apparatus Grouping The same gas groupings are used for flameproof and intrinsically safe equipment, and tables are available showing the equipment classification which can be used with particular groups of gases. Table 11.3 gives some examples with the IEC and North American classifications, Gas groups E, F, and 0 are concerned with hazards associated with the presence of dust. The overall term used in Europe covering all methods of protection is explosion-proof, and the symbol Ex is used. In the United States engineers tend to use the term explosion-proof as being synonymous with the European term flameproof and this often causes confusion. Methods of Safe Control Understanding design methods for operating equipment in hazardous areas starts with the combustion triangle. Fuel, Oxygen and a source of ignition (spark or temperature) must be present at the same time (and in the necessary proportions) for combustion to occur. One approach to creating a safe environment for hazardous areas is confinement, isolating the area reduces the possibility of accidents. Isolation involves removing or confining any possible element which could create a spark and ignite an explosion. There are three common methods of providing safety within a hazardous location, categorized by the power technology used: (1) pneumatic, (2) explosion-proof, and (3) intrinsically safe systems. Pneumatic Systems Pneumatic Systems are, by their nature, a safe means of control because they are powered by air. Pneumatic systems are generally clean and easy to service, but the number of control operations performed by pneumatic sequencers is limited. This can be augmented by an electropneumatic interface which enables pneumatics to be controlled by a Programmable Logic Controller. The drawbacks to pneumatic systems are in distance and reaction time. Where installations are spread over a wide area, the slow reaction time of pneumatic systems increases control reaction time. The length of control circuits in a total pneumatic system must be limited for the control cycle time to remain short. Explosion-proof housings Explosion-proof housings provides a simple means to adapt electric and electromechanical and electropneumatic controls to hazardous locations. Explosion-proof housings are designed to withstand the explosion of a mixture inside the enclosure and to prevent the spread of the flame to the outside. These enclosure are effective, especially for interrupting high currents to motors using limit switches. However, this methods lacks flexibility in the use of sensing techniques because of the size of the devices. In addition to the space required for explosion-proof devices, material and labour costs for installation and service may be high.

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NEMA classifications. The NEMA classifies electrical equipment and enclosures for industrial applications as follows:
I. General purpose II. Driptight Project against indirect splashing of dust and light but is not dusttight, primarily prevents contact with live parts, used indoors and under normal atmospheric conditions. Similar to type I, with addition of drip shields or equivalent, used where condensation may be severe as in cooling rooms and laundries. Protects against weather hazards such as rain and sleet, used outdoors on ship docks, for construction work, and in tunnels and subways. Must exclude at least 65 gal/mm (247 L/m) of water from 1-in (25-mm) nozzle delivered from a distance of not less than 10 ft (3m) for 5mm. Used outdoors on ship docks, in dairies, and in breweries. Provided with gaskets or equivalent to exclude dust, used in steel mills and cement plants. Design depends on specified conditions of pressure and time, used for submersion in water, as in quarries, mines, and man holes. Meets applications requirements class I of National Electrical Code, conforms with specifications of Underwriters Laboratories Inc. used for atmosphere containing gasoline, hexane, naphtha, benzene, butane, propane, acetone, benzol, lacquer-solvent vapors, and natural gas. Type 8 enclosures are for indoor or outdoor use in locations classified as class I, Groups A, B, C, or fl as defined in the National Electrical Code.

III. Weather resistant IV. Waterlight (weatherproof) V. Dusttight VI. Submersible

VII. Hazardous location (explosive gas or vapor) Type 8 enclosure (VIII. Hazardous locations, oilimmersed) Type 9 enclosure (hazardous locations, dustignition proof) IX. Hazardous locations (combustible dust)

Type 9 enclosures are for use in indoor locations classified as class II, groups E, F, and G as defined in the National Electrical Code.

Meets applications requirements class II of National Electrical Code, conforms with specifications of Underwriters Laboratories Inc. used for atmosphere containing metal dust, carbon black, coal or coke dust, flour, starch or grain dusts.

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