EEX 208.01 Classification of and Protection For Hazardous Locations

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
CLASSIFICATION OF AND
PROTECTION FOR HAZARDOUS LOCATIONS
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramcos employees.
Any material contained in this document which is not already in the public
domain may not be copied, reproduced, sold, given, or disclosed to third
parties, or otherwise used in whole, or in part, without the written permission
of the Vice President, Engineering Services, Saudi Aramco.
Chapter : Electrical
File Reference: EEX-208.01
For additional information on this subject, contact

PEDD Coordinator on 874-6556
Design Criteria for Hazardous Areas

Classification of and
Protection for Hazardous Locations
Content
PAGE
INTRODUCTION............................................................................................................. 3
PRINCIPLES OF COMBUSTION.................................................................................... 4
Fire Triangle ......................................................................................................... 4
Flammable and Combustible Liquids.................................................................... 5
Ignition Temperature ............................................................................................ 6
Explosive Range................................................................................................... 9
POTENTIAL IGNITION SOURCES IN A HAZARDOUS LOCATION ............................ 12
Arcs and Sparks ................................................................................................. 13
Hot Surfaces....................................................................................................... 14
HAZARDOUS LOCATION CLASSIFICATION SYSTEM ........................................... 15
Factors Used To Determine The Classification Of A Location............................ 15
Specific Location Classifications......................................................................... 16
Class I Hazardous Locations ................................................................... 16
Groups................................................................................................................ 16
Divisions ............................................................................................................. 19
Class I, Division 1 .................................................................................... 19
Class I, Division 2 .................................................................................... 20
Differences Between Class I, Class II, And Class III Hazardous
Locations ............................................................................................................ 21
PROTECTION METHODS FOR ELECTRICAL EQUIPMENT ...................................... 24
Fundamental Protection Philosophy ................................................................... 24
Confining the Explosion ...................................................................................... 25
Isolation .............................................................................................................. 26
Energy Limitation................................................................................................ 27

Miscellaneous..................................................................................................... 27
Summary of Protection Techniques and Their Application ................................ 28
GLOSSARY .................................................................................................................. 30
ADDENDUM A .............................................................................................................. 32
LIST OF FIGURES
Figure 1. Fire Triangle .................................................................................................... 4
Figure 2. Flash Points of Common Flammable and Combustible Liquids ...................... 6
Figure 3. Ignition Temperature of Common Vapors and Gases ..................................... 8
Figure 4. Ignition Temperatures of Common Chemical Dusts........................................ 9
Figure 5. Upper and Lower Flammable (Explosive)
Limits for Common Vapors and Gases ................................................................. 10
Figure 6. Ignition Energy vs. Volume Concentration for Propane and Hydrogen ......... 11
Figure 7. Minimum Energy Needed to Ignite Common Flammable Gases................... 12
Figure 8. Group Classifications of Common Flammable Gases and Vapors............... 18
Figure 9. Summary of Class I, II, III Hazardous Locations ........................................... 23
Figure 10. Summary of Protection Techniques ............................................................ 28
ii

INTRODUCTION
Saudi Aramco operates a number of plants and facilities that
contain hydrocarbons and other flammable materials. The
electrical equipment that is installed in these plants and facilities
must be designed to minimize the risk of fire and explosion. In
order to perform tasks that relate to the design, specification,
and commissioning of electrical equipment that is to be installed
and operated in locations subject to explosion and fire, the
Engineer must understand the following topics discussed in this
module:
Principles Of Combustion
Potential Ignition Sources
Principles Of Combustion
Hazardous Location Classification Scheme
Protection Methods For Electrical Equipment

PRINCIPLES OF COMBUSTION
This section provides information on the following topics that
pertain to the principles of combustion:
Fire Triangle
Flammable and Combustible Liquids
Ignition Temperature
Explosive Range
Fire Triangle
Fires and explosions result from the chemical reaction among
the three elements shown in Figure 1:
Fuel
Oxygen
Heat (Ignition Source)
Fuel
Heat
(Ignition
Source)
Oxygen
Figure 1. Fire Triangle

Fires and explosions can occur only in locations in which all

three elements of the fire triangle are present. In locations that
Saudi Aramco classifies as hazardous, the fuel source is
normally a flammable gas, a vapor from a flammable or
combustible liquid, a combustible dust, or an easily ignitable
fiber. One of these fuels must then be mixed in air or oxygen in
a proportion that will produce a flammable or explosive mixture.
The source of oxygen is normally the atmosphere surrounding
the hazardous location. Finally, an ignition source of sufficient
energy must be present to ignite the mixture. Ignition sources
are discussed in more detail later in this module.
Flammable and Combustible Liquids
Liquids are classified as flammable or combustible on the basis
of the ease with which they release vapors. The ease with
which a liquid releases vapor is referred to as volatility: the
more volatile a liquid is, the more easily it releases vapor; the
less volatile a liquid is, the less easily it releases vapor.
The volatility of a liquid can be defined in terms of flash point:
technically, the temperature at which a liquid has become hot
enough to release sufficient vapor to cause ignition when a
flame is applied. Liquids can also be classified as flammable or
combustible in relation to flash point:
The flash point of a flammable liquid is below

100F (37.8C).
The flash point of a combustible liquid is at or

above 100F (37.8C).
Figure 2 lists the flash points of the most common flammable

and combustible liquids that occur in Saudi Aramco plants and
facilities.

Flash Point
Material
Acetone
Benzene
Di-isobutylene
Fuel Oils
Gasoline
Heptane
Jet Fuels
A and A-1
B and JP4
JP5
JP6
Methanol
Toluene
Xylenes
-4
12
23
100 to 270
-45
25
-110 to 150
-10 to 30
95 to 145
100
52
40
81
-20
-11
-5
38 to 132
-43
-4
-43 to 66
-23 to -1
35 to 63
38
11
4
27
Figure 2. Flash Points of Common Flammable and Combustible Liquids

The ignition temperature of a solid, a liquid, or a gaseous
substance is the minimum temperature that is required to initiate
self-sustained combustion.
Ignition temperature is more
correctly referred to as auto-ignition temperature (AIT) or
spontaneous ignition temperature (SIT) because a substance
will, at its AIT or SIT, automatically or spontaneously ignite
due to the heat energy that is present.

The published ignition temperatures for materials are extremely

conservative because they have been determined under ideal
conditions. The ignition temperature of a substance can change
substantially due to the following variables:
The percentage of the vapor or gas in the air.
The shape and the size of the space where the
ignition occurs.
The type and the temperature of the ignition
source.
The catalytic or other effects of the materials that
may be present.
The oxygen concentration.

Figure 3 shows the ignition temperatures for common vapors

and gases found in Saudi Aramco plants and facilities.
Material
Acetone
Acetylene
Benzene
Butane
Carbon Monoxide
Di-isobutylene
Ethane
Fuel Oils
No. 1
No. 2
No. 3
Gasoline
Heptane
Hexane
Hydrogen
Hydrogen Sulfide
Jet Fuels
JP4
JP5
JP6
Methane
Methanol
Naphtha
Propane
Toluene
Xylenes
869
581
928
550
1128
736
882
410
494
505
536 to 880
399
437
968
500
464
475
446
999
725
550
842
896
986
465
305
498
288
609
391
472
210
257
236
280 to 471
204
225
520
260
240
246
230
630
385
288
450
480
530
Figure 3. Ignition Temperature of Common Vapors and Gases

The AITs (SITs) of agricultural and chemical dusts are similar to

the AITs (SITs) of flammable vapors and gases. Figure 4
shows the ignition temperatures for common chemical dusts.
Chemical Dust Material
Acetoacetanilide
Adipic Acid
Benzoic Acid
Dicyclopentadiene dioxide
Hydroxyethyl cellulose
Nitrosoamine
Sorbic acid
Stearic acid, aluminum salt
Sulfur
824
1022
824
784
770
518
860
572
428
440
550
440
420
410
270
460
300
220
Figure 4. Ignition Temperatures of Common Chemical Dusts

Explosive Range
All flammable gases, and all flammable and combustible liquids
that are heated above their flash point are potentially ignitable.
However, ignition will only occur when the fuel-air concentration
(vapor/air mixture) is in the explosive range. The explosive
range for a flammable gas encompasses all fuel-air
concentrations between the lower flammable or explosive limit
(LFL or LEL) and the upper flammable or explosive limit (UFL or
UEL). For fuel-air concentrations below the LFL (LEL) and
above the UFL (UEL), no sustained ignition will occur when the
fuel-air mixture is exposed to an ignition source. The LFL (LEL)
and the UFL (UEL) for a flammable gas are usually expressed
in terms of percentage by volume of gas or vapor in air under
normal ambient conditions.

The explosive ranges of materials are highly variable as

demonstrated in Figure 5. Acetylene, an example of a material
with a broad explosive range, has an LFL (LEL) of 2.5% by
volume in air and an UFL (UEL) of 100%. This explosive range
shows that no air or oxygen is needed for acetylene to ignite
explosively since a volume consisting of 100% acetylene will
ignite. Gasoline, an example of a material with a narrow
explosive range, has a LFL (LEL) of 1.4% by volume in air and
an UFL (UEL) of 1.6%. This explosive range shows that a
relatively small amount of gasoline vapors in air is required to
form an explosive mixture.
Flammable Limits % by Volume
Material
Acetone
Acetylene
Benzene
Butane
Carbon Monoxide
Di-isobutylene
Ethane
Fuel Oil No. 1
Gasoline
Heptane
Hexane
Hydrogen
Hydrogen Sulfide
Jet Fuel (JP4)
Jet Fuel (JP6)
Methane
Methanol
Naphtha
Propane
Toluene
Xylenes
Lower Limit
Upper Limit
2.5
2.5
1.3
1.6
12.5
0.8
3
0.7
1.4
1.05
1.1
4
4
1.3
0.6
5
6
1.1
2.1
1.2
1.1
13
100
7.9
8.4
74
4.8
12.5
5
7.6
6.7
7.5
75
44
8
3.7
15
36
5.9
9.5
7.1
7
Figure 5. Upper and Lower Flammable (Explosive) Limits

for Common Vapors and Gases
10

Figure 6 shows curves for two flammable gases, propane and

hydrogen, with ignition energy in joules plotted against volume
concentration in air. Ignition energy is the energy that is needed
to ignite flammable and combustible materials. It is expressed
as a finite quantity that depends on:
Material.
Concentration.
Time period over which the energy release occurs.
The parabolic shape is characteristic of all gases and vapors.

This figure is useful in demonstrating some of the terminology
used in the text as well as reminding everyone that the mere
presence of a flammable material does not make an area
hazardous from an explosive perspective.
Propane-air, 1 ATM
1.0
0.1
Hydrogen-air, 1 ATM
0.01
10
20
30
40
50
60
70
80
90
100
Volume Concentration (%)

Figure 6. Ignition Energy vs. Volume Concentration for Propane and Hydrogen
11

POTENTIAL IGNITION SOURCES IN A HAZARDOUS LOCATION

A finite quantity of energy is needed to ignite flammable and
combustible materials. The energy that is necessary depends
upon the particular material involved, the concentration of this
material in the air or with an oxidizing agent, and the time period
over which the energy release occurs.
Much laboratory
experimentation has been conducted to determine the minimum
ignition energy required to ignite many materials. Figure 7
shows the results of some of this work for a few common
materials. It should be noted that these energy levels were
recorded under the most ideal conditions. For every day
conditions found in the refinery environment, the energy levels
required for ignition of any of these materials is considerably
higher - in excess of 1 watt.
Considerably more energy is required to cause ignition of finely
divided dusts, and even more energy is needed for solid
materials. This need for greater energy is due to the fact that
the same homogeneous mixture which occurs with gases and
vapors does not occur with dusts and solids, making the ignition
process much less efficient.
Flammable Material
Minimum Ignition Energy,

Millijoules (Milliwatt-Seconds)
Acetylene
Hydrogen
Ethylene
Methane
0.017
0.017
0.08
0.3
Figure 7. Minimum Energy Needed to Ignite Common Flammable Gases

This section provides information on the following potential
ignition sources that are associated with electrical equipment:
Arcs and Sparks
Hot Surfaces
Additional information on these subjects is found on pages 43
through 48 of the supplemental textbook, "Electrical Installations
in Hazardous Locations," by Peter J. Schram and Mark W.
Earley.
12

Arcs and Sparks

Electrical arcs and sparks are potential ignition sources because
they produce heat. These sources can be described as follows:
An electrical arc is a sustained luminous discharge
of electricity across a gap in a circuit or between
electrodes.
An electrical spark is a luminous electrical discharge of very short duration between two
conductors that are separated by a gas, such as
air.
The duration of the luminous discharge of electricity is the only
major difference between an electrical arc and an electrical
spark.
Electrical arcs and sparks can be generated from a number of
sources including the following:
Arcs due to intermittent contact in electrical
equipment.
Static electricity (except lightning).
Lightning.
The latter two are caused by natural phenomena and are not
included in this discussion.
Electrical equipment such as motor controllers, circuit breakers,
switches, and relays produce electrical arcs as part of their
normal operation. These electrical arcs occur each time a
motor controller, circuit breaker, switch, or relay performs a
switching
function.
Except
for
certain
signaling,
communications, and data processing circuits where the energy
released at the contacts is maintained below the energy
required to cause ignition, the arc at the contacts of the
switching equipment is capable of causing ignition.
The
contacts of such equipment must be protected to prevent the
propagation of explosions to the surrounding flammable
atmosphere.
13

In addition to the anticipated arcs at the contacts of switching

equipment, arcs can occur as a result of insulation breakdown
between live parts at different polarities, or between live parts
and grounded metal. Arcs also can occur when wires break or
fuses open. For example, an electrical conductor can burn open
when subjected to a high level of current, such as a ground fault
or short circuit. If the protective system does not isolate power,
and if the voltage is high enough, an arc can occur across the
open space.
Hot Surfaces
A hot surface refers to any surface at an elevated temperature
in electrical equipment that is exposed to the surrounding
atmosphere. A hot surface is another potential source of
ignition. Certain types of electrical equipment can produce high
surface temperatures during operation. If the external surface
temperature of an explosionproof enclosure is above the ignition
temperature, the external surface itself can act as an ignition
source such that the protective enclosure is inconsequential.
High surface temperatures can be created by the normal
operation of electrical equipment such as a resistance heater or
an incandescent lamp in a light fixture.
High surface
temperatures can also be created by the abnormal operation of
electrical equipment such as when a rotor stalls or when an
arcing fault occurs inside a motor enclosure.
Electrical equipment that is certified for use in explosive
atmospheres has been examined and tested to assure that the
potential for ignition due to high surface temperature has been
prevented or minimized.
14

HAZARDOUS LOCATION CLASSIFICATION SYSTEM

Factors Used To Determine The Classification Of A Location
For a description of non-hazardous and hazardous locations
read the section titled "What Hazardous Locations Are Not" on
page 11 and What Hazardous Locations Are on page 15 of the
supplemental textbook "Electrical Installations in Hazardous
Locations" by Peter J. Schram and Mark W. Earley.
A location needs to be classified relative to the presence of
flammable gases, vapors and the like, only if electrical
equipment is to be installed in that location. The classification of
a location will serve as the basis for the minimum requirements
that the electrical equipment must meet to be installed in the
location. The factors to be considered in determining whether
or not a location is classified as hazardous are as follows:
The likelihood that flammable gases will be
present; the quantity of flammable gases
expected; the rate at which flammable gases and
vapors could be released.
The adequacy of the ventilation in the location
under consideration.
The total volume
consideration.
of
the
location
under
These three factors are interdependent and must be considered

as a group when determining if a location need be classified as
hazardous.
Certain flammable material containment systems are
considered not subject to failure; therefore, the surrounding
location is not classified as hazardous. Such systems include:
All-welded closed piping systems without valves,
flanges, or similar devices.
Closed
piping
systems
constructed
with
continuous metallic tubing without valves, fittings,
flanges, or similar devices.
15

Specific Location Classifications

One of the most common hazardous location classification
systems used, and the one used at Saudi Aramco facilities,
identifies the type of material present, the specific category of
material present, and the probability of its presence. This is
stated using the class, group, and division designations,
respectively.
Class I Hazardous Locations
Class I hazardous locations are defined as locations in which
flammable gases or vapors are or may be present in quantities
sufficient to produce explosive or ignitable mixtures. This section
further describes the system used to define Class I hazardous
locations into groups and divisions and the importance of group
and division designations to equipment protection techniques.
Groups
Class I hazardous locations are further defined into groups
according to the type of flammable gas or vapor present in an
atmosphere. The groups were originally established based on
tests to determine gap width and lengths required to prevent
transmission of the explosion to the surrounding atmosphere.
These tests led to the determination of explosion pressure and
pressure rise times which affected the flame path lengths and
widths required to prevent explosion transmission. The wide
range of data also led to the concept of having different
groupings of gases based on their explosion characteristics.
This test work relates directly to the explosionproof housing
protection technique which relies on enclosures designed to be
strong enough to withstand internal explosion pressures and
with flame path lengths and gap widths conservative relative to
the results obtained in the above-described tests.
The
groupings allowed different design criteria based on the same
test results and the grouping of gases as described below.
16

Class I hazardous locations are divided into four groups, with

each group containing materials of similar explosion
characteristics. The characteristic gas for each group was
chosen based on the most commonly available commercial
materials at that time:
Group A hazardous locations have atmospheres
containing acetylene.
Group B hazardous locations have atmospheres
containing hydrogen and other gases and vapors
with equivalent characteristics.
Group C hazardous locations have atmospheres
containing diethyl ether and other gases and
vapors with equivalent characteristics.
Group D hazardous locations have atmospheres
containing gasoline and other gases and vapors
with equivalent characteristics.
Many flammable gases and vapors were placed in one of the
four chosen groups. A study of the chemical characteristics
(such as the structure, weight, and other factors) of these
flammable gases and vapors showed that the gases and vapors
in different groups were distinctly different from each other, but
that flammable gases and vapors within a particular group were
similar to each other. This finding led to the current practice of
grouping unknown gases and vapors by their chemical
characteristics rather than by a formal test program which was
found to be unnecessary for many materials.
The original work was based on establishing requirements for
flame paths in explosionproof enclosures by determining
maximum experimental safe gaps (MESG) for many materials.
Later work in determining minimum ignition energy (MIE) of
materials from electrical arcing and sparking showed a close
correlation to the MESG data.
This correlation allowed
researchers and practitioners to conclude that the gas
groupings were valid whether explosion protection of electrical
parts was by means of containment (explosionproof enclosures)
or by limiting available electrical energy in the circuits (intrinsic
safety) located in the classified location.
17

Figure 8 lists the group classifications of the common flammable

gases and vapors found in Saudi Aramco plants and facilities.
Additional information on groups can be found on pages 33
through 37 of the supplemental textbook, "Electrical Installation
in Hazardous Locations", by Peter J. Schram and Mark W.
Earley.
Material
Acetone
Acetylene
Benzene
Butane
Carbon Monoxide
Ethane
Ether
Fuel Oils
Gasoline
Heptane
Hexane
Hydrogen
Hydrogen Sulfide
Methane
Methanol
Naphtha
Propane
Toluene
Group Designation
D
A
D
D
C
D
C
D
D
D
D
B
C
D
D
D
D
D
Figure 8. Group Classifications of Common Flammable Gases and Vapors
18

Divisions
The criterion for designating a location as a Class I hazardous
location is the probable presence of flammable gases or vapors
in a location where electrical equipment is intended to be
installed. Once the decision is made to classify a location, the
location is assigned a group designation according to the
specific gas or vapor that is present in the location. The final
description of a Class I hazardous location is to designate the
location Division 1 or Division 2. This final classification must
consider the likelihood or probability of the presence of a
combustible gas or vapor during normal operations.
Class I, Division 1
As defined in API Recommended Practice 500 (RP 500), Class
I, Division 1 locations are locations that meet one or more of the
following criteria:
Ignitable concentrations of flammable gases or
vapors exist under normal operating conditions.
Ignitable concentrations of flammable gases or
vapors may exist frequently because of repair or
maintenance operations or because of leakage.
Breakdown, faulty processes, or faulty operation of
equipment might lead to the release of ignitable
concentrations of flammable gases or vapors and
might also be the cause of simultaneous failure of
electrical equipment that could become a source
of ignition.
Additionally, API Recommended Practice 500 (RP 500) provides
the following examples of locations that would be classified as
Class I, Division 1:
Locations where volatile flammable liquids or
liquefied flammable gases are transferred from
one container to another.
Interior locations
solvents are used.
where
volatile
flammable
19

Locations containing
flammable liquids.
open
tanks
of
volatile
Inadequately ventilated locations where flammable

gases accumulate or volatile flammable liquids
stand or collect.
Interiors of refrigerators and freezers in which
volatile flammable materials are stored in open,
lightly stoppered, or easily ruptured containers.
All other locations where ignitable concentrations
of flammable gases or vapors are likely to occur
during normal operation.
For additional Class I, Division 1 considerations, read the
section of API Recommended Practice 500 (RP 500) titled
"Classification Criteria" (part 4.3).
Class I, Division 2
As defined in API Recommended Practice 500 (RP 500), Class
I, Division 2 locations are locations that meet one or more of the
following criteria:
Locations where volatile flammable liquids, vapors
or gases are handled, processed or used, but are
normally confined in closed containers or closed
systems from which they can only escape in cases
of accidental rupture or breakdown of such
containers or in cases of abnormal equipment
operation.
Locations where ignitable concentrations of
flammable gases or vapors are normally
prevented by positive ventilation but might become
ignitable through failure or abnormal operation of
the ventilating equipment.
20

Locations adjacent to Class I, Division 1 locations

(and not separated by a vaportight barrier) and to
which ignitable concentrations of gases or vapors
might occasionally be transferred unless such
transfers are prevented by adequate positive
pressure ventilation from a source of clean air, and
effective safeguards are provided to prevent
ventilation failures.
Class I, Division 2 locations usually include locations where
volatile flammable liquids or flammable gases or vapors are
used in containment and would not pose a risk of explosion
unless there was a malfunction of both the containment of the
flammable materials and any suitable (for Division 2 locations)
electrical equipment.
For additional Class I, Division 2 considerations, read the
section of API Recommended Practice 500 (RP 500) that is
titled "Classification Criteria" (part 4.4).
Additional information on divisions can be found on pages 31
and 32 of the supplemental textbook, "Electrical Installation in
Hazardous Locations", by Peter J. Schram and Mark W. Earley.
Differences Between Class I, Class II,
And Class III Hazardous Locations
The differences between Class I, Class II, and Class III
hazardous locations are best described by their associated
definitions. The definition for a Class I hazardous location is
given here for comparison with the definitions for Class II and
Class III locations as follows:
Class I locations are those locations in which
flammable gases or vapors are or may be present
in quantities sufficient to produce explosive or
ignitable mixtures.
Class II locations are those locations that are
hazardous because of the presence of
combustible dusts.
21

Class III locations are those locations that are

hazardous because of the presence of easily
ignitable fibers or flyings that are not likely to be in
suspension in the air in sufficient quantities to
produce ignitable mixtures.
These definitions point out that the only major difference
between the different classes of hazardous locations is the type
of fuel that is present.
For further information on the differences between Class I,
Class II, and Class III hazardous locations, read the following
sections of the supplemental textbook, "Electrical Installations in
Hazardous Locations", by Peter Schram and Mark W. Earley:
Section 2-4, Class I Locations pages 16-32
Section 2-5, Class II Locations pages 32-40
Section 2-6, Class III Locations pages 40-41
The table in Figure 9 summarizes the characteristics of Class I,
Class II and Class II hazardous locations.
22

Divisions
Classes
I - Gases,
Vapors, and
Liquids
Groups
A: Acetylene
B: Hydrogen, etc.
C: Ether, etc.
1
Explosive
concentrations may
be normally present
and are hazardous.
Explosive
concentrations are
not normally present
(but may
accidentally exist).
Ignitable quantities
of dust normally is
or may be in
suspension, or
conductive dust
may be present.
Dust is not normally

suspended in an
ignitable
concentration (but
may accidentally
exist). Dust layers
are present.
D: Hydrocarbons, fuels,
solvents, etc.
II - Dusts
E: Metal dusts
(conductive* and
explosive)
F: Carbon dusts (some
are conductive, * and
all are explosive)
G: Flour, starch, grain,
combustible plastic or
chemical dusts
(explosive)
III - Fibers and

Flyings
Textiles, woodworking,
Ignitable
etc. (easily ignitable, but concentrations may
not likely to be explosive) be present as a
result of fibrous
material being
handled or used in
manufacturing.
A location where
flyings or fibers are
stored or handled in
storage (exclusive
of manufacturing).
* Note: Electrically conductive dusts are dusts with a resistivity less than
105 ohm-centimeter.
Figure 9. Summary of Class I, II, III Hazardous Locations
23

PROTECTION METHODS FOR ELECTRICAL EQUIPMENT

This section provides information on the various methods of
protection for electrical equipment for use in hazardous
locations as follows:
Fundamental protection philosophy
Confining the explosion
Isolation
Energy limitation
Miscellaneous
Summary of protection techniques and there
application
Comparison of the three major techniques
Fundamental Protection Philosophy
The fundamental protection philosophy has two parts: the first
concerned with location and the second with precautions.
When planning any facility, every effort should be made to
locate electrical equipment outside of the hazardous location.
This approach has several benefits, with the primary one being
a reduction of the risk of explosion to nearly zero regardless of
the circumstances.
There are, however, many occasions when protection by
location is not possible. When this condition exists, then
extraordinary precautions are required to reduce the risk of
explosion that may be caused by electrical equipment to an
acceptable level. The acceptable level or acceptable risk is
addressed by the second part of the fundamental philosophy:
that is, safety experts worldwide agree that any protection
technique applied to electrical equipment should require two
independent events, each of low probability, between safe
operation and a potential explosion. All protection techniques in
use today meet this fundamental criterion as will be
demonstrated in the following discussion.
24

Confining the Explosion

This method has one technique - the explosionproof housing. In
this case, it is fully expected that ignitions or explosions will
occur within the enclosure because no attempt is made to
prevent entrance of flammable materials.
However, the
enclosure is designed to withstand the explosion pressure from
any internal explosions for the highest gas rating of the
enclosure (Groups A, B, C, or D), and any openings in the
enclosure are tight enough and long enough to sufficiently cool
any products of combustion to a temperature that will not ignite
the external atmosphere. Such enclosures are gas group
dependent, with the design requirements for Group D materials
being the least restrictive.
The two independent event criterion applied to this technique
is subtle, but effective as the following indicates:
1.
The first level of protection obviously consists of

the design requirements to be applied to the
enclosure.
2.
The second level of protection is more subtle and

relates to the tightness of the enclosure and the
nature of the electrical parts within.
Most
enclosure designs are relatively tight, designed for
outdoor use to prevent entrance of the elements.
Such enclosures have at least restricted breathing
and would require presence of flammable
materials for long periods of time to enter the
enclosure. Assuming that flammable materials do
gain entrance, either of two conditions would exist:
(1) if there are ignition-capable arcs and sparks
occurring in normal service,
any entering
flammables will simply burn off before they reach
an explosive concentration; or (2), if there are no
normally arcing or sparking parts, the mixture will
sit harmlessly unless there is a concurrent
equipment failure resulting in an ignition-capable
energy release. If the latter should occur, then the
enclosure would be called upon to perform its
intended function - to confine the explosion. In
either event, the requisite two fault criterion is
satisfied.
25

Isolation
There are several equipment design techniques that may be
used to satisfy the objective of the isolation method: to isolate
the ignition source from the flammable mixture. Techniques
include oil immersion, sealing and restricted breathing, potting,
and encapsulation. The most common technique is
pressurization, also known as purging. This technique is based
on maintaining a pressure within the enclosure using a
protective gas, normally air, at a level higher than the external
pressure. Any flow, therefore, is from within to the outside
atmosphere such that no externally present flammables can
enter the enclosure. The three levels of protection are as
follows:
1.
The application of the pressurizing gas to maintain

the internal pressure.
2.
Automatic shutdown at loss of pressure, activated

by a pressure sensitive cut-off switch that is
applied when there are normally ignition-capable
arcing parts or hot surfaces in the enclosure.
3.
A visible or audible alarm at loss of pressure that

is activated by a pressure sensing device when
the internal parts are non-sparking and that is
suitable for use in a Division 2 hazardous location.
The faults as described above make such equipment suitable

for use in a Class I, Division 1 hazardous location without regard
to the gas group present.
26

Energy Limitation
The energy limitation method has two techniques that may be
applied: intrinsic safety and non-incendivity. The former is
intended for use in Division 1 hazardous locations while the
latter is intended for use in Division 2 hazardous locations. For
intrinsic safety, two levels of protection are provided if we
assume that two faults must occur within the circuitry to cause
an increase in the energy levels present. But even after two
faults, or one fault with the application a factor of safety of 1.5
to voltage, current, or a combination of both as appropriate, no
ignition of the test gas is allowed. The intrinsic safety technique
is sensitive to group classifications of hazardous locations since
it is based on ignition energy, which increases from Group A to
Group D.
Miscellaneous
Several miscellaneous protection techniques are used which do
not fit into any of the above categories. These techniques
include:
Sand filling (a type of isolation)
Increased safety
Dust-ignitionproof
Continuous dilution
Each of these protection techniques is used in specific

locations. For example, increased safety is a popular European
technique used for non-sparking motors and lighting fixtures.
Such designs are suitable for international Zone 1, as shown in
Figure 10, which includes the international classifications of
hazardous locations.
27

Summary of Protection
Techniques and Their Application
Figure 10 provides a summary of the various protection
techniques and locations where they may, and may not be
used.
External Location Classification

Type Of Protection
Non-Haz
Zone 2
Zone 1
Zone 0
Special Protection
Ex s
Some
Intrinsic Safety
Ex ia
Intrinsic Safety
Ex ib
Flameproof
Ex d
Pressurized
Ex p
Increased Safety
Ex e
Encapsulation
Ex m
Hermetic Seal
Ex h
Type N, Non-incendive
Ex n
Restricted Breathing
Ex n
Unprotected Electrical
Equipment
Some
Figure 10. Summary of Protection Techniques
28

The table in Figure 10 lists the international designations for the

types of protection and the hazardous locations. An X in a box
means that pertinent type of protection is generally permitted in
the X'ed zone classification. The Special Protection, Ex s
(special constructions), category can include double protection
techniques, such as an explosionproof enclosure that is also
pressurized. This use of double protection techniques would be
acceptable for use in a Zone 0 location.
29

GLOSSARY
AIT
Auto- (Apparent) ignition temperature. The ignition

temperature of a substance required to initiate or cause
self-sustained combustion.
combustible liquid
A liquid with a flash point at or above 100F (37.8C); a

liquid that releases ignitable concentrations of vapor less
easily than a flammable liquid. (See flammable liquid.)
explosionproof
Pertaining to electrical equipment that is designed so that

an explosion of flammable gas within the enclosure of the
equipment will not ignite inflammable gas outside the
enclosure.
flammable liquid
A liquid with a flash point below 100F (37.8C); a liquid

that releases ignitable concentrations of vapor more easily
than a combustible liquid. (See combustible liquid.)
flying
An airborne combustible material such as jute, hemp,

rayon, and similar materials.
grade level
A datum or reference level such as ground level.
hermetically sealed
An enclosure sealed through use of a fusion joint rather

than through use of a gasket joint. Sealed by welding,
silver soldering, brazing, or similar techniques).
lower explosive limit

(LEL) or lower
flammability limit (LFL)
The minimum concentration of a material in air that will

allow propagation of a flame when the gas/air mixture is in
contact with an ignition source.
MESG
Maximum experimental safe gap. The maximum gap

between mating surfaces that just prevents explosion
propagation determined by explosion test experimentation.
MIE
Minimum ignition energy. The least amount of energy

required to ignite a gas-air mixture at its most easily ignited
concentration.
propagation
Spreading out and affecting a greater area.
pyrophorics
Materials that ignite spontaneously in contact with air.
30

SIT
Same as AIT above.
The maximum concentration of a material in air that will

upper explosive limit
allow propagation of a flame when the gas/air mixture is in
(UEL) or upper
flammability limit (UFL) contact with an ignition source.
vapor pressure
The pressure measured in psia (kilopascals) that is exerted

by a volatile liquid.
vapors
Common term for use in referring to the gas emitted from

the surface of a flammable or combustible liquid.
volatile
Descriptive of a liquid that releases vapor with relative

ease.
31

ADDENDUM A
TABLE OF CONTENTS
API Recommended Practice 500 (RP 500) Section 4 - Classification Criteria
API Recommended Practice 500 (RP 500) Section 5 - Extent of a Classified Location
32

EEX 208.01 Classification of and Protection For Hazardous Locations

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Engineering Encyclopedia

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Design Criteria for Hazardous Areas

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Design Criteria for Hazardous Areas

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Design Criteria for Hazardous Areas

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Design Criteria for Hazardous Areas

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Design Criteria for Hazardous Areas

Fires and explosions can occur only in locations in which all

The flash point of a flammable liquid is below

The flash point of a combustible liquid is at or

Figure 2 lists the flash points of the most common flammable

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Design Criteria for Hazardous Areas

Figure 2. Flash Points of Common Flammable and Combustible Liquids

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Design Criteria for Hazardous Areas

The published ignition temperatures for materials are extremely

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Design Criteria for Hazardous Areas

Figure 3 shows the ignition temperatures for common vapors

Figure 3. Ignition Temperature of Common Vapors and Gases

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Design Criteria for Hazardous Areas

The AITs (SITs) of agricultural and chemical dusts are similar to

Figure 4. Ignition Temperatures of Common Chemical Dusts

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Design Criteria for Hazardous Areas

The explosive ranges of materials are highly variable as

Figure 5. Upper and Lower Flammable (Explosive) Limits

Design Criteria for Hazardous Areas

Figure 6 shows curves for two flammable gases, propane and

Time period over which the energy release occurs.

The parabolic shape is characteristic of all gases and vapors.

Volume Concentration (%)

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Design Criteria for Hazardous Areas

POTENTIAL IGNITION SOURCES IN A HAZARDOUS LOCATION

Minimum Ignition Energy,

Figure 7. Minimum Energy Needed to Ignite Common Flammable Gases

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Design Criteria for Hazardous Areas

Arcs and Sparks

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Design Criteria for Hazardous Areas

In addition to the anticipated arcs at the contacts of switching

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Design Criteria for Hazardous Areas

HAZARDOUS LOCATION CLASSIFICATION SYSTEM

These three factors are interdependent and must be considered

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Design Criteria for Hazardous Areas

Specific Location Classifications

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Design Criteria for Hazardous Areas

Class I hazardous locations are divided into four groups, with

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Design Criteria for Hazardous Areas

Figure 8 lists the group classifications of the common flammable