HAZARDOUS AREA CLASSIFICATION

Debabrata Das
Indian Oil Corporation Limited
 Objective

1 2

Understand concept of Understand the selection of

Hazardous area Classification Equipments for Hazardous Area
 Agenda
 Basic concept of Hazardous area

 Classification of Hazardous area

 Statutory requirements

 Selection of Equipments
 Why Classify an Area as Hazardous?

Potential for explosion Safety of personnel Property Damage

Blast in a refinery due to non-classification of Cooling

Tower as Hazardous Area
 What is Hazardous Area Classification?

 A method of analyzing and classifying the environment

 Proper selection of electrical apparatus

 Enable electrical apparatus to be operated safely

IS 5572

An area in which an explosive gas atmosphere is present,

or likely to be present, in quantities such as to require
special precautions for the construction, installation and
use of electrical apparatus.
 Hazardous Areas-Definitions

Petroleum Rule 1976

An area shall be deemed to be a hazardous area, where

(i) Petroleum liquid having flash point below 65°C or any

flammable gas or vapour in a concentration capable of
ignition is likely to be present.

(ii) Petroleum or any flammable liquid having flash point

above 65°C is likely to be refined, blended, handled or
stored at or above its flash point.
 Classification of Flammable Liquids
Flash Point
The minimum temperature at which the liquid gives so
much vapour that this vapour, when mixed with air, forms
an ignitable mixture and gives a momentary flash on
application of a small pilot flame under specified
conditions of test.

Flammable Liquids classification

Class A: Flash point below 23°C
Class B: Flash point 23°C and above but below 65°C
Class C: Flash point 65°C and above but below 93°C
 Explosive Atmosphere
Explosive Gas Atmosphere
 A mixture with air of flammable materials

 In the form of gas, vapour, or mist

 After ignition, combustion spreads throughout the mixture

Explosive Limit
 Lower Explosive Limit (LEL) – below which an explosive gas
atmosphere will not be formed.

 Upper Explosive Limit (UEL) –above which an explosive gas

atmosphere will not be formed.

Measured with Explosive Meter at out Locations

 Agenda
 Basic concept of Hazardous area

 Classification of Hazardous area

 Statutory requirements

 Selection of Equipments
 Classification of Hazardous Area

Class I Class II Class III

Areas where flammable Areas where Areas where
gaes/vapours may be combustible dust be combustible dust be
present may present may present

Typical Environment Typical Environment Typical Environment

• Oil Refinery • Coal Mine • Textile Mill
• Terminal • Grain Silo • Paper Mill
• Bottling Plant • Hay Storage • Wook factory
 Classification of Hazardous Area

Classified in 03 zones based upon the Frequency of the appearance and

duration of an explosive gas atmosphere

 Zone 0- explosive atmosphere is present continuously or for long

periods or frequently

 Zone 1- explosive atmosphere is likely to occur in normal operation

occasionally

 Zone 2- explosive atmosphere is not likely to occur in normal

operation but, if it does occur, will persist for a short period
only

NEC Classification: Div 1( Zone 0+ Zone 1) & Div 2( Zone 2)

 Zone 0 -Typical areas

 Vapour space above

closed process vessels
 Storage tanks
 Closed containers
 Areas containing open
tanks of volatile,
flammable liquid

An area in which an explosive atmosphere is present

continuously or for long periods or frequently
 Zone 1 Typical Area

 Flammable gas or vapour Examples

concentration is likely to exist in the air
under normal operating conditions
 Is likely to occur frequently because of
maintenance, repairs or leakage
 Piping system (containing valves,
meters, or screwed or flanged fittings)
is in an inadequately ventilated area
 The area below the surrounding
elevation or grade is such vapours may
accumulate therein
 Failure of equipment is likely to cause
an electrical system failure
simultaneously with the release of
flammable gas
 Imperfectly fitting peripheral seals on
floating roof tanks
 Inadequately ventilated pump rooms
for flammable gas /liquid
 Oily waste water sewer / basins
 Loading / unloading gantries
 Interiors of Sample Retention Room
 Areas in the immediate vicinity of
vents and filling hatches

An area in which an explosive atmosphere is not likely to occur in

normal operation but, if it does occur, will persist for a short period only
 Zone 2 Typical Area

 The system handling flammable liquid /vapour is in an adequately

ventilated area
 Release of flammable liquid/gas in abnormal conditions such as accidental
release of a gasket or packing
 The flammable vapours can be conducted to the location as through
trenches, pipes or ducts
 Locations adjacent to Zone 1 areas
 Pressurized rooms where flammable gas / vapour can enter in the case of
failure of positive mechanical ventilation

An area in which an explosive atmosphere is likely to occur in

normal operation occasionally.
 Areas Not Classified

 Piping system without valves,  Diesel Generator room / shed

fittings, flanges having adequate ventilation.
 Flammable material are
transported only in suitable  Oil/gas fired boilers installation
containers or vessels.
 Areas where permanent ignition-
 Enclosed premises in which
flare tips, flare pits, other open
purging stream from safe
flames and hot surfaces.
atmosphere maintained

A protected fired vessel is not considered a source

of ignition and the surrounding area is classified the
same as for a hydrocarbon pressure vessel.
 Properties of Flammable Substance
 Relative density- The lighter vapour will rise in a comparatively still
atmosphere and heavier vapour will tend to sink, and may thereby spread
over some distance horizontally at a lower level.

 Flammable limits- The lower the “LEL” the larger will be the extent of the
hazardous area.

 Flash point- The lower the flash point, the larger may be the extent of the
hazardous area.

Volatility- The more volatile a liquid and the lower will be its boiling point

 Ignition temperature & Energy - affect the design of electrical apparatus

for hazardous areas so that these do not present an ignition risk.
 Factors Affecting Extent of Hazard

Temp Air Ventilation

•Increasing temperature •A very mild breeze may •Increased rate of
of process liquid serve to extend the area ventilation, the extent of
in those directions to hazardous area may be
•The lower the IBP which vapours might reduced
results in greater normally be carried.
concentration of vapour •Obstacles e.g. dykes,
at the release source •A stronger breeze may walls may impede the
so accelerate the ventilation and thus may
•Rate of release of dispersion of vapours enlarge the extent.
flammable material that the extent of
potentially hazardous • On the other hand,
area would be greatly they may limit the
reduced. movement of a cloud of
an explosive gas
atmosphere and thus
may reduce the extent.

Elevated or depressed sources of release will alter the areas of potential hazards.
Grouping Of Industrial Gas
Categorized into Group-I and Group-II gases(IS-9570)

Group-I : Found in the coal mining

industry(Methane)
Group-II: Subgroups in the increasing order of
their explosiveness.
 Group-IIA: Acetone, ammonia, ethyl
alcohol, gasoline, LGP/ Propane.
 Group-IIB: Ethylene, acetaldehyde.

Group-IIC: Acetylene, hydrogen

 Temperature Class
To classify a flammable gas or vapour by its ability to get ignited by a hot
surface.
The temperature class defines the maximum surface temperature an electrical
apparatus is allowed to operate at.
The maximum surface temperature of the apparatus must always be lower than
the ignition temperature of the surrounding gases.
Apparatus, that are certified suitable for use in a hazardous area, should be
marked with their temperature class.

Temperature Class Max Surface Temperature of Ignition Temperature of the

Apparatus in C Flammable Substance in C
T1 450 >450
T2 300 >300<=450
T3 200 >200<=300
T4 135 >135<=200
T5 100 >100<=135
T6 85 >85<=100
 Gas group-Ignition Energy

GAS GROUP REPRESENATATIVE GAS IGNITION ENERGY

(mj)
I METHANE 280

II A PROPANE 260

II B ETHYLENE 95

II C HYDROGEN 18
 VARIOUS GASES/VAPOURS (IS 13408 Part I)

S No Name of the Minimum Flash point Iignition Flammable limit

chemical Ignition Deg. Cen. temperatur LEL UEL
Curre nt e
(MIC) mA (Deg C)
1 Methane I, 85 - 595 5% 15%
T1
2 Ammonia - - 630 105 mg/l 200 mg/l
II A T1
3 Ethylene 45 - 425 2.7% 34%
II B T2
4 Propane 70 - 470 2% 9.5%
II A T1
5 Acetylene 24 - 305 1.5 % 100%
II C T2
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 Agenda
 Basic concept of Hazardous area

 Classification of Hazardous area

 Regulations, Guidelines

 Selection of Equipments
Various Standards
 Certifying Agencies

Factory Mutual Underwriters Laboratories

CMRI
Dhanbad
 Statutory Regulations

• Petroleum Act, 1884

– Petroleum Rules, 1976
• Explosive Act, 1934
– Explosive Rules, 1983
– Gas Cylinder Rules, 1981
– Static & Mobile pressure Vessel (Unfired) Rules, 1981

CCoE, Department of Explosives is entrusted with the

responsibility of administration of the above statutory rules
in India
 Agenda
 Basic concept of Hazardous area

 Classification of Hazardous area

 Statutory requirements

 Selection of Equipments
 How to select equipment for various zones?

Area Classification Div/Zone

Gas Group

Protection concept IP Codes

Temp Class
 FLAMMABLE
MIXTURE, EXPLOSION
 Protection concepts
 No Arcs, sparks, or hot surface-
Increased Safety, Non-incendive

 Containing the explosion and extinguishing the flame-

Explosion proof, flame proof, power filled

 Limiting energy – Intrinsically Safe

Keeping Flammable material Out

Pressurized, encapsulated, oil emersion,

 Type of Protection

Type Ex- Description Location Use

Code
Flameproof d A method of protection where the Zone 1 if gas Motors,
enclosure of apparatus will group & lighting,
withstand an internal explosion of temp. class junction
the inflammable gas which may correct boxes,
enter it without causing damage electronics
and without communicating the
internal inflammation to the
external flammable gas. he escaping
(hot) gases must sufficiently cool
down along the escape path that by
the time they reach the outside of
the enclosure not to be a source of
ignition of the outside, potentially
ignitable surroundings.
 Type of Protection
Type Ex- Description Location Use
Code
Intrinsically i A protection technique based upon 'ia‘ : Zone 0 Instrumentation,
safe based on restriction of electrical 'ib‘: Zone1 measurement,
energy within apparatus and in the 'ic : Zone 2 control
interconnecting wiring, exposed to
potentially explosive atmosphere, to
a level below that which can cause
ignition by either sparking or
heating effects. Because of the
method by which intrinsic safety is
achieved it is necessary that not
only the electrical apparatus
exposed to the potentially explosive
atmosphere but also other electrical
apparatus with which it is
interconnected is suitably
constructed
 Type of Protection
Type Ex- Description Location Use
Code
Pressurized/ p Equipment is pressurized to a Zone 1 (px Analyzers,
purged positive pressure relative to the or py), or motors, control
surrounding atmosphere with air or zone 2 (pz) boxes,
an inert gas, thus the surrounding computers
ignitable atmosphere can not come
in contact with energized parts of
the apparatus. The overpressure is
monitored, maintained and
controlled.
Oil o A method of protection where switchgear
immersed electrical apparatus is made safe by
oil immersion in the sense that
flammable gasses or vapors above Zone 2 or
the oil or outside the enclosure will Zone 1
not be ignited
 Type of Protection

Non n A type of protection applied to an Motors, lighting,

Incendive electrical apparatus such that in junction boxes,
normal operation, it is not capable electronic
Zone 2
of igniting a surrounding explosive equipment
atmosphere, and a fault capable of
causing ignition is not likely to occur
Special s A concept for those type of As its
Protection electrical apparatus that, by their certification
Zone
nature do not comply with the states
depending
constructional or other
upon
requirements specified for
Manufactur
apparatus with established types of
ers
protection, but which nevertheless
Certificatio
can be shown, where necessary by
n.
test, to be suitable for use in
hazardous areas in prescribed zones
 Type of Protection
Increased e A method of protection by which Motors, lighting,
Safety additional measures are applied to junction boxes
an electrical apparatus to give
increased security against the
possibility of excessive
temperatures and of the
Zone 2 or
occurrences of arcs and sparks
Zone 1
during service life of the apparatus.
It applies only to an electrical
apparatus, no part of which produce
arcs or sparks or exceed the limiting
temperature in normal service

Sand filled q A method of protection where the Electronics,

enclosure of the electrical apparatus telephones,
Zone 2 or
is filled with a mass of powdery chokes
Zone 1
material such that, if an arc occurs,
the arc will not be liable to ignite
the outer flammable atmosphere
IP Types and Protection Details
IP XY
Degree of Solid ingress Ingress of Liquid

FIRST NUMERAL SECOND NUMERAL

0 No protection 0 No protection
1 Objects greater than 50 mm 1 Vertically dripping
2 Objects greater than 12 mm 2 Angular dripping
3 Objects greater than 2.5 mm 3 Sprayed water
4 Objects greater than 1.0 mm 4 Splashed water
5 Dust - protected 5 Water jets
6 Dust tight 6 Heavy seas
7 Effects of immersion
8 Indefinite immersion
 Recommended Protection in Zone-0

No electrical equipment should be allowed. When

this is not practicable, Ex ‘ i ‘ (ia or ib) apparatus or
circuits to be used

• No transformers, motors, lights, switch gear or

control gear
 Recommended Protection in Zone-1

Motors- Ex d, Ex p
Transformers & Capacitors - Ex d
Control & Instrument Transformers - Ex i
Lighting Fitting - Ex d
Switch Gear & Control Gear - Ex d
Communication/ Telephone equipment/Meters - Ex i
Portable Hand Lamps- Ex i

*Ex o, Ex q type equipment are also allowed for use

as per IS 5571
 Recommended Protection in Zone-2

Motors- Ex d, Ex p, Ex n, Ex e,
Transformers & Capacitors - Ex d, Ex p (auxiliary devices to be
located in pressurized room/hermetically sealed /
intrinsically safe)
Control & Instrument Transformers - Ex i
Lighting Fitting - Ex d, Ex e, Ex n
Switch Gear & Control Gear - Ex d, Ex o, Ex
Communication/ Telephone equipment/Meters - Ex i
Portable Hand Lamps- Ex i

* Minimum IP 55 (for UN-insulated parts) and IP 44 (for

insulated parts) if Ex e protection is used for outdoor
applications