31 May 2001

A universal approach for hazardous area classifications

by Jim Peterson

Intrinsic safety is cost effective everywhere.

The adoption by the National Electric Code of the International Electrotechnical Commission
standard allowing use of zones, an alternative to the traditional division method of area
classification, was added to the 1996 code and greatly expanded in the 1999 code. The availability
of two area classification methods increases flexibility when choosing the electrical equipment used
in hazardous areas. Though the traditional, North American method of area classification in North
America is still useful, engineers can now use the zone method for new installations or reclassifying
existing facilities.
The zone method allows designers to use a wider variety of equipment and techniques than the
traditional method in all but Zone 0 applications, where intrinsic safety (IS) is the only method that
may be used. The only technique allowed in all area classifications worldwide is IS.
The designer's choice of a technique depends on the type of equipment required. Low-power signal
and process control equipment is readily available and easily applied in all area classifications using
IS, which is by far the safest standard, regardless of the area classification. IS systems are not only
safest but also very cost effective. Further, IS is a truly universal approach because devices certified
for a higher classification can be used in lower classifications of a similar gas group and temperature
rating.

Intrinsic safety's advantages

When choosing a method of protection, evaluate the following:
Are adequate field and interface devices available for the application? The number of IS field devices
and interfaces is large and steadily growing. The devices now available include transmitters, valve
positioners, electropneumatic valve actuators, displays, current-to-pneumatic converter and
pneumatic-to-current converter devices, proximity sensors, and many more.
Can designers use general-purpose devices in a hazardous area? The use of "simple apparatus"
devices that will neither store nor generate more than 1.2 volts, 25 milliwatts, or 20 microjoules of
energy, as defined in NEC Article 504-2, is an advantage of the IS method. Some examples are
light-emitting diodes, remote terminal displays, thermocouples, and switches. These devices require
no certification when used with suitable "associated apparatus" (intrinsically safe barriers).
Are live maintenance (powered loops) and troubleshooting permitted in the hazardous area? The
design of IS loops allows field devices and cables to be safely serviced without shutting down power.
The low-power and fault-tolerant circuitry associated with IS provides added safety for personnel.
Is there an acceptable level of safety for both personnel and property? By choosing IS, you are
afforded the safest proven method available.
Is mounting space a problem? IS devices, by nature of their low-power design, are smaller than
other hazardous-area devices. The IS interfaces can be the high packing density type, which saves
control-room real estate. Designers can mount devices in Class 1, Division 2/ Zone 2 areas in
general-purpose enclosures, thus limiting expensive cable runs. Further, incorporating IS eliminates
requirements for rigid sealed conduit because IS cable installation can use any method approved for
ordinary areas. Owners realize cost savings with installation, access to cables for maintenance and
repair, and overall cost of ownership.

Is adequate, clear, and concise technical support of the chosen method readily available? IS is a
well-understood, universally accepted method of protection with well-defined design, certification
testing, and installation practices.
Are the field devices and interfaces compatible with major control systems? A wide variety of
devices is available for interfacing IS field devices with controllers, ranging from application-specific
devices geared to the large distributed control system and programmable logic controller
manufacturers to custom solutions for any conceivable controller configuration.
Traditionally, engineers use intrinsically safe systems in only the most hazardous environments. IS
need not be restricted to these areas, however. The extremely high degree of safety, low-cost
maintenance, installation ease, increasingly broad availability of components, and worldwide
acceptance make IS the most sensible choice for any hazardous-area application. IT
Jim Peterson ( peterson@mtlnh.com) is a senior applications engineer at MTL, Inc. in Hampton, N.H.