HAC MAterial

Hazardous Area
Classification
N. Sanei
October 2017
Hazardous Area Classification
 Hazardous Area Classification, Why?

Gases, vapors, mists and dusts can all form explosive
atmospheres with air;
Hazardous area classification is used to identify places
where, because of the potential for an explosive
atmosphere, special precautions over sources of ignition
are needed to prevent fires and explosions;
 Hazardous Area
Hazardous areas are defined as:
“Any place, in which an explosive atmosphere may occur in
quantities such as to require special precautions to protect
the safety of workers“;
In this context, “special precautions” is best taken as
relating to the construction, installation and use of
apparatus (both electrical & mechanical);
 The Philosophy
Hazardous Area classification is a method of analyzing and
classifying the environment where explosive gas
atmospheres may occur;
The main purpose is to facilitate the proper selection and
installation of apparatus to be used safely in that
environment, taking into account the properties of the
flammable materials that will be present;
When the hazardous areas of a plant have been classified,
the remainder will be defined as “non-hazardous”,
sometimes referred to as “safe areas”;
 The Triangle
Oxygen
Ignition Flammable
Source Material
 Conventional Ignition Source
Flammable Vapor/
Flashing Liquid/ Dust
Spark/ Ignition Source

 Auto-Ignition Temperature
Leaking Liquid/
Flammable Vapor
HOT
SURFACE
 Probability of a Component Leak (API 4615)

 Potential Ignition sources

The following ignition sources are examples that can cause
an explosion in the right circumstances:
 Electric arcs and spark;

 Flames and hot surfaces;
 Electrostatic sparks;
 Thermite sparks;
 Mechanical friction;
 Mechanical sparks produced by grinding;
 Smoldering deposits;
 Compression ignition;
 Electromagnetic radiation;
 Chemical reactions;
 Ultrasonic;
 Ignition Sources of Major Fires (FM Global)

 Potential Leak Sources

The following are some of the most common potential leak
sources in different systems:
 Flange gasket connection points on local piping, tubing, or

at equipment;
 Flange gaskets or screwed connections in main headers;
 Seals (unless seal-less) at pumps / at compressors;
 Pressure relief devices due to overpressure in the
system;
 Gas relief points located in the open air;
 Storage tanks, vaporizer, and diked areas;
 Gas storage cylinders;
 What is Hazardous Area Classification?

- Reducing to a minimum the probability of coincidence of
a flammable atmosphere and a source of ignition;
- A method to analyze & classify environments where
flammable/ explosive gases/ dusts are present;
- Facilitates selection of suitable equipment to reduce
fire/ explosion risk;
- Allows potential sources of high risk to be identified
clearly on a dedicated drawing;
 Purpose of an Area Classification

- Identify the possibility of an explosive atmosphere
being present and influencing the design of the plant or
facility to minimize the risk of ignition;
- Based on normal operating conditions - does not deal
with the potential of catastrophic failures;
- Primarily used for establishing the type of electrical
(mechanical as well) equipment and wiring methods that
can be used within a hazardous area;
 Hazardous Area Classification Risk Assessment

- Based on the likelihood of a flammable mixture being
present;
- Source of ignition is not a criteria for classification of a

location;
- Must be carried out before the choice of appropriately
certified equipment is made;
- Requires an understanding of process, mechanical and
electrical engineering concepts;
- Requires an understanding of the various codes and
practices and knowing which one is most suitable for a
given situation;
 Explosive Atmosphere, The Probability

The Probability that an Explosive Atmosphere will exist
depends on:
 Flammable Material Present;

 Source of Release;
 Grade of Release:
- Continuous (>1000 hours per year);
- Primary (10-1000 hours per year);
- Secondary (1-10 hours per year);
 Rate of Release;
 Degree of Ventilation;
 Extent of a Hazardous Area Classification

Extent of a Hazardous Area Classification depends on:
 Properties of the flammable material:

- Concentration;
- Volatility;
- Temperature & Pressure;
- Density;
 Release rate:
- Geometry of the source of release;
- Release velocity;
 Ventilation;
 Climate condition & Topography;
 How does it work?

- Identifies properties of fluid/dust to allow correct
selection of equipment to help minimize risk of
explosion;
- Divides areas of a plant into “ZONES” according to
risk/likelihood of inventory release, rate of release and
properties of the fluid/dust;
- Allows mitigation of explosion risks by assessment of
ventilation;
- Also determines type of electrical equipment permitted
within zones;
 Who is impacted?
- Engineering;
- Equipment manufacturers;
- Installers;
- Inspectors;
- Operation, maintenance and the safety personal;
- Insurers;
 Codes & Standards

- Alberta OHSA Requirements, Part 10, Fire and Explosion
Hazards;
- (API RP500), Recom. practice for classification of
locations for electrical installations at petroleum facilities
classified as Class I, Division 1 and Division 2 (refers to
Division Classified area as defined in Article 500 of the
NEC);
- (ANSI/API RP505), Recom. practice for classification of
locations for electrical installations at petroleum facilities
classified as Class I, Zone 0, Zone 1, and Zone 2 (refers to
Zone Classified areas as defined in Article 505 of the
NEC);
 Codes & Standards (cont'd)

- National electrical code: NFPA 70;
- NFPA 497, Recommended practice for classification of
Flammable Liquids, Gases, or Vapors and of Hazardous
(Classified) Locations for Electrical Installations in
Chemical Process Areas (Makes reference to both the
Zone and Division method of Classification, in accordance
with other parts such as 30, 55, 101, 325 and 499);
- Area Classification Code for Petroleum Installations,
Institute of Petroleum, Part 15 (IP 15 is the first code to
use dispersion modeling as a basis for defining the extent
of classified areas);
 Codes & Standards (cont'd)

- EN1127-1, Explosive atmospheres: Explosion prevention
and protection, Part 1: Basic concepts and methodology;
- Electrical apparatus for explosive gas atmospheres, EN
60079 (IEC 60079, different parts);
- ISA RP 12.24.01 (IEC 79-10 Mod), Revision of IEC 60079-
10 to suit North American standards and definitions;
- Russian PUE standards / Brazilian ABNT code;
- Canadian Electrical Code, CSA C22.1 (CEC Section 19
provides guidelines for upstream oil and gas and drilling
facilities);
 North America vs. Europe

 North America:
Hazardous locations in North America are separated by

classes, divisions, and groups to define the level of safety
required for equipment installed in these locations;
 Europe:
Hazardous areas in Europe are classified by gas groups

and zones;
 Definitions
 Class:
Definition of the Hazard;
 Zone / Division:
Probability that a hazard may exist;
 Group:
Characteristics of the hazardous substance;
 Temperature Code:
Maximum Surface Temperature allowable in
the area;
 Class, Definition of the Hazard

 Class I : Flammable gases and vapors;
 Class II : Combustible / Conductive Dusts;
 Class III : Ignitable Fibers or Flyings;
 Non-hazardous : Areas where Class I, II or III
substances are not expected to be present in quantities as
to require special precautions;
 Division, Probability that a hazard may exist

 Division 1:
The substance referred to by the class is present during

normal conditions;
 Division 2:
The substance referred to by the class is present only in

abnormal conditions, such as a container failure or system
breakdown;
 Zone (ATEX)
Zone 0: A place in which an explosive atmosphere
consisting of a mixture with air of dangerous substances in
the form of gas, vapor or mist is present continuously or
for long periods or frequently;
the form of gas, vapor or mist is likely to occur in normal
operation occasionally;

the form of gas, vapor or mist is not likely to occur in
normal operation but, if it does occur, will persist for a
short period only;
 Zone (cont'd)
Zone 20: A place in which an explosive atmosphere in the
form of a cloud of combustible dust in air is present
continuously, or for long periods or frequently;
form of a cloud of combustible dust in air is likely to occur
in normal operation occasionally;

form or a cloud of combustible dust in air is not likely to
occur in normal operation but, if it does occur, will persist
for a short period only;
Unclassified: Areas that are not classified as zone 0, 1 or 2
(accordingly as zone 20, 21 and 22);
 Area Classification Shading Conventions for

Drawings
Zone 0
Zone 1
Zone 2
 Area Classification on Drawings (Example)

Drilling Rig
Compressor or
Pump in an
adequately
ventilated
non-closed
area
Atmospheric vent, from zone 1 & from zone 2

 Area Classification Layout (Example)

 Area Classification Section Details (Example)

 Zone Classification System

 Division Classification System

 Zone vs. Division (Classification System)

 Zone vs. Division (cont'd)
Zone 0 (gas) Class I, Division 1 (gas)

Zone 20 (dust) Class II, Division 1 (dust)
-------------------------------------------------------------------
-------------------------------------------------------------------
Class III, Division 1 (fiber)
Class III, Division 2 (fiber)
 Normal Operation
“Normal operation” is considered the situation when facility
equipment is operating within its design parameters;
Minor releases of flammable material may be part of normal
operations, e.g. minor releases include the releases from
mechanical packing on pumps;
Failures that involve repair or shutdown (such as the
breakdown of pump seats and flange gaskets, and spillage
caused by accidents) are not considered normal operation;
 Abnormal Operation
“Abnormal operations” are considered as situations such as:
Start-up & Shutdown, and Plant maintenance activities;
Reasonable to ignore if the activity is expected to exist
less than 1% of the time (100 hours per year) and no
continuous or primary grade releases expected;
Zone 2 locations are likely to have flammable gases or
vapors present only under abnormal conditions (e.g. an
adequately ventilated location containing a process pump
with a leaking mechanical shaft seal that releases
flammable gases, this condition is “abnormal”, thus the area
surrounding the pump is classified as “zone 2”, and not
“zone 1”)
 Group
Describes the Characteristics of the Hazardous Substance
in terms of:
 MESG (Maximum Experimental Safe Gap)
The maximum gap between two parallel metal surfaces
under specified test conditions that will prevent an
explosion from propagating to an adjacent test chamber;
 MIE (Minimum Ignition Energy)
The minimum energy required from a capacitive spark
discharge to ignite the gas or vapor;
 MIC (Minimum Ignition Current Ratio)
The ratio of minimum inductive current required to ignite
a gas or vapor as compared to that of methane;
 Group (Europe), Gas

Characteristics of the Hazardous Substance:
 Group I : Intended for describing atmospheres

(mines) that contain “firedamp” (Comprised mostly of
methane & coal dust);
 Group IIA : Flammable material having a MESG greater
than 0.90 mm or a minimum MIC ratio greater than 0.80;
 Group IIB : Flammable material having a MESG greater
than 0.50mm and less than 0.90mm or a minimum MIC
ratio greater than 0.45 and less than 0.80;
 Group IIC : Flammable material having a MESG less
than 0.50mm or a minimum MIC ratio less than 0.45;
 Group (Europe), Dust

Dusts and fibers are defined as “Group III” and classified
in terms of their physical properties:
 Group IIIA : Fibers;
 Group IIIB : Non-conductive dust;
 Group IIIC : Conductive dust;

 Group (North America)

Characteristics of the Hazardous Substance:
 Group A : Acetylene;
 Group B : Flammable gas, flammable liquid–produced vapor,
or combustible liquid–produced vapor mixed with air that may
burn or explode, having either a MESG value less than or equal
to 0.45 mm or a MIC ratio less than or equal to 0.40;
 Group C : Flammable gas, flammable liquid–produced vapor,
burn or explode, having either a MESG value greater than 0.45
mm and less than or equal to 0.75 mm, or a MIC ratio greater
than 0.40 and less than or equal to 0.80;
 Group D : Flammable gas, flammable liquid–produced vapor,
burn or explode, having either a MESG value greater than 0.75
mm or a MIC ratio greater than 0.80;
 Group (North America) (cont'd)
Group Hazardous Material in Surrounding Atmosphere

A (Class I) Acetylene;
B (Class I) Hydrogen, fuel and combustible process gases

containing more than 30% hydrogen by volume or
gases of equivalent hazard such as butadiene,
ethylene, oxide, propylene oxide and acrolein;
C (Class I) Carbon monoxide, ether, hydrogen sulfide,
morphline, cyclopropane, ethyl and ethylene or
gases of equivalent hazard;
D (Class I) Gasoline, acetone, ammonia, benzene, butane,
ethanol, cyclopropane, hexane, methanol, methane,
vinyl chloride, natural gas, naphtha, propane or
gases of equivalent hazard;
 Group (North America) (cont'd)
Group Hazardous Material in Surrounding Atmosphere

E (Class II) Combustible metal dusts, including aluminum,
magnesium and their commercial alloys or other
combustible dusts whose particle size,
abrasiveness and conductivity present similar
hazards in connection with electrical equipment;
F (Class II) Carbonaceous dusts, carbon black, coal black,
charcoal, coal or coke dusts that have more than
8% total entrapped volatiles or dusts that have
been sensitized by other material so they present
an explosion hazard;
G (Class II) Flour dust, grain dust, flour, starch, sugar, wood,
plastic and chemicals;
 Comparison between Division and Zone Methods

for Group Classification
Division System Zone System

Group MESG MIC Group MESG MIC
(mm) Ratio (mm) Ratio
A Acetylene
IIC ≤ 0.50 ≤ 0.45
B ≤ 0.45 ≤ 0.40
> 0.45 > 0.40 > 0.50 > 0.45
C IIB
≤ 0.75 ≤ 0.80 ≤ 0.90 ≤ 0.80
D > 0.75 > 0.80 IIA > 0.90 > 0.80
 Group Classification, Examples
Group Material MESG MIE MIC

(mm) (mJ) Ratio
Methane 1.12 0.280 1.00
Propane 0.97 0.280 0.97
IIA Butane 1.07 0.250 0.94
Heptane 0.91 0.240 0.88
Pentane 0.93 0.280 0.97
H2S 0.89 0.068 0.51
IIB
Ethylene 0.65 0.070 0.53
Hydrogen 0.28 0.019 0.25
IIC
C2H2 0.25 0.017 0.25
 MIE in Practical Terms

 Auto-Ignition Temperature (AIT)

The lowest temperature of a heated surface, at which
under specified conditions, the ignition of a flammable
substance in the form of a gas or vapor mixture with air will
occur;
API RP 505, IEC 79-10 – Mod
The minimum temperature required to initiate or cause

self-sustained combustion of a solid, liquid or gas
independently of a heated or heating element;
NFPA 497
 Factors affecting AIT

 Molecular structure of the hydrocarbon mixture;
 Concentration,
% composition of the vapor in air mixture;
 Hot surface material,
Type and reactivity of other materials present;
 Rate and duration of heating;
 Environmental Conditions,
Initial temperature and the atmospheric pressure;
 AIT of Selected Materials

 Temperature Code
Used as a means to indicate the maximum operating
temperature of an electrical device;
- Equipments shall not be installed in areas where the

vapor or gas ignition temperature is less than the
maximum external temperature of the equipment;
- Some equipment items are marked with a maximum
operating temperature;
- If no temperature code or maximum operating
temperature is indicated, 100ºC is assumed;
- No relation between a Group Classification and the
Auto-ignition temperature (AIT) of flammable material;
 Temperature Code (cont'd)

Unless the certification documents state otherwise (in
which case there will be an addition to the T-Classification
code on the equipment label such as T4 (@ 60°C Amb.)), the
equipment is only certified in ambient temperatures in the
range of -20 °C up to 40 °C;
If exposed to higher temperatures there are two possible
dangers: First the stated T-Class temperature may be
exceeded and secondly safety components within the
equipment could fail to an unsafe condition;
An equipment to be subjected to temperatures above 40°C
(such as in direct sunshine or in a roof space), shall be
certified for a higher ambient temperature;
 Temperature Codes
Temperature Classification Maximum surface Temp.
European (IEC) North America (°C)
T1 T1 450
T2 T2 300
T2A 280
T2B 260
T2C 230
T2D 215
T3 T3 200
T3A 180
T3B 165
T3C 160
T4 T4 135
T4A 120
T5 T5 100
T6 T6 85
 Ingress Protection (IP)

A 2 digit code (European), which is used to denote the level
of ingress protection that a piece of apparatus enjoys:
“IP XY”
The first digit (i.e. the X) denotes the level of protection

against solid objects, the second digit (i.e. the Y) denotes
the level of protection against liquids);
North American practice is to use NEMA standards to

describe ingress protection;
 IP (cont'd)
Solid
0 No protection;
1 Protected against solid objects up to 50mm, e.g. hands;
2 Protected against solid objects up to 12mm, e.g. fingers;
3 Protected against solid objects up to 2.5mm, e.g. tools;
4 Protected against solid objects over 1mm, e.g. wires;
5 Protected against dusts (No harmful deposits);
6 Totally protected against dust;
 IP (cont'd)
Liquid
0 No protection;
1 Protected against vertically falling drops of water;
2 Protected against water spray up to 15 ° from vertical;
3 Protected against water spray up to 60 ° from vertical;
4 Protected against water sprays from all directions;
5 Protected against water jets from all directions;
6 Protected against strong water jets from all directions,
e.g. Offshore;
7 Protected against immersion between 15 cm and 1 m in
depth;
8 Protected against long immersion under pressure;
 IP Examples
An equipment protected against dusts as well as against
water jets from all directions shall be coded as:
“IP 56”
North American (NEMA) vs. European (IP):
NEMA 3 is similar to IP 54;

NEMA 4x is similar to IP 56;
 Protective Enclosure Types, ANSI/NEMA 250
Enclosure Description
1 Incidental personnel contact, falling dirt *
2 Same as 1 + dripping liquids and light splashing *
Incidental personnel contact, falling dirt; rain, sleet,
3
snow, windblown dust, external ice formation
3R Same as 3 without windblown dust protection
Same as 3 + external mechanisms operable with ice
3S
formation
4 snow, windblown dust, splashing water, hose-directed
water, external ice formation
4X Same as 4 + corrosion resistant
* Indoor use only
Incidental personnel contact, falling dirt, airborne
5 dust, lint, fibers, and flyings, dripping liquids and
light splashing *
snow, windblown dust, splashing water, hose-directed
6
water, occasional limited depth submersion,
external ice formation
6P Same as 6 + prolonged limited depth submersion
7 Class I, Div. 1, Groups A, B, C, or D *
8 Class I, Div. 1, Groups A, B, C, and D
9 Class II, Div. 1, Groups E, F, or G *
* Indoor use only
10 MSHA, 30 CFR, Part 18
Incidental personnel contact, falling dirt, circulating
12 dust, lint, fibers, and flyings; dripping liquids and
light splashing (without knockouts) *
12K Same as 12 (with knockouts) *
Same as 12 + spray and seepage of water, oil, and
13
noncorrosive coolants *
* Indoor use only
 Types of Electrical Equipment Suitable for use

in Potentially Explosive Atmospheres
Electrical apparatus for use in hazardous areas needs to be
designed and constructed in such a way that it will not
provide a source of ignition;
There are ten recognized types of protection for

hazardous area electrical apparatus;
Each type of protection achieves its safety from ignition in

different ways and not all are equally safe;
The type of protection must be suitable for the zone, in

which it is to be installed;
 Protection Concept, Types of Electrical

Equipment for Gas (European, IEC 60079)
Protection Symbol Description Suitable for

Method Zones
Intended to prevent Ex e Increased safety 1, 2
a potential ignition
arising Ex nA Type -n protection 2
Ex ia Intrinsic safety ‘ia’ 0, 1, 2
Intended to limit Ex ib Intrinsic safety ‘ib’ 1, 2
the ignition energy
of the equipment Ex ic Intrinsic Safety ‘ic’ 2
Ex nL Type-n protection 2
Intended to prevent Ex d Flameproof protection 1, 2
an ignition from
Ex q Sand/Quartz filling 1, 2
escaping outside the
equipment Ex nC Type-n protection 2

Equipment for Gas (European, IEC 60079)
Protection Symbol Description Suitable for
Method Zones
Ex p Purge/pressurized protection 1, 2
Ex px Purge/pressurized protec. ‘px’ 1, 2
Ex py Purge/pressurized protec. ‘py’ 1, 2
Intended to
prevent the Ex pz Purge/pressurized protec. ‘pz’ 2
explosive
Ex m Encapsulation 1, 2
atmosphere
contacting the Ex ma Encapsulation 0, 1, 2
ignition source
Ex mb Encapsulation 1, 2
Ex o Oil immersion 1, 2
Ex nR Type -n protection 2
Special Ex s Special protection 0, 1, 2

Equipment for Dust Hazardous Locations
Symbol Description Suitable for Zones

tDA20 Protection by enclosure 20, 21, 22
tDB20 Protection by enclosure 20, 21, 22
iaD Intrinsic Safety 20, 21, 22
maD Encapsulation 20, 21, 22
tDA21 Protection by enclosure 21,22
tDB21 Protection by enclosure 21,22
ibD Intrinsic Safety 21,22
mbD Encapsulation 21,22
pD Pressurization 21,22
tDA22 Protection by enclosure 22
tDB22 Protection by enclosure 22
icD Intrinsic Safety 22
 Protection Types
 Ex i (Intrinsic Safety)
A protection concept, in which the electrical energy
within the equipment is restricted to a level which is
below that, what may cause an ignition or to limit the
heating of the surface of the equipment;
There are two main sub types to Ex i protection, these
being “ia” and “ib”;
Type “ia” protection allows for the occurrence of two
faults during operation;
Type “ib” protection allows for the occurrence of one
fault during operation;
 Protection Types (cont'd)

 Ex d (Flameproof)
The equipment that may cause an explosion is
contained within an enclosure, which can withstand the
force of an explosion and prevent transmission to the
outside hazardous atmosphere;
This method of protection also prevents the hazardous
atmosphere from entering the enclosure and coming
into contact with equipment;

 Ex m (Encapsulation)
A protection concept where by equipment that could
potentially cause an ignition is encapsulated within a
compound or resin, so as to prevent contact with the
explosive atmosphere;
The concept also limits the surface temperature of the
equipment under normal operating conditions;
 Ex s (Special)
This method of protection, as its name indicates, has
no specific parameters or construction rules, it does
not fall under any specific protection method and may
in fact be a combination of more than one;

 Ex e (Increased Safety)
Precautions are applied to the installation to ensure
increased security against the possibility of excessive
temperatures and sparks from electrical equipment,
equipments that normally cause sparks are excluded
from use within this method of protection;
 Ex o (Oil Immersion)
All equipment that has the potential to arc and
potentially cause an ignition is immersed in a protective
liquid or oil. The oil provides an insulating method to
prevent ignition;

 Ex p (Pressurized)
One process ensures that the pressure inside an
enclosure is sufficient to prevent the entrance of a
flammable gas, vapor, dust, or fiber, and prevents a
possible ignition;
Another process maintains a constant flow of air (or an
inert gas) to dilute/to take away any potentially
 Ex q (Powder Filling)
All equipments that has the potential to arc are
contained within an enclosure filled with quartz or
glass powder particles, which prevent the possibility of
an ignition;

 Ex n (Non-Sparking)
A type of protection where precautions are taken so
that the electrical equipment that has the potential to
arc is not capable of igniting a surrounding explosive
atmosphere. This can be further categorized as
follows:
- Ex nA, components used in construction are
non-sparking;
- Ex nC, components used in construction are
non-incendive;
- Ex nR, components used are tightly enclosed
to restrict the breathing and prevent
ignition;
- Ex nL, components used in construction do
not contain enough energy to cause an
ignition;
 Equipment Protection Levels - EPL

From 2007 onwards, the IEC Technical Standards in the
series IEC 60079, and in particular IEC 60079 Part 14,
have recognized that there may be occasions where it is
necessary to increase, above the normal levels, the
protection against ignition sources;
This concept allows for consideration of risk (i.e.
consequences of an explosion) as opposed to just the
probability of a flammable atmosphere existing - the
conventional selection criteria between the types of
protection and the zone of use;
 Equipment Protection Levels – EPL (cont'd)

Three Equipment Protection Levels are specified as shown
in the table below:
Equipment Protection Level Normal Applicable
(EPL) Zone(s)
Ga 0 (and 1 and 2)
Gb 1 (and 2)
Gc 2
In normal circumstances the effect of these EPLs will be to
retain the normal zone/equipment protection relationship;
If, however, the risk is considered especially severe, then
the required EPL for the zone may be increased. Similarly,
if the risk is deemed to be especially small or negligible, the
EPL may be reduced from the norm;
 The EPL awarded to each type of protection
Symbol Description EPL

Ex p Purge/pressurized protection Gb
Ex px Purge/pressurized protec. ‘px’ Gb
Ex py Purge/pressurized protec. ‘py’ Gb
Ex pz Purge/pressurized protec. ‘pz’ Gc
Ex m Encapsulation Gb
Ex ma Encapsulation Ga
Ex mb Encapsulation Gb
Ex o Oil immersion Gb
Ex nR Type -n protection Gc
Ex s Special protection Special
 The EPL awarded to each type of protection
Symbol Description EPL

Ex e Increased safety Gb
Ex nA Type -n protection Gc
Ex ia Intrinsic safety ‘ia’ Ga
Ex ib Intrinsic safety ‘ib’ Gb
Ex ic Intrinsic Safety ‘ic’ Gc
Ex nL Type-n protection Gc
Ex d Flameproof protection Gb
Ex q Sand/Quartz filling Gb
Ex nC Type-n protection Gc
 EPL for Dust Hazards
Equipment Protection Level Normal Applicable

(EPL) Zone(s)
Da 20 (and 21 and 22)
Db 21 (and 22)
Dc 22
 Marking of Hazardous Area Equipment (Europe)

All equipments for use in hazardous areas should be marked
as prescribed in 60079-0, this includes, where appropriate,
such information as:
- Company/Manufacturers name and address;

- Hazardous area certificate number(s);
- Protection concept - Gas group(s);
- Temperature class;
- Ambient temperature range;
- Product identification;
- Serial number and year of manufacture;
- Electrical parameters;
- CE marking and ATEX notified Body ID number;
- ATEX coding -IP code;
 Comparison: Europe, IEC, North-American

European – IEC – USA –
Area of use Area of use Area of use
.
Designation Designation Designation
Standard Standard Standard
Zones 1 & 2 Zones 1 & 2 Class 1
Flameproof
EExd Exd Divisions 1 & 2
Enclosure EN50018 IEC60079-1 UL1203
Zones 0, 1 & 2 Zones 1 & 2 Class 1
Intrinsic
EExi Exi Divisions 1 & 2
Safety EN50020 IEC60079-11 UL913
Zones 1 & 2 Zones 1 & 2 -
Increased
EExe Exe
Safety EN50019 IEC60079-7
Purged and
EExp Exp Divisions 1 & 2
Pressurized EN50016 IEC60079-2 NFPA496
Encapsulation EExm Exm
EN50028 IEC60079-18
 Comparison: Europe, IEC, North-American
European – IEC – USA –

Area of use Area of use Area of use
.
Designation Designation Designation
Standard Standard Standard
Oil Immersion EExo Exo Division 2
EN50015 IEC60079-6 UL698
Powder Filling EExq Exq
EN50017 IEC60079-5
Zone 2 Zone 2 -
Non-Sparking EExn Exn
EN50021 IEC60079-15
Special Zones 0, 1 & 2 Zones 0, 1 & 2 -
Protection Exs Exs

Equipment for Gas (North America)
For the US, the National Electrical Code (NEC) includes
the following six articles regarding hazardous locations:
Article 500, General Class I, II, & III Division requirements;

Article 501, Specific Class I, Division requirements;
Article 502, Specific Class II, Division requirements;
Article 503, Specific Class III, Division requirements;
Article 504, Specific Class I, II, & III, Division requirements;
Article 505, General and Specific Class I, Zone requirements;

Equipment for Gas (North America) (cont'd)
For Canada, the Canadian Electrical Code (CEC) includes the
following rules, along with an appendix, regarding hazardous
locations:
Rule 18-000, General Class I, Zone and Class II & III, Division
requirements;
Rule 18-090, Specific Class I, Zone 0 requirements;
Rule 18-100, Specific Class I, Zone 1 & 2 requirements;
Rule 18-200, Specific Class II, Division requirements;
Rule 18-300, Specific Class III, Division requirements;
Appendix J, General and Specific Class I, Division requirements;
 Explosion Protection Methods, North-American
Class Area NEC 500 NEC 505

Intrinsic safety 'ia‘,
Zone 0 -
Class I, division 1 intrinsic safety
Encapsulated, 'm‘, Flameproof, 'd‘,
Increased safety, 'e‘, Intrinsic
safety, 'ib‘, Oil immersed, 'o‘,
Zone 1 - Powder filled, 'q‘, Purged/
pressurised, 'p‘,
I Any class I, zone 0 method
Any class I, division 1 method
Hermetically sealed, 'nC’, Non-
incendive, 'nC’, Non-sparking, 'nA’,
Restricted breathing, 'nR’,
Zone 2 -
Sealed device, 'nC’,
Any class I, zone 0 or 1 method,
Any class I, division 1 or 2 method

Explosion proof,
Division 1 Intrinsic safety, -
Purged/pressurized (type X or Y)
Hermetically sealed,
Non-incendive circuits,
Non-incendive components,
I Non-incendive equipments,
Non-sparking devices,
Division 2 -
Oil immersion,
purged/ pressurized (type z),
Any class I, division 1 method,
Any class I, zone 0, 1 or 2
method

Dust-ignition proof,
Division 1 Intrinsic safety, -
Purged/pressurized
Dust tight,
II Hermetically sealed,
Non-incendive circuits,
Division 2 Non-incendive components, -
Non-incendive equipment,
Any class II, division 1 method

Dust tight,
Intrinsic safety,
Division 1 -
Hermetically sealed,
Purged/pressurized
III Non-incendive circuits,
Non-incendive components,
Division 2 Non-incendive equipments, -
Any class III, division 1 method
 Marking of Hazardous Area Equipment

(North-America)
The marking of hazardous location equipments varies in
accordance with the relevant Electrical Code, and
equipments should be marked as follows:
- Company/ Manufacturers name;

- Class I, II and/ or III;
- Division 1 and/ or 2;
- Group A, B, C, D, E, F and/ or G;
- Approving NRTL (Nationally Recognized Testing
Laboratory) logo;
- Product identification;
- Serial number;
- Other relevant safety information;
- Enclosure Type Rating;
 Marking, North America: Class, Division

The equipment must be marked to show the class, group,
and operating temperature or temperature class
referenced to a 40 °C ambient temperature;
Electrical equipment suitable for ambient temperatures
exceeding 40 °C must be marked with both the ambient
temperature and the operating temperature or
temperature class at that ambient temperature;
The coding is identical for the USA and Canada:
Class I, Division 1, Groups A&B T4

- Class I: Flammable gas or vapor;
- Division 1: Area classification (explosive atmosphere can
exist under normal operating conditions);
- Groups A&B: A: acetylene, B: hydrogen;
- T4: Temperature code (135 °C);
 Marking, North America: IEC based

The marking between the USA and Canada is different, The
Canadian marking is identical to the IEC marking:
USA: Class I, Zone 0, AEx ia IIC T4

- Class I: Flammable gas or vapor;
- Zone 0: Area classification (explosive atmosphere always present)
- AEx: Approved to US standards;
- ia: Protection method (intrinsic safety);
- IIC: Gas group (Acetylene & Hydrogen);
- T4: Temperature class (135 °C);
CANADA: Ex ia IIC T4
- Ex: Approved to US standards;
- ia: Protection method (intrinsic safety);
- IIC: Gas group (Acetylene & Hydrogen);
- T4: Temperature class (135 °C);
 The Certification Process

All Electrical Equipment, intended for use in a Potentially
Explosive Atmosphere, should be certified as suitable for
such use;
The methods of obtaining certification differ in detail
between each certifying body or group of bodies (e.g.
CENELEC);
Basically this process consists of supplying a representative
sample of the equipment along with a set of drawings to a
recognized test/certification body, e.g. TÜV, which in turn
test the equipment against a recognized standard, e.g.
IEC 60079-14, and issues a certificate;
The user of the equipment can then refer to this
certificate to enable him to safely put the item into service
in a zone appropriate to the certification;
 The Certification Process – European

Since 1st July 2003: all equipments both electrical and
mechanical, intended to be put into service within the EU
have to be certified in accordance with the ATEX
directive;
It should be noted also that MECHANICAL equipment is
covered by the ATEX Directive so for the first time items
such as gearboxes will have to carry ATEX certification;
 The Certification Process – North American

Sample equipment and supporting documentation are
submitted to the appropriate authority e.g. UL
(Underwriters Laboratories), FM Global (the Factory
Mutuals), CSA international (Canadian Standards
Association);
The equipment is tested in accordance with relevant
standards for explosion protection and also for general
electrical requirements e.g. light fittings;
After successful testing a listing is issued allowing the
manufacturer to place the product on the market;
The product is marked with the certification details such
as the gas groups A,B,C,D the area of use e.g. Class 1
Division 1;
 The Certification Process – Worldwide

Most countries outside Europe or North America use the
IEC standards as a basis for their own national standards;
The Russian Federation certifies equipments to GOST ‘R’
standards, these closely follow CENELEC (European
committee for electrotechnical standardization) practice;
In Russia, certain products used in fire alarm systems may
be required to carry the Russian fire approval (VNIIPO);
Certification in China is based on compliance with
international standards such as CENELEC or UL;
 European Approach, ATEX Directive

Manufacturers of mechanical and electrical equipment, as
well as protective systems, intended for safe operation in
and around potentially explosive atmospheres and who wish
to place their products on the market within the European
Union need to comply with the ATEX Directive;
The 'Directive on Equipment and Protective Systems

Intended for use in Potentially Explosive Atmospheres'
(94/9/EC), in force since March 1996, is commonly
referred to as the 'ATEX' Directive ('ATmospheres
EXplosibles'), but may also be called the ATEX Equipment
Directive or ATEX 95;
 ATEX Directive Scope

The Directive applies to electrical and/or mechanical
equipment used on the surface, below the ground and on
fixed offshore installations, specifically, the Directive
covers:
 All equipment intended for use in potentially explosive

atmospheres and which are capable of causing an
explosion through their own potential sources of ignition;
 Protective systems intended for use in potentially
explosive atmospheres;
 Components, which are defined as any item essential to
the safe functioning of equipment and protective systems
but with no autonomous function;
 ATEX Groups and Categories

Equipment and Products that fall within the scope of the
Directive are divided into two Groups:
 Group I comprises equipment intended for use in mines,

above and below ground;
 Group II comprise equipment intended for use in other
locations endangered by explosive atmospheres;
 ATEX Groups and Categories (cont'd)

Equipment and Products in each Group are divided into
Categories based on the level of protection required;
The categories for the Group I:
- Category M1: Equipments in this category are required
to remain functional with an explosive atmosphere
present;
- Category M2: Equipments are intended to be de-
energized in the event of an explosive atmosphere
forming;
 ATEX Groups and Categories (cont'd)

And the categories for the Group II:
- Category 1: Equipments for use in areas in which

explosive atmospheres caused by mixtures of air and
gases, vapors or mists or by air/dust, mixtures are
present continuously, for long periods or frequently;
- Category 2: Equipments intended for use in areas in
which explosive atmospheres caused by gases, vapors,
mists or air/dust mixtures are likely to occur;
- Category 3: Equipments for use in areas in which
explosive atmospheres caused by gases, vapors, mists or
air/dust mixtures are unlikely to occur or, if they do
occur, are likely to do so only infrequently and for a short
period only;
 ATEX Zones
In addition to the ATEX Directive 94/9/EC, which covers
the safety requirements for equipment to be used in
potentially explosive atmospheres, there is an additional
European ATEX Directive 99/92/EC, also known as the
'ATEX Workplace Directive' or 'ATEX 137‘;
'ATEX 137‘ highlights, what employers must do to minimize

the risk to workers from explosive atmospheres;
ATEX 137 also classifies hazardous areas where an

explosive atmosphere could form, by type of hazard, into
'Zones‘;
 ATEX Zones (cont'd)

the form of gas, vapor or mist is present continuously or
for long periods or frequently;
the form of gas, vapor or mist is likely to occur in normal
operation occasionally;

the form of gas, vapor or mist is not likely to occur in
normal operation but, if it does occur, will persist for a
short period only;
 ATEX Zones (cont'd)

form of a cloud of combustible dust in air is present
continuously, or for long periods or frequently;
form of a cloud of combustible dust in air is likely to occur
in normal operation occasionally;
form or a cloud of combustible dust in air is not likely to
occur in normal operation but, if it does occur, will persist
for a short period only;
 ATEX Requirements
It is a requirement of ATEX 137 that only certain
categories of Group II ATEX certified equipment are used
in specific Zones. This requirement can help guide
manufacturers on what Category of ATEX certification
their product(s) need to achieve;
The Zones and their applicable equipment Categories are as

follows:
- Zones 0 & 20 : Category 1 Equipment only;

- Zones 1 & 21 : Category 1 or 2 Equipments;
- Zones 2 & 22 : Category 1,2 or 3, Equipments;
 Routes to ATEX Compliance

The ATEX Directive stipulates that products within its
scope must satisfy the relevant essential health and safety
requirements (EHSRs), and there are three methods of
compliance, equipment must be manufactured in conformity
with either:
1. European harmonized standards, or;

2. National technical standards and specifications, or;
3. Essential health and safety requirements;
In every case the standards, specifications or EHSRs

applied by a manufacturer must be applicable and relevant
to a product's intended ATEX Group & Category and the
Zone in which it is to be used;
 Conformity Assessment Procedures

Depending on the category of equipment involved,
manufacturers are also required to install a quality system
that ensures that a product that has been type examined
will be faithfully replicated;
It is mandatory for manufacturers to obtain an EC Type
Examination Certificate from a notified body if they are
manufacturing electrical equipment in Categories M1, M2, 1
and 2 or diesel engine protection systems in Category 2;
In all other cases manufacturers are free to certify their
own equipment;
 Conformity Assessment Procedures (cont'd)

There are 5 annexes in the ATEX Directive, which identify
different quality systems for this purpose;
These annexes require manufacturers to have in place

either an ISO 9000 quality management system or a
notified body must be involved in the inspection of product
in some capacity;
In either case a notified body is responsible for ensuring

that a manufacturer produces products, which fully accord
with the design, which was the subject of the original EC
Type Examination Certificate;

Quality management systems must either be audited by the
notified body, if that body holds accreditation to EN 45012
or another organization that has this qualification, and is
accepted by the notified body, the latter provides
manufacturers greater freedom of choice;
By the design, manufacturing or selling any equipment or

protective system intended for use in potentially explosive
atmospheres, it is a must to comply with the ATEX
Directive 94/9/EC and the CE Marking Directive (CE
Marking required, an equipment can be CE marked when
certified to ATEX);

Once these have been met, a manufacturer is entitled to
display the distinctive European Mark, recognized
throughout the European Union:
 Limits
The directive only applies to equipment that introduces
energy, electrically or mechanically, into a potentially
The directive does not define atmospheric conditions but a
guide of -20 to 60 °C and 0.8 to 1.1 bar are suggested;
Equipment and protective systems used outside the
hazardous area but contributing to the safety in the
hazardous area (sometimes known as associated equipment)
are also covered (barriers for intrinsically safe circuits,
control systems of explosion suppression, inerting and
decoupling systems);
 Exclusion
There are some exclusions which are common with other
directives;
These are mostly carefully chosen items of equipment
where application of the ATEX requirements would lead to
anomalies in the application of other directives or
difficulties in application due to other treaties which cover
areas greater than just the EEA;
Examples of excluded equipment include medical devices,
personal protective equipment and domestic gas appliances,
as well as equipment used for transport by sea, air, rail and
road;
 Technical File
The Directive requires for a Technical File containing
documentary evidence that the machinery complies with the
directive;
 Drawing(s) of the equipment with information related to

explosion protection;
 Copy of installation/ user/ maintenance manuals;
 Wiring and circuit diagrams;
 Copies of reports and certification from Notified Body;
 Assessment of the electrical system to the appropriate
standards;
 Assessment of the mechanical equipment to the
appropriate standards;
 Technical File (cont'd)

The Equipment shall have the CE logo clearly affixed to
indicate compliance/ also the ATEX symbol alongside the
relevant hazardous atmosphere specification markings;
 Assessment of the equipment as a whole to the EHSR's

of the Directive;
 Zoning assessment, calculations and zone diagrams
where applicable;
 Ignition hazard assessment report;
 Design calculations/ Manufacturer's data sheets;
 Copy of the Declaration of Conformity;
 Drawings of markings and labels related to explosion
protection and where they are located on the product;
 ATEX Labeling Example

Marking to Directive 94/9/EC (ATEX 95):
II 2 GD
- CE: CE marking;
- 0102: The number specifying the notified body;
- Єx: ATEX marking;
- II: Group;
- 2: Category;
- G: Gas;
- D: Dust;
 ATEX Labeling Example (cont'd)

Marking to Standard IEC/EN 60079-0:
Ex de IIC T5 Gb
- Ex de: Equipment type, here multi-protection concept,
i.e. flameproof + increased safety;
- IIC: Gas group, here hydrogen & acetylene;
- T5: Temperature class, max. admissible equipment
surface temperature here 95 °C;
- Gb: Equipment protection level (EPL), zones 1 & 2;
For Dust service:

Ex tb IIIC T95°C Db
 Notified Body List

The notified body is the official organization for the
certification of the equipment as well as for the QA:
- 0102: Physikalisch-Technische Bundesanstalt PTB, Germany;
- 0158: DEKRA EXAM GmbH, Germany;
- 0032: TÜV CERT GmbH, Germany;
- 0637: IBExU, Institut für Sicherheitstechnik, Germany;
- 0344: KEMA Quality B.V., The Netherlands;
- 0081: LCIE Laboratoire, France;
- 0080: INERIS, France;
- 0600: EECS Electrical Equipment Certification Service, UK;
- 1258: Electrosuisse SEV, Switzerland;
- 0722: CESI, Italy;
- 0539: Ul International DEMKO, Denmark;
- 0470: NEMKO, Norway;


Hazardous Area Classification, Summary
 Summary and Wrap-up

By a hazardous area classification study, four major fields
have to be taken into account:
 Design considerations;
 Documentation requirements;
 Operational requirements;
 Change management;
 Design considerations
Based on the likelihood of a flammable mixture being
present:
 Source of ignition is not a criteria for classification of a

location;
 Area Classification should be carried out before the
plot plan is finalized;
 Must be carried out before the choice of appropriately
certified equipment is made;
 “Abnormal” operation of an equipment;
 Open and Closed Drains;
 Natural barriers and depressions;
 Design considerations (cont'd)
 Locate electrical and continuous flame source equipment

outside of classified areas whenever possible;
 For enclosed areas that are classified:
- Stay involved in the design of the HVAC systems;
- Specify the flammable materials required to be
detected by the gas detection systems;
- Specify the location of gas detection equipment;
 Careful about reclassifying Zone 2 to Unclassified;
 Facilities such as storage pumps, loading and discharge
facilities – classification should be based on the most
volatile material anticipated;
 Design considerations (cont'd)
 Manned and Unmanned facilities;

 Communication is key:
- Interface with other disciplines on projects;
- Insure vendors are made aware of area classification
requirements;
- Inspection authorities must also be made aware;
 Adopt physical plant features to denote area
classification boundary lines (roads paved areas etc.);
 Not a good idea to denote small pockets of non
hazardous areas within hazardous areas;
 Documentation requirements
All area classification drawings should reference an area
classification study, signed under a professional seal;
 Specify the Auto-ignition temperature on the drawings

rather than a T-Code:
- Reduce the confusion;
- Buy some ºC;
 Periodically review the Engineering Guidelines on Area
Classification;
 Operational Considerations
Posting of area classifications on building entrances or plant
areas:
 Training of plant and construction personnel;

 Impact of natural barriers (e.g. snow removal
operations;
 Beware of Operator Intervention;
 Change Management
 Area classification may change over the life of the

facility based on operating and maintenance
experiences:
- Reviews should be carried out throughout the life of
the facility;
- New or modified equipment;
- Changes in installation protection;
- Operations experience;
- Changes in operational procedures;
- Actual measurements;
 Must be incorporated into a facility’s change
management procedure;

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Hazardous Area

 Hazardous Area Classification, Why?

 Conventional Ignition Source

Spark/ Ignition Source

 Probability of a Component Leak (API 4615)

 Potential Ignition sources

 Electric arcs and spark;

 Ignition Sources of Major Fires (FM Global)

 Potential Leak Sources

 Flange gasket connection points on local piping, tubing, or

 What is Hazardous Area Classification?

 Purpose of an Area Classification

 Hazardous Area Classification Risk Assessment

- Source of ignition is not a criteria for classification of a

 Explosive Atmosphere, The Probability

 Flammable Material Present;

 Extent of a Hazardous Area Classification

 Properties of the flammable material:

 How does it work?

 Codes & Standards

 Codes & Standards (cont'd)

 Codes & Standards (cont'd)

 North America vs. Europe

Hazardous locations in North America are separated by

Hazardous areas in Europe are classified by gas groups

 Class, Definition of the Hazard

 Division, Probability that a hazard may exist

The substance referred to by the class is present during

The substance referred to by the class is present only in

Zone 2: A place in which an explosive atmosphere

Zone 22: A place in which an explosive atmosphere in the

 Area Classification Shading Conventions for

 Area Classification on Drawings (Example)

 Area Classification on Drawings (Example)

 Area Classification on Drawings (Example)

 Area Classification on Drawings (Example)

Atmospheric vent, from zone 1 & from zone 2

 Area Classification Layout (Example)

 Area Classification Section Details (Example)

 Zone Classification System

 Division Classification System

 Zone vs. Division (Classification System)

 Zone vs. Division (cont'd)

Zone 0 (gas) Class I, Division 1 (gas)

 Group (Europe), Gas

 Group I : Intended for describing atmospheres

 Group (Europe), Dust

 Group IIIA : Fibers;

 Group IIIB : Non-conductive dust;

 Group IIIC : Conductive dust;

 Group (North America)

 Group (North America) (cont'd)

Group Hazardous Material in Surrounding Atmosphere

B (Class I) Hydrogen, fuel and combustible process gases

 Group (North America) (cont'd)

Group Hazardous Material in Surrounding Atmosphere

 Comparison between Division and Zone Methods

Division System Zone System

 Group Classification, Examples

Group Material MESG MIE MIC

 MIE in Practical Terms

 Auto-Ignition Temperature (AIT)

The minimum temperature required to initiate or cause