06 - Hazardous Area Classification and Explosion Protection

INSTRUMENT AND CONTROL ENGINEERING COURSE
Section 1: Hazardous Area Classification
General principles
Nature of flammable materials
Fire triangle
The fire triangle represents the three elements which must be present before combustion can
take place. Each point of the triangle represents one of the essential elements which are:
(1) Fuel: This can be in the form of a gas, vapour, mist or dust.
(2) Oxygen: Plentiful supply since there is approximately 21% by volume

in air.
(3) Source of ignition: This can be an arc, spark, naked flame or hot surface.
Combustion will take place if all three elements, in one form or another, are present, the
gas/air mixture is within certain limits and the source of ignition has sufficient energy. The
removal of one element is sufficient to prevent combustion as is the isolation or separation of
the source of ignition from the gas/air mixture. These are two techniques used in explosion
protected equipment. Other protection techniques allow the three elements to co-exist and
either ensure that the energy of the source of ignition is maintained below specific values, or
allow an explosion to take place and contain it within a robust enclosure. These techniques
are addressed in the various sections of this manual.
Prepared by: Bui Hai Phu -1-

Flammable (Explosive) Limits
Combustion will only occur if the flammable mixture comprising fuel, in the form of a gas or
vapour, and air are within certain limits. These limits are the ‘lower explosive limit’ (LEL),
and the ‘upper explosive limit’ (UEL), and between these limits is known as the flammable
range.
An every day example of this is the carburettor of a petrol engine, which must be tuned to a
particular point between these limits in order that the engine may function efficiently.
Lower Explosive Limit: 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.
Upper Explosive Limit: 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.
The flammable limits of some materials are given below.
LEL UEL
Material
% by Volume % by Volume
Propane 2 9.5
Ethylene 2.7 34
Hydrogen 4 75.6
Acetylene 1.5 100
Diethyl Ether 1.7 36
Paraffin 0.7 5
Carbon Disulphide 1 60

Flammable (Explosive) Limits (continued)
Different gases or vapours have different flammable limits, and the greater the difference
between the LEL and the UEL, known as the flammable range, the more dangerous the
material. An explosive (flammable) atmosphere, therefore, only exists between these limits.
Operational safety with flammable mixtures above the UEL is possible, but is not a practical
proposition. It is more practical to operate below the LEL.
Sources of ignition
Sources of ignition are many and varied and include:
(a) electrical arcs/sparks;
(b) frictional sparks;
(c) hot surfaces;
(d) welding activities
(e) cigarettes;
(f) static discharges;
(g) batteries;
(h) exhausts of combustion engines;
(i) thermite action;
(j) sodium exposed to water
(k) pyrophoric reaction;
(l) chemical reactions;
(m) lightning strikes;
The source of ignition as far as this text is concerned is primarily electrical equipment.

Flashpoint
By definition flashpoint is: ‘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’. Typical values are given below
Material Flashpoint
°C
Propane -104
Ethylene -120
Hydrogen -256
Acetylene -82
Diethyl Ether -45
Paraffin 38
Carbon Disulphide -95
The flashpoint of a material gives an indication of how readily that material will ignite in
normal ambient temperatures.
Materials with high flashpoints should not be overlooked as a potential hazard since exposure
to hot surfaces can allow a flammable mixture to form locally. Furthermore, if a flammable
material is discharged under pressure from a jet, its flashpoint may be reduced.
Amount of vapour released

dependant on temperature

Flashpoint (continued)
Kerosene: flashpoint 38 oC

Ignition temperature
Ignition temperature is defined as: ‘the minimum temperature at which a flammable

material will spontaneously ignite’.
Ignition temperature, formerly known as auto-ignition temperature, is an important

parameter since many industrial processes generate heat. Careful selection of electrical
equipment will ensure that the surface temperatures produced by the equipment, indicated by
the T-rating, will not exceed the ignition temperature of the flammable atmosphere which
may be present around the equipment. Typical values of ignition temperature are:
Material Ignition
Temperature
o
C
Propane 470
Ethylene 425
Hydrogen 560
Acetylene 305
Diethyl Ether 170
Paraffin 210
Carbon Disulphide 102

Oxygen enrichment
The normal oxygen content in the atmosphere is around 20.95%, and if a given location has a
value which exceeds this it is deemed to be oxygen enriched. Typical examples of where
oxygen enrichment may occur are gas manufacturing plants, hospitals, and where oxy-
acetylene equipment is used.
Oxygen enrichment has three distinct disadvantages. First of all, it can lower the ignition
temperature of flammable materials as shown in the table below.
Air Increased Oxygen

Material Ignition temperature Ignition temperature
°C °C
Hydrogen sulphide 260 220
Acetylene 305 296
Ethane 512 506
Secondly, oxygen enrichment significantly raises the upper explosive limit (UEL) of the
majority of gases and vapours, thereby widening their flammable range. This is illustrated in
the following table.
Air Increased oxygen

Material LEL UE LEL UEL
% % % %
Methane 5 15 5.2 79
Propane 2.2 9.5 2.3 55
Hydrogen 4 75 4.7 94
Thirdly, oxygen enrichment of a flammable atmosphere can allow it to be ignited with much
lower values of electrical energy.
Explosion protected equipment will have been tested in normal atmospheric conditions and,
therefore, the safety of such equipment in an oxygen enriched atmosphere cannot be assured
because of the modified nature of the flammable mixture.

Density
If a flammable material is released, it is important to know whether the material will rise or
fall in the atmosphere. The different flammable materials are compared with air and
allocated a number to denote their relative density with air. Since air is the reference, its
relative density is 1 so that for a material twice as heavy as air, its relative density will be 2.
Therefore, materials with a relative density less than unity will rise in the atmosphere, and
those greater than unity will fall in the atmosphere.
Materials which rise in the atmosphere can collect in roof spaces, and those which fall, such
as butane or propane, can drift along at ground level and possibly into a non-hazardous
location, or may collect in locations lower than ground level without ever dispersing. Such
locations should be well ventilated in order to avoid ignition due to a stray spark or a
discarded cigarette.
Knowledge of where a flammable material will collect ensures that gas detectors when fitted
will be located at the correct level and ventilation is directed accordingly.
Relative vapour
Material
density
Air 1
Propane 1.56
Ethylene 0.97
Hydrogen 0.07
Acetylene 0.9
Diethyl Ether 2.55
Paraffin 4.5
Carbon Disulphide 2.64

Area classification
An 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.
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.
Zones
Zoning is a means of representing the frequency of the occurrence and duration of an

explosive gas atmosphere based on the identification and consideration of each and every
source of release in the given areas of an installation. Zoning will have a bearing on, and
simplify the selection of, the type of explosion protected equipment which may be used.
Hazardous areas are, therefore, divided into three Zones which represent this risk in terms of
the probability, frequency and duration of a release.
The three Zones, as defined in BS EN60079-l0: Electrical apparatus for explosive gas
atmospheres, Part 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;
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, is likely to do
so only infrequently and will exist for a short period only.
Although not specified in the standards, it is generally accepted in the industry that the
duration of a gas release, or a number of gas releases, on an annual basis (one year comprises
circa 8760 hours), for the different Zones is as follows.
Zone 2 - 0- l0 hours
Zone 1 - 10 - l000 hours
Zone 0 - over 1000 hours

Area classification (continued)
Zones - diagram representation of
Prepared by: Bui Hai Phu - 10 -

Fixed roof storage tank

Sources of release

Platform hazardous areas

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, and Group II which is subdivided into
IIC, IIB and IIA for surface industries using. The representative gases for the sub-groups are
shown in the table below.
Two methods have been used to ‘group’ these flammable materials according to the degree of
risk they represent when ignited. One method involved determining the minimum ignition
energy which would ignite the representative gases. In the table below it can be seen that for
Group II, hydrogen and acetylene are the most easily ignited and propane the least easily
ignited.
The other method involved tests using, for example, a special flameproof enclosure in the
form of an 8 litre sphere which was situated inside a gas-tight enclosure. Both halves of the
sphere had 25 mm flanges and a mechanism enabled the gap dimension between the flanges
to be varied. During tests, the area inside and outside the sphere was occupied with a gas in
its most explosive concentration in air and, by means of a spark-plug, the gas inside the
sphere was ignited. The maximum dimension between the flanges, which prevented ignition
of the gas/air mixture, is known as the ‘maximum experimental safe gap’ (MESG), and the
values for the representative gases are shown in the table below. The more dangerous a gas,
the tighter the gap at the flanges has to be.
The table also shows that these flammable materials fall into the same order for both tests, i.e.
in a relative context, hydrogen and acetylene present the most risk and propane the least risk
in terms of ‘minimum ignition energy’ and ‘MESG’.
Maximum Minimum
Gas Group Representative MESG Working Ignition
Gas Gap Energy
(mm) (mm) (μJ)
Methane
I 1.17 0.5 280
(Firedamp)
IIA Propane 0.97 0.4 260
IIB Ethylene 0.71 0.2 95

Hydrogen &
IIC 0.5 0.1 20
Acetylene

The group sub-division marking is one of the important considerations during the selection
process of explosion protected apparatus. For example, apparatus marked IIA can only be
used in IIA hazards such as propane, it can not be used in IIB or IIC hazards. Apparatus
marked IIB can be used in IIB and IIA hazards but not IIC hazards. Apparatus marked IIC
can be used in all hazards.
Apparatus for determination of M.E.S.G.

Temperature Classification
Approved electrical equipment must be selected with due regard to the ignition temperature
of the flammable gas or vapour which may be present in the hazardous location. Apparatus
will usually be marked with one of the temperature codes shown in the table below.
Temperature codes
Temperature code Maximum surface

temperature
T1 450°C
T2 300°C
T3 200°C
T4 135°C
T5 100°C
T6 85°C
In the table below, it will be observed that for each material, the T-rating temperature is
below the ignition temperature of the flammable material. Moreover, the T-rating
temperatures are based on a maximum ambient rating of 40 °C. For example, apparatus
classified T5, based on a 40 °C ambient rating will have a maximum permitted temperature
rise of 60 °C. In order to avoid infringement of the apparatus certification, the ambient rating
must be compatible with environmental ambient temperatures, and the temperature rise not
exceeded.
A further consideration is that apparatus for use in hotter climates, typically found in Middle
and Far Eastern countries, will usually require ambient ratings greater than 40 °C.
Material Ignition T-rating

temperature
Methane 595 °C T1 (450 °C)
Ethylene 425 °C T2 (300 °C)
Cyclohexane 259 °C T3 (200 °C)
Diethyl Ether 170 °C T4 (135 °C)
Carbon Disulphide 102 °C T5 (100 °C)
T6 ( 85 °C)

Temperature Classification (continued)

Ingress Protection
Enclosures of electrical equipment are classified according to their ability to resist the ingress
of solid objects and water by means of a system of numbers known as the ‘International
Protection (IP) Code’. This Code, which is not always marked on apparatus, consists of the
letters IP followed by two numbers, e.g. IP56.
The first number, in the range 0 - 6, indicates the degree of protection against solid bodies,
and the higher the number the smaller the solid object that is prevented from entering the
enclosure. Zero (0) indicates no protection and 6 indicates the apparatus is dust-tight.
The second number, ranging from 0 - 8, identifies the level of protection against water
entering the enclosure, i.e. 0 indicates that no protection is afforded, and 8 that the apparatus
can withstand continuous immersion in water at a specified pressure.
An abridged version of the full table is shown below.
Solid Objects Water

First Second
Level of Protection Level of Protection
Numeral Numeral
0 No protection 0 No protection
Protection against objects Protection against drops of
1 1
greater than 50 mm water falling vertically
Protection against objects Protection against drops of
2 2
greater than 12 mm water when tilted up to 15°
Protection against objects Protection against sprayed
3 3
greater than 2.5 mm water up to 60°
Protection against objects Protection against splashed
4 4
greater than 1.0 mm water from any direction
Protection against jets of water
5 Dust-protected 5
from any direction
Protection against heavy seas
6 Dust-tight 6
- deck watertight
Protection against immersion
7 in water 1m in depth and for a
specified time
Protection against indefinite
8 immersion in water at a
specified depth

Section 2: Explosion Protection Certification
Certification symbols
The following symbols are used to identify apparatus approved/certified by recognised

European and American authorities.
European marks
1) Equipment marked with this symbol may only be

used for underground (mining) applications in the
UK.
2) This is the EECS (BASEEFA) symbol and used

to identify equipment for surface industry use
only.
3) Equipment marked with this symbol, the

European Community mark, in addition to the
above symbol (2), indicates that the apparatus has
been constructed and tested in accordance with
the CENELEC/EURONORM standards.
4) The symbol used by the German certification

authority PTB.
UL mark
5) The most common UL listing mark.

Apparatus marking
Apparatus approved/certified as providing a method of protection for use in hazardous

locations are required to display the following markings.
(a) The symbols Ex or EEx; and
(b) The type of protection used, e.g. ‘d’, ‘e’, ‘N’, and
(c) The gas group, e.g. IIA, IIB or IIC; and
(d) The T-rating, e.g. T1, T2 etc.
Examples: i) Ex d IIB T3
ii) EEx d IIC T4
iii) EEx e II T6
In example (i), equipment marked thus (Ex), as far as Europe is concerned, can only be used
in the UK because it has been constructed to the British Standard BS 4683, which is not a
harmonised European standard. Apparatus constructed to this standard, however, is used in
other countries outwith the European Community. Such equipment would also be marked
with the EECS certification authority symbol (2) on the previous page.
For apparatus marked EEx as in examples (ii) and (iii), the additional letter ’E’ indicates that
the apparatus has been constructed to a harmonised European standard. Such apparatus
would be marked with the EECS certification authority symbol (2) as well as the European
Community mark (3).
Sample labels are shown below, and it should be noted that the construction standard to
which the equipment has been manufactured to, i.e. BS 4683: Part 2, BS 5501: Parts 1 & 5
and EN50 014 & EN50 018 are also given on the labels. For BS 4683 equipment, the IEC
equivalent standard, i.e. IEC 79-1 in example (a) below, is usually included.
(a) BS 4683: Pt.2 (IEC79-1) (b) BS 5501: Pt.1 & 5 (EN50 014 & EN50 018)

Certification marking

Certificate number

ATEX
ATEX represents the European Union’s Directive 94/9/EC which specifies the new
requirements which manufacturers of, for example, explosion protected equipment must
comply with. These requirements are wide ranging and beyond the scope of this section but,
what is important is the influence the directive will have on the marking of explosion
protected apparatus. This will be the most obvious difference to those involved in the
selection, installation and maintenance of explosion protected apparatus.
The marking required by the EU Directive 94/9/EC is illustrated below and is additional to
the marking requirements already discussed.
The categories are defined overleaf.

Category definitions
Group II Category 1: Very high level of protection.

Equipment with this category of protection may be used
where an explosive atmosphere is present continuously or for
long periods, i.e. Zone 0 or Zone 20.
Category 2: High level of protection.

where an explosive atmosphere is likely to occur in normal
operation, i.e. Zone 1 or Zone 21.
Category 3: Normal level of protection.

where an explosive atmosphere is unlikely to occur or be of
short duration, i.e. Zone 2 or Zone 22.
Group I Category Ml: Very high level of protection.

Equipment can be operated in the presence of an explosive
atmosphere.
Category M2: High level of protection.

Equipment to be de-energised in the presence of an explosive
atmosphere.

Flameproof EEx d or Ex d
Flameproof is one of the original methods of explosion protection developed for use in the
mining industry. It has a wide range of applications, typically junction boxes, lighting fittings,
electric motors etc.
The letter ‘d’, which symbolises this type of protection, is from the German word ‘druckfeste’
(kapselung), which roughly translated means ‘pressure tight’ (enclosure).
Flameproof apparatus, when properly installed in the intended location, enables components
such as switches, contactors and relays etc. to be safely used in hazardous areas. Flameproof is
the only one of the nine different methods of explosion protection in which an explosion is
permitted. This explosion, however, must be contained by the robustly constructed flameproof
enclosure.

Definition
‘A type of protection in which the parts which can ignite an explosive atmosphere are
placed in an enclosure which can withstand the pressure developed during an internal
explosion of an explosive mixture and which prevents the transmission of the explosion
to the explosive atmosphere surrounding the enclosure’.
Zone of Use: 1&2
Ambient conditions
Flameproof enclosures are normally designed for use in ambient temperatures in the range -20°C
to +40°C unless otherwise marked

Increased Safety Ex e or EEx e
This method of protection has a good safety record and comparable with the other methods of
protection. The letter ‘e’ which symbolises this method of protection is taken from the German
phrase Erhohte Sicherheit, which roughly translated means ‘increased security’. Typical
applications are induction motors, lighting fittings and junction boxes.
Definition
‘A protection method in which increased measures are taken to prevent the possibility of
excessive HEAT, ARCS or SPARKS occurring on internal or external parts of the apparatus in
normal operation’.
Zones of use: 1&2
Ambient temperatures
Increased Safety enclosures are normally designed for use in ambient temperatures in the range -
20 °C to +40 °C unless otherwise marked.


Type ‘n’ protection
Since the presence of a flammable gas or vapour is less likely in Zone 2, the constructional
requirements for electrical equipment used in these hazardous locations are not as strict as those
for equipment used in Zone 1. A method of protection which falls into this category is type ‘n’
apparatus, which is basically similar to increased safety type “e” apparatus except that there is a
relaxation in the constructional requirements.
Definition
The definition for Electrical apparatus with type of protection “n” as given in the CENELEC
Standard BS EN50 021 and also BS 6941 states:
‘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’.
Zone of use: Zone 2
Ambient conditions
Type ‘n’ apparatus is normally designed for use in ambient temperatures in the range -20 °C to +
40 °C unless otherwise marked.

Pressurised equipment
Introduction
Pressurisation is a simple technique for providing explosion protection. If the interior of an

enclosure is at a pressure above that externally, any flammable gases around the enclosure will
be prevented from entering the enclosure. Components which are a source of ignition, i.e. they
produce arcs/sparks or hot surfaces, are permitted within the enclosure and, clearly, safety is
dependent on the maintenance of the safe gas. The safe gas is the medium which ‘segregates’
the flammable gas from the source of ignition, and its continued presence will be confirmed by
an approved/certified ‘fail-safe’ control/monitoring system. A slight over-pressure is usually
adequate to maintain safe operation.
Definition
Pressurisation is defined as:
‘The technique of guarding against the ingress of the external atmosphere, which may be
explosive, into an enclosure by maintaining a protective gas therein at a pressure above
that of the external atmosphere’.
Zones of use: 1&2


Intrinsic safety Ex i or EEx i

Intrinsic Safety is a widely used method of explosion protection. It is used for very low power
applications only, and typical examples are control and instrumentation circuits.
Definition
BS EN50 020 defines an intrinsically safe circuit as:
‘A circuit in which no spark or any thermal effect produced in the test conditions prescribed in
this standard (which include normal operation and specified fault conditions) is capable of
causing ignition of a given explosive atmosphere’.
Zones of use: 0, 1 & 2 (Exi‘a’ & Eexi‘a’)

1 & 2 (Exi‘b’ & Eexi‘b’)

Other methods of protection

Oil-immersion Ex o or EEx o
Oil-immersion is not a popular method of explosion protection but is typically used for heavy
duty transformers and switchgear.
Definition
The definition for this type of protection is:
‘A type of protection in which the electrical apparatus or parts of the electrical apparatus are
immersed in oil in such a way that an explosive atmosphere, which may be above the oil or
outside the enclosure, cannot be ignited’.
Zones of Use: 1&2

Powder filling Ex q or EEx q
The explosion protection concept powder filling is not widely used and typical applications are,
for example, capacitors in Increased Safety EEx ‘edq’ lighting fittings, and telecommunications
equipment in some European countries.
Definition
‘A type of protection in which the enclosure of electrical apparatus is filled with a material in a
finely granulated state so that, in the intended conditions of service, any arc occurring within the
enclosure of an electrical apparatus will not ignite the surrounding atmosphere. No ignition shall
be caused either by flame or by excessive temperature of the surfaces of the enclosure’.
Zone of Use: 1&2

Encapsulation Ex m or EEx m
The method of protection, encapsulation, is used mainly for smaller items of equipment such as
solenoid coils and electronic components.
Definition
‘A type of protection in which the parts which could ignite an explosive atmosphere by either
sparking or heating are enclosed in a compound in such a way that this explosive atmosphere
cannot be ignited’.
Zone of Use: 1&2

Special protection Ex s
Apparatus which has not quite met the requirements of a particular construction standard will
have been additionally certified under the BASEEFA Standard ‘Special Protection Ex s’
provided it had been established that, after close scrutiny of the design and testing of the
apparatus, it was capable of operating safely in the hazard for which it was designed.
Zones of Use: 0, 1 & 2

Reference:
National training and certification of personnel for work on electrical apparatus for use in
potentially hazardous atmospheres - Aberdeen College, 3rd Edition, January 2000.

06 - Hazardous Area Classification and Explosion Protection

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06 - Hazardous Area Classification and Explosion Protection

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INSTRUMENT AND CONTROL ENGINEERING COURSE

Nature of flammable materials

(2) Oxygen: Plentiful supply since there is approximately 21% by volume

Prepared by: Bui Hai Phu -1-

Flammable (Explosive) Limits

The flammable limits of some materials are given below.

Prepared by: Bui Hai Phu -2-

Flammable (Explosive) Limits (continued)

Sources of ignition are many and varied and include:

(a) electrical arcs/sparks;

(b) frictional sparks;

(c) hot surfaces;

(d) welding activities

(f) static discharges;

(h) exhausts of combustion engines;

(i) thermite action;

(j) sodium exposed to water

(k) pyrophoric reaction;

(l) chemical reactions;

(m) lightning strikes;

Prepared by: Bui Hai Phu -3-

Amount of vapour released

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Ignition temperature is defined as: ‘the minimum temperature at which a flammable

Ignition temperature, formerly known as auto-ignition temperature, is an important

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Air Increased Oxygen

Air Increased oxygen

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Zoning is a means of representing the frequency of the occurrence and duration of an

Zone 0 - In this Zone, an explosive gas atmosphere is continuously

Zone 1 - In this Zone, an explosive gas atmosphere is likely to occur in

Zone 2 - In this Zone, an explosive gas atmosphere is not likely to

Zone 1 - 10 - l000 hours

Zone 0 - over 1000 hours

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Area classification (continued)

Zones - diagram representation of

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Area classification (continued)

Fixed roof storage tank

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Area classification (continued)

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Area classification (continued)

Platform hazardous areas

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Gas / apparatus grouping

IIB Ethylene 0.71 0.2 95

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Gas / apparatus grouping

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

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Gas / apparatus grouping

Temperature code Maximum surface

Material Ignition T-rating

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Temperature Classification (continued)

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An abridged version of the full table is shown below.

Solid Objects Water