Hazardous Area Classification: Codes of Practice and Standards

Hazardous Area Classification
Codes of Practice and Standards

Equipment Protection in Mining Industry
1700s Mines go deeper because ’new’ steam engines

allow water to be pumped out. Ventilation is poor so
methane (‘firedamp’) builds up and explodes.
1815 Miner’s ‘Davy’ lamp with flame arrestor
1880s Ventilation introduced to disperse ‘firedamp’ and
electric motors enclosed
1908 Use of Ex ‘d’ type equipment in Germany
1913 Pit explosion in UK killed 439 miners
1914 Pit explosion in Canada killed 189 miners
Caused by arcing from signalling bells used for hoisting
‘Intrinsic safety’ devised for LV signalling bells
Standards Development
UK EUROPE WORLD
1926
1958
British Std.
British Std. 1259
229 issued 1943 Intrinsic Safety
1912 First rules for 1975
Ex protection construction of CENELEC 1994 2009
introduced Ex equipment Harmonisation ATEX IEC 60079
1920 1928 1947 1971 1996

NEC Material Class and Division Operating NEC
classification introduced temperature introduced
zones
CENELEC = European Committee for UNITED STATES
Electrotechnical Standardisation
HAC Standards
USA NFPA 70 (NEC) and API 500 / 505

International IEC 60079-10
UK Energy Institute - Model Code of Practice IP 15
Europe ATEX 95 Equipment Directive
ATEX 137 Workplace Directive
ATEX is primarily concerned with equipment certification

based on conformance to a range of EU standards and relies
on IEC 60079-10 for detailed technical guidance on HAC.
US Standards
API RP 500 (gases and vapours) and API RP 505 (for dusts).
Recommended Practice for Classification of Locations for
Electrical Installations at Petroleum Facilities Classified as
Class I, Division 1 and Division 2;
API RP500/505 relates to petroleum related facilities and
utilises the Class, Group, and Division definitions established
in NFPA 70, the National Electrical Code (NEC);
The API approach is prescriptive and takes virtually no
account of individual release scenarios. It is easier to use
than IEC, which is easier to use than IP15, but is the least
representative of real life situations.
Divisions and Zones
The original API / NEC approach of having only two divisions covers
the majority of outcomes of classification.
The increased risk of continuous presence requires a much higher
integrity approach for protection under the IEC rules.
This is now accepted in the USA where ‘Division 1 - Zone 0’
conditions are recognised in API RP 505 / NEC 505.
Using Zones allows protection methods not allowed under Divisions.
Other NFPA Standards
 NFPA 497 : ‘Classification of Flammable Liquids, Gases or
Vapors and of Hazardous (Classified) Locations for Electrical
Installations in Chemical Process Areas, 2017 Edition.’
NFPA 497 provides information on specific Class I flammable

gases and vapors, flammable liquids, and combustible liquids
to allow their classification into the groups.
 The Flammable Liquids Code NFPA 30 covers ventilation,

handling, and storage of flammable and combustible liquids.
 NFPA 493 applies to intrinsically safe apparatus and

associated apparatus for use in Class 1, 2, 3, Division I
hazardous locations.
IEC 60079-10
1. IEC has the same objectives as API 500 / 505 : identify areas
of hazard, eliminate ignition sources or make them
ineffective.
2. API is a prescriptive approach based on area protection –
not requiring individual release points to be assessed
3. IEC is a more detailed and analytical approach.
4. IEC calculates the size of gas clouds around individual
sources of release - API uses standard sizes of clouds.
5. IEC (and API 505) ‘zones’ are based on frequency and
duration of hazard – API 500 uses ‘normally present’ or not.
6. In general, IEC is more time-consuming but better reflects
the extent of individual releases. API is easier to apply.
Energy Institute : Model Code of Practice IP15
IEC 60079-10-1 (gases and liquids) has limitations.
 No detailed guidance on zone sizes for a given release.
 Ventilation rates (12 air changes per hour) are too conservative
and flammable cloud volumes are grossly overestimated.
IP15 has 2 approaches for HAC covering flammable gases and vapours
(not dusts) specific to petroleum industry applications.
 ‘Direct Example’ approach for open areas such as tankfarms and
tanker loading;
 ‘Point Source’ approach for ‘enclosed’ areas such as plant areas.
The name of the code changed to EI15 when ownership transferred from the Institute
of Petroleum to the Energy Institute but it still commonly referred to as IP15.
IP 15 ‘Point Source’ Method
It provides a very detailed methodology, i.e.

 identify point sources;
 determine grade of release and fluid category;
 establish zone classification;
 determine hazard radii;
 determine hazardous area.
 where appropriate, combine the hazardous areas from different
point sources.
IP15 has tables of ventilation rates within enclosures and hazard

radius for a range of specific hole sizes / release pressures / fluid
categories / grades of release.
‘ATEX 95’ EQUIPMENT EU Directive
To meet the requirements of ATEX 95, it is necessary for
manufacturers of equipment and protective systems to :
 conduct a risk assessment
 ensure their products undergo conformity procedures, usually

involving testing by a 'third-party' certification body. Once
certified, the equipment is marked by the 'EX' symbol.
 design equipment and protective systems from the point of

view of ‘Integrated explosion safety’, taking account of
possible technical and operating faults.
Integrated explosion safety
‘Integrated explosion safety’ is the prevention of explosive
atmospheres and sources of ignition and to limit its effects.
In most cases manufacturers will not know the severity of the
consequences of an explosion since this is depends on the user’s
circumstances.
So the manufacturer's risk assessment will be restricted to
assessing the ignition hazard and the control function of a
protective system or safety device
ATEX 137 WORKPLACE EU Directive
Article 4 Assessment of explosion risks

Employer to assess specific risks arising from explosive atmospheres, i.e.
 the likelihood that explosive atmospheres will occur and their persistence,
 the likelihood that ignition sources, including electrostatic discharges, will
be present and become active and effective,
 the installations, substances used, processes, and possible interactions,
 the scale of the anticipated explosion effects.
Article 7 Places where explosive atmospheres may occur

Employer to classify places where explosive atmospheres may occur into zones.
Article 8 Explosion protection document

 explosion risks have been assessed,
 adequate protection measures are in place,
 areas have been classified into zones.

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Hazardous Area Classification

Codes of Practice and Standards

1700s Mines go deeper because ’new’ steam engines

1920 1928 1947 1971 1996

USA NFPA 70 (NEC) and API 500 / 505

ATEX is primarily concerned with equipment certification

NFPA 497 provides information on specific Class I flammable

 The Flammable Liquids Code NFPA 30 covers ventilation,

 NFPA 493 applies to intrinsically safe apparatus and

It provides a very detailed methodology, i.e.

IP15 has tables of ventilation rates within enclosures and hazard

 conduct a risk assessment

 ensure their products undergo conformity procedures, usually

 design equipment and protective systems from the point of

Article 4 Assessment of explosion risks

Article 7 Places where explosive atmospheres may occur

Article 8 Explosion protection document

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