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Hazardous Area Classifications

A GUIDE TO HAZARDOUS AREAS

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INTRODUCTION

Hazardous areas are those in which there exists a risk of explosion because
flammable atmospheres are likely to be present.

These conditions can be man-made as in Petro-chemical plants or occur naturally as

in coal mining.

It is therefore necessary to ensure that all electrical apparatus installed in a

hazardous area cannot form a spark or hot surface, which would ignite the
flammable atmosphere.

Before a piece of apparatus can be used in a hazardous area, R must be examined

and tested by a recognized testing authority. Should the apparatus pass this
examination, then a Certificate of Conformity is issued which specifies the limits of
use of the apparatus.

ZONES

Hazardous areas are classified into zones according to the degree of risk.

ZONE 0 - Where an explosive atmosphere is continuously present for long periods.

ZONE 1 - Where an explosive atmosphere is likely to occur in normal operation

ZONE 2 - Where an explosive atmosphere is not likely to occur in normal operation

and if it occurs it is only present for a short period.

ZONE 10 - Where explosive dusts are present constantly or for long periods.

ZONE 11 - Where explosive dusts are present occasionally.

GASES

Gases are grouped together according to their degree of hazard. This is based on the
amount of energy required to light the gas/air mixture.

Gas Group Representative Gas

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I (Mining) Methane
IIA (Surface) Propane
IIB (Surface) Ethylene
IIC (Surface) Hydrogen

TEMPERATURE

A gas lair mixture can ignite when it comes into close contact with an excessively
hot surface. The surface temperature at which equipment operates is therefore of
crucial importance.

This equipment is temperature classified as follows:

Temp. Class Max. Surface Temp.

T1 450°C
T2 300°C
T3 200°C
T4 135°C
T5 100°C
T6 85°C

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TYPES OF EXPLOSION PROTECTION

There are various methods used to prevent electrical apparatus from igniting the
surrounding atmosphere when energized.

Flameproof Enclosures

Ex protection type ‘d’ (EN 50018, BS 5501 Part 5).

Equipment that could ignite an explosive atmosphere is housed within a substantial

enclosure. This is capable of containing an internal explosion without transmitting
that explosion to the surrounding explosive atmosphere.

Increased Safety

Ex protection type ‘e’ (EN50020, BS5501 Part 7).

Increased measures are taken to prevent the generation of arcs, sparks and
excessively hot areas in equipment thus preventing the risk of explosion inside or
outside of the enclosure.

Intrinsic Safety

Ex protection type 'i' (EN50020, BS5501 Part 7).

Power is limited to this equipment in such a way that a spark or a hot surface would
not he hat enough to ignite the explosive atmosphere.

Pressurized or Purged

Ex protection type 'p' (EN 50016, BS 5501 Part 3) here the concept used is to house
the equipment in an enclosure, which is pressurized or purged by inert gas, thus
preventing an explosive atmosphere from reaching the equipment.

Oil Immersion

Ex protection type ‘o’ (EN50015, BS5501 Part 2).

All equipment is totally immersed in oil, thus preventing an explosive atmosphere
from reaching the equipment.
Powder filled
Ex protection type 'q' (EN50017, BS5501, Part 4).

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All equipment is totally immersed in powder, thus preventing an explosive

atmosphere from reaching the equipment.

Non-sparking and Restricted Breathing

Ex protection type 'n' or ‘N’ (BS4683 Part 3)

This gives a level of protection by housing electrical equipment in substantial

enclosures that inhibit mechanical damage and give some degree of ingress
protection.

Special Protection
Ex protection type 'S'

This applies to items of equipment not entirety covered by any of the foregoing
concepts but one that can clearly be demonstrated to be explosion-proof.

Moulded /Encapsulated
Ex protection type 'm' (EN50028, BS5501 Part 8).
The apparatus is totally encapsulated by a non-porous compound. Electrical
connection is by flying leads.
Codes of Practice for Selection, Installation & Maintenance of Explosion-proof
Equipment
The correct selection, safe installation and maintenance of explosion-proof
equipment is of the utmost importance the following table gives the relevant British
Standard:-
BS5345, Part 1 General Requirements
BS5345, Part 2 Zone Classifications
BS5345, Part 3 Flameproof EEx ‘d’
BS5345, Part 4 Intrinsic Safety EEx ‘i’
BS5345, Part 5 Pressurized EEx 'p'
BS5345, Part 6 Increased Safety EEx 'e'
BS5345, Part 7 Non-Sparking ExN
BS5345, Part 8 Special Apparatus Ex's'

In addition, care must be taken to comply with local requirements, which vary from
country to country.

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The selection of the correct type of cable glands is critical. The above standard gives
details of the types that can be used.

Corrosion can attack flame paths and render an enclosure unsafe. Care must be
taken to prevent or reduce corrosion where possible.

Spares for, and repairs to explosion-proof equipment should be obtained from the
original equipment manufacturer to ensure compliance with the certificate.

Apparatus Selection within Zones

Zone Suitable Apparatus

Zone 0 Exi ‘a’, some Exs

Zone 1 All types except Exn
Zone 2 All types

Apparatus Marking

The following information should appear on an Explosion-proof product:-

Information Typical Example

1. The Manufacturer's name Any Co.

2. The model designation Luminaire Type FL1
3. Code (Cenelec standard) EEx
4. The type of protection edm
5. Gas Group llC
6. Temperature classification T4
7. Serial No A005
8. Certifying Authority Certificate No BASEEFA No. Ex92C3166
9. CENELEC Symbol
10.British Standard Symbol
11.Electric Rating

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The Symbols

Temperature/Gas Classification

The following chart gives the minimum temperature class of equipment for use in
the various gases most commonly found in hazardous areas.

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e.g. T6 rated equipment can be used in any of the above gases but for example, T4
rated equipment can only be used in T1-T4 applications.

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Ingress Protection

2 digits are used to denote the level of ingress protection that a piece of apparatus
enjoys: IP  

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INSTRUMENTATION IN HAZARDOUS AREAS

Typical Hazardous Area Zoning

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INTRINSIC SAFETY

Definition:

Intrinsic safety is defined in the Code of Practice BS 5345 Part 4 1977 as a

protection technique based upon the restriction of electrical energy within apparatus
and inter-connecting wiring, exposed to a potentially explosive atmosphere, to a
level below that which can cause ignition by either sparking or heating effects.

Applies to complete circuit

The main advantage of using intrinsically safe equipment is that the safety principle
is made to apply to the whole circuit, including interconnecting cables. Transmitters
and transducers can be fairly readily designed to be intrinsically safe. Such
apparatus may be safely calibrated and adjusted by skilled personnel (if necessary
with the circuit live) without obtaining a 'gas-free' certificate for the area.

Categories

Category (ia) for all areas

The symbol for intrinsic safety is 'i'. There are two categories - 'ia' and 'ib'.

Apparatus and systems, or parts of systems, in category 'ia' are suitable for all
hazardous areas. If there are sparking contacts, additional measures will have to be
taken by the manufacturer. The apparatus must be incapable of causing ignition in
normal operation with one fault or two faults and with the following safety factors:

- Normal operation and with one fault……………. 1.5,

- Two faults……………………………………….. 1.0.

The safety factor is applied to the current or voltage or a specified combination of

these under fault conditions.

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Category (ib) Zone 1 or less

Apparatus and systems in category 'ib' are suitable for Zone 1 and less hazardous
areas only. Apparatus of this category must be incapable of causing ignition in
normal operation, and with one fault with the following safety factors:

- normal operation and with one fault………………………… 1.5,

- one fault if the apparatus contains no unprotected

switch contacts and the fault is self-revealing………………..1.0.

For both categories 'ia' and 'ib' the factor of safety on surface temperature
classification is 1.0.

Energy Grouping

The grouping of intrinsically safe apparatus is related to the maximum energy

available to produce a spark under fault conditions. This energy must always be
considerably less than the minimum energy required to ignite an explosive gas-air
mixture which may be present. Therefore, the group of apparatus which may be used
in a given area will be related to the minimum energy required to ignite the gas or
gases responsible for the hazard.

Maximum Electrical energy must be less than minimum ignition energy

The energy required for ignition depends on the concentration of the combustible
mixture. The graph in the following diagram illustrates the influence of
concentration on the critical energy required to cause ignition. It can be seen that a
hydrogen/air mixture, one of the most easily ignited atmospheric mixtures, supports
combustion over a wide range of concentrations. On the other hand the propane/air
mixture which is typical of many common hazardous materials, is flammable only
over a narrow range of concentrations. The amount of energy required to ignite the
most easily ignited concentration of a mixture under ideal conditions is the
minimum ignition energy.

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Effect of concentration of ignition energy

The minimum energy required to ignite a methane/air mixture under ideal conditions
is of the order of 0.29 milli joules (M), while the minimum energy required for a
whole range of fuels, such as propane, n-butane, n-hexane and n-heptane, is of the
order of 0.25 mJ. Ethylene/air mixture, on the other hand, requires only 0.12 mJ,
while hydrogen/air mixture is ignited by 0.019 mJ. Thus, methane requires apparatus
in Group 1, propane Group II.A, ethylene Group II.B and hydrogen Group II.C.

Standards Bodies

To simplify the selection and use of electrical equipment in flammable atmospheres

many bodies, both national and international have produced coding systems. Some
of these are:

IEC - International Electro-technical Commission (IEC),

CENELEC -European Committee for Electro-technical Standardization

(CENELEC),

BSI - British Standards Institution (BSI)

HSE - Health and Safety Executive (HSE)

BASEEFA - British Approvals Service for Electrical Equipment in

Flammable Atmospheres (BASEEFA).

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The principal systems are those adopted by the IEC, the Center European des
Normes Electriques (CENELEC), and those adopted by the United Kingdom.

International Electro-technical Commission (IEC)

Official International with ISO

This is the official, permanent, international body for Electro-technical

standardization in the field of international commerce.

The IEC is affiliated to the International Organization for Standardization (ISO) as

its Electro-technical division, but has technical and financial autonomy.

European Committee for Electro-technical Standardization (CENELEC)

Controls fifteen member countries

This Committee has the task of harmonizing the electrical standards of its fifteen
member countries. CENELEC standards are then adopted as national standards
without modification. Members are the National Electro-technical Committees of
the EEC nations (except Luxembourg) plus Austria, Finland, Norway, Portugal,
Spain, Sweden and Switzerland.

British Standards Institution (BSI)

This organization is too well known to require much detailed comment. It is worth
mentioning that British Standards are now being created by publishing CENELEC
standards without modification.
This is part of the membership requirements of CENELEC and also results from the
EEC legislation on the harmonization of standards.

Part of membership requirements for CENELEC

Health and Safety Executive and Health and Safety Commission (HSE and HSC)

Applies to all UK citizens

These bodies were established by the Health and Safety at Work, etc. Act 1974. The
Commission is the body appointed by the Secretary of State to supervise the
Executive. The Executive brings together the various Inspectorates from their

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separate Departments and includes various allied organizations such as BASEEFA

and SMRE (Safety in Mines Research Establishment).

Health and Safety Organogram:-

Secretary of State
:
Health and Safety Commission (Political)
:
Health and Safety Executive (Civil Service)
:
:
: :
Factory Inspectorate Safety in Mines :
Research British Approvals
Establishment Service for
(SMRE) Electrical
Equipment in
Flammable
Atmospheres
(BASEEFA)

British Approvals Service for Electrical Equipment in Flammable Atmospheres

(BASEEFA)

BASEEFA reports to HSE

This is the official certifying organization for electrical equipment for use other than
in mines and is part of the Health and Safety Executive. It has an Advisory Council
appointed by the Health and Safety Commission, which advises on broad policy
matters. The Council also recommends research and development work to be
financed by Government grant.

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Issues license to manufacture

BASEEFA certification involves license to manufacture and surveillance of

manufacture by the Director or his agent. BASEEFA issues a guide free on request.

A comparison of standards as issued by the relevant bodies is shown in the adjacent

table.

COMPARISON OF STANDARDS

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Instrumentation in Hazardous Areas

The following figures shows practical Zener Barrier Circuits:

Practical Zener barrier circuits

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Practical Zener Barriers

Three diodes as insurance for voltage clamping
Since the zener safety barrier is normally required to meet the requirements of
category 'ia' intrinsic safety, consideration must be given to the possibility of two
faults on the assembly. If these two faults are both at diodes failing to open circuit,
then a third diode will be required to give the necessary voltage clamping (see
diagram (b)).

Two high quality diodes usually suffice

In practice, it is highly unlikely that diodes will fail in this way so the standards
generally allow a concession to a two-diode configuration, provided that the two
diodes conform to an especially high standard.
The final version of a practical, simple Zener barrier would then be as shown in
diagram (c)).
To summarize, two diodes are included t' o meet the requirements of 'ia' intrinsic
safety, the resistance (R) sets the safety rating of the barrier, and the fuse (F 1)
prevents overloading the diodes in the event of high voltage invasion of the safe area
circuitry.
Testing facility
The resistance (R1) allows the barrier to be tested, to ensure that both diodes are
functioning correctly.
Not safety rating resistance
In certain applications, there may be concern about the resistance, which the barrier
will introduce into the circuit. It is important to note that is not the resistance
corresponding to the safety rating but a rather larger value including the value of
resistance R1 and any resistance associated with the fuse. Normally, manufacturers
will supply this data in the barrier specifications.
Wire wound resistors used
Resistors in a wire require to be wire wound and insulated (or plotted), otherwise
there is a remote possibility that they may fail to short circuit. Working voltage will
be less than the barrier safety rating since at the safety rating, the barrier will ‘leak’ a
large current.
The following figures shows the typical Zener Barrier applications:

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Typical Zener Barrier Applications

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Knee characteristic
The Zener breakdown point is slightly curved; this is known as the ‘knee’ of the
characteristic.

Leakage Current
At some voltage (V1) below the quoted Zener voltage (normally 2-3 volts below) the
leakage current through the device is measured (test voltage). This leakage current is
very small (of the order of 2-3 microamps), but due to the tolerances to which the
diode manufacturers work it is normally quoted as being less than 10 microamps.

Example
The test voltage may in practice be taken as the maximum working voltage of the
barrier. For example, a 28 volt 300 ohm barrier will generally have the leakage
current measured at around 26 volts so the barrier is ideal for 24-volt applications.
The end-to-end resistance of this barrier would probably be around 370 ohms.

Simple a.c. and d.c. Barriers

Polarized barrier circuit
The system described so far is suitable for where the hazardous area apparatus has
one wire polarized and the other forms an earth return. Thus, if the device in
question has one wire always positive with respect to earth and the other grounded,
a barrier circuit as shown in the accompanying diagram (a) would be appropriate.

Conversely, if the wires are respectively negative with respect to earth, the barrier is
identical, with the direction of the diodes reversed.

Non-polarized barrier circuit

If the barrier is non-polarized, that is, if the signal lines fluctuate about earth, two
pairs of Zener diodes connected back-to-back are required, as shown in diagram (b).

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Single and Two-channel Barriers

Two-channel used where no earth return

The arrangement of typical practical barrier units is shown in diagram (c). In a

single channel barrier unit, safe area and hazardous area earth terminals are
frequently provided simply for convenience in wiring. Alternatively, a two-channel
barrier packaged in a single unit is particularly useful in applications where it is not
possible to have an earthed return.

Diode Barrier

Low voltage applications

In certain low voltage applications, it is riot possible to have a Zener diode of
sufficiently low rating. Instead, a diode barrier as illustrated in diagram (d) is used.
In this arrangement, the forward characteristic of the diode is exploited such that the
breakdown voltage is now the forward voltage drop of the diode. To attain voltage
ratings of up to 2 volts, several diodes may be connected in series. Note also that for
this system to be safe a diode pair must be used, giving protection from both
positive and negative going voltages.

Diode pair must be used

Externally, and in terms of its operating characteristics, this type of device is

indistinguishable from a Zener barrier.

Barrier labelling

To comply with standards, the Zener barrier must be labelled. Since the barrier is
strictly 'associated apparatus' it contains the letters EEx within square brackets, as
shown in the following diagram.

- the name of the manufacturer or his registered trade mark,

- the manufacturer's type identification,

- the symbol EEx,

- the type of protection ('ia' or ‘ib’),

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- the apparatus - gas group II.A, II.B, etc.),

- the temperature class,

- the serial number,

- the test station mark,

- the certificate number,

- the maximum voltage (generally 250V),

- the zener breakdown voltage,

- the value of the safety resistance.

Although not a legal requirement, it is standard practice to identify the

connection ports. In addition, the polarity of a barrier is indicated by the colouring
of its case: -

red - positive,
black - negative,
grey - a.c.

Typical barrier label

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