HAZARDOUS AREA CLASSIFICATIONS

In an industrial plant such as a refinery or Chemical process plant, handling of large quantities of flammable liquids and
gases creates a risk of leaks. In some cases the gas, ignitable vapor or dust is present all the time or for long periods. Other
areas would have a dangerous concentration of flammable substances only during process upsets, equipment deterioration
between maintenance periods, or during an incident. Refineries and chemical plants are then divided into areas of risk of release
of gas, vapor or dust known as divisions or zones. The process of determining the type and size of these hazardous areas is
called area classification. Guidance on assessing the extent of the hazard is given in the NFPA 497 Standard, or API 500 and
according to their adaptation by other areas gas zones is given in the current edition of IEC 60079.10. For hazardous dusts, the
guiding standard is IEC 61421.10.
Typical gas hazards are from hydrocarbon compounds
Hazardous areas are defined by three main criteria:

The type of hazard

The likelihood of the hazard being present in flammable concentrations
The (auto) ignition temperature of the hazardous material

The type of hazard (Groups)

Group I - For application in below ground installations (mines) where methane (firedamp) and coal dust may be
present.
Group IIA - For application in above ground installation where hazards due to propane may exist.
Group IIB - For application in above ground installations where hazards due to ethylene may exist.
Group IIC - For application in above ground installations where hazards due to hydrogen or acetylene may exist.
Group III - For application in above ground installations where hazards due to dusts & fibres may exist.

Hazardous area zones

Gases, vapours, 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 places are classified in terms of zones on the basis of the frequency and duration of the
occurrence of an explosive atmosphere.
For gases, vapours and mists the zone classifications are:

Zone 0 A place in which an explosive atmosphere consisting of a mixture with air of dangerous substances in the form
of gas, vapour or mist is likely to occur in normal for more than 1000hrs per year.
Zone 1 A place in which an explosive atmosphere consisting of a mixture with air of dangerous substances in the form
of gas, vapour or mist is likely to occur in normal operation between 10-1000hrs per year.
Zone 2 A place in which an explosive atmosphere consisting of a mixture with air of dangerous substances in the form
of gas, vapour or mist is not likely to occur in normal operation but, if it does occur, will persist for less than 10hrs per
year.

For dusts the zone classifications are:

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 more than 1000hrs per year.
Zone 21 A place in which an explosive atmosphere in the form of a cloud of combustible dust in air is likely to occur in
normal operation between 10-1000hrs per year.
Zone 22 A place in which an explosive atmosphere in the form of a cloud of combustible dust in air is not likely to occur
in normal operation but, if it does occur, will persist for less than 10hrs per year.

Hazardous Area Electrical Equipment

When designing systems where equipment is required for use in a hazardous area environment the equipment must meet the
requirements of the classified zone.
Hazardous Area Zone 0

Ex ia - Intrinsically Safe
Ex s - Special protection, must be certified for use in Zone 0

Hazardous Area Zone 1

Any equipment suitable for Zone 0

EX d - Fame Proof
Ex p - Pressurised or Purging
Ex q - Powder filled
Ex o - Oil Filled/immersion
Ex e - Increased Safety
Ex ib - Intrinsically Safe
Ex m - Encapsulation

Hazardous Area Zone 2

Any equipment suitable for Zone 0 or Zone 1

Ex n - Certified that the equipment is not capable under normal operation of igniting a surrounding explosive
atmosphere.

Temperature Classification
Temperature classification is an important part of hazardous area equipment designation and gives the maximum surface
temperature that any part of the equipment can reach under operational or fault conditions, assuming an ambient temperature of
40oC.
Germany C
USAC
UK C
Continuous - Short Time
T1 - Surface temperature must not exceed 450oC
T2 - Surface temperature must not exceed 300oC
T1 - 450 T3A - 180 T1 - 450
G1: 360 - 400
T3 - Surface temperature must not exceed 200oC
T2 - 300 T3B - 165 T2 - 300
G2: 240 - 270
T4 - Surface temperature must not exceed 135oC
T2A
280
T3C
160
T3
200
G3: 160 - 180
T5 - Surface temperature must not exceed 100oC
T2B - 260 T4 - 135 T4 - 135
G4: 110 - 125
T6 - Surface temperature must not exceed 85oC
T2C - 230 T4A - 120 T5 - 100
T2D - 215 T5 - 100 T6 - 85
T3 - 200

T6 - 85

G5: 80 - 90

Auto-ignition temperatures (vapors & gases)

Gas

The auto-ignition temperature of a liquid, gas or

vapor is the temperature at which the substance will
ignite without any external heat source. The exact
temperature value determined depends on the
laboratory test conditions and apparatus. The autoignition temperature of a dust is usually higher than
that of vapors & gases.

Temperature

Methane

580 C

Hydrogen

560 C

Propane

Substance Temperature
Sugar

460 C

493 C

Wood

340 C

Ethylene

425 C

Flour

340 C

Acetylene

305 C

Naphtha

290 C

Grain dust

300 C

Carbon disulfide

102 C

Tea

300 C

Type of protection
To ensure safety in a given situation, equipment is placed into protection level categories according to manufacture method and
suitability for different situations. Category 1 is the highest safety level and Category 3 the lowest. Although there are many types
of protection, a few are detailed:

Flameproof

Increased
Safety

Oil Filled

Sand/Powder
/Quartz Filled

Ex
Code

Notified Body Name

Will
have
a
CENELEC Hexagon
followed by apparatus
group and Safety
Category

Will
have
a
CENELEC Hexagon Equipment is very robust and
followed by apparatus components are made to a high
group and Safety quality
Category

Motors,
lighting,
junction boxes

Will
have
a
CENELEC Hexagon
Equipment
components
are
followed by apparatus
completely covered with a layer of oil
group and Safety
Category

Zone 2 or Zone 1,
depending
on Heavy
current
edition of the equipment
standard used.

Will
have
a
CENELEC Hexagon Equipment
components
are
followed by apparatus completely covered with a layer of Zone 2
group and Safety Sand, powder or quartz
Category

Description

Location

Use

Equipment is robust can stand an

explosion from within, without
Zone 1 if gas
Motors,
lighting,
transmitting the flame to the outside.
group & temp.
Equipment has flameproof gaps (max
junction boxes
class correct
0.006" propane/ethylene, 0.004"
acetylene/hydrogen)

Electronics,
telephones, chokes

Encapsulated

Pressurised
/purged

Intrinsically
safe

Non
Incendive

Special
Protection

Will
have
a
CENELEC Hexagon Equipment components of the
Zone 1 (Ex mb) or Electronics
followed by apparatus equipment are usually encased in a
Zone 0 (Ex ma)
heat)
group and Safety resin type material
Category

Will
have
a
CENELEC Hexagon
followed by apparatus
group and Safety
Category

Any arcs or sparks in this equipment

has insufficient energy (heat) to ignite
Will
have
a a vapour
Instrumentation,
CENELEC Hexagon
'ia': Zone 0 & 1
measurement,
followed by apparatus Equipment can be installed in ANY
'ib': Zone 1
control
group and Safety housing
provided
to
IP54
Category
A 'Zener Barrier' or 'opto isol' or
'galvanic' unit may be used to assist
with certification.

Now
CENELEC
recognised; so will
have a hexagon Equipment is non-incendive or nonZone 2
followed by apparatus sparking.
group and Safety
Category

This method, being by definition

special, has no specific rules. In effect
it is any method which can be shown
Has a BASEEFA to have the required degree of safety
Crown
in use. Much early equipment having
Ex s protection was designed with
Not
CENELEC encapsulation and this has now been
recognised;
no incorporated into IEC 60079-18 [Ex
m]. Ex s is a coding referenced in IEC
hexagon.
60079-0. The use of EPL and ATEX
Category directly is an alternative for
s marking.

Equipment is pressurised with a

positive pressure; gas cannot get in
for air coming out or equipment is
Zone 1
purged with a diluting gas such as air.
If air is used, it is ducted in from
outside the hazardous area.

(no

Analysers, motors,
control
boxes,
computers

Motors,
lighting,
junction
boxes,
electronic
equipment

Zone 1 depending
upon
As its certification
Manufacturers
states
Certification.

Multiple Protection
Many items of EEx rated equipment will employ more than one method of protection in different components of the apparatus.
These would be then labeled with each of the individual methods. For example a socket outlet labeled EEx'de' might have a
case made to EEx 'e' and switches that are made to EEx 'd'.
Hazardous Locations Classifications Descriptions - ANSI/NFPA(NEC)terms

Class I, Div. 1 - Where ignitable concentrations of flammable gases, vapors or liquids are present within the
atmosphere under normal operation conditions.
Class I, Div. 2 - Where ignitable concentrations of flammable gases, vapors, or liquids are present within the
atmosphere under abnormal operating conditions.
Class II, Div. 1 - Where ignitable concentrations of combustible dusts are present within the atmosphere under
normal operation conditions.
Class II, Div. 2 - Where ignitable concentrations of combustible dust are present within the atmosphere under
abnormal operating conditions.
Class III, Div. 1 - Where easily ignitable fibers or materials producing combustible flyings are present within the
atmosphere under normal operation conditions.
Class III, Div. 2 - Where easily ignitable fibers or materials producing combustible flyings are present within the
atmosphere under abnormal operating conditions.

Common Materials within Associated Class & Group Ratings, such as "Class I, Division 1, Group A":

Class I Areas: Group A: Acetylene / Group B: Hydrogen / Group C: Propane and Ethylene / Group D: Benzene,
Butane & Propane
Class II Areas: Group E: Metal Dust / Group F: Carbon & Charcoal / Group G: Flour, Starch, Wood & Plastic
Class III Areas: NO GROUP: Cotton & Sawdust

Equipment category
The equipment category indicates the level of protection offered by the equipment.

Category 1 equipment may be used in zone 0, zone 1 or zone 2 areas.

Category 2 equipment may be used in zone 1 or zone 2 areas.
Category 3 equipment may only be used in zone 2 areas.

Labeling
Allequipmentcertifiedforuseinhazardousareasmustbelabelledtoshowthetypeandlevelof
protectionapplied.
1.InEuropethelabelmustshow:
a)TheCEmark.
b)Thecodenumberofthecertifyingbodyforthequalitycertificate.
c)CEmarkingiscomplementedwiththeExmark,followedbytheindicationoftheGroup,Category
and,ifgroupIIequipment,theindicationrelatingtogases(G)ordust(D).Forexample:ExII1G
(Explosionprotected,Group2,Category1,Gas)
2.Inaddition,thenormativemarkingwillbeabletoestablishthespecifictypeortypesofprotection
beingused,forexample:
EExiaIICT4.(Typeia,Group2Cgases,Temperaturecategory4).
EExnAIIT3X(Typen,nonsparking,Group2gases,Temperaturecategory3,specialconditionsapply).

3.ThesuitabilityofequipmentforthespecifichazardousareaintheANSI/NFPA(NEC)regulatedmarket
isrequiredtobetestedbyaNRTL(NationallyRecognizedTestingLaboratory).SuchinstitutesareUL,
FMorETL,justtonameafew.
a)Dependentonthespecificequipmentandtheapplicabledivisionthelabelwillalwayslistthe
Class(es),Division(s)andmaylisttheGroup(s)andtemperatureCode.
b)Directlyadjacentonthelabelonewillfindthemarkofthelistingagency.
c)Somemanufacturersclaim"suitability"or"builtto"hazardousareasintheirtechnicalliterature,but
ineffectlackthetestingagency'scertificationandthusunacceptablefortheAHJ(AuthorityHaving
Jurisdiction)topermitoperationoftheelectricalinstallation/system.

4.Alsoincludedinthemarkingare:
a)Themanufacturersnameortrademarkandaddress.
b)Theapparatustype,nameandserialnumber.
c)Yearofmanufacture.
d)Anyspecialconditionsofuse.
e)TheNEMAenclosureratingorIP codemayalsobeindicated,butitisusuallyindependentofthe
ClassifiedAreasuitability.

5.Manufacturerswillprovidespecificinstallationinstructionsthatmustbefollowedfor:
a)theequipmenttofunctionproperly,and
b)toprovidethedesignedprotectionintheClassifiedAreaaccordingtothelisting.