Hazardous Area Classification Study,

UN International Classification System for

Dangerous Goods,
GHS

By

G.V.Choudhary
 What is Hazardous Area Classification?
• A process used to identify and categorize areas
where flammable gases, vapors, or dust may exist

• Purpose: To minimize the risk of fire and explosion

by controlling ignition sources

• Used in oil & gas, chemical plants, refineries, and

grain handling facilities
 Why Conduct Hazardous Area
Classification?
• Ensure the safety of personnel and assets
• Comply with national and international standards
(e.g., IEC, NEC, IS)
• Identify locations where special electrical
equipment is required
• Guide engineering design and maintenance
practices
 Key Concepts in HAC Study
• Source of release (e.g., flange, pump seal, vent)

• Grade of release (continuous, primary,

secondary)

• Ventilation rate and effectiveness

• Zone classification based on the presence of an

explosive atmosphere
Zone Classification (Gases/Vapors)
• Zone 0: Explosive atmosphere present
continuously or for long periods

• Zone 1: Likely to occur in normal operation

• Zone 2: Not likely in normal operation and if it

occurs, it exists for a short time
 Definition
Gas/Vapor Extent of
Zone
Environment Hazardous
Zone:
Continuous Based on gas
Zone 0
presence dispersion
Likely during modeling or
Zone 1 normal standard tables
operations (e.g., API 505,
Not likely, but IEC 60079-10-
Zone 2 1/2).
possible
 Zone Classification (Dust)
• Zone 20: Combustible dust cloud present
continuously or frequently

• Zone 21: Likely to occur occasionally in normal

operation

• Zone 22: Not likely in normal operation and if

it occurs, it exists briefly
 Definition
Dust Extent of
Zone
Environment Hazardous
Zone:
Continuous Based on gas
Zone 20
presence dispersion
Likely during modeling or
Zone 21 normal standard tables
operations (e.g., API 505,
Not likely, but IEC 60079-10-
Zone 22 1/2).
possible
 Applicable Standards and Guidelines

• IEC 60079 Series (International)

• NEC 500/505 (USA)

• IS/IEC 60079 (India)

• API RP 505, NFPA 70

• OISD Guidelines for oil and gas sector (India)

Outputs of the HAC Study
•Hazardous Area Classification drawings
showing zones.

•HAC report with basis of classification.

•Equipment selection guidance (e.g.,

explosion-proof motors, intrinsic safety
barriers).

•Maintenance and inspection criteria for

equipment in hazardous areas.
 Example Application
In a LPG storage terminal, the pump seals
and vent stack would be considered
primary release sources.

Depending on the ventilation,

a Zone 1 could extend 1-3 meters around
these points,

with a Zone 2 surrounding it.

The Hazardous Area Classification (HAC)
Study and the UN Classification of
Dangerous Goods are both crucial
frameworks used for managing the risks
associated with hazardous substances, but
they serve different purposes and apply in
different contexts. However, they are
complementary and interrelated in practice,
especially in high-risk industries like oil &
gas, chemicals, and logistics.
 UN Classification of Dangerous
Aspect Hazardous Area Classification (HAC)
Goods

Identifies areas (locations) where Classifies substances based on

Focus
explosive atmospheres may exist hazards during transport

Used for designing Used for safe transport, labeling,

Application electrical/equipment safety in packaging, and emergency
potentially explosive zones response

Based on chemical and physical

Based on presence of flammable
Basis properties (e.g., flammability,
gases, vapors, dusts in a process area
toxicity, reactivity)

UN number, hazard class (e.g.,

Area zones: Zone 0, 1, 2 (gases) or
Output Class 3 for flammable liquids),
Zone 20, 21, 22 (dust)
packing group
UN Recommendations on the
Governing IEC 60079, IS/IEC 60079, NEC, API RP
Transport of Dangerous Goods
Standards 505
(Orange Book)
Zone 2 area around a fuel pump due UN1203 (Gasoline), Class 3, PG II
Example
to vapor release – Flammable Liquid
How They Correlate in Real-World Scenarios
1. Using UN Classification in HAC Studies
•During a HAC study, the material properties
(like flash point, vapor pressure, autoignition
temperature) are critical inputs.
•These properties are derived from SDS, which
use UN and GHS classifications (e.g., Class 3 for
flammable liquids).
•For example, if a substance is UN Class 3, it
likely has a Zone 0, 1, or 2 classification in
process areas.
 2. Shared Data Sources
•Both systems rely on chemical identity and hazard
characteristics:
• Flammability
• Reactivity
• Explosiveness
•These are determined using standardized tests and criteria,
often harmonized under GHS/UN systems.

3. Design and Safety Integration

HAC determines where explosion-proof equipment is required.
UN classification ensures proper transport labeling, packaging,
and handling during storage or movement.
In integrated facilities (e.g., refineries or ports), both systems
must be used together to avoid incidents.
 4. Emergency Planning and Regulatory Compliance
•Emergency response teams use UN classification for spill/fire
scenarios.
•Plant engineers use HAC zoning to control ignition sources and
protect workers.

•GHS, UN, and HAC systems are interconnected in fire risk

assessments.
•Example – Diesel Fuel (UN1202)
UN Classification:
UN Number: 1202
Class: 3 (Flammable Liquid)
Packing Group: III
HAC Classification:
Area around tank vents and pumps = Zone 1 or Zone 2
Requires flameproof lighting and ATEX-certified equipment
Conclusion
While UN Classification is used to identify
and communicate chemical hazards,
Hazardous Area Classification uses those
hazard properties to design safe plant
layouts and specify equipment.
Together, they ensure:
•Safe transport
•Safe storage
•Safe handling
•Regulatory compliance
 Example: Oil & Gas Industry
• Flammable vapor release from pump seals in
petroleum terminals
• Classified as Zone 2 (secondary release, short
duration)
• Requires flameproof/explosion-proof motors
and junction boxes
• Area layout maps prepared to indicate
hazardous zones
Purpose of the UN Classification System

• Standardize the classification of dangerous goods

across countries

• Ensure safe packaging, labeling, and transport

• Facilitate emergency response and risk mitigation

 Class 1 Explosives - UN Divisions Overview
Division Description Examples Typical UN
Numbers
1.1 Mass explosion hazard TNT, Dynamite, RDX, ANFO UN0081, UN0209

1.2 Projection hazard only Flares, Rocket motors, UN0101, UN0351

Signal cartridges
1.3 Fire hazard, minor Propellants, Incendiary UN0186, UN0349
blast ammunition

1.4 Minor explosion Small arms ammo, UN0012, UN0337

hazard Fireworks (consumer)
1.5 Insensitive substances ANFO (bulk), Emulsion UN0331, UN0332
with mass explosion explosives

1.6 Extremely insensitive Specialized military UN0486, UN0487

articles munition
Class Hazard Type Divisions/Subtypes Examples
Class 1 Explosives 1.1 to 1.6 Ammunition, fireworks
2.1: Flammable
2.2: Non-flammable,
Class 2 Gases LPG, nitrogen, chlorine
non-toxic
2.3: Toxic
Class 3 Flammable Liquids - Petrol, acetone
4.1: Flammable solids
4.2: Spontaneously
Class 4 Flammable Solids Sulfur, phosphorus
combustible
4.3: Dangerous when wet
Oxidizing Substances 5.1: Oxidizers Ammonium nitrate,
Class 5
& Organic Peroxides 5.2: Organic peroxides benzoyl peroxide
Toxic & Infectious 6.1: Toxic
Class 6 Cyanide, medical waste
Substances 6.2: Infectious
Class 7 Radioactive Material - Uranium, cobalt-60
Sulfuric acid, sodium
Class 8 Corrosives -
hydroxide
Miscellaneous Lithium batteries, dry
Class 9 -
Dangerous Goods ice, asbestos
The UN TDG system forms the foundation for
international and national transport regulations,
such as:
•IMDG Code (International Maritime Dangerous
Goods – Sea)
•ICAO Technical Instructions / IATA DGR (Air
transport)
•ADR (European Road Transport)
•RID (European Rail Transport)
•49 CFR (DOT) (United States)
•Indian Motor Vehicle Rules (India)
 UN Numbers and Labeling
• UN Numbers: 4-digit codes for identifying

substances (e.g., UN1203 for gasoline)

• Diamond-shaped hazard labels with class

number and symbols

• Required for packaging and transport

containers
 Application and Importance
• Used in air, sea, road, and rail transport
• Referenced by ICAO (air), IMO (IMDG Code),
ADR (Europe – road), RID (rail)
• Supports emergency planning and
International safety standards
• Forms the basis of the Globally Harmonized
System (GHS)
 What is GHS?
The Globally Harmonized System of Classification and
Labelling of Chemicals (GHS) is an international system
developed by the United Nations to standardize the
classification, labeling, and safety communication of
hazardous chemicals.
It ensures that:
Hazards are identified consistently, regardless of the
country.
Labels and Safety Data Sheets (SDS) follow a uniform
format.
Worker safety and environmental protection are
improved globally.
 Key Components of GHS
• Hazard Classification (Physical, Health,
Environmental)
• Label Elements:
- Signal Words (Danger, Warning)
- Hazard and Precautionary Statements
- Standardized Pictograms

• 16-section Safety Data Sheets (SDS)

 GHS-Compliant 16-Section SDS Format
Section Title What It Includes
- Product name- Manufacturer/supplier details- Recommended use-
1 Identification
Emergency phone number
- GHS classification- Signal word (e.g., Danger)- Hazard statements-
2 Hazard(s) Identification
Pictograms- Precautionary statements
Composition/Information on - Chemical identity- Common names- CAS numbers- Concentration of
3
Ingredients ingredients
4 First-Aid Measures - Symptoms- Emergency first aid instructions- Recommendations for doctors
- Suitable extinguishing media- Special hazards from combustion- Firefighting
5 Fire-Fighting Measures
procedures
6 Accidental Release Measures - Spill/leak response- Containment methods- Protective equipment
7 Handling and Storage - Safe handling practices- Storage requirements (temperature, separation)
Exposure Controls/Personal - Exposure limits (e.g., OSHA, ACGIH)- Engineering controls- PPE (gloves,
8
Protection goggles, etc.)
9 Physical and Chemical Properties - Appearance, odor, pH, boiling point, flash point, etc.
- Chemical stability- Incompatible materials- Hazardous decomposition
10 Stability and Reactivity
products
- Acute/chronic toxicity- Routes of exposure- Carcinogenicity, mutagenicity,
11 Toxicological Information
etc.
12 Ecological Information - Environmental impact- Aquatic toxicity- Persistence and degradability
13 Disposal Considerations - Waste handling- Disposal methods- Applicable regulations
14 Transport Information - UN number- Hazard class- Packing group- Shipping labels
15 Regulatory Information - Safety, health, environmental laws applicable (non-transport)
16 Other Information - SDS revision date- References- Additional safety details
UN System GHS Relationship
UN's Transport of Dangerous GHS expands this to include
Goods (TDG) classifies workplace, consumer, and
substances for shipping environmental hazards
UN classification provides the
technical criteria for physical GHS adopts these same
hazards (e.g., explosives, criteria for hazard classification
flammable gases)
UN hazard communication
GHS provides labels and SDS
(placards, UN numbers) is used
for non-transport applications
in transport
UN Numbers (e.g., UN1203 for GHS requires inclusion of
gasoline) identify dangerous chemical identity and hazards
goods in labels and SDS
 UN Classification as the Basis of GHS
• UN TDG classification used for physical hazard
criteria in GHS
• GHS expands scope to workplace, consumer,
and environmental uses
• GHS labeling complements UN transport
placards
• UN Numbers used to identify hazardous
chemicals in GHS documentation
 Global Adoption of GHS
• Adopted by many countries: US (OSHA),
EU (CLP), India, China, Japan, Brazil
• Replaces inconsistent national hazard
standards
• Applies to transport, workplace, and consumer
chemical safety
• Supported by the UN and international
regulatory bodies
So, GHS builds upon and harmonizes the
UN’s transport classification, but applies it
more broadly to:

•Workplaces

•Industrial processes

•Consumer products
 Example: Gasoline
• UN Classification:
- UN1203, Class 3 (Flammable Liquid)
• GHS Classification:
- Physical: Flammable liquid, Category 1
- Health: Skin irritant, Carcinogen (possible)
• GHS Label:
- Danger: Highly flammable liquid and
vapor
 Legal Framework Supporting GHS in India
• MSIHC Rules, 1989 (THE MANUFACTURE, STORAGE AND
IMPORT OF HAZARDOUS CHEMICALS RULES, 1989} –
GHS-based hazard classification and SDS
• Factories Act, 1948 – Worker safety and hazard
communication
• OSHWC Code, 2020 – Occupational Safety, Health and
Working Conditions Code, 2020 Strengthens chemical
safety
• Chemical Accidents Rules, 1996 – Emergency planning
and SDS
• BIS Standards – GHS-aligned classification and labeling
guidance
 Overview: OSHWC Code, 2020
Occupational Safety, Health and
Full Name
Working Conditions Code, 2020
Government of India (Ministry of
Enacted by
Labour and Employment)
September 2020 (yet to be fully
Passed in
enforced, pending rules)

13 older labor laws related to safety,

Replaces
health, and working conditions
Relevance to GHS and Chemical Safety
•Supports hazard communication
standards like:
• Labeling hazardous substances
• Providing Safety Data Sheets (SDS)
• Employee training on chemical risks.

•Promotes safety audits, inspections, and

compliance aligned with global systems like
GHS and UN TDG
 Overview: OSHWC Code, 2020
Status (as of 2024–2025)
•The Code is passed by Parliament but
awaits implementation at the state
level, pending finalization of rules.

•Many large organizations are

proactively aligning their safety
systems to be OSHWC-compliant.
 How Indian Companies Implement
GHS
• Labeling with GHS pictograms and signal words

• 16-section Safety Data Sheets (SDS)

• Worker training and awareness programs

• Use of EHS compliance software (SAP, etc.)

 Sectors Leading GHS Adoption

• Chemical manufacturing

• Pharmaceuticals

• Petrochemicals and refineries

• Paints and coatings

• Agrochemical industries
Challenges in GHS Implementation
• Inconsistent enforcement across states

• Awareness gaps in SMEs(Small and Medium

Enterprises)

• Incomplete or outdated SDS

• Language barriers for workers

Recent Improvements and Support

• Draft National Chemical Policy promoting GHS

• Involvement of ICC, BIS, MoEF&CC (Ministry of

Environment, Forest and Climate Change)

• Increasing EHS training programs

• Digital access to SDS and hazard data

 Example: GHS in Practice (Indian
Refinery)
• Benzene tank labeled with GHS pictogram
( Skull)
• Signal Word: Danger
• Hazard Statement: 'Causes cancer. Toxic if
inhaled.'
• SDS available digitally on-site via QR code
Thanks for your kind attention

Open for questions…..