Hazardous Area Classification

1. 1. HAZARDOUS AREA CLASSIFICATION Debabrata Das Indian Oil Corporation Limited

2. 2. Objective 1 Understand concept of Hazardous area Classification 2 Understand the
selection of Equipments for Hazardous Area
3. 3. Agenda  Basic concept of Hazardous area  Classification of Hazardous area 
Statutory requirements  Selection of Equipments
4. 4. 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
5. 5. 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.
6. 6. 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.
7. 7. 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 Classification of
Flammable Liquids
8. 8. 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. 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 Measured with Explosive Meter at out Locations
9. 9. Agenda  Basic concept of Hazardous area  Classification of Hazardous area 
Statutory requirements  Selection of Equipments
10. 10. Classification of Hazardous Area Class I Typical Environment • Oil Refinery • Terminal •
Bottling Plant Class II Typical Environment • Coal Mine • Grain Silo • Hay Storage Areas
where flammable gaes/vapours may be present Areas where combustible dust be may
present Class III Areas where combustible dust be may present Typical Environment •
Textile Mill • Paper Mill • Wook factory
11. 11. Classification of Hazardous Area  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 Classified in 03
zones based upon the Frequency of the appearance and duration of an explosive gas
atmosphere NEC Classification: Div 1( Zone 0+ Zone 1) & Div 2( Zone 2)
12. 12. 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
13. 13. Zone 1 Typical Area  Flammable gas or vapour 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 Examples
14. 14. 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.
15. 15. Areas Not Classified  Piping system without valves, fittings, flanges  Flammable
material are transported only in suitable containers or vessels. Areas where permanent
ignition- flare tips, flare pits, other open flames and hot surfaces.  Diesel Generator room /
shed having adequate ventilation.  Oil/gas fired boilers installation  Enclosed premises in
which purging stream from safe 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.
16. 16. 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.
17. 17. Factors Affecting Extent of Hazard •Increasing temperature of process liquid •The lower
the IBP results in greater concentration of vapour at the release source •Rate of release of
flammable material Temp Air •A very mild breeze may serve to extend the area in those
directions to which vapours might normally be carried. •A stronger breeze may so accelerate
the dispersion of vapours that the extent of potentially hazardous area would be greatly
reduced. Ventilation •Increased rate of ventilation, the extent of hazardous area may be
reduced •Obstacles e.g. dykes, walls may impede the ventilation and thus may enlarge the
extent. • On the other hand, they may limit the 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.
18. 18. 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
19. 19. 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 Temperature Class Max Surface Temperature of Apparatus in C Ignition
Temperature of the 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
20. 20. 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
21. 21. VARIOUS GASES/VAPOURS (IS 13408 Part I) Flammable limitS No Name of the
chemical Minimum Ignition Current (MIC) mA Flash point Deg. Cen. Iignition temperatur e
(Deg C) LEL UEL 1 Methane I, T1 85 - 595 5% 15% 2 Ammonia II A T1 - - 630 105 mg/l 200
mg/l 3 Ethylene II B T2 45 - 425 2.7% 34% 4 Propane II A T1 70 - 470 2% 9.5% 5 Acetylene
II C T2 24 - 305 1.5 % 100%
22. 22. Case-1
23. 23. Case-2
24. 24. Case-3
25. 25. Case-4
26. 26. Case-5
27. 27. Case-6
28. 28. Case-7
29. 29. Case-8
30. 30. Case-9
31. 31. Agenda  Basic concept of Hazardous area  Classification of Hazardous area 
Regulations, Guidelines  Selection of Equipments
32. 32. Various Standards
33. 33. Certifying Agencies Factory Mutual Underwriters Laboratories CMRI Dhanbad
34. 34. 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
35. 35. Agenda  Basic concept of Hazardous area  Classification of Hazardous area 
Statutory requirements  Selection of Equipments
36. 36. How to select equipment for various zones? Area Classification Div/Zone Gas Group
Temp Class Protection concept IP Codes
37. 37. FLAMMABLE MIXTURE, EXPLOSION
38. 38. 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,
39. 39. Type of Protection Type Ex- Code Description Location Use Flameproof d A method of
protection where the enclosure of apparatus will withstand an internal explosion of the
inflammable gas which may enter it without causing damage 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.
Zone 1 if gas group & temp. class correct Motors, lighting, junction boxes, electronics
40. 40. Type of Protection Type Ex- Code Description Location Use Intrinsically safe i A
protection technique based upon based on restriction of electrical energy within apparatus
and in the 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 'ia‘ : Zone 0 'ib‘: Zone1 'ic :
Zone 2 Instrumentation, measurement, control
41. 41. Type of Protection Type Ex- Code Description Location Use Pressurized/ purged p
Equipment is pressurized to a positive pressure relative to the surrounding atmosphere with
 air or an inert gas, thus the surrounding ignitable atmosphere can not come in contact with
energized parts of the apparatus. The overpressure is monitored, maintained and controlled.
Zone 1 (px or py), or zone 2 (pz) Analyzers, motors, control boxes, computers Oil immersed
o A method of protection where electrical apparatus is made safe by oil immersion in the
sense that flammable gasses or vapors above the oil or outside the enclosure will not be
ignited Zone 2 or Zone 1 switchgear
42. 42. Type of Protection Non Incendive n A type of protection applied to an 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 2 Motors,
lighting, junction boxes, electronic equipment Special Protection s A concept for those type
of electrical apparatus that, 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 hazardous
areas in prescribed zones Zone depending upon Manufactur ers Certificatio n. As its
certification states
43. 43. Type of Protection Increased Safety e A method of protection by which additional
measures are applied to an electrical apparatus to give increased security against the
possibility of excessive temperatures and of the occurrences of arcs and sparks 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 Zone 2 or Zone
1 Motors, lighting, junction boxes Sand filled q A method of protection where the enclosure of
the electrical apparatus is filled with a mass of powdery material such that, if an arc occurs,
the arc will not be liable to ignite the outer flammable atmosphere Zone 2 or Zone 1
Electronics, telephones, chokes
44. 44. IP Types and Protection Details FIRST NUMERAL 0 No protection 1 Objects greater
than 50 mm 2 Objects greater than 12 mm 3 Objects greater than 2.5 mm 4 Objects greater
than 1.0 mm 5 Dust - protected 6 Dust tight SECOND NUMERAL 0 No protection 1 Vertically
dripping 2 Angular dripping 3 Sprayed water 4 Splashed water 5 Water jets 6 Heavy seas 7
Effects of immersion 8 Indefinite immersion IP XY Degree of Solid ingress Ingress of Liquid
45. 45. 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
46. 46. 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
47. 47. 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