An Overview of Hazardous (Classified) Location

Area Electrical Classification

by
David Wechsler
April 3, 2003

Overview EAC by David Wechsler 1

 Area Electrical
Classification
.

Installation of Electrical Apparatus

Electrical Equipment Certifications, Listings
Hazardous Area
–Explosion proof Markings
–Pressurized
–Oil Immersion
–Non incendive
–Hermetically sealed
–Intrinsic Safety

2
Area Electrical Classification

What's involved with it?

Risk Assessment

Overview EAC by David Wechsler 3

 What is an Area Electrical
Classification?
Risk based methodology used to quantify material
characteristics with potential electrical ignition
sources resulting in the objective of reducing a
fire/explosion potential.

Areas found to be applicable are considered

“hazardous (classified) locations”.

Overview EAC by David Wechsler 4

 Location Electrical Classification Team

Develop Classification Team Procedural Plan

that defines:
Objectives Electrical Classification
Team Members and responsibilities
Documentation of Classification work

Overview EAC by David Wechsler 5

The Area Electrical Classification
Team
• Assemble team
Minimum 3 people with expertise levels -
Operations - process
Electrical - maintenance and design
Process Safety

Overview EAC by David Wechsler 6

 Location Electrical Classification Team
Maintain well documented, complete, area Electrical
Classification information that is readily available.
Suggestion: Use dated Classification Drawing to reflect
Specific Materials and their Material Group, AIT
Notes if the classification is different
from “Standard” criteria
Notes to link supportive information
i.e., purged building

Overview EAC by David Wechsler 7

 The Fire Triangle
The Hazardous (Classified) Location Methodology

Fuel Oxygen
Class I, II, etc. Atmosphere

Ignition Source
Electricals

Overview EAC by David Wechsler 8

 Data Collection
What are the processing conditions?

What materials are used?

Where are the materials used?

How are the materials used?

Are there any ignition sources, actual or potential, in the area?

Note: Not all potential ignition sources are electrical in nature.

Example, High pressure steam lines.

Overview EAC by David Wechsler 9

 Data Collection
Example of some forms for data collection:

Overview EAC by David Wechsler 10

 Assessment of Risk
What is the Risk?
The Fire Triangle

Not much control over

Presence of fuel Fuel Oxygen
in the atmosphere

Ignition Source

Mitigation as needed -
Electrical Apparatus selection

Overview EAC by David Wechsler 11

 the Standards World
ATEX
Canada
CENELEC
CEC
US OSHA IEC
NEC

Overview EAC by David Wechsler 12

 Comparison
Classification Methodologies
• “Class, Division” • “Zone 0”
– Zone 0
– Class I, Division 1 – Zone 1
– Class I, Division 2 – Zone 2
– Unclassified – Unclassified
– Group A – Group IIC
– Group B (hydrogen) – Group IIC
– Group C (ethylene) – Group IIB
– Group D – Group IIA
– T Code T1, T2, T2A- – T Code T1-T6
D, T3, T3A-C, T4-A, (450-85 C)
T5, T6 (450-85 C) 13
Division System Zone System
Division 2 Zone 2
Division 1 Zone 1

Division 1 Zone 0

Overview EAC by David Wechsler 14

 HazLoc Classification based
upon the NEC
I. Definitions and Explanations
A. Class I, II, III - Define the material
B. Divisions- Address the risk; probability and frequency
the material being present in
hazardous (ignitable) concentrations.
Division 1 - Present frequently
Division 2 - Present only under abnormal operations
Unclassified - Not likely to be present at all

Overview EAC by David Wechsler 15

 NEC Group B(D) Clarification
Example, NFPA 497 Selected Class I Chemicals
Material CAS No. NEC Flash AIT °C %LFL %UFL Vapor
Group point Density
°C
Styrene 100-42-5 D 31 490 0.9 6.8 3.6
Isoprene 78-79-5 D -54 220 1.5 8.9 2.4
Butadiene 106-99-0 B*D -76 420 2 12 1.9

Note: B*D means this material exhibits properties that places it into the Group B
category. However, permission to use Group D electrical equipment is given, provided all
conduit ½ in. and larger is sealed. This is a design choice and for classification purposes
the area(s) where this material is used should be reflected as Group B*D locations.

Overview EAC by David Wechsler 16

 NFPA 4 9 7 A - Pro c e s s Equipme nt

Effe c t s o f Siz e Pre s s ure Flo w

S O URCE

GRADE

Pro ces s S m a ll/ Lo w Mo de rate La rg e / Hig h

Equipment
Pro ce s s
Size ( gnt
allo ns ) e <5 0 0 0 5 0 0 0 -2 5 0 0 0 >25000
Equipme Siz
Pre
P res ssure
s ( p s i) <1 0 0 1 0 0 -5 0 0 >5 0 0

F lo
Flo w wRat e ( g pm) <100 1 00 -50 0 >5 0 0

S iz e
Pre s s
F lo w

Overview EAC by David Wechsler 17

 25'
NFPA 4 9 7 A
Effe ct s o f S O URCE

Siz e GRADE

3'
Pre s s ure A{ 10'
Flo w B 15'
50'
C{ 100'

A B
Pro c e s s S m a ll/ Lo w Mo de rat e La r g e / Hig h Pro c e s s S m a ll / Lo w Mod e rate La rg e / Hi g h
Equipme nt Equipme nt
S iz e Proc e s s
S iz ip
Equ e me nt S iz e
Pre s s PPrrees ss s

F lo w FFlo
l oww

C
Pro c e s s S m a ll/ Lo w Mo de rat e La r g e / Hig h
Equipme nt
S iz e

Pre s s

F lo w

Overview EAC by David Wechsler 18

Classification Documentation
Classification Drawing should contain:
a) Specific chemical(s), AIT, Group information
b) Notes regarding classification details
c) Approvals with signatures for
Process Engineering
Manufacturing
Control Systems/Electrical
Safety
d) Dates for drawing, Revisions, and sign-offs

Overview EAC by David Wechsler 19

 Combustible Dust - Ignitible Fiber Zone
New NEC proposal
( under consideration)

Existing: Proposed:
NEC Article 502 - Combustible Dusts
NEC Article 506 - Zone 20, 21, and 22 Locations
NEC Article 503 - Ignitible Fibers for Flammable Dusts, Fibers, and Flyings

Class II, Division 1

Division 2
Unclassified
Groups E, F, and G Zone 20
Zone 21
Zone 22 No groups
Class III, Division 1 Unclassified
Division 2
Unclassified

Overview EAC by David Wechsler 20

 Area Electrical
Classification
.

Electrical Apparatus Electrical Apparatus

Considerations Certifications, Listings
Hazardous Area
–Explosion proof Markings
–Pressurized
–Oil Immersion
–Non incendive
–Hermetically sealed
–Intrinsic Safety

21
 STREET

50' PLOT BOUNDARY

ELECTRICAL SUBSTATION
"SOURCE BOX"
AREA Pump 1

CLASSIFICATION 50' Compressor

CONTROL Seals,
ROOM Samples:
S Vents, S
Drains,
T T
Sumps,
R COOLING Control 50' R
E Valves, E
TOWER
Manifold
E E
50' Etc.
T T
PROCESS UNIT
Classified Areas
WITH Class I Div 2 50'
AREA
CLASSIFICATION FIRED HEATER
DIMENSIONS
Top of Deck Only (if
req'd)

PLOT BOUNDARY

STREET

Overview EAC by David Wechsler 22

 the Standards World
ATEX
Canada
CENELEC
CEC
US OSHA IEC
NEC

Overview EAC by David Wechsler 23

 Decisions, decisions....

Zone 0
Division
Class I

Affecting:
Instrumentation Control Systems
Area Electrical Classification
Equipment, Installation,
Maintenance

Intrinsic safety

Explosion- proof Pressurized

Overview EAC by David Wechsler 24

 Equipment Type Comparisons
Electrical Code
• US Electrical Code • IEC Electrical Codes
• Class, Division • Zone 0
– Explosion proof – Flameproof
– Pressurized – Pressurized
– Oil Immersion – Oil Immersion
– Non incendive – Non sparking
– Hermetically sealed – Encapsulated
– Intrinsic safety (partial) – Intrinsic safety (full)
– Increased safety
– Special protection
25
 Installation Consideration Comparisons

US Electrical Code IEC Electrical Codes

• Conduit with • Cable, with Cable
Explosionproof seals glands
• Cable Tray • Cable Tray
• Thread type and • Metric Thread type and
engagement engagement
• Wire gauge/ampacity • Wire gauge/ampacity
• Grounding/bonding • Earthing

26
 Equipment selection
Some considerations -

What is the application?

What is the best functional apparatus within cost considerations?

Installation and wiring/cabling method?

Is the apparatus available as being “suitable” for the Area

Electrical Classification?

Overview EAC by David Wechsler 27

 Is the apparatus “suitable”
suitable for
the Area
Electrical Classification?
Suitability of identified equipment may be determined by one of the following:
(1) Equipment listing or labeling

(2) Evidence of equipment evaluation from a qualified testing laboratory or

inspection agency concerned with product evaluation

(3) Evidence acceptable to the authority having jurisdiction such as a manufacturer's

self-evaluation or an owner's engineering judgment

Overview EAC by David Wechsler 28

 Cross-Fertilization
of Electrical Apparatus
Can IEC electrical apparatus be
installed as a general rule in a US Class I, Division 2 location?

Answer: Highly probable

Can IEC electrical apparatus be

installed as a general rule in a US Class I, Division 1 location?
Answer: Only if you are one of those unique folks that
daily enjoys running 25 miles, when the temperature
exceeds 101F and the humidity exceeds 88%,
you might find a way, but not as a general installation rule.
Overview EAC by David Wechsler 29
 Area Electrical
Classification
.

Electrical Apparatus Electrical Apparatus

Considerations Certifications, Listings
Hazardous Area
–Explosion proof Markings
–Pressurized
–Oil Immersion
–Non incendive
–Hermetically sealed
–Intrinsic Safety

30
 the Standards World
ATEX
Canada
CENELEC
CEC
US OSHA IEC
NEC

Overview EAC by David Wechsler 31

 Electrical Equipment Markings
United States
Underwriter Laboratory Listing UL

Fa c t o ry
Factory Mutual Approval Mu t u a l
Sys t e m
Ap p ro v e d

Canada

Canadian Standards Approval Certification CSA

Overview EAC by David Wechsler 32

 Equipment Marking
CENELEC & IEC
Ce rt ific a t io n Co d e fo r CENELEC

EEx ia IIC T4 CENELEC Pro te ct io n Co d e

{

{
{

{
Te m p e r a t u re c la s s ific a t io n d Fla m e p r o o f
Ap p ar at us Gro up ( g a s ) ia In t r ins ic Sa f e t y
Pro t e ct io n co nc e p t ( IS) e Inc re a s e d Sa fe t y
Exp los io n p rot e ct e d p Pr e s s u r iz a t io n
Ce rt ifie d t o t he CENELEC s t an da rd n No n -in c e n d iv e
s S p e c ia l

IP or Ing re s s P ro t e c t ion Cod e s

Firs t n um e ra l S e c on d Num e ra l IP vs NEMA

P ro t e ct io n Aga ins t s o lid b od ie s P ro t e ct io n Ag a ins t liqu id 30 1
0 No p ro t e c t io n 31 2
0 No pro t e c t ion 32 3R
1 Ve rt ica lly d rip ping wa t e r
1 Ob je c t s g re a t e r t han 50 mm 2 Angle d ripp in g wa t e r 64 3
2 Ob je c t s g re a t e r t han 12 mm
3 Spr aye d wa t e r 65 1 2 , 1 2 X a nd 1 3
3 Ob je c t s g re a t e r t h an 2 .5 mm
4 Spla s he d wa t e r 66 4 a nd 4 X
4 Ob je c t s g re a t e r t h an 1 .0 mm
5 Wa t e r je t s
5 Du s t -Pr o t e c t e d
6 He a vy s e a s
6 Du s t - T ig h t
7 Eff e ct s o f imme rs io n
33
8 In d e f in it e imm e r s io n
 Equipment Marking
US - IEC
Ce rt ific a ti n Co de fo r E E

AEx
EEx ia IIC T4 CENELEC Pro te ct io n Co d e
{

{
{

{
Te m p e r a t ur e c la s s ific a t io n d Fla m e p r o o f
Ap pa ra t u s Gro up ( g as ) ia In t r ins ic Sa f e t y
Pr ot e ct io n c o nc e p t ( IS) e Inc re a s e d Sa fe t y
Exp lo s io n pr ot e ct e d p Pr e s s u r iz a t io n
Ce rt if ie d t o t he CENELEC s t a nd a rd n No n -in c e n d iv e
s S p e c ia l

IP or Ing re s s P ro t e c t ion Cod e s

Firs t n um e ra l S e c on d Num e ra l IP vs NEMA

P ro t e ct io n Aga ins t s o lid b od ie s P ro t e ct io n Ag a ins t liqu id 30 1
0 No p ro t e c t io n 31 2
0 No pro t e c t ion 32 3R
1 Ve rt ica lly d rip ping wa t e r
1 Ob je c t s g re a t e r t han 50 mm 2 Angle d ripp in g wa t e r 64 3
2 Ob je c t s g re a t e r t han 12 mm
3 Spr aye d wa t e r 65 1 2 , 1 2 X a nd 1 3
3 Ob je c t s g re a t e r t h an 2 .5 mm
4 Spla s he d wa t e r 66 4 a nd 4 X
4 Ob je c t s g re a t e r t h an 1 .0 mm
5 Wa t e r je t s
5 Du s t -Pr o t e c t e d
6 He a vy s e a s
6 Du s t - T ig h t
7 Eff e ct s o f imme rs io n
34
8 In d e f in it e imm e r s io n
 ATEX Marking Equipment Group

ID-Number of Category
Notfied Bodies
Gas (G) or Dust (D)

0102 II 1 G
EXLUX 6008/142-8 3Example for type of series ATEX 100
R. Stahl 3Example for Manufacturer
Zone 0

EEx de IIB T4 3Example for type of explos. protection EN 50014

PTB 96 ATEX 2144X 3 Example for test number

0102 II 2 G
Zone 1 EEx ia IIC T4 3Example for type of explos. protection
PTB 96 ATEX 3844X 3 Example for test number

0102 II 3 G
Zone 2 EEx n IIA T4 3Example for type of explos. protection
PTB 96 ATEX 3244X 3 Example for test number 35
 Certifications

Country Applicable Certification

USA Nationally Recognized Testing

Laboratory (NRTL)- example: FM,
UL, ETL
Canada Standards Council of Canada certified
body- example: CSA
Europe ATEX- EU Notified Body
Australia ANZEx scheme for certification body

Overview EAC by David Wechsler 36

 The certification “mark” will drive where the
electrical apparatus may be installed.

While an objective is to be able to have

globally acceptable markings, there currently is
none yet.
Overview EAC by David Wechsler 37
 Area Electrical
Classification
.

Installation of Electrical Apparatus

Electrical Equipment Certifications, Listings
Hazardous Area
–Explosion proof Markings
–Pressurized
–Oil Immersion
–Non incendive
–Hermetically sealed
–Intrinsic Safety

38
 The Speaker - Dave Wechsler is a
Global Process Safety Technology Leader
located at the Dow Chemical Freeport TX facility.
He is also the Technical Resource Leader for
Dow's Global Electrical Area Classification
Technical Resource Network which is the core
group that addresses area classification issues for
the Dow Chemical Company locations, globally.
Dave is the Principle American Chemistry Council,
formerly CMA, representative on the NEC CMP-14
responsible for the Chapter 5 Hazardous (Classified) Locations Articles,
and on the Electrical Equipment in Chemical Atmospheres (EECA)
that is responsible for NFPA 496, 497 and 499, as its former vice chairman.
A senior member of ISA, Dave is also very active on SP12 and many of its
hazardous locations committees. He is also a member of the
ANSI/IEC -Technical Advisory Group working with IEC standards
representing "user" interests.
Overview EAC by David Wechsler 39