Hazardous Area

Electrical Training
Hazardous Area Explosion Protected Apparatus
Installation, Maintenance & Inspection Training
Course

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EX Training
Unit 1

General Principles

Unit 01 - General Principles

Unit 01 - General Principles

Basic Requirements for Combustion to
Occur:

FUEL

OXYGEN

SOURCE OF IGNITION

Unit 01 - General Principles

FUEL
GAS - VAPOUR - MIST - DUST
OXYGEN
21% IN AIR BY VOLUME
SOURCE OF IGNITION
ARC - SPARK - FLAME - HEAT

Unit 01 - General Principles

Basic Requirements for Combustion to Occur:
GAS or VAPOUR.

FIRE
TRIANGLE.
OXYGEN
(21% In Air).

SOURCE Of
IGNITION.

Unit 01 - General Principles

To prevent combustion occurring we can:
Remove any one of the three combustion
elements.
Isolate or Separate the Source of Ignition
from the gas/air mixture.

Unit 01 - General Principles

Allow the explosion to take place & contain it
within a robust enclosure.
Allow the three elements to co-exist & ensure
that the source of ignition is kept below specific
values.

Unit 01 - General Principles

Flammable (Explosive) Limits:
Combustion will only occur if the Flammable
mixture is between certain limits
i.e. between the LEL and the UEL

Unit 01 - General Principles

The Lower Explosive Limit - LEL
When the percentage of gas by volume is below
this limit,the mixture is too weak to burn.
i.e.
insufficient fuel
and/or
too much air

Unit 01 - General Principles

The Upper Explosive Limit - UEL
When the percentage of gas by volume is above
this limit, the mixture is too rich to burn.
i.e.
insufficient air
and/or
too much fuel.

Unit 01 - General Principles

Upper
UpperExplosive
ExplosiveLimit
Limit
(UEL)
(UEL)

Too
TooRich
Rich
Insufficient
InsufficientOxygen
Oxygen

Lower Explosive Limit

Too
TooWeak
Weak
Insufficient
InsufficientFuel
Fuel

(LEL)

Unit 01 - General Principles

Flammable (Explosive) Limits:
Different gasses and vapours will have
different flammable limits.
The greater the difference between the LEL
and the UEL.(flammable range).
The more dangerous the material.

Unit 01 - General Principles

We can operate safely with flammable
mixtures above the LEL
It is more practical to operate below the
LEL.

Unit 01 - General Principles

Flammable (Explosive) Limits:
The Flammable Limits of Some Materials are given in the table

Material
Propane.
Ethylene.
Hydrogen.
Acetylene.
Paraffin.
CarbonDisulphide.
Methane

LEL % by Volume

UEL % by Volume

2
2.7
4
1.5
0.7

9.5
34
75.6
100
5

1
5

60
15

Unit 01 - General Principles

Sources of Ignition:
The possible sources of ignition are many and varied.
They include the following:
Electrical arcs/sparks
Frictional sparks
Welding activities
Static discharges
Hot surfaces
Cigarettes
Batteries

Unit 01 - General Principles

Sources of ignition
Engine exhausts
Chemical reaction
Thermite action
Pyrophoric reaction
Lightning strikes

Unit 01 - General Principles

Flashpoint:
Definition:
The lowest temperature at which sufficient vapour is given
off a liquid, to form a flammable mixture with air that can be
ignited by an arc, spark or naked flame.

Unit 01 - General Principles

Flashpoint:
Some typical values are given in the table below;

Material

Flashpoint oC

Propane.
Ethylene.
Hydrogen.
Acetylene.
Diethyl Ether.
Paraffin.
Carbon Disulphide.

<-20.
<-20.
<-20.
<-20.
<-20.
+38.
<-20.

Unit 01 - General Principles

The flashpoint of a material gives an indication of how
readily that material will ignite in normal ambient
temperatures.
Reference to tables taken from:
The UK Code of Practice - BS 5345: Pt (1)
The IEC Code of Practice - IEC 60079-20

Unit 01 - General Principles

Materials with high flashpoints should not be
overlooked as a potential hazard.
If a flammable material is discharged under
pressure from a jet its flashpoint may be reduced.

Unit 01 - General Principles

Ignition temperature:
Definition:
The minimum temperature at which a flammable
material will spontaneously ignite without a spark or
flame.

Unit 01 - General Principles

Ignition temperature :
The surface temperature of equipment, indicated by its T
rating will not exceed the Ignition Temperature of the
flammable atmosphere, which may be present around the
equipment.

Unit 01 - General Principles

Ignition temperature:

Some typical values for Ignition Temperature are given in the table below:
Ref: BS 5345 Pt (1) and IEC 60079-20 codes of practice.

Material
Propane.
Ethylene.
Hydrogen.
Acetylene.
Diethyl Ether.
Paraffin.
Carbon Disulphide.
Methane

Ignition Temperature oC
470.
425.
560.
305.
185.
210.
102.
595

Unit 01 - General Principles

Oxygen enrichment:
The normal oxygen content in air is around 20.95%.
Any value which exceeds this is deemed to be
oxygen enriched.
Typical examples of where Oxygen Enrichment may occur
are :

Gas Manufacturing Plants

Hospitals
Oxy-Acetylene Equipment

Unit 01 - General Principles

Oxygen enrichment has three disadvantages:
(1) It can lower the Ignition Temperature of flammable
materials as shown in the examples below:

Material;

Hydrogen Sulphide.
Acetylene.
Ethane.

Air
Ignition Temp. 0C;

470.
425.
560.

Increased Oxygen
Ignition Temp. 0C;

220.
296.
506.

Unit 01 - General Principles

(2) It can significantly raise the Upper Flammable
Limit of the majority of gasses and vapours, thereby
widening their Flammable Limits .
This is illustrated in the examples below:
Air
Material;
Methane.
Propane.
Hydrogen.

Increased Oxygen

LEL %; UEL %;

5.
2.2
4.

15.
9.5
75

LEL %;

UEL %;

5.2
2.3
4.7

79
55
94

Unit 01 - General Principles

(3)

Oxygen enrichment of a flammable atmosphere

can allow it to be ignited with much lower values
of electrical energy.

Note:
Explosion protected equipment is tested in normal
atmospheric conditions.
Certification for equipment in an oxygen enriched
environment would be compromised.

Unit 01 - General Principles

Density
If a flammable material is released, it is important to know
whether the material will rise or fall in the atmosphere.
Since air is the standard reference
Its relative density is 1.

Unit 01 - General Principles

If a material is twice as heavy as air its relative density
will be 2.
Therefore:

Materials with a relative density less than 1

will rise in the atmosphere.

Materials with a relative density greater than 1

will fall in the atmosphere.

Unit 01 - General Principles

Density:
Materials which rise in the atmosphere can collect in
roof spaces.
Those which fall can drift along at ground level and
possibly into a non hazardous location.
May collect in locations without ever dispersing.
Detectors must be installed at correct level and
location

Unit 01 - General Principles

Density:
Some typical values are given in the table below:
Material
Air
Propane.
Ethylene.
Hydrogen.
Acetylene.
Diethyl Ether.
Paraffin.
Carbon Disulphide.
Hydrogen Sulphide.

Relative Vapour Density

1.
1.56.
0.97.
0.07.
0.9.
2.55.
4.5.
2.64.
1.19

Unit 01 - General Principles

Area Classification:
A hazardous area is defined as:
An area in which an explosive gas atmosphere is
present, or may be expected to be present, in quantities
such as to require special precautions for the
construction, installation and use of apparatus.

Unit 01 - General Principles

A non-hazardous area is defined as:
An area in which an explosive gas atmosphere is not
expected to be present, in quantities such as to require
special precautions for the construction, installation and
use of apparatus.

Unit 01 - General Principles

Area classification-zones:
zoning is a means of representing the following:
the frequency of the occurrence
the duration of an explosive gas atmosphere
It assists in proper selection and installation of
apparatus

Unit 01 - General Principles

Evaluation of the area within each zone is based on
The grade of release
Presence of artificial ventilation
Extent and volume of release
Hazardous areas are, therefore, divided into three zones.
They represent the risk in terms of:
The probability, frequency and duration of a release.

Unit 01 - General Principles

Ref BSEN 60079-10
Classification of hazardous areas, are as follows:
Zone 0:
In this Zone, an explosive gas atmosphere is
continuously present, or present for long periods.

Unit 01 - General Principles

Zone 1:
In this zone, an explosive gas atmosphere is likely to
occur in normal operation.
Zone 2:
In this zone, an explosive gas atmosphere is not likely to
occur in normal operation and, if it does occur, it is likely
to do so infrequently and will exist for a short period only.

Unit 01 - General Principles

Although not specified in the standards, the following
figures are generally accepted in industry.
The duration of a gas release, on a normal annual basis,
for the different Zones is as follows:
Zone 0 = over 1000 hours / year
Zone 1 = 10 to 1000 hours / year
Zone 2 = <10 hours / year

Unit 01 - General Principles

Zone Diagrams.

Zone 0

Zone 1

NonHazardous

Old Zone 0

Zone 2

Unit 01 - General Principles

a = 3m from vent
openings.
b = 3m above the
roof.
c = 3m
horizontally from
tank.

Unit 01 - General Principles

Sources of Release

Zone 0

SPACE ABOVE LIQUID

IN A CLOSED TANK
- ZONE 0

FLANGED JOINT
- ZONE 2

PUMP GLAND
- ZONE 1

WELDED JOINT
- NON HAZARDOUS

Unit 01 - General Principles

Typical Platform Hazardous Areas

HAZARDOUS ZONE 1

HAZARDOUS ZONE 2

NON HAZARDOUS AREA

Unit 01 - General Principles

Gas/Apparatus grouping
In the IEC system, the group allocation for surface and
underground (mining) industries are separate.
Group I is reserved for the Mining industry
Group II is for Surface industries
This course deals with group II

Unit 01 - General Principles

Group II is further subdivided into the following:
Group IIA i.e. Propane
Group IIB i.e. Ethylene
Group IIC i.e. Hydrogen

Unit 01 - General Principles

Two methods have been used to group these
flammable materials
According to the degree of risk they represent
when ignited
The first involved determining the MIE for each
gas
This proved that Hydrogen and Acetylene were
the most easily ignited
Propane was the least easily ignited

Unit 01 - General Principles

The second, involved determination of the MESG.

Using a flameproof bronze sphere

The 25mm flame-path gaps could be varied
A gas/air mixture was introduced inside and outside
Under test, the gas inside is ignited
The MESG is the maximum gap which prevents
ignition of the outside gas
The more dangerous the gas the smaller the gap

Unit 01 - General Principles

Apparatus for determination of M.E.S.G.

FLANGE
1(25mm)
M.E.S.G.

FLAMMABLE
MIXTURE

Unit 01 - General Principles

Gas Group

Representative Gas

MESG
(mm)

MWG
(mm)

MIE
(J)

Methane (Firedamp)

1.17

0.5

280

IIA

Propane

0.97

0.4

260

IIB

Ethylene

0.71

0.2

95

IIC

Hydrogen/Acetylene

0.5

0.1

20

Unit 01 - General Principles

Note 1:
Apparatus marked II, i.e. with no sub-division letter A, B,
or C means that this can be used in all hazards
Note 2:
Apparatus marked II XXX.
XXX represents the chemical formulae or name of a
material and should only be used in this hazard

Unit 01 - General Principles

Note 3:
Apparatus marked IIA can only be used in IIA
hazards
Apparatus marked IIB can be used in IIA and IIB
hazards
Apparatus marked IIC can be used in IIA, IIB
and IIC hazards.

Unit 01 - General Principles

Temperature classification:
Is based on the maximum temperature which any
relevant part of the apparatus, which may be in contact
with an explosive gas will reach when operated within its
normal design rating and ambient temperature.
Apparatus is classified into one of six temperature ranges
See following slide

Unit 01 - General Principles

Temperature Codes are given in the table below:
Temperature Code
T1.
T2.
T3.
T4.
T5.
T6.

Maximum Surface
Temperature oC
450.
300.
200.
135.
100.
85.

Unit 01 - General Principles

Equipment T-Rating must be below the
temperature of any gas / vapour surrounding it.

ignition

The T- Rating temperatures are based on a maximum

Ambient temperature rating of 40 0C, for use in the UK.
Note
Higher Ambient Temperature Ratings are available

Unit 01 - General Principles

T-Rating and Ignition Temperature Comparison of Some
Materials are given in the table below:
Material
Methane.
Ethylene.
Cyclohexane.
Diethyl - Ether.
Carbon - Disulphide.

Ignition Temperature
595 0C
425 0C
259 0C
170 0C
102 0C

T - Rating
T 1 (450 0C)
T 2 (300 0C)
T 3 (200 0C)
T 4 (135 0C)
T 5 (100 0C)
T 6 (85 0C)

Unit 01 - General Principles

Temperature classification example:
If apparatus is tested in a room with an air temperature
of 20C and the surface temperature reached 100C
(T5), this would be an 80C temperature rise.
However if the test had been conducted at 40C this
would then be calculated as 100C + 20C = 120C
(T4).
The correct method would be to start at 40C ambient
with a maximum 60C temperature rise to stay within
the 100C or T5 rating.

Unit 01 - General Principles

In order to avoid infringement of the apparatus
certification:
The ambient temperature rating must be
compatible with the environmental ambient
temperatures
The temperature rise must not be exceeded.
This is demonstrated in the following example:

Unit 01 - General Principles

TEMPERATURE CLASSIFICATION:
Ambient Air Temperature Less than Apparatus Ambient Rating;

(T 5)

(T 5)

1000C

1000C
800C
Temp. Rise.

600C
Temp. Rise.

400 C

Ambient Rating
of Apparatus
Air
Temperature

200 C
00 C
Correct

400 C
200 C
00 C
Incorrect

Unit 01 - General Principles

Ingress Protection:
Enclosures of electrical equipment are classified
according to their ability to resist:
The ingress of solid objects
The ingress of water
By means of a system of numbers known as the:
Ingress of Protection (IP CODE)
Ref BS EN 60 529.

Unit 01 - General Principles

The Code consists of the letters IP followed by two
numbers
For example - IP54
The first digit is for protection from solid objects
The second digit is for protection from water
Therefore for IP 54
5 = Dust protected
4 = Splashed water from any direction

Unit 01 - General Principles

INGRESS PROTECTION:

Abridged version of full table shown below;

SOLID OBJECTS
First
Numeral

Level of Protection

WATER
Second
Numeral

Level of Protection

No Protection

No Protection

Protection against objects

greater than 50 mm

Protection against drops of

water falling vertically

Protection against objects

greater than 12 mm

Protection against drops of

water when tilted up to 15

Protection against objects

greater than 2.5 mm

Protection against sprayed

water up to 60

Protection against objects

greater than 1 mm

Protection against splashed

water from any direction

Unit 01 - General Principles

INGRESS PROTECTION:

Abridged version of full table shown below;

SOLID OBJECTS
First
Numeral

Level of Protection

WATER
Second
Numeral

Level of Protection

Dust Protected

Protection against jets of

water from any direction

Dust Tight

Protection against heavy seas

deck watertight

Protection against immersion

in water 1m in depth and for
a specific time

Protection against indefinite

immersion in water at a
specified depth