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istorically, hazardous area classification has been the responsibility of the plant electrical engineer In actuality, however, many projects were being designed with minimum input from plant engineering. Most consulting firms would use an ultra-conservative approach with little input from process engineers and no consideration for potential cost savings. The existing national standards and guidelines are written to provide safety and flexibility of design and are difficult for the inexperienced engineer to interpret Even for the experienced engineers, this flexibility often leads to different interpretations for similar situations. In 1993 a small group of electrical engineers recognized a need for standardization without compromising safety, and formed a technical committee to address this issue This paper will present the result of the committees work as a corporate engineering technical guideline that is currently being used by Eli Lilly and Company. It must be stressed that the purpose of this guideline is to provide guidance for the design, construction, operation, and maintenance of facilities for Eli Lilly and Company only. It is based on more than 158 years of engineering and operational experiences, national guidelines, and standards. Other companies may find this article useful in developing their own guidelines for hazardous area classifications; however, Eli Lilly and Company takes no responsibility for their decisions in classifying areas The guideline is intended to assist in the classification of most (about 90%) hazardous

Thzs artzcle appeared zn zts orzgznalf i r m at the 1995

Petroleum and Chemzcal InduJ-try Conference. Hernandez zs chazrman of the Elz Lzlly Hazardous Areas Technzcal Commzttee Other members znclude Barry A Bradley, Ronald W. Crooke, Eric B Faulkner, Wzllzam M LewzJ-,Vzet Q Maz, Kenneth A. Mes~zck, James K Mzles, and Kevzn D Wzlhelm.
IFFFlndosfry App/imfions Mugazine Murch/Aprill997

locations encountered a t this company as defined by the National Electrical Code, and does not cover unique installations The guideline is intended to I I increase consistency from project to project by standardizing the classification approval procedure and the final documentation improve and ensure personnel safety and prevent property loss W deliver a facility for the lowest cost without compromising safety I I speed design I I make future changes and revisions easier w define involvement of the appropriate individuals needed for the classification process improve communications of hazardous locations to personnel by providing clear references and documents In the past, hazardous area classifications were done in a variety of ways, often resulting in bad experiences, such as improper classifications and finger-pointing among the design team. At our company, a design team for a project is usually composed of an engineer of each discipline (chemical, electrical, process control, mechanical, structural) all led by a project engineer who usually has no electrical background and is mostly focused on budget and schedule. This team operates from a central location and is usually not in tune with individual plant operations The same team format existed at the consulting firm with even less plant operations experience Due to personnel turnover at the company and at the consulting firm, there were communication gaps that led to errors in classification. Because of the ultra-conservative nature of the classifications, we have experienced no physical losses or injuries due to improper classification. The only losses experienced were financial, due to the excessive cost of equipment and the difficulty of designing to satisfy restrictive classification requirements. Due to the guideline, several projects have progressed smoothly throughout the design and con1077-2618/97/$10 0001997 IEEE

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struction phases. Especially the electrical classification portion and the HVAC design. Due to standardizing on practices, equipment issues have saved time and money. Drawings and other supporting documentation are easier to follow. Some of the key elements that made the guideline a success are: 1. Clearly stated goals 2. Easy-to-follow procedures 3. Clear definition of responsibilities 4. Identification of required documentation 5 . Standardization and simplification of drawings and documentation 6. Identification of all resources 7 . Clear definitions 8. Recommended standard equipment To successfully write your own guideline, identify the gaps in your classification process. Establish some goals and a clear scope. Then develop an outline to provide the framework for the body of the technical guideline.

Acknowledgments
The committee would like to acknowledge the following peers for helping in the review of this guideline: Robert W. Butler, Stephen I. Meiners, Steven A. Mezsick. Following is the technical guideline; comments are shown in bold italics.

Engheering Technical Guideline for Hazardous (Classified) locations

I. Scope The main purpose of this guideline is to communicate philosophies in order to design, build, maintain, and operate facilities at Eli Lilly and Company. This guideline is intended to assist in the classification of most hazardous locations as defined by t h e National Electrical Code (NEC) in the United States and Puerto Rico. Unique installations may not be covered in this guideline.

The guideline intends to educate consulting firms working in projects for the company, process engineers, and other engineers involved in the classification of areas. Ultimately it prevents the classification of areas without input from an electrical engineer. 11. Basis of Technical Guideline This guideline is based on the following: A. NFPA Articles 1. 30-1993-Flammable and Combustible Liquids Code 2. 70-1993-National Electrical Code 1993 3. 325M-1991-Fire Hazard Properties of Flammable Liquids, Gases and Volatile Solids 4. 496- 1993-Purged and Pressurized Enclosures for Electrical Equipment 5 . 497A-1992-Classification of Class I Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas 6. 497B-1991-Classification of Class II Hazardous (Classified)Locations for Electrical Installations in Chemical Process Areas 7. 497M-1991-Classification of Gases, Vapors and Dusts for Electrical Equipment in Hazardous (Classified) Locations 8. 654-1994-Standard for the Prevention of Fire and Dust Explosions in the Chemical, Dye, Pharmaceutical and Plastic Industries B. Eli Lilly and Company Engineering Technical Guidelines (ETGs) 1. 15801-Ventilation Design of Hazardous Areas 2. 16910-Instrumentation and Enclosures in Hazardous Areas C. Instrument Society of America 1. ISA 12.1-1991-Electrical Instruments in Hazardous Atmospheres 2. ISA 12.4-1970-Instrument Purging for Reduction of Hazardous Area Classification. 3. ISA 12.6-1987-Installation of Intrinsically Safe Systems for Hazardous (Classified) Locations 4. ISA 12.10-1988-Area Classification in Hazardous Dust Locations 5 . ISA-S12.12-1984-Electrical Equipment for Use in Class I, Division Hazardous (Classified) Locations D. American Petroleum Institute-Recommended Practices API-RP500 E. Operating experiences at Eli Lilly and Company The guideline i s based on dated standards and publications. Whenever they change, then the guideline will be researched and changed accordingly .

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Eli L i l l y Tippecanoe Laboratories near Lafayette, Ind. Photo by Gale C Whyte.

111. Definitions Adequate Ventilation is defined in ETG #1580 1. Authority having jurisdiction-the organization, office or individual responsible for approving equipment, an installation or a procedure. (Note: The phrase authority having jurisdiction is used
/Elndustry Applications Mogozine
Morch/Aprill997

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in NFPA documents in a broad manner since jurisdictions and approval agencies vary, as do their responsibilities. Where public safety is primary, the authority having jurisdiction may be a federal, state, local or other regional department or individual such as a fire chief, fire marshal, chief of a fire prevention bureau, labor department, health department, building official, electrical inspector, or other having statutory authority. For insurance purposes, an insurance inspection department, rating bureau or other insurance company representative may be the authority having jurisdiction. In many circumstances the property owner or his designated agent assumes the role of the authority having jurisdiction.) Auto-Ignition Temperature (A1T)-the minimum temperature required to initiate or cause selfsustained combustion of a solid, liquid, or gas independently of the heating or heated element as defined in NFPA 497M-1991. Combustible liquid-A liquid having a flash point at or above 100 degrees Fahrenheit (37.8 degrees Celsius). Flammable liquid-A liquid having a flash point below 100 degrees Fahrenheit (37.8 degrees Celsius). Flash point-the minimum temperature at which a liquid gives off vapor in sufficient concentration to form an ignitable mixture. (See NFPA

325M-1991.)
Intrinsically sa$-equipment and wiring which is incapable of releasing sufficient electrical or thermal energy under normal or abnormal conditions to cause ignition of a specific hazardous atmospheric mixture or hazardous dust layer. Lower explosive limit (LEL)-the minimum amount of gas or vapor that must be mixed with air to produce an explosive mixture. Non-incendive-equipment and wiring which in its normal operating condition i s incapable of igniting a specific hazardous atmosphere or dust layer. Upper explosive limit (UELj-the maximum amount of gas or vapor that can be mixed with air to produce an explosive mixture. IV. Goals The goals of this technical guideline are to: A. Standardize design, construction, and purchased equipment for hazardous (classified) locations. B. Increase consistency from project to project and site to site. C. Improve and ensure personnel safety and avoid property loss. D. Make future changes and revisions easier. E. Deliver a facility for the lowest cost without compromising safety. F. Create a standardized classification approval procedure.
/E Indusfry ApplicofionsMogozine M Morch/Apri/ 1997

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G Develop standard drawing elements and definitions for classified location drawings H. Improve communication of hazardous (classified) locations. I Speed design and construction of hazardous (classified) facilities J. Standardize equipment specificationsfor hazardous (classified) locations K Provide a guide and reference for operations personnel L Standardize documentation V Classification Procedure A Responsibility 1 Engineering a It will be the responsibility of the electrical engineer, as designated by project management or area management, to interpret the tules and regulations as set forth in the NFPA codes, standards, and recommended practices for establishing the classification of an area b It will be the responsibility ofthe designated electrical engineer or the assigned representative to provide the required electrical hazardous (classified) area design The electrical, mechanical and general design shall meet the conditions described by NFPA regulating codes and insurance carriers The electrical hazardous (classified) area design will include: T h e designuted electricul engineer will normally be the plant electrical engineer or project electrical engineer. However, project managem e n t m a y designute un electricul engineer f r o m an outside consulting compuny involved in the project. (1) Criteria for the classification including: E Air Flow Direction-Auto-Ignition Temperature (AIT) Division Group Boundaries Typical Hazardous Classification Charts I Electrical Hazardous Locations Investigation Report (2 j Documented information related to the electrical classification design for the operating area to post in the area affected Special operating conditions, if any, relating to the classified area and/or equipment shall also be posted 2. Operating Division a It will be the responsibility of the operating division to provide information regarding the process conditions and operating procedures of the area to establish the classification b. It will be the responsibility of the operating ision to post the classification of the area and special operating conditions, if any, relating to the classified area and/or equipment. c It will be the responsibility of the operating division to function within the limits of the classification established and to cause a review using this

guideline to re-classify an area if changes in methods, equipment, or operations occur that might affect the previously specified classification. 3. Insurance Approvals It will be the responsibility of the fire protection representative to obtain fire insurance approvals if required. 4. Electrical Engineering Consultant It will be the responsibility of the Electrical Engineering Consultant to advise the designated electrical engineer or the assigned representative on the application of NFPA codes, other governing codes, and adopted standards. A t Eli Lilly, Electrical Engineering Consultant is a title given to an experienced engineer who has the responsibility to coordinate work of other electrical engineers. There i s no Electrical Engineering department. 5 . Investigation Committee It will be the responsibility of the Investigation Committee to discuss the operating procedures including the materials and arrive at a decision as to the proper electrical classification of an area. 6. Approval Group It will be the responsibility of the Approval Group to review and approve the Investigation Committees proposed classification. B. General Work Procedure 1. Request to Classify or Reclassify A request to classify or reclassify an area can originate from either the operating or engineering division and shall be submitted to the designated electrical engineer. The designated electrical engineer will convene the Investigation Committee. The recommended membership shall be: a. Representative(s) of the operating division b. Designated building and/or plant electrical engineer c. Plant safety representative d. Plant fire protection representative e. Design engineers (1)Designated Process Engineer ( 2 ) Designated Mechanical Engineer (3) Designated Civil Engineer The sign-offprocedure assures there will be a plantlbuilding electrical engineer or project electrical engineer involved, even if an outside consultdnt i s designated to develop the classification. 2. Reviews for Consistency All requests to classify or reclassify an area will be reviewed by the Approval Group and returned to the originaror. This review is made to assure, as near as possible, consistency of interpretation and application ofNFPA codes, other governing codes, and adopted standards. The Approval Group will consist of: a. Plant electrical engineer b. Plant fire protection representative c. Area supervision

d. Electrical Engineering Consultant e. Building engineer (where applicable) This assures there i s enough thought given to the ared classification. Also, it assures consistency in the approach dnd end result of the area classification. VI. Classification Forms A. Purpose The purpose of the classification forms is to provide consistent guidance for classifying or reclassifying an area. They also serve as standard and official documents of hazardous (classified) locations. The forms convey the philosophy of considerable quantities present in the area to be classified. This dddresses the fact that if there are not considerable quantities, perhaps the ared should not be classified a s strictly. B. Procedure and Responsibility Refer to Section V. C. Document Retention After the forms are approved by the Investigation Committee and Approval Group, the master form will be kept in the project file and a copy of each form will be sent to the Plant Electrical/Building Engineer. The master copy will later be transferred to the buildings users when the project is closed out. D. Revision or Addition to Forms All revisions and/or additions to the forms must be submitted to the Chairman of the Hazardous Locations Technical Committee. See Section XVI. E. Location and Owner of Forms The Chairman of the Hazardous Locations Technical Committee is the owner of the forms. Blank forms will be electronically stored in a public folder. Blank forms are kept in an electronic public folder which i s available to anyone working in classifying an area. VII. Classification Charts A. Purpose 1. The primary purpose of the classification charts is to recommend a classification for the most common areas and equipment types likely to be encountered. 2. The secondarypurpose is to offer a blank template to use for a new area classification or for a reclassification. 3.These charts can offer a check in classifying an area or equipment. B. Using these charts: 1. For Class I areas use the ROOMiAREA chart. 2. For Class I equipment use the EQUIPMENT chart. 3. For Class I1 areas or equipment use the DUST chart. Note: For Group E dusts consult NFPA 497B-

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4 Find the row that exactly matches the conditions 5 Utilize the recommended classification 6 If an exact match cannot be found, use sound engineering judgment to determine the classification The charts will prevent an unnecessary blanket area classification. C E x p l a n a t i o n of C h a r t C o l u m n s (Room-Area and Equipment) Adequate Ventzlatzon is defined in ETG #15801 AIT-The Auto-Ignition Temperature of the material should be greater than the temperature shown Closedsystem asks if the process allows any openings for vapors, liquids, dusts, or material(s) to escape Dust Collectzon System asks if a system or mechanical method exists to prevent the buildup of dust Dust Layer (equatzon) 118 asks if an 118-inchthick coating of dust can be seen on the surfaces in the area F l a b Poznt-The material should generally have a lower flash point Flow Rate is the amount of flow in gallons per minute. The system should have less flow than that shown Good Housekeepzngasks if regular clean-ups occur to prevent the build-up of a dust layer Group identifies the material(s) being handled as defined by NFPA 30-1993 The material(s) should be the same group as shown Low Level Exhaust asks if there are exhaust pickups lower than 3 feet above finished floor Pressure is the pressure the system is operating under in pounds per square inch The system should operate at a lower pressure than the one shown. Process Szze is the volume in gallons being processed The system should contain less than the amount shown Process Temperature-It should generally be between the flash point and the Auto-Ignition Temperature Recommended Classification is based on sound engineering judgment and experience In addition, it complies with the intent and spirit of all applicable NFPA articles and American Petroleum Institute Recommended Practices API RP 500 Few, if any, areas handling dusts at Eli Lilly and Company need to be classified Refer to NFPA 497B-1991 for additional information concerning the classification of dust areas Surface Color Dzscernzble means the color of objects and surfaces can be determined in the area Vapor Denszty asks if the vapor of the material(s) is heavier than air Larger than 1 0 means it is heavier than air
IFF lndurfry ApplicationsMuguzine
m

Visible Dust Cloud by definition in NFPA 497%

1991 states that visibility beyond 3 to 5 feet is impossible. Answering N O means you should NOT be able to see the dust suspended in the air. D. Revisions or Additions to Charts Submit any revisions or additions to these charts to the chairman of the Hazardous (Classified) Locations Technical Committee. See section XVI. E. Location and Owner of Charts The chairman ofthe Hazardous Locations Technical Committee is the owner of these charts and will store them on a public folder. The charts are kept in an electronic public folder which i s available to anyone working in classifying an area. VIII. Hazardous (Classified) Locations Series Drawings And Reusable Elements A. Purpose 1. Hazardous (Classified) Locations series drawings convey graphically to engineers and contractors the classification for all the areas of the facility. The Hazardous (Classified) Locations series drawings will help determine what type of equipment can be installed. 2. Hazardous (Classified) Locations series drawings help convey important life safety information for insurance purposes. 3.Hazardous (Classified)Locations series drawings identify classified areas to operations and maintenance personnel. 4. Hazardous (Classified) Locations series drawings convey graphically to an engineer in a future project the rationale for classifying a specific area, and therefore must be kept current. B. Reusable Elements The purpose of Reusable Elements is to provide a standard legend for all Hazardous (Classified)Locations series drawings. They are stored in a drafting computer file REE-422 and cannot be changed without approval from the Hazardous Locations Technical Committee. 1 For Division 1areas use cross-hatch pattern. 2 . For Division 2 areas use slanted pattern 3. For any special classifications use the flex or hex pattern. Example: One area could be classified Class I, Division 2, from finished floor to ceiling while another area in the same proximity or adjacent could be classified Class I, Division 2, from finished floor up to a height of six feet. 4. For Unclassified areas do not use any graphic patterns. 5 . Use split diamond in each classified area to show the Auto-Ignition Temperature (AIT) in degrees Centigrade and the group of the most hazardous chemical handled in the area. The temperature shall be shown on top, while the group shall be shown on the bottom of the diaI

March/April I997

mond. The group will identify the Class I or Class I1 area. 6. Air-flow arrows are a useful part of the Hazardous (Classified) Locations series drawings because they are required for insurance approval determine if an area has been properly classified help when reclassifying an area clarify the area for containment and operations purposes Consult with the projects Mechanical Engineer in order to show the air flow arrows in the Hazardous (Classified) Locations series drawings. 7 . Conductive floors shall not be shown in Hazardous (Classified)Locations series drawings. Refer to Engineering Technical Guideline 16456. 8. For any revisions to Hazardous (Classified) Locations series drawings follow Section V of this Technical Guideline. IX. Chemical Data Table A. Purpose The purpose of the chemical data table is to provide a list of material characteristics for the most common chemicals and solvents that are used at Eli Lilly. These characteristics should be considered when classifying an area for electrical equipment. B. Using This Table 1. Identify the chemicals that you have in the area. 2. Utilize the listed material characteristics to assist in classifying the area for electrical equipment. 3. If you can not find the chemical on the table, refer to the Material Safety Data Sheet (MSDS), which can be found on the Engineering VAX system. 4. Additional information can be found in NFPA 497M-1991, 30-1993, and 325M-1991. 5 . Consult with the projects process engineer if information cannot be found in the above resources. C. Explanation of Table Columns 1. Upper Explosive Limit (UEL) is the maximum limit on the percentage of gas or vapor that can be mixed with air to produce an explosive mixture. 2. Lower ExplosiveLimit (LEL) is the minimum amount of gas or vapor that can be mixed with air to produce an explosive mixture. 3. Refer to Sections I11 and VI1 for other definitions. D. Revisions or Additions to the Table Please submit any revisions or additions to this table to the chairman of the Hazardous Locations Technical Committee. See section XVI. E. Location and Owner of the Table The chairman of the Hazardous LocationsTechnical Committee is the owner of this Table. The
E

chairman has this table stored on a public folder. See Section XVI. X. References To Hazardous (Classified) Locations The following documents refer to hazardous (classified) locations. They provide input and discussions on proper designs. A. ETG 01540-Fire Protection and Loss Control Design Criteria B. ETG 01 590-Process Safety Considerations for New Operations C. ETG 11000-Shipping and Receiving Docks D. ETG 15501-Insurance Considerations E. ETG 15801-Ventilation Design of Hazardous Areas XI. Class I And I1 Locations The following requirements are based on years of operating experience. Many requirements could be interpretedas not complying with codes andstandards, however, it is our belief that these requirements are safe andadequate for our applications, and they do meet codes and standards. A. Requirements 1. Adjustable Speed Drives (ASDs) The application of ASDs and Motors is addressed more completely in specification 16154-Motors. In general ASDs should be located outside of classified areas and TEFC motors in Division 2 areas driven by ASDs should have sealed contact thermostats imbedded in the windings because of the uncertainties of the operation temperatures at various speeds and supply voltage wave shapes. 2. Automatic Doors Refer to Engineering Technical Guideline 08460-Automatic Doors for details. 3. Calculators Hand-held calculators shall be permitted in Division 1 and 2 classified locations. 4. Clocks Only labeled or listed clocks shall be permitted in Division 1 classified locations. Battery operated clocks without make-or-break contacts shall be permitted in Division 2 classified locations. 5. Conductive Floors The requirement for conductive floors is outlined in ETG 16456-Bonding and Electrostatic Grounding and is beyond the scope of this guideline. It is also covered in the Eli Lilly Safety Manual and ETG 01 588-Avoidance of Dust Explosions. 6. Flashlights Only labeled or listed flashlights shall be permitted in Division 1 classified locations. For Division 2 locations, flashlights must be approved by plant electrical engineering or building engineer. 7. Fork Trucks NFPA 505 covers the use of fork trucks in electrically classified hazardous areas. In summary:
IFF Industry Appbrotions Mogozine U Morrh/Apri/ I997

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Class I and 11, Division 1, Groups D and G-Type EX units are allowed. Class I and 11, Division 2, Groups D and G-Type DY, EE, and EX are allowed. In addition Type DS, ES, GS, LPS or GS/LPS may possess sufficient safeguards to be used in Class I and 11,Division 2, Groups D and G areas The authority having jurisdiction can authorize their use, taking into account the quantity of flammable material that might escape in case of accident, the adequacy of ventilation, the total area involved, etc. In most cases these type of units are acceptable for operations outdoors and within warehouses at Eli Lilly and Company 8. Grounding and Bonding Refer to ETG 16456-Bonding and Electrostatic Grounding 9 Hearing Aids Hearing aids are considered non-incendive, and are acceptable for use in classified locations. 10 HVAC Design shall meet or exceed the design criteria specified in ETG 15801 for all classified locations 11 Intercoms Use Intercom Systems approved for hazardous conditions Refer to ETG 16760- Intercom Systems for details. 12. NEMA/NFPA vs. IEC In making the decision to use IEC-rated equipment over NEMA-rated equipment in NFPA hazardous areas, the engineer should employ sound engineering judgment to hazardous design Using IEC standards, the selection procedure is more involved and requires the engineer to address additional considerations in order to achieve the desired performance IEC equipment is rated closer to its capabilities than a corresponding NEMA equipment, and cost savings can be achieved with understanding the comparisons between IEC and NEMA. IEC standards use Zones to identify the Iikelihood of explosion Zone 0 has an explosivemixture continuously present Zone 1 has an explosivemixture likely to occur in normal operating conditions Zone 2 has an explosivemixture not likely to occur in normal operating conditions IEC classifies the enclosures as flameproof d and increased safety e Flameproof dmust contain an internal explosion without permanent distortion, guarantee the flame cannot be transmitted to the surrounding atmosphere, and present an external surface temperature that is lower than the ignition temperature of the surrounding gases and vapors Increased safety eelectrical devices must not produce arcs, sparks or excessive temperature in normal operation IEC Zone 0 is roughly equivalent to NFPA Class I or IUDivision 1 Zone 1 is roughly equivalent to NFPA Class I or II/Division 1or 2 Zone 2 is roughly equivalent to NFPA Class I or IIiDivision 2 If IEC rated equipment is to be used, a review by
IEEElndusiryApplicufioiis Maguzine VI March/April1997

the insurance carrier, the Manager of Property Loss Prevention and Control and the Manager of Elec trical Engineering should be undertaken Overall IEC rated equipment can translate to NEMA rated equipment in most situations, but NFPA codes and philosophies must be met for most locations in the United States and Puerto Rico. 13. Non-IncendiveiIntrinsically Safe Refer t o d e f i n i t i o n s and E T G 1 6 9 1 0 Instrumentation and Enclosures in Hazardous Areas 14 Pagers Only labeled or listed pagers shall be permitted in Division 1 and 2 classified locations. 13 Pallet Jacks and Material Handling Equipment Only labeled or listed electric pallet jacks or material handling equipment shall be permitted in Division 1 and 2 electrically classified hazardous locations 16. Portable Radios Only labeled or listed radios shall be permitted in Division 1 and 2 classified locations. 17 Power transformers Avoid transformers in Division 1 and 2 classified locations. 18 Purging Refer to ETG 16910-Instrumentation and Enclosures in Hazardous Areas 19. Sealing and drainage Place equipment outside hazardous areas or use factory-sealedequipment where practical to eliminate the need for seal-offs Drains shall be used where there is a probability that liquid or other condensed vapor may be trapped within the enclosure or raceway system due to temperature differences and exposure to moisture. Examples: outdoor installations, chill rooms, wash-down areas, etc Consult NFPA 70-501-5 for the need for seal-offs and drains 20 Signs Place a sign mounted on the doors or approach entering a hazardous area, measuring twelve inches by twelve inches with yellow background black letters, stating. THIS AREA IS AN ELECTRICALLY CLASSIFIED HAZARDOUS AREA FOLLOW APPROPRIATE SAFETY GUIDELINES. 21 Smoke DetectorsiHeat Detectors Refer to Engineering Technical Guideline 16720 22 Solenoids For Division I , solenoid enclosures shall be approved for the area Solenoids without make-orbreak contacts are permitted in non-rated enclosures for Division 2 locations. 23 Speakers For lay-in or plaster ceiling-mounted speaker in Division 2 situations use standard speaker and housing with trim pot mounted internal to housing, accessible to qualified personnel only. For

surface-mounted speakers use speakers approved for hazardous conditions. Refer to Engineering Technical Guideline 16770, Emergency Announcement System, ETG 16760, Intercom Systems and 16770, Emergency Announcement System (Public Addrcss) for details. 24. Telephones LJse telephones approved for hazardous conditions. Rcfer to Engineering Technical Guideline 16745-Telecommunications and ETG 16760Intercom Systems for details. 25. Testing Equipment, Meters, Sensors,Scanners Permanent: Only approved equipment shall be permitted in classified locations. Portable or temporary: Equipment which is not approved shall be permitted when Open Flame procedures have been followed. Portable equipment shall not be applicable for use in Division 1 locations. Non-listed or non-labeled equipment: meer, Must he approved by plant electrical en& building engineer, or Hazardous Locations Technical Committee. 26. Watches Watches are considered non-incendive, and are acceptable for use in classified locations. XII. Class I Locations Only A. Requirements 1 . Diethyl Ether Diethyl ether is a group C material with an Auto-Ignition Temperature of 160 degrees (320 degrees F)-the Chemical Data Tables (see sample table) have more chemical characteristics for this material. In mosr cases, the equipment use in area(s) processing diethyl ether do not require a group C rating, except for Class I Division 1 area(s). The main concern is the maximum surface opcrating temperature. The equipments maximum surface operating temperature shall be 80%) of the AIT or less. or having a T rating ofl3C or higher. If a group C rating is required, consult other s r c tions in this guideline for proper classification and recommendations of equipment to be used with Diethyl Ether. 2. Hydrogen A three-foot, Division 2 bubble around the hydrogen line I S not necessary according to the Narional Electric Code, section jOO-S(b). FPN nu111. 2., if the pipe handling the hydrogen is welded. However, where there are valves, checks, meters, and similar devices, according to NFPA 497 Figure 1-4.27, these devices require a fifteen foot radius, Division 2, Group B bubble around the device. Division 1, Group C and D enclosures that are located at or below the level of the previously mentioned devices can be within this fifteen-footradius bubble, because the pressure inside the Group C and D enclosure will not he negative with

respect to the atmosphere. Also, hydrogen is at a low pressure is lighter than air, and it will dissipate rapidly once released to the atmosphere. All these facts virtually eliminate the possibility of hydrogen entering the group C and D enclosures. Neverthelcss, use sound engineering judgment when designing hydrogen systems. 3. Laboratory Hoods Generally laboratory hoods shall beconsidered as unclassified electrically with respect to NFPA 45. All receptacles, switches, and controls shall be located as not to be subject to liquid spills. If there is engineering judgment that a specific operation creates a hazard then the hazard should be evaluated in terms of likeli hood, severity, and the consequences of an explosion, as well as the protection required to substantially reduce the hazard. In these cases all wiring and appurtenances, apparatus! lighting, signal systems, alarm systems, remote control systems, or parts thereof, shall comply with Article 500 of NFPA 70, The National Electrical Code. 4.Lighting A common practice is to classify the area above a ceiling as non-hazardous and use non-rated lighting in these areas where a room might be Division 2. If surface-mounted or suspended fixtures are used, then either the appropriately rated fixture must be provided or the area must be de-rated in the area of the light fixtures. The most common problem associated with proper lighting application in Division 2 areas is the proper T-rating. If a fixcure does not have a T-rating lower than the AIT of the potential hazardous atmosphere, then the surface temperature of the lamp muct he less than 8 0 2 of the AIT or it must be approved for Class I, Division I . 5 . Motors For Division 2 equipment, groupdesignation is insignificant, and Division 1 or explosion-proof motors are not required. The important criterion is the surface operating temperature or T-number. The T-number is derived from tests at a specified ambient temperature and can sometimes be adjusted, but it must always be considered for Division I or 2 locations. For Division 1 locations, we have an understanding with our insurers that where we classify areas Division 1, Group C matrrials arc so rarely used that the area is really Division 2. Therefore, motors can normally he applied which are rated for Group D, Division 1 only, provided that the T-number is appropriate. A special circumstance where a Group C material will be routinely open will still require Group C-approved equipment. TEFC or ODP 3-phase motors are safe in Division 2 areas without special approval because a 3-phase squirrel cage motor has no arcing or sparking components to provide an ignition source under normal operation. The NEMA standard for maximum operating temperature with class B insulation
IEEF lndusy Applications Magazine
March/April I997

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is 80 degrees Centigrade. Class B rise is what is specifiedwith Class F insulation for an added safety factor. Maximum design temperature for class F insulation (at service factor) is 105 degrees Centigrade. This is well below 80% of the AIT of Hydrazine, agroup C chemical, which has the lowest AIT which can be identified (0.8 x 156 = 125). 6. Quantities Class I In non-processing areas such as laboratories and developmental facilities the quantity of flammable liquids is a critical factor in determining the need to classify. Other factors include ventilation, containment, drains, ignition sources,and skillsitraining of lab personnel. Generally lab quantities are less than 1 gallon (4 liters approximately) of each liquid, and total for the lab would not exceed 100 gallons. In most cases labs do not have or handle sufficient quantities to justify classifying these rooms. 7. Refrigerators Domestic refrigerators shall comply with NFPA 45 Standard on Fire Protection for Laboratories using Chemicals (Chapter 9 and Table 1). 8. Relationship of exposure levels to explosive limits in classified location A decision between Division 1 or Division 2 can often be clarified by considering the lower exposure limits and operating procedures. The exposure limit of most flammable liquids handled and processed at this campany is much lower than the lower explosive limit percentage. Normally the lower exposure level is less than 25% of the lower explosive limit. Therefore, ifpersonnel can be in the areas without being required to wear respirators, then the containment or ventilation or both are adequate to prevent explosive concentrations, and a Division 1classification may not be required. 9. Safety Disconnect Switches In Division 1 areas, all switches must be approved for the area and group. For Division 2 areas, switches intended to interrupt current in the normal performance of the function for which they are installed shall be provided with enclosures approved for Division 1 locations, unless the contacts are hermetically sealed, oil-immersed, or within a factory-sealed explosion-proof chamber. It is the current practice that motor safety disconnect switches will be NEMA 4 or 4 X in Class I or Class 11, Division 2 areas to provide an additional level of safety and to provide wash-down capability. If safety disconnect switches are installed in Division 2 areas where it will be normal operation for them to interrupt current, then explosion-proof enclosures will be required. Also, if isolating (non interrupting) switches are used in Division 2 areas, the switches can be non-rated, and must be labeled Do Not Open Under Load. XIII. Class I1 Locations Only A. Requirements 1.Lighting

A common practice at Eli Lilly and Company is to classify the area above a ceiling as non-hazardous and use non-rated lighting in these areas where a room might be Division 2. If surface-mounted or suspended fixtures are used, then either the appropriately rated fixture must be provided or the area must be de-rated in the area of the light fixtures. The most common problem associatedwith proper lighting application in Division 2 areas is the proper T-rating. If a fixture does not have a Trating lower than the AIT of the potential hazardous atmosphere, then the surface temperature of the lamp must be less than 80% of the AIT or it must be approved for Class 11, Division 1. Documented housekeeping procedures can justify downgrading a classification from Class 11, Division 1 to Class 11, Division 2. 2. Magnesium and Metal Dusts Metal dusts are considered Division 1,Group E. Metal shavings and pellets are not considered metal dusts. Water-reactive dusts should not be considered when classifying an area for electrical equipment. 3. Motors For Division 2 equipment, group designation i s insignificant, and Division 1 or explosion-proof motors are not required. The important criterion is the surface operating temperature, or T-number. The T-number is derived from tests at a specified ambient temperature and can sometimes be adjusted, but it must always be considered for Division 1or 2 locations. TEFC or ODP +phase motors are safe in Division 2 areas without special approval because a 3-phase, squirrel cage motor has no arcing or sparking components to provide an ignition source under normal operation. For Class 11, Division 1 areas, the important criterion is operation under the specified temperature with a dust layer. Motors must be labeled for use in Class IT, Division 1areas. Documented housekeeping procedures can justify downgrading a classification from Division 1 to Division 2. 4. Quantities In non-processing areas such as laboratories and developmental facilities, the quantity of ignitable dusts is a critical factor in determining the need to classify. Other factors include ventilation, containment, drains, ignition sources, and skillsitraining of lab personnel. Generally lab quantities are less than 1 pound (454 grams) of each dust, and total for the lab would not exceed 100 pounds. In most cases labs do not have or handle sufficient quantities to justify classifying these rooms. 5 . Safety Disconnect Switches In Division 1 areas, all switches must be approved for the area and group. For Division 2 areas, switches intended to interrupt current in the normal performance of the function for which they are installed shall be provided with enclosures approved for Division 1 locations, unless the contacts

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are hermetically sealed, oil-immersed, or within a factory-sealed explosion-proof chamber. It is the current practice that motor safety disconnect switches will be NEMA 4 or 4 X in Class I or Class 11, Division 2 areas to provide an additional level of safety and to provide wash-down capability. If safety disconnect switches are installed in Division 2 areas where it will be normal operation for them to interrupt current, then explosion-proof enclosures will be required. Also, if isolating (noninterrupting) switches are used in Division 2 areas, the switches can be non-rated, and must be labeled Do Not Open Under Load. Documented housekeeping procedures can justify downgrading a classification from Division 1 to Division 2. 6. Sealing Sealing in Class I1 areas is significantly different than in Class I, NFPA 70-502-5 shall be consulted

for requirements. In general, place equipment outside the hazardous area where practical. XIV. Class I11 Locations This Technical Guideline does not cover Class I11 locations. XV. Interpretation The Hazardous Locations Technical Committee is the owner of this Technical Guideline; therefore it will interpret the intent of this document. The Committee will be responsible for resolving differences of opinion whenever these arise. For any changes or suggestions to this Technical Guideline, please contact any committee member. XVI. Consultation For any questions about how to use this guideline or for further direction, contact: William M. Lewis, 317-277-1409 Electrical Engineering Consultant

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1. Chemical Data Table-SAMPLE (Class I Chemicals as Defined in NFPA 30)*

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1 Chemicalswhich are commonly used or produced at EliLilly for consideration when classifying areas for electrical equipment:
1 Class I Chemicalsas Definedin NFPA 30
Material Group AIT (C) Flash PI (C)

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VD (Vapor Density)

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LE1(%)

UEL (%)

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1 Acetaldehyde

I Acetone 1 Acetonitrile
Material Acetic Acid

1C
ID

I175 1465 I524 14.4 11.4

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ID
Group

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1 Class II Chemicalsas Defined in NFPA 30:

AIT (C)
Flash PI (C)

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UEL (%)

VD (Vapor Density)

D
D ID

464 316 1245

39 49 144

19.9

2 . 1 1.1 13.4

Acetic Anydride

2.7
11.1

10.3
19.4

1 Class MA Chemicalsas Defined in NFPA 30:

Material Analine Group AlT (0 Flash Pt (C) LE1 (%) UEL (%) VD (Vapor Density)

I Cyclohexanone

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3.2
4.4 3.5
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Cyclohexanol

D
D

585
300

I *Class I, II and M A chemicals should not be confused with Class I, 11, or 111 electrical classification.

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IEEE Industry Applications Magazine

March/Apri/ I997

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ELECTRICAL H

~ TI^^^ R ~ ~ U

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INVESTIGATION

REPORT

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Are flammable iiquids, vapors or gases likely to be present in quantrtles sufficient to produce explosive or ignltlble mixtures'
Are combustible liquids likely to be handled, processed, or stored at temperatures above their flash points in quantities sufficient to produce exploslve or ignitlble mixtures?

iNSWER
1.

is an ignitible atmospheric mixture likely to exist under normal operating conditions?

2.

Is an ignitible atmospheric mlxture likely to occur frequently due to maintenance, repair or leakage?

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3. Would a failure of process equipment, storage vessels, or piping systems be likely to cause a failure of
the electrical system simukaneously with the release of the combustible material?

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4.
5.

Is a piping system containing a combustible material in an inadequately ventilated space, and is the piping system likely to leak?
is the space or area in question below grade level such that vapors may accumulate therein?

6. Are pressure relief valve discharges located within the area?

Division 2 locations are distinguisticd by an affirmative a i ? w e r io air#on6! of the f:Jliuwing qcicstiuns:

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lNSWER
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I s a piping system containing a combustible material in an inadequately ventilated space, and is the piping system not likely to leak?
Is a process equipment system containing a combustible material in an inadequately ventilated space, and can the material escape only during abnormal situations, such as a failure of a gasket or packing?
Is the location adjacent and open to a Division 1 location, or can gas or vapor be transmitted from a Division 1 location to the location in question by trenches, pipes, or ducts?

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3.

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If mechanical Ventilation Is used. can failure or abnormal operation of the ventilation equipment permit an ignitible atmospheric mixture? Are the operations In this area likely to require a Rivision2 classification in the near future? Extent of a hazardous location maybe determinedfrom diagrams, figures 3-4.1 through 3-4.34 NFPA Code 497A, efiective 2/10/92 Lllly Safety InformationManual, Sec.V p.10 Lilly EngineeringTechnical Guidelines 01555 (Hazardous Locations Classifications)
Rev. 12115194

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5.

References:

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Fig. 1A. Investigation report-Class

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rb

/Elndusfry ApplicationsMagazine I Morch/Apri/ 1997

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DATE:

REQUESTER:

AREA:

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REASON .. . .F . ~ ~ . ! . ~ . ~ . ~ S ~ ~ ~ ~ ~ ! ~ ~
Process Change Equipment Changes New Project Other

1Y.f% DE ~

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Location to be Classified

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GroupE GroupF GroupG

Location to be Re-classified

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PRESENT CLASSIFICATION
Class I Class II Class 111

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0 0 0

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Division 1 Division 2

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General

Purpose

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Investtgattian Committee Chairman Electrical Engr. Member Fire Protection Rep. Member Bullding Engineer Member
Civil Engineer

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Other

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MEW CLASSIFICATION
Class I Class 1 I Class 111
Class ICopy

0 0 0

~ r o u p ~ GroupB GroupC GroupD

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0 0

GroupE GroupF GroupG

c]

Division 1 Division 2 Approval Group Plant Electrical Engr. Plant Fire Protection Representative Area Supervision

0
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~A

0
c]

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Chairman Electrical Engineer Drawing No. Drawings Updated (Date) Area Posted (Date)
Class I Copy

Initials Initials

Building Engineer Electrical Engineering Consultant

Rev 12/16!94

Fig. 1B . Class I investigation report (continued).

/FEE lndustry Applications Mojozine m Morch/April I997

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Need for classification, if the following question IS answered aftirmarive

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a. Are combustible dusts likely to be present in quantltles sufficient to produce explosive or Ignitible mixtures?

ANSWER

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Division 1 iocationlit are distinguished hy a n afllrinntivc answer t o ai?* oi3e o f tiic ioiiowing questions:

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a.
b.

Is a Group E dust present in hazardous quanlities?

is a dust likely to be in suspension in air continuously, periodically. or intermttentiy under normal conditions in quantities sufficient to produce explosive or ignitible mixtures?

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c.

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Will mechanicaifailure or abnormal operation of machinery or equipment cause such explosive or ignitible mixtures to be produced, and might it also provide a source o f ignition through simultaneous failure of electrical equipment operation of protective devices or from other causes?

d.

Are there dust layers or accumulations on surlaces deeper than 118 in. (3.18 mm)?

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Division 2 laciltiafls lor Group F o r G dusts are dirjlinguishlrc! ay dii affirniatrve questions:

IIS W B I

to any 0118 ol the following

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a.

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I s the dust not normally in suspension in the air in quantities sufficient to produce explosive or ignitible mixlures, but could be thrown into suspension by infrequent malfunctioningof handling
or processing equipment?

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Are the dust accumulations insufficient to interfere with the normal operation of electrical equipment, but could the accumulations be ignited by the abnormal operation or failure of electrical equipment?

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c.
d.

isthere a dust layerthat makes the colors of the surfaces indiscernible? Would the failure of mechanicai dust collection allow an ignitible suspension of dust or a layer deeper than 1/8 in (3.18 mm) to build up?

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References:

Extent of a hazardous location maybe determined from diagrams, figures 5-3.1 through 5-3.9 NFPA Code 4978, effective 2/08/91 Liliy Safety Information Manual, Sec.V p.10 Lllly Engineering Technical Guidelines 01555 (Hazardous Locations Classifications)

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Fig. 2A. Investigation report-Class

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/E lndusfry Applications Magazine

March/Aprrl 1997

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DATE
E A S P N FOR INVESTIGATION
Process Change Equipment Changes

REQUESTER

AREA

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TYPE OF I N ~ ~ S ~ ~ A T I ~ ~

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New Project
Other

Location to be Classified Location to be Re-class~fied

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GroupE GroupF GroupG

0 0

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_ PRESENT _ ~ _ CLASSIFICATION ~ _ _ _ _ Class I Class II Class111

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0 0

Division 1 Division 2

~~~~~

GroupC GroupD

M A

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Investigation Committee Chairman Electrical Engr. Member Fire Protection Rep. Member Building Engineer Member Civil Engineer Member Plant Safety Rap. Member Other Member Operation Rep. Member Mechanical Engineer Member

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Process Engineer

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DESCRIPTION:

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NE-W CJLASSIFICATION I
GroupA Group8

Class I
Class II
Class 111

0
[7

Group E GroupF

GroupC GroupD

0
[7

GroupG

0 0 0

Division 1 Division 2 Approval Group

0
0

General Purpose
N/A

0
0

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Plant Electrical Engr

Chainan Electrical Engineer Drawing No Area Supervision Drawings Updated (Date) Area Posted
(Date)

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Plant Fire Protection Representative

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Initials lnnials

Building Engineer Electrical Engineering ConsultantRev ,2,,6184

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Fig. 2B. Class I investigation report (continued).

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I fndusfry Applirofions Mogozhe I Morch/April I 997

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Table 2. Equipment Classification

Valve

Cl00

ClOO

ARENROOM

Tote Filling

I Unclassified

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HAZARDOUS AREA CLASSIFICATION LEGEND

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DIVISION 1 DIVISION 2 SPECIAL CLASSIFICATION DIV -

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SPECIAL CLASSIFICATION DIVUNCLASSIFIED

AUTO IGNITIONTEMP IN DEGREES C"

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I: % : INCLUDES GROUPS A, 0. C. & C CLASS I 1 INCLUDES GROUPS E, F. 8 .G

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INDICATES DIRECTION OF AIR FLOW

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Fig. 3. Hazardous area classification diagram.

/FEE industry Apphtions Muguzine II Murch/April I997