Hazardous Area Classification Presentation

Presented By :
Date
:

What

is explosion ????
When explosion Occurs ????
What is fire triangle ???
Protection & Design
Violation in Hazardous Area Installation.

Ignition Source
Minor Explsion

Major Explosion

el
Fu

Ox
yg
en

Explosion Occurs when the Fire Triangle completes.

The Fire Angle Consists of
1 ) Hazardous Gas , Vapor and Dust
2) Support of Combustion ( Air Oxygen & Oxidation
Gas Mixture )
3) Source of Ignition

The Following are the Source of Ignition

1)Hot Surfaces
2)Electrical Arcs and Sparks
3)Electro Static Discharge
4)Electro Magnetic Radiation
5)Atmospheric Discharge
6)Mechanical Friction and Impact Sparks
7)Ultrasonic
8)Ionization Energy Radiation
9)Chemical Reaction
10)Open Flames

Fuel ( Gas ,Vapor , Dust / Fiber )

Hazardous locations are those locations where fire or

explosion hazards may exist due to flammable gases
or vapors, flammable liquids, combustible dust, or
ignitible fibers or flying.

There are two Major Standards

NEC Standard ( Class and Division )
IEC ( Zones )

NEC

Standard (Class and Division )

Hazardous ( Classified ) Locations are divided into three based on the explosive characteristics
of the
material.
Class 1 : Gas
Class 2 : Vapor / Mist
Class 3 : Dust / Fibers
Division is further divided into Division 1 and Division 2 based on the risk of fire or explosion
that the material present .
Division 1
Division 1 locations are those where the explosion hazard exists under normal operating conditions. In terms
of hours hazardous gas may present more than10 hours.
Division 2

Division 2 location are those where the explosion hazard does not exit under normal operation . Explosive
gas may exist only at abnormal conditions .
In term of hours less than10 hours .
Unclassified
Area in which an explosive gas atmosphere is not expected to be present in quantities.
In term of hours less than 1 hour.

IEC Standard ( Zone )

According to IEC Standard , there is only gas is considered as
hazardous materials.
Zone 0
In which the explosive air gas- air mixture is continuously present or
present for long periods. In terms of duration more than 1000 hours.
Zone 1
In which an explosive gas- air is likely to occur in normal operation
In terms of duration more than 10 hours and less than 1000 hours.
Zone 2
In which an explosive gas-air mixture is not likely to occur in normal
operation and it occurs will exist for a short time..
In term of duration less than 10 hours.
Safe Zone
Area in which an explosive gas atmosphere is not expected to be
present in quantities.
In term of hours less than 1 hour.

The illustration below compares the Division and Zone

systems in term of the risk assessment.

Zone 0
Division 1
Zone 1

Division 2

Zone 2

Not
Classified

Not
Classified
1 Hour
per Year

10 Hours
per Year

Duration of time gas is present

1 Hour
per Year

10 Hours
per Year

Duration of time gas is present

1000 Hours
per Year

Flash Point
Flash Point is the minimum temperature of a liquid at which
sufficient vapor is given off to form an ignitable mixture
with air near the surface of the liquid .
Auto Ignition Temperature ( Splash Point )
The auto ignition temperature of a gas , sometimes refer as
auto ignition temperature , is the lowest surface
temperature which will ignite the flammable atmosphere.
Ammonia : 630C
Methane : 595C
Hydrogen : 560C
Propane : 470C
Ethylene : 425C
Carbon Disulphide : 105C

Ignition by Energy
Sufficient Energy in the presence of flammable mixture will
cause ignition to take place . Energy can occurs in two ways
Spark Energy or Flame Energy.

Gas Group

Gas

Energy Band

Group I

Methane

200uJoule

Group II A

Propane

180 u Joule

Group II B

Ethylene

60 u Joule

Group IIC

Hydrogen

20 u Joule

Types of
Protection
for electrical apparatus in
hazardous areas

Types of Protection

CENELEC Types of Protection

Technique

Protection type

Segregation

Pressurisation
Oil immersion
Powder filling
Encapsulation

Refined
mechanical
design
Energy
limiting
Containment
Special

Ex

CENELEC
standard

Typical applications

p
o
q
m

EN50 016
EN50 015
EN50 017
EN50 028

Control rooms, analysers

Transformers, switchgear
Instrumentation, sub assy
Instrumentation, control gear

Increased safety

EN50 019

Motors, lighting fittings, JBs

Non-incendive

n (N) EN50 021 Motors, lighting, boxes

Intrinsic safety

ia/ib

Flameproof
Special

d
s

General requirements for all methods

EN50 020 Instrumentation, control gear

EN50 018
EN50 014

Switchgear, motors, pumps

CENELEC Types of Protection

Technique

Protection type

Segregation

Pressurisation
Oil immersion
Powder filling
Encapsulation

Refined
mechanical
design

Increased safety

Energy
limiting
Containment
Special

Non-incendive

Ex

CENELEC
standard

p
o
q
m
e
n (N)

Intrinsic safety

Control rooms, analysers

Transformers, switchgear
Instrumentation, sub assy
Instrumentation, control gear

EN50 019

Motors, lighting fittings, JBs

EN50 021

Motors, lighting, boxes

ia/ib

EN50 020

Instrumentation, control ge

EN50 018

Switchgear, motors, pumps

Flameproof
Special

EN50 016
EN50 015
EN50 017
EN50 028

Typical applications

General requirements for all methods

EN50 014

Ex p

Design Standards:
BS 5501: Part 3
EN 50016
IEC 79-2
Definitions
Pressurising..
A method of safeguarding, whereby air or inert gas in a room or
enclosure is maintained at a pressure sufficient to prevent the
ingress of the surrounding atmosphere, which might be flammable
Purging.
A method of safeguarding whereby a flow of air or inert gas is
maintained through a room or enclosure in sufficient quantity to
reduce or prevent any hazard, which could arise in the absence of
the purge
Pressurising/purging
This is a method employing both pressurising and purging
Installation Code of Practice:
BS 5345: Part 5
BS EN 60079-14:2003
IEC60079-14

Ex p - Principles
Principles
Establishes and maintains air or an inert gas (sometimes called a
Protective Gas) inside an enclosure containing unprotected, ignition
capable, electrical equipment.
The internal pressure is maintained higher than the surrounding
atmospheric pressure (called Overpressure)

Conditions
A monitoring system is required to ensure the internal is maintained
(typically 1 w.g. / 50 Pascals)
An Initial Purge, (at least 5 times original enclosure volume) must
sweep out any trace of hazardous atmosphere
Only then can the contents of the enclosure are energised
Monitoring system times the minimum period of the Initial Purge

Ex p - Details
Interior
Two

of enclosure can be considered as an artificial safe area

techniques

Pressurisation (Leakage Compensation)

Overpressure must be maintained

Continuous Flow (Purging)

Flow through must be maintained

Mains power is interlocked with the pressure switch to give automatic

disconnection on pressure failure
ZONE 1: automatic power-off on air failure or access opening
ZONE 2: audible and visual alarms on air failure or access opening
Suitable for use in Zone 1 and Zone 2

Ex p : Pressurisation
Leakage Compensation
Pressure switch

Initial
purge

Control System
(Ex protected)
Timer &
Control
Circuits

Air inlet

Contactor

Mains
Supply

Ex p : Purging
Continuous Dilution

Flow switch

Initial
purge

Control System
(Ex protected)
Timer &
Control
Circuits

Air inlet

Contactor

Mains
Supply

Ex p - pros and cons

Pros

Sometimes

the only solution

Can protect large volumes, panels and control rooms
Can have large margin of error before danger results
Useful for VDUs
Cons
Clean

air is not free: has to be filtered, pumped etc.

Can be expensive
Live working is not permissible
May influence area classification

Ex o : Oil Immersion

Design

Standards:

CENELEC: EN 50015
BS 5501: Part 2 (Apparatus code EEx o)
IEC 60079-6
Definition

A type of protection in which the electrical apparatus or

parts of the electrical apparatus are immersed in a
protective liquid in such a way that an explosive
atmosphere which may be above the liquid or outside the
enclosure cannot be ignited.
Code

of Practice:

BS EN 60079-14:2003/PD 60079-14:2000
BS 5345: Part 9

Principles
Prevents

Ex o

access of flammable atmosphere to possible

ignition sources by immersion in oil

Pros

and Cons

Commonly used for heavy current switch-gear and

transformers
Permits contact movement and quenches sparks
Mineral Insulating Oils are generally used
Care that oils do not breakdown to give off ignitable vapours
Silicone oils poison pellistor type gas detectors!
Containment of Oil requires enclosure with suitable glands
Dip-stick (for testing oil level)

Equipment
being protected

Oil
Hazardous
Area

Cabling/Glanding
must be oil
resistant
Entries to enclosure
must maintain oil
seal

Ex q : Powder Filling
Design

Standards:

CENELEC: EN 50017
BS 5501: Part 4 (Apparatus code EEx q)
IEC 60079-5
Definition

A type of protection in which the parts capable of igniting an explosive

atmosphere are fixed in position and completely surrounded by filling
material to prevent the ignition of an external explosive atmosphere.
UK

Code of Practice:

BS EN60079-14/PD 60079-14?
BS 5345: Part 9

Ex q

Code

letter 'q' stands for quartz

Filling

medium is commonly small glass or

silica beads

Common

uses are electronic assemblies in

hazardous area e.g. weighing system
Canister
electronics,
telephones,
luminaires
Lid

Terminals (Ex e)
or Flying Leads
Filling

Ex m : Encapsulation
Design

Standard:

CENELEC: EN 50028: 1988

BS 5501: Part 8 (Apparatus code EEx m)
IEC standard: none
Definition

Protection of electrical components by enclosure in a resin in such a

way that an explosive atmosphere cannot be ignited during operation
by either sparking or overheating which may occur within the
encapsulation.
Code

of Practice:

BS EN 60079-14/PD 60079-14
BS 5345: Not included

Ex m
Principles

encloses ignition capable apparatus in a protective resin

dissipates heat through appropriate type of resin

Features

Enhanced mechanical properties

robust
resistant to vibration, environmental and chemical attack
may be used to deal with energy- storing or power-dissipating components

often used in combination with other types of protection

Two types
Encapsulant molded with enclosure
Encapsulant removed from any initial mold
Examples:

solenoid valves, proximity sensors, field mounting dc supplies, gas

detector heads

Ex m
Advantages

Mechanical ruggedness of encapsulated circuit

Range of different resins to suit application
Solid or semi flexible
Thermal insulating or dissipating
Disadvantages

Does not permit moving parts

Care required with electrical protection
Not repairable (fuses integral with parts)
External connections difficult to engineer

Notes
Encapsulated apparatus was previously certified Ex s
Often used in combination with other types of protection

CENELEC Types of Protection

Technique

Protection type

Segregation

Pressurisation
Oil immersion
Powder filling
Encapsulation

Refined
mechanical
design

Non-incendive

Special

Special

Increased safety

Ex

CENELEC
standard

Typical applications

EN50 016 Control rooms, analysers

EN50 015 Transformers, switchgear
EN50 017 Instrumentation
EN50 028 Instrumentation, control gear

p
o
q
m
e

EN50 019 Motors, lighting fittings, JBs

n (N)EN50 021 Motors, lighting, boxes

General requirements for all methods

EN50 014

Ex e : Increased Safety
Design

Standards:

BS 4683: Part 4
EN 50019 = BS 5501: Part 6
IEC 60079-7
Definition

A method of protection by which additional measures are applied to

electrical equipment so as to give increased security against the
possibility of excessive temperatures and of the occurrence of arcs
and sparks during the service life of the apparatus. It applies only to
electrical equipment no parts of which produce arcs or sparks or
exceed the limiting temperatures in normal service
Code

of Practice:

BS EN 60079-14:2003/PD 60079-14 : 2000

BS 5345: Part 6

Ex e

Principles
Originally conceived for higher power applications
Philosophy of careful design and construction
Sparking eliminated
Heating effects minimised

High reliability, suitable for Zone 1 and 2

Origin
German: Erhhte sicherheit means increased safety

Description

High reliability insulation

Good quality materials, design and assembly
Heating effects in conducting parts minimised by careful design
Enclosure required
moisture- and dust-tight (IP54)
Impact resistant
Weatherproof
Solvent proof
does not need to be gas tight

Ex e

Examples:-

Terminations prevented from becoming intermittent (High integrity clamping

arrangement) - sparking and arcing eliminated
Connections oversized to provide adequately low resistance - controlled power
dissipation

Installation Guide

Nut
Shake-proof washer
Crinkle Washer
Upper grooved clamp bar
Conductor (wrapped around post)
Lower grooved clamp bar
Crinkle Washer

Moulded Terminal Block

Component Certified Ex./U
Fixing Bolt

Ex e
Power

Applications

include induction motors, lighting fittings, junction boxes, terminal

housings, anti-frost heaters, trace heating
Enclosures

not required to withstand explosion

must be weatherproof; IP 54 is usual minimum
impact resistant and solvent-proof
Plastic or metal

Ex

e apparatus uses component certified (/U) parts.

Junction

box capacity is determined by wattage dissipation or

terminal rating factors

German

wiring practice

toughened plastic sheaths give mechanical protection

armoured cable is rarely used

Ex e
May

be used in Zone 1

Many

Conditions for Safe Use to be adhered

to on installation
e.g. Crimped connections may not be permitted!

Increasing

use in Instrument systems

High power levels than Ex i will permit

Use seen in i/o system hubs in Zone 1
Barriers and Isolators are not Ex e Apparatus or
Component Certified

Ex n : Non-Incendive
Design

Standards:

(OLD: Div 2 Apparatus, BS 4683:Part 3:1983)

BS 6941:1988 (Ex N)
EN 50021:1999 EEx n
IEC 60079-15:

Definition

A type of protection applied to electrical apparatus such that, in normal

operation, it is not capable of igniting a surrounding explosive atmosphere
and a fault capable of causing ignition is not likely to occur.
Codes

of Practice:

BS 5345 : Part 7
BS 60079-14:2003
PD 60079-14 : 2000

Ex n
Principles

Comprises apparatus in suitable enclosure

Normal industrial-grade apparatus with few modification.
Heating permitted but hot surfaces must not exceed T class
Faults not considered
Zone 2 only

Features

Enclosure to withstand IP54 & 7Nm impact test

Sparking devices may be protected by additional means
Non-incendive component
Sealed device
Enclosed break device

Originally conceived for higher power applications

Lighting, junction boxes, rotating machines, transformers

Ex n
Ex

n to later Standards permit use in instrumentation

more specific additional protection techniques

uses an additional letter to denote
nA

non-sparking apparatus
nC

otherwise protected sparking apparatus

nR

restricted breathing enclosures

nL

energy limited circuits

nP

simplified pressurisation
Use

in i/o systems for mounting in Zone 2

CENELEC Methods of Protection

Technique

Protection type

Segregation

Pressurisation
Oil immersion
Powder filling
Encapsulation

Refined
mechanical
design
Energy
limiting
Special

Ex

CENELEC
standard

p
o
q
m

c
i
s
n
i
r
t
n
I
Increased safety

Non-incendive

Intrinsic safe

Special

y
t
e
f
a
S

EN50 016 Control rooms, analysers

EN50 015 Transformers, switchgear
EN50 017 Instrumentation
EN50 028 Instrumentation, control gear
EN50 019

n (N) EN50 021

ia/ib

Typical applications

Motors, lighting fittings, JBs

Motors, lighting, boxes

EN50 020 Instrumentation, control gear

General requirements for all methods

EN50 014

CENELEC Methods of Protection

Technique

Protection type

Segregation

Pressurisation
Oil immersion
Powder filling
Encapsulation

Refined
mechanical
design

Increased safety
Non-incendive

Energy
Intrinsic safety
limiting
Containment
Flameproof
Special

Special

Ex

CENELEC
standard
EN50
EN50
EN50
EN50

p
o
q
m
e

Typical applications

016 Control rooms, analysers

015 Transformers, switchgear
017 Instrumentation
028 Instrumentation, control gear

EN50 019

Motors, lighting fittings, JBs

n (N) EN50 021 Motors, lighting, boxes

ia/ib EN50 020 Instrumentation, control gear
d

EN50 018

General requirements for all methods

EN50 014

Switchgear, motors, pumps

Flameproof : Ex d
Design

Standards:

(OLD: BS 229, BS 889 and BS 4683: Pt 2)

CENELEC: EN 50018 = BS 5501: Part 5
IEC 60079-1
Definition

An enclosure for electrical apparatus that will withstand an internal

explosion of the flammable gas or vapour which may enter it
without suffering damage and without communicating the internal
flammation to the external flammable gas or vapour for which it is
designed, through any joints or structural openings in the
enclosure
UK

Code of Practice:

BS EN 60079-14:2003/PD 60079-14 : 2000

BS 5345: Part 3

Ex d
Points

of Principle

It is based on the design of an enclosure containing electrical

equipment
The enclosure is not designed to be gas tight
A hazardous atmosphere may form inside the enclosure
This gas may be ignited by internal hot surfaces and/or sparks
The resultant explosion causes a large pressure rise in enclosure
Resultant flames try to escape though any joint
If the burning gasses find an exit path (referred to as a Flame
path) sufficient energy must be extracted from the flame such
that it cannot ignite any outside surrounding flammable
atmosphere.
The pressure withstand may must be adequately maintained to
prevent the widening of Flamepaths
Pressure does not need to be and sometimes cannot be actually
contained (Clearance on shafts, etc)
Joints are designed to prevent transmission of flame from inside
to outside

Ex d
Standards

There shall be no intentional gap. in Flamepath joints

Pros

state:

and Cons

Heavy
Expensive
High maintenance overhead
No live working without Gas Clearance

Certification based on Enclosure AND Contents

Changes to contents limited

Pressure piling concern restricts enclosure layout
Use of Armoured Cable
Use of Correct cable glands

Ex d
Flameproof (Europe) or Explosionproof (USA)
Permits gas-air mixture access to the inside of the enclosure but
prevents ignition transfer to the outside
'd' comes from "druckfest", German for pressure-tight

Ex d - gaps in enclosures
Ex d standards concentrate on the constructional
aspects of boxes and maximum permissible
gaps.
Flame Path Length

Gap

Gaps are not a requirement but are a consequence of any

practical box design .

CENELECTypes of Protection
Technique

Protection type

Segregation

Pressurisation
Oil immersion
Powder filling
Encapsulation

Refined
mechanical
design

Increased safety
Non-incendive

Energy
Intrinsic safety
limiting
Containment
Flameproof
Special

Special

Ex

CENELEC
standard
EN50
EN50
EN50
EN50

p
o
q
m
e

016
015
017
028

EN50 019

n (N) EN50 021

ia/i
d

Typical applications

Control rooms, analysers

Transformers, switchgear
Instrumentation
Instrumentation, control gear
Motors, lighting fittings, JBs
Motors, lighting, boxes

EN50 020 Instrumentation, control gear

EN50 018

General requirements for all methods

EN50 014

Switchgear, motors, pumps

Special protection Ex s
Design

Standards:

BASEEFA SFA 3009

BS / CENELEC / IEC : none
Definition

A concept which has been adopted to permit the certification

of those types of electrical apparatus which, by their nature,
do not comply with the constructional or other requirements
specified for apparatus with established types of protection,
but which nevertheless can be shown, where necessary by
test, to be suitable for use in prescribed Zones or hazardous
areas.
UK

Code of Practice:

BS 5345: Part 8

Ex s
Used

only by BASEEFA for apparatus which is

deemed to be safe, but which does not comply
with any of the recognised methods of protection

Common
Sintered

use is for pellistors in gas detectors

metal disc acts as Flametrap

Now being incorporated into EEx d

Use

in Zone 0 specially certified as Ex s(Zone 0)

Gas
enters

Heat removed from any combustion by gauze effect

Zones of use
Types of protection:
IEC / Europe
Zone 0

Zone 1

Zone 2

North America

Ex ia
Ex s (Zone 0)
Ex
Ex
Ex
Ex
Ex
Ex
Ex
Ex

Div 1 Zone 0
now recognised

d - flameproof
p - pressurised
i - intrinsic safety ia & ib
e - increased safety
q - powder filled***
m - encapsulation
o - oil immersion
s - special

All types suitable

for Zone 0 & 1 and
Type N, Ex N or Ex n

Class I
Division 1

Class I
Division 2

Types of protection:
- explosionproof
- purged
- intrinsic safety
- oil immersion

Types of protection:
all types suitable
for Div 1 and
Non-incendive

*** Ex q to old Standard is confined to Zone 2

And now refer to the ATEX Directive

Advantages of Intrinsic Safety

Least expensive:
no requirement for lockable fused isolators, protected cable, special glands

Simple apparatus:
permits the use of normal industrial devices if they are non-energy storing.

Fault tolerant:
Ex i is the only technique which remains safe after faults develop in cables and
fallible components

Live maintenance:
Ex i is the only technique which permits live working without gas clearance
certification

Unarmoured cable:
system is electrically-, not mechanically-protected

Safe for personnel:

extra low voltages and currents

Safest possible technique:

Temperature

Rating

Temperature Class

Maximum Surface
Temperature

T1

450

T2

300

T3

200

T4

135

T5

100

T6

85

Maximum Surface of the Equipment shall not

be exceed above mentioned Level.

Selection

of Temperature Rating for

Equipments .

Example

Ignition
Temperature

Hydrogen

560C

Cyclonexane

259 C

Diethyi Ether

170C

Carbon Di Suplhide

100C

Suitable Equipment Temperature

Classification
T1

T2

T3

T4

T5

T6

T3

T4

T5

T6

T4

T5

T6

T5

T6

IP

Rating ( Ingress Protection )

Protect from Duct and Water Ingression .
IP XX

Dust Ingress
Protection
The first characteristic numeral
indicates that
The enclosure provides protection of
persons against access to hazardous
parts by preventing or limiting the
ingress of a part of the human body
or an object held by a person.
And simultaneous
The enclosure provides protection of
equipment againt the indress of
solid foreign objects.

Water Ingress
Protection
The second charcteristic numeral
indicates the degree of protection
provided by enclosures with
respect to harmful effects on the
equipment due to the ingress of
water

Dust Ingress Protection

First
charact
eristic

Brief description

Definition

Non Protected

Non Protected

Protected against solid foreign objects

of 50 mm and greater

The object probe, sphere of

50mm shall not fully penetrate

Protected against solid foreign objects

of 12.5mm and greater

The object probe , sphere of

12.5mm shall not fully
penetrate.

Protected against solid foreign objects

of 2.5mm and greater

The object probe , sphere of

2.5mm , shall not penetrate at
all.

Protected against solid objects of

1.0mm and greater

The object of probe 1.0mm

shall not penetrate at all.

Dust protected

Ingress of dust is not totally

prevented but dust shall not
penetrate in quantity to
interfere with satisfactory
operation of the apparatus or
to impair safety

Dust Tight

No ingress of Dust

Second
Charact
eristic

Brief Discription

Defination

Non Protected

Protected against vertically falling

water drops

Vertically falling drops shall have no harmful

effects

Protected against vertically faliing

water drops when enclosure titled
up to 15

Vertically falling drops shall have harmful effects

when the enclosure is tilted at any angle up to 15
on either side of the vertical.

Protected against spraying water

Water sprayed at an angle up to 60 on either side

of the vertical shall have no harmful effects.

Protected against splashing water

Water splashed against the enclosure from any

direction shall have no harmful effects .

Protected against water jets

Water protected in jets against the enclosure from

any direction shall have no harmful effects.

Protected against powerful water

jets

Water projected in powerful jets against the

enclosure from any direction shall have no
harmful effects .

Protected against the effects of

temporary immersion in water

Ingress of water in quantities causes harmful

effects shall not be possible when the enclosure is
temporary immersed in water under standardized
condition of pressure and time.

Protected against the effects of

continuous immersion in water

Ingress of water in quantities causing harmful

effect shall not be possible when the enclosure is
continuously immersed in water under conditions
which shall be agreed between manufacturer and
user but which are more severe than numeral 7.

k
n
a
h
T

u
o