Welcome

To A Discussion On

Hazardous Area Classification And Equipment Selection Alex Ezenwa. 26/07/2008

We are going to discuss

Classification Temperature Class Gas Groups

Ice Breakers
Hazard Explosion Explosive substances Explosive mixture Explosive atmosphere Potentially explosive atmosphere Atmosphere with explosion hazard Lower explosive limit (LEL) Higher Explosive Limit (HEL)

 ICE BREAKERS
HazardThe present,or the risk of presence, of a flammable gas-air mixture. Explosive MixtureIt is mixture of a combustion agent( oxidizing product)and a fuel(oxidisable product) in such a proportion that it could give rise to a very rapid and lively oxidisation reaction liberating more energy than is dissipated through conduction and convection Hazardous (flammable) AtmosphereAn atmosphere containing any flammable gas or vapour in a concentration capable of ignition. Hazardous areaAn area where during normal operations, a hazardous

atmosphere is likely to occur.

Terminologies. Explosive(flammable) Limits -

The extreme values for the concentration of a flammable gas or vapour in air under atmospheric conditions, which can be ignited by an electrical arc or spark. These limits are called the lower explosive limit (LEL) and the Upper explosive limit (UEL).

Flash Point-

The flash point is the min. temp. at which an air- gas mixture, in normal pressure conditions, can be ignited.

Ignition Temp.-

The ignition temp. of a gas or of a vapour is the min. temp.at which normal mixtures of gases/vapours, ignite spontaneously.

What are the basic requirements ?

To avoid such situation causing fire or explosion,
there are two basic requirements.

The elect. equipment should be Mechanically Strong

to withstand the worst fault taking place anywhere in the equipment. Hence, the spark will not come out.

Construction of

the equipment should be such that,

after any fault in the equipment, temperature of the

hot gases coming out, is less than ignition temp. of

the flammable gas/mixture in that area.

Design Considerations
1.
Gases come out at temp. lower than the ignition temp. of the surrounding gases

Hot gases

Proper, required length of flame path is available for sufficient cooling.

2. For pressurized enclosures, low pressure trip will be provided. Before starting, scavenging facility will be there. 3. In Ex e enclosures, temperature rise designed shall be 10 degree less than that allowed for that insulation class.

Why special Elect. Equipment is required ?

FUEL + OXY ( in right proportion ) => Heated up to temperature higher than the Ignition Temp. of the gas in that area

It will result in FIRE or EXPLOSION

Hazardous Areas

Hazardous Areas
The locations,where the potential for fire or explosion exists because of gases, dust or easily ignitable fibers or flyings in the atmosphere

Area Classification
Area classification schemes and systems of material classification provide a succinct description of hazard so that appropriate level of safe guards in proper selection of electrical apparatus may be taken. They specify: the kind of flammable material that may be present and the probability that it will be present in explosive concentration.

PRINCIPAL CONSIDERATION FOR DETERMINING HAZARDOUS AREAS

A. Type of Material B. Vapour density/molecular weight C. Process of storage pressure D. Size of release and multiplicity of locations E. Type of ventilation F. Explosive limits G. Source of release H. Flash points

(A) TYPE OF MATERIAL : - VAPOURS/ GASES - RATE OF DEFUSION (B) VAPOUR DENSITY OF MATERIAL : - Heavier gases - Lighter gases (C) PROCESS OR STORAGE PRESSURE : - Higher pressure of gases changes areas considerably - Gas travels larger distance before it diffuses

D. Size of release : - Examples : - Glands in process plant equipments - Flange connections of piping and storage tanks E. Type of Ventilation: - Open area/natural ventilation - Artificial ventilation F. Explosive limits : - LEL - UEL

Area Classification
Zone (Division) Class Group

Classifications

As defined by IEC 79.10, there are three Zones

(Divisions) for the area containing flammable substances in the atmosphere.

Gas group depends upon the kind of gas or vapor handled. There are four Gas Groups I, IIA, IIB & IIC.

Depending on the maximum surface temperature

allowed, there are six Temperature class. These are T1 to T6.

Zone
Zone 0: hazardous material is present during normal operation Zone 1: hazardous material can appear in normal operation Zone 2: hazardous material is not likely to appear in normal operation

ZONE ( DIVISION) - 0

In Zone 0 (Div. 0), flammable or explosive

substance (gas, vapor or volatile liquid) is always present, during normal operation- It is

present for more than 1000 Hrs/Annum.

Therefore, in this zone, only special types of control circuits-Intrinsically safe circuits Ex i

are used. Energy generated during breaking

of current is so low, that it can not ignite the explosive mixture.

For dust, this zone is classified as Zone- 20.

ZONE ( DIVISION) - 1
An area of the plant within which, any flammable
or explosive substance whether gas, vapor or

volatile liquid is processed, handled or stored

and where, during normal operations, an explosive or ignitable concentration is likely to

occur, in quantity sufficient to produce with a

probability between 10 Hrs & 1000 Hrs/Annum

In Zone-1, Flameproof (Explosion proof) Ex d

and pressurized Ex p equipments are used.

For powder/dust, this zone is known as Zone- 21.

Zone 1 (Primary grade)

Flammable atmospheric concentration is likely to occur frequently because of maintenance, repairs or leakage Flammable liquid or vapour piping system (containing valves, meters, or screwed or flanged fittings) is in an inadequately ventilated area. The area below the surrounding elevation or grade is such that flammable liquids or vapours may accumulate therein.

Zone 1 (Primary grade)

Imperfectly fitting peripheral seals on floating roof tanks.
Inadequately ventilated pump rooms for flammable gas or for volatile, flammable liquids. Oily waste water sewer / basins. Loading / unloading gantries of hazardous products.

ZONE ( DIVISION) - 2
An area of the plant within which, any flammable
or explosive substance whether gas, vapor or volatile liquid processed, handled or stored is

so well under control that production (or release)

of an explosive or ignitable concentration in quantity sufficient to constitute a hazard is only

likely under abnormal conditions & can occur

with a probability of less than 10 Hrs/Annum.

In Zone-2, Ex d, Ex p, Ex e (Increased safety)

or Exn equipments are used.

For powder/dust, this zone is known as Zone-22.

Zone 2 (Secondary Grade)

The flammable vapours can be conducted to the location as through trenches, pipes or ducts Locations adjacent to Zone 1 areas
Pressurized rooms where flammable gas / vapour can enter in the case of failure of positive mechanical ventilation

Safe Areas
The following locations are considered safe from the point of view of electrical installation:
Areas where the piping system is without valves, fittings, flanges or similar appurtenances Areas where flammable liquids or vapours are transported only in suitable containers or vessels

Areas where permanent ignition sources area present e.g. flare pits, tips, other open flames & hot surfaces.

Class
Class I: flammable gases and vapours

Class II: combustible dusts Class III: flying (cotton linters, saw dust, textile fibres etc.)

Class II Combustible Dusts

Group E: metallic dusts

Group F: carbonaceous dusts Group G: agricultural chemicals and plastic dusts

EXAMPLE OF HAZARDOUS AREA ZONES

Zone 0

Zone1

Zone 2

Petrol station forecourt

Flammable material in liquid form

Fuel storage tank

Temperature Class

Temperature Class
T1 (450 deg.C.) - Acetone, Ammonia, Xylene,
Town Gas, Hydrogen, Benzene

T2 (300 deg.C.) T3 (200 deg.C.) T4 (135 deg.C.) T5 (100 deg.C.) T6 ( 85

- Methane,Butane, Propane, Xylol, Iso-Octane,Ethylene, Ethylene Oxide - Hexane, Refinery-Gas, Heptane, Pentane,Turpentine, Cychlohexane - Decane, Octane, Methyl Ether - Acetic Aldehyde, Butyl Ether, Ethyl Ether

deg.C.) - Nitro Ethyl

PROTECTION CONCEPTS

Protection Techniques for Flammable Atmosphere

Confining the explosion

Isolation Energy limitation

Miscellaneous

Confining the Explosion

Flame proof enclosure (ex d)

Surface temperature limitation Gas group dependent

Isolation
Pressurization or purging (ex p) Oil immersion (Ex o)

Restrictive breathing or sealing (Ex nR)

Encapsulation or potting (Ex m)

Energy Limitation
Intrinsic safety (ex i) Non-incendivity (ex n)

PROTECTION CONCEPT-1
Concept
Oil immersion
Symbol

Gen requirements.
by immersing ignition

EN Std.

Explosive gas excluded. EN

50015 EN 50016

Ex o

source in oil by surrounding ignition

Pressurized Ex p Powder Filled

source with pressurized Inert gas

Explosive gas excluded. EN

Ex q

by immersing ignition Source in sand Ignition within the apparatus enclosure is contained & will not ignite surrounding Explosive atmosphere.

50017

Flameproof

EN 50018

Ex d

PROTECTION CONCEPT-2
Concept
Increased Safety
Intrinsic safety Encapsuln. Symbol

Gen requirements.
Design excludes possibility

EN Std

EN

Ex e

of incendive arcs, sparks

& hot surfaces Energy in circuit & temp.

50019
EN 50020 EN 50028 EN

Ex i

on components reduced to a safe level Explosive gas excluded. by encapsulating ignition source in resin

Ex m

NonSparking

Ex n

.will not ignite explosive Gas in normal operation Faults unlikely to occur

50021

Types of Enclosures

Explosion proof ( FLP ) Increased Safety : : Ex d Ex e

Non sparking
Pressurized Intrinsically Safe

:
: :

Ex n
Ex p Ex i

Oil Immersed
Filled with powder Encapsulated

:
: :

Ex o
Ex q Ex m

Flameproof Enclosure Ex-d

Parts which can ignite an explosive atmosphere are placed in an enclosure which, if there is an ignition of an explosive mixture internally, will withstand the pressure and prevent the explosion being transmitted to the atmosphere around the enclosure.

Ex-d examples
EEx-d

Pressurised Enclosure Ex-p

The formation of an explosive atmosphere inside an enclosure is prevented by using a protective gas to maintain an internal overpressure relative to the surrounding atmosphere

Increased Safety Ex-e

With non-sparking equipment additional measures are taken to achieve a higher level of safety and avoid the risk of impermissibly high temperatures and the occurrence of sparks and arcs internally or on external parts of electrical equipment, which in normal use produce neither sparks, arcs nor dangerous temperatures.

Ex- e Equipment

Intrinsically Safe Ex-i

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

Ex- i barriers

GAS GROUP
G R O U P I

Typical Hazard Methane

Max. safe sparking Energy- Intrinsic Safety Ex i

Maximum safe gap Applicable Flameproofconcepts

Ex d

All concepts

IIA
IIB IIC

Propane
Ex d, Ethylene
Acetylene Hydrogen

Ex i

II

All gases

Mining use Group I

Industrial use Group II

GAS GROUPS
1 2A Methane ( Fire damp) Butane, Pentane, Ethane, Propane, Heptane, Decane, Industrial Methane, Blast Furnace Gas, Acetone, Carbon Monoxide, Iso Octane, Benzene, Ethanol, Hexane, Cyclo Hexane, n-Propyl Acetate, n- Butyl Acetate, Amyl Acetate, Methyl Acetate, n-Butanol, Chloro Ethylene, Xylene, Ethyl Nitrate, Ethyl Methyl Ketone, Methanol, Amyl Alcohol..... Butadiene-1,3, Coke Oven Gas, Ethylene, EO, Town Gas, Di-Ethyl Ether Hydrogen, Acetylene.

2B

2C

Equivalent Nomenclature
IEC NEC

I II A II B II C Zone 0 Zone 1 Zone 2

Gaseous mines D C A, B Division 1 Division 1 Division 2

Hazardous substances handled at EPCL Plant C Olefins Hazardous Substance Hydrogen Acetylene Ethylene Propylene Propylene Hydrogen LEL UEL Auto Ignition 400 305 490 460 460 400 490 405

PP

4.0 2.5 2.7 2.0 2.0 4.0 2.7 1.9

75 100 36 11.1 11.1 75 36 8.5

PE Ethylene Butene-1 Butane

Div. (Zone) & Type of Enclosure

Division 0 - Ex i . Intrinsically safe - Only control circuits No power equipments-

Division I - Ex d Flameproof ( Explosion proof)

- Ex p Pressurized

Division II - Ex d Flameproof ( Explosion proof)

- Ex e Increased safety - Ex n Non sparking - Ex p Pressurized

What does each letter mean ?

On a nameplate a of classified area equipment, following text is there.

E Ex d IIB T6
Let us see what does it mean ?

Enclosure protection is Flameproof (Explosion proof) Hence, the area of use is Division 1 or Division 2.

Gas group is IIB Temperature class is T6. Hence maximum surface

temperature allowed is 85 degree C.

EEx-d IIC T4
E Ex d IIC - European Certification - Hazardous Area Equipment - Protection Method - Apparatus Grouping

T4 - Temperature Classification IP66 - Ingress Protection

Amendment No. 5 and 6 to IS 2148- 1981 required that for Group II C area, enclosures are required to be batch tested as per sampling plan as per Clause No. 31.1.2

[E, Ex, ia ] II C

T4

Temp.Classification

Apparatus gas group Protection Concept (intrinsically safe) Explosion Protected Certified to CENELEC standard

Associated apparatus

LET US MAKE OUR PLANT SAFER !!!

Thank you.