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Understanding the Zone

Area Classification Method


in the NEC

By Edward M. Briesch and Mark C. Ode

T
he division classification method has been used zone classification method as Class I, Zone 0, 1, and 2
in the United States since being incorporated into and provided a basis to build upon in subsequent edi-
NEC 1920 to cover electrical and electronic equip- tions of the NEC.
ment and wiring in extra-hazardous areas where fire This new method of protection was based primarily
or explosion hazards may exist from flammable and upon the international method of zone protection and
combustible liquids, vapors, or gases. The use of the covered only limited concepts of the international tech-
term extra-hazardous locations implied that an elec- nique. Definitions for this new method of zone protec-
trical installation was already a hazardous installation tion were provided in a new Article 505 but contained
but where used in areas, rooms, or compartments with limited information and application techniques. The
some chemicals, it was more hazardous than usual. In NEC 1996 tied the division type of hazardous location
NEC 1931, the term classifications was added to the articles together with the new zone type of protection
NEC along with Class I, Class II, and III. The term ex- techniques but the information was rather difficult to
tra-hazardous has been dropped from the NEC. These find since the new zone protection text was inserted
areas are now called hazardous (classified) locations into various places within the general hazardous loca-
which differentiates the hazardous chemical areas with tions articles. Even though the bulk of the information
electrical equipment from hazardous health areas. was in Article 505, it was necessary to extract some of
The NEC 1996 was the first edition to address the the zone classification information from Articles 500
new hazardous (classified) method of zone classifica- and 501 primarily covering Class I, Division 1 and 2
tion. The NEC 1996 identified the newly introduced hazardous (classified) locations.

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UNDERSTANDING THE ZONE AREA CLASSIFICATION METHOD IN THE NEC

In NEC 1999, all references to the zone concept of special electrical equipment must be installed in the
hazardous (classified) locations were removed from hazardous (classified) location. All of the factors that
Article 500 for general hazardous location concepts and are normally associated with division area classification
from most of Article 501 for Class I, Division 1 and 2 would apply to a zone classification, such as tempera-
installations. A fine print note was left in 500-1 to pro- ture, density or molecular weight of the substance, air
vide the user with direction to Article 505 containing circulation, quantity, pressure, and so forth.
the bulk of the information on the zone concept of Highly oxygenated areas are outside the scope of
area classification. both the zone classification and the division classifica-
This single article concept for zone applications pro- tion systems. These areas have had the ignition and
vided a more user-friendly method to access pertinent burning characteristics of materials changed by exceed-
information where applying the zone concept. Article ing the normal volume of oxygen of air that is mixed
505 provides information on equipment and wiring with the flammable gas or vapor. Where highly oxygen-
methods that are permitted in a Zone 0, Zone 1, and ated areas are encountered, the user should refer to
Zone 2 classified area. All other applicable rules would the specialized documents that deal with these types
apply to these installations, except as amended by Ar- of areas and comply with the requirements for installa-
ticle 505 or amended by those requirements in Article tion of electrical equipment in those areas.
504 dealing with intrinsically safe installations. Areas where pyrophoric materials are present or
The zone concept was further enhanced in NEC 2002 handled are also outside the scope of both the zone
by changing the basic layout of Article 505 to fit the classification and the division classification systems.
new numbering sequence required by the NEC Style Pyrophoric materials can be ignited just by introduc-
Manual. All definitions were moved to 505.2; 505.3 ing the material to air. Where these chemicals are used,
covers other applicable rules located in other articles; installation of special electrical equipment is usually
and 505.4 provides general information pertaining to not necessary. However, care should be taken since
zone installations. This was done to provide consis- there may be other combustible chemicals in the area
tency of section numbering with other similar articles. that may require special electrical equipment.
Further changes to Article 505 made it completely Since much of the electrical equipment built for the
independent of Articles 500 and 501. Section 505.15 European and other world markets incorporate metric
for wiring methods in a zone area was expanded to measurement and sizing, it may be necessary to pro-
match its counterpart in 501.4 for wiring methods in a vide adapters to convert from the standard NPT threads
Class I, Division 1 and 2 area. Section 505.16 was in- that are used in the United States to the metric threaded
serted to cover the sealing requirements for zone meth- entries or fittings provided with the equipment. If
ods rather than just referring back to 501.5 as was done equipment with metric threads is provided for use in
in the previous Codes. the United States, the NEC requires that metric to NPT
adapters be included with the equipment or be marked
Location and General Requirements for to identify the threaded entries as metric threads.
Article 505 NPT threads provide a ¾ inch per foot taper. Most
In zone applications, hazardous locations are classi- standard conduit threading equipment available in the
fied in accordance with the properties of flammable United States uses NPT thread. By conforming to a stan-
liquids, gases, or vapors that may be present in the area dard threaded system and providing a standard to
where electrical equipment is installed. The liquids, metric adapter, electrical equipment with metric threads
gases, or vapors must be likely to form ignitable con- can be readily and safely adapted. Good electrical and
centrations and the quantities of the material must be mechanical continuity of conduit connections by the
sufficient to pose a hazard when mixed with a suffi- proper threaded adaptor to the enclosure can prevent
cient quantity of air. These conditions are similar or sparking between the fitting, the conduit, and the en-
often the same as the conditions required for a similar closure during an electrical fault. The proper fitting
location being designed and installed in the division can also ensure the integrity of the explosionproof or
concept. flameproof path by permitting the venting and subse-
Each area should be considered individually in de- quent cooling of the hot flaming gases after an explo-
termining the classification and care should be taken sion occurs within the enclosure.
to not over-classify, as well as to not under-classify. Elec-
trical equipment should be installed and connected in Definitions of Zone Classification
an area that is outside the hazardous (classified) loca- Zone 0 Locations
tion; however, where this not possible or practical, then A Zone 0 location involves ignitable concentrations
of flammable gases or vapors that are present con-

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UNDERSTANDING THE ZONE AREA CLASSIFICATION METHOD IN THE NEC

tinuously or present for long periods of time. This centrations of gases or vapors and simultaneous fail-
classification includes locations inside tanks in which ure of electrical equipment. Areas that are adjacent to
flammable or combustible liquids, gases, or vapors a Class I, Zone 0 location where ignitable concentra-
tions of gases or vapors could migrate are also con-
sidered to be Zone 1 locations.
The normal classification for Zone 1 locations does
not take into consideration catastrophic leaks. It does,
however, consider small leaks from valves, pump pack-
ing glands, and other similar leakage considered com-
mon for equipment handling hazardous materials.
Zone 2 Locations
A Zone 2 location and a Division 2 location are es-
sentially the same and have similar definitions. It is a
location where vapors or gases are not likely to occur
during normal operation but if a leak does occur, it
would normally be for a short duration of time.
A Zone 2 location is one where the liquids, gases, or
vapors are handled, processed, or used in an area but
are normally confined within closed piping or contain-
ers that can only leak as a result of a rupture or some
other abnormal condition.
Positive mechanical ventilation is often used to pre-
vent the buildup of ignitable concentrations of gases
Photo 1. Flameproof Control Switch with Increased Safety TTerminals
erminals or vapors and, thus, to reclassify or declassify the area.
Should the ventilation system break down, an ignit-
able concentration could require classification as a Zone
are stored or locations such as between the inner or 2 location.
outer roof sections of a floating roof tank containing An area that is adjacent to a Class I, Zone 1 location
volatile flammable liquids. If venting is provided to from which ignitable concentrations of flammable gases
allow the gases or vapors to escape from inside the or vapors could migrate would be a Zone 2 location,
tank during the process of filling, there may be an unless positive mechanical ventilation has been pro-
area outside of the tank near the opening of the vent vided and there are safeguards to ensure against venti-
that is considered to be a Zone 0 location. In some lation failure.
cases, the area around the vent outlet would be con-
sidered to be a Class I, Zone 1 location, depending
upon the amount of air circulation and the type of
material involved.
For Zone 0 locations, it is recommended that elec-
trical equipment be located in an area outside the Zone
0 location. This is not always feasible since measure-
ment equipment and other electrical equipment may
be necessary for the function and monitoring of the
system. In a Zone 0 location, intrinsically safe appara-
tus and the associated intrinsically safe circuit are the
only wiring methods and protection technique that are
permitted to be installed.
Zone 1 Locations
A Zone 1 location, similar to Class I, Division 1 lo-
cation, is one in which there may be ignitable concen-
trations during normal operating conditions or ignit-
able concentrations exist frequently from repair or
maintenance of the equipment. A Zone 1 would be a
location where equipment breakdown or faulty op-
eration of the equipment could release ignitable con- Photo 2. Intrinsic Safe Telephone

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UNDERSTANDING THE ZONE AREA CLASSIFICATION METHOD IN THE NEC

Protection Techniques for Zone plosion pressure without damaging the enclosure and
Locations without permitting the flame to leave the enclosure
Many of the protection techniques for zone locations through any joints or other openings in the enclosure
in the NEC are modeled after the International and without igniting the surrounding gases.
Electrotechnical Commission (IEC) standards and the 2. Purged and Pressurized (Type “p”) Equipment
International Standards Organization (ISO) standards. Purged and pressurized (Type “p”) is a type of protec-
These international organizations have been primarily tion that uses inert gas or instrument quality air as a pro-
responsible for providing standards on electrical equip- tective gas to purge the inside of the enclosure of any haz-
ment for many countries. ardous quantity of flammable gases or vapors. The enclo-
Underwriters Laboratories Inc. (UL) has further sure is then kept pressurized at a pressure high enough
above the outer atmosphere surrounding the enclosure to
prevent the flammable gas or vapor from re-entering the
enclosure. This guards against an ignitable concentration
of gas accumulating within the enclosure and then being
ignited by an arcing or sparking part or hot electrical equip-
ment. This protection technique also permits a general type
enclosure to be used rather than an explosionproof or
flameproof enclosure, as would normally be the case.
3. Intrinsic Safety (Types “ia” or “ib”) Equipment
Intrinsic Safety (Types “ia” or “ib”) is a type of pro-
tection technique that uses an apparatus that limits the
maximum level of current and voltage measured as
energy (usually in millijoules) under normal or fault
conditions that can be delivered into the hazardous
location. The intrinsically safe associated apparatus
providing this energy limitation has a further identifi-
cation marking on the equipment that indicates the
Photo 3. Battery Operated Intrinsic Safety (IS) Gas Detector type of intrinsic safety. The marking will be “ia” or “ib”
and should be located on the nameplate of the appara-
adapted these IEC documents with minor changes into tus. This equipment should provide a level of safety
a multi-part American National Standards Institute that, even in a double fault condition (“ia”) or a single
(ANSI) document, ANSI/UL 2279-2001, the Standard for fault condition (“ib”), there will not be enough igni-
Electrical Equipment for Use in Class I, Zone 0, 1, and tion energy to ignite the gas or vapor in that area.
2 Hazardous (Classified) Locations. This UL standard 4. Protection (Type “n”) Equipment
is used for testing and listing of electrical equipment Protection (Type “n”) equipment is a protection tech-
for use in zone classified areas and provides the manu- nique applied to electrical equipment which does not
facturer and the user with a detailed description of the have enough ignition energy to ignite the gas or vapor
particular protection techniques that can be used for during normal operation and is not likely to have a
these areas. fault that could cause ignition. This type of protection
Section 505.4(B), fine print notes provides standard is similar to the nonincendive circuits and equipment
references for important information involving hazard- used in Class I, Division 2 locations. If there is a possi-
ous locations. Each protection technique permitted in bility of a fault occurring within the system, then some
a zone installation is covered in 505.8 and in fine print other method of protection should be chosen or extra
notes that immediately follow many of these protec- protection against faults should be incorporated.
tion techniques. 5. Oil Immersion (Type “o”) Equipment
1. Flameproof (Type “d”) Equipment Oil immersion (Type “o”) equipment is a type of
Flameproof (Type “d”) is a type of protection that is protection in which the electrical equipment is im-
similar to explosionproof equipment protection that has mersed in a protective fluid of nonconductive silicone
been one of the most common protection techniques or mineral oil. The fluid level should be such that the
used in the United States. In this protection technique, electrical parts and any arcing or sparking parts of the
the equipment is in an enclosure that has been tested to oil-encased equipment are immersed and the liquid
withstand an internal explosion of a gas- or vapor-to-air always covers the electrical parts. This ensures that the
mixture that can penetrate into the interior of the enclo- gas or vapor located above the arcing or sparking parts
sure. The enclosure must contain the flame and the ex- or the gas or vapor located exterior to the enclosure

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UNDERSTANDING THE ZONE AREA CLASSIFICATION METHOD IN THE NEC

Photo 4. Open View of Control Station Photo 6. Close Up of Increased Safety Equipment Terminals

Photo 5. Close Up Shot of Control Station Photo 7. Control Station Protection Method “edm” Increased Safety
Enclosure with Flameproof Switches and Enscapsulated Indicating Light

cannot be ignited by the electrical arcing parts within


the oil.
6. Increased Safety (Type “e”) Equipment arcing or sparking has been encapsulated in a com-
Increased safety (Type “e”) equipment is a type of pound of some sort. This encapsulation will prevent
protection applied to electrical equipment that does the flammable or combustible material from migrating
not produce arcs or sparks during normal operation into the enclosure in a large enough volume to form
and under certain abnormal conditions. This equip- an ignitable atmosphere at the point of excessive tem-
ment has additional security against the possibility of perature or electrical arc within the equipment.
excessive temperature and the equipment is assembled 8. Powder Filling (Type “q”) Equipment
very carefully to ensure that arcing or sparking from Similar to encapsulation equipment, powder filling
part to part or connection to connection will not oc- (Type “q”) equipment protection incorporates a quartz
cur. The increased safety concept is often combined or glass powder as a filling material. This method sur-
with flameproof and other protection techniques at the rounds the hot or arcing electrical parts and doesn’t
termination point outside of the enclosure to permit a permit the ignition of the gas or vapor at a point either
connection point. inside or outside the equipment enclosure.
7. Encapsulation (Type “m”) Equipment
Encapsulation (Type “m”) equipment is a type in Special Precaution with Zone Equipment
which any parts that could cause ignition of an explo- and Area Classification
sive atmosphere by either excessive temperature or by The proper use and maintenance of zone equipment

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UNDERSTANDING THE ZONE AREA CLASSIFICATION METHOD IN THE NEC

Dual classification permits these two different clas-


sification methods with their different wiring methods
to exist at a single facility but to provide a clear line of
delineation between the two different systems. A user
could reclassify a Class I, Division 1 or Division 2 area
as a Class I, Zone 0, Zone 1 or Zone 2 area provided all
of the reclassified space is classified using a single flam-
mable gas or vapor source.

Grouping and Classification of Areas


Based on the Chemicals Used.
For the purposes of testing and approval of the electri-
cal equipment suitable for the zone area and to help in
area classification of the location itself, air mixtures that
have not been oxygen enriched have been classified
Photo 8. Spark Test Apparatus for Determination of MIC Ratio into three groups. The three group classifications for
zone applications are based upon the maximum ex-
perimental safe gap (MESG) or the minimum igniting
is as critical as the ability to properly classify the area current (MIC) ratio or both. The MIC ratio is based
for the electrical installation for the facility. It is impor- upon the use of methane gas as a base for comparison
tant that all personnel involved in the design, installa- to the other gases in question.
tion, maintenance, and inspection of zone areas be very These group classifications are subdivided into
familiar with the zone concept. Groups IIC, IIB, and IIA according to the nature of the
If abnormally low temperatures are encountered at gas or vapor and the type of protection technique. Pro-
the installation, such as below -20°C (-4°F), special tection techniques, such as increased safety “e”, encap-
equipment may need to be installed. If these low tem- sulation “m”, purged and pressurized “p”, and pow-
peratures are encountered, it should be noted that der filled “q” equipment, are not dependent upon the
many liquids are well below their flash points and are ignition properties of the gases in the group. Their in-
no longer a hazardous concentration issue; however, herent designs will preclude the gases or vapors from
low temperature may also adversely affect the equip- entering the enclosures or being ignited by an arcing
ment operation, unless the equipment has been de- or hot electrical part.
signed to operate in extremely low temperatures. Group IIC is an atmosphere containing acetylene,
For Class I, Zone 0, 1, and 2 areas, NEC 1996, 1999, hydrogen, or flammable gas, flammable liquid-pro-
and 2002 require classification of areas, selection of duced vapor, or combustible liquid-produced vapor
equipment, and selection of wiring methods to be mixed with air that may burn or explode when ignited,
handled under the supervision of a qualified, registered having either an MESG less than or equal to 0.50 mm
professional engineer. The use of a qualified, registered or an MIC ratio less than or equal to 0.45.
professional engineer for these systems should help Group IIB is an atmosphere containing acetaldehyde,
ensure a degree of accountability for the installation ethylene, or flammable gas, flammable liquid-produced
and will remain a requirement until a significant num- vapor, or combustible liquid-produced vapor mixed
ber of trained personnel familiar with the equipment with air that may burn or explode when ignited, hav-
design and installation are available. ing either an MESG greater than 0.50 mm and less than
Care should be taken where an installation that has or equal to 0.90 mm or an MIC ratio greater than 0.45
both division and zone locations exists at the same fa- and less than or equal to 0.80.
cility. There may be some applications where the zone Group IIA is an atmosphere containing acetone,
system is located adjacent to an existing division area, ammonia, ethyl alcohol, gasoline, methane, propane,
and this may require different area classification meth- or flammable gas, flammable liquid-produced vapor,
ods for the same plant or facility. This dual classifica- or combustible liquid-produced vapor mixed with air
tion of a facility is acceptable; however, there are cer- that may burn or explode when ignited, having either
tain cautions that the user must observe. Class I, Zone an MESG greater than 0.90 mm or an MIC ratio greater
0 and Zone 1 locations must not abut or overlap any than 0.80.
Class I, Division 1 or 2 locations. It is permissible to Equipment can be listed for the specific gas or va-
have Class I, Division 2 and Class I, Zone 2 areas that por, specific mixtures of gases or vapors, or any spe-
are adjacent to each other. cific combination of gases or vapors. This permits elec-

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UNDERSTANDING THE ZONE AREA CLASSIFICATION METHOD IN THE NEC

trical equipment to be cal equipment requirements


designed, tested, and for shock and fire hazards.
listed based upon a
specific anticipated us- Temperature
age. For example, elec- Classification of Zone
trical equipment that Equipment
has been tested as a Electrical equipment used in
Group IIB would nor- a zone location must be
mally be required for marked with the operating
ethylene-based chemi- temperature of the equip-
cal atmospheres but ment using a reference am-
may also have been bient temperature of 40°C
tested for hydrogen- (104°F). This ambient tem-
based chemicals. This perature provides a starting
permits the equipment point at which to test and as
to be marked with a IIB Photo 9. Westerberg Apparatus for Determining Maximum a reference to the operating
marking instead of hav- Experimental Safe Gap (MESG) temperature of the equip-
ing to be subjected to ment. The temperature class
the more rigid tests for acetylene, as would normally must be marked on the equipment in the form of a
be required if a IIC equipment listing is used. “T” code. “T1” is for equipment operating at equal
to or less than 450°C; “T2,” for equal to or less than
Listing, Marking, and Documentation 300°C; “T3,” for equal to or less than 200°C; “T4,”
Listing of zone equipment is a requirement in 505.20. for equal to or less than 135°C; “T5,” for equal to or
Equipment listed for use in a Zone 0 location can be less than 100°C; and “T6,” for equal to or less than
used in a Zone 1 or Zone 2 location for the same gas or 85°C. Electrical equipment designed for use in an
vapor. Listed Zone 1 equipment can be used in a Zone ambient temperature of between -20°C and +40°C
2 location for the same gas or vapor. Electrical equip- do not require any additional temperature marking,
ment may be marked with both Division 1 or Division other than the “T” code.
2 marking and Zone 1 or Zone 2 for the same gas at- Equipment designed be used in an ambient tem-
mosphere. Where marking division equipment for the perature below -20°C or above +40°C must have the
zone designation, the marking should include the Class ambient temperature range marked on the equipment.
I, Zone 1 or Zone 2 designation, the applicable gas This is necessary since the ambient temperature at
classification group, and the temperature class (T Code) which it has been designed may affect the operating
of the equipment. temperature of the equipment. These extremely low
Zone equipment must be marked to indicate the or high ambient temperatures may also affect the
class and the particular zone for which it has been listed. amounts of gases or vapors present. Low temperatures
Zone equipment marked for use in the United States may also produce higher explosion pressures in flame-
will have an “AEx” marking to indicate that the equip- proof or explosionproof equipment.
ment has been listed in accordance with United States Equipment suitable for use in an ambient tempera-
nationally recognized testing and listing standards. ture exceeding 40°C (104°F) must be marked with both
Many European and other countries permit the maximum ambient temperature in which it may be
manufacturer’s self-certification of electrical equipment operated and the operating range of the equipment at
for suitability of the equipment for environmental con- that elevated temperature. Extremely high ambient tem-
ditions, wire bending spaces, electrical insulation, in peratures may elevate the gas or vapor close to the
other words, the ordinary electrical equipment require- autoignition temperature of the gas or vapor. It is criti-
ments. These countries do, however, require the equip- cal that the autoignition temperature of a gas or vapor
ment used in a zone location be third party certified is not exceeded by contact with extremely hot electri-
for the hazardous location into which the equipment cal equipment.
will be installed. The “AEx” mark and the testing lab Electrical equipment that is not of the heat produc-
mark should indicate to all persons involved in the in- ing type or that operates at no greater than 100°C
stallation that the electrical equipment has been tested (212°F) is not required to have a marked temperature
and listed by a third party certification organization range or a marked operating temperature. Many haz-
based on U.S. standards for the particular protection ardous chemicals have a much higher autoignition tem-
techniques plus the aforementioned ordinary electri- perature than 100°C, but even if dealing with a chemi-

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cal that has a low autoignition temperature, the elec-
trical equipment is just one of many items that could
be located in the area and be a concern for causing
possible ignition of the material.

Conclusion
By providing the user with an optional method for area
classification and an expanded number of equipment
options, the NEC has become a more global and pro-
gressive document. It has also expanded the ability of
manufacturers to enter into the global market in a more
competitive way.

Ed Briesch is a senior staff engineer with Underwriters


Laboratories and has been involved with Hazardous Loca-
tions equipment and installations for over 30 years. He is a
principle member of NEC CMP-14 and the NFPA Technical
Committee on Electrical Equipment in Chemical Atmo-
spheres. He is also a member of several IEC, ASTM, IEEE and
ISA technical committees related to explosion protected
equipment. Ed has a BSChE from the Illinois Institute of Tech-
nology and is a Registered Professional Engineer in the State
of Illinois.
Mark C. Ode, staff engineering asso-
ciate at the Underwriters Laboratories
Inc. in the Research Triangle Park, North
Carolina Regulatory Services Depart-
ment, was a senior electrical specialist
for the National Fire Protection Associa-
tion. He is a former staff liaison and
secretary to the NFPA Electrical Equip-
ment in Chemical Atmospheres Commit-
tee. He was the executive secretary for the NFPA Electrical
Section and editor of the Electrical Section news bulletin,
Current Flashes. Prior to joining NFPA, Mr. Ode worked for
over 27 years as a licensed electrician and a licensed elec-
trical contractor. He is a licensed electrician in the State of
Massachusetts. He has taught the National Electrical Code
throughout the United States. He also taught the NEC for
10 years at Maricopa County Community College in Phoe-
nix, Arizona. He is certified for electrical inspection for
one and two family dwellings, general electrical installa-
tions, and for electrical plan review by the International
Association of Electrical Inspectors (IAEI), and is certified
as a general electrical inspector by the International Con-
ference of Building Officials (ICBO).
He is certified as an electrical instructor for the States of
Wyoming, New Jersey, North Carolina, Michigan, and Mas-
sachusetts, as well as others. He was Vice-President of Field
Operations for an engineering firm for two years and was
President of Ode Electric for 15 years. He is an electrical
code columnist for Electrical Contractor magazine. He was
a principle member of NEC Panel 20 for the 1990 NEC and
an alternate member of NEC Panel 3 for the 2002 NEC. He is
a principle member of CMP 4, an alternate member of CMP
1, and an alternate on the NEC Technical Correlating Com-
mittee for the 2005 NEC. He has been a member of IAEI since
September 15, 1975.

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