Electrical Equipment in Hazardous Areas

• Danger of explosion where ever potentially

explosive atmospheres exist due the mixtures of
gas/air,vapour/air,dust/air or other flammable
combinations.

• Special methods of safeguarding apparatus must

be employed.

• To have an ignition , both flammable atmosphere

and means of ignition must exist simultaneously.

• Hence care should be taken to avoid flammable or

explosive atmosphere.
• Lower Explosive limit- Lowest concentration of gas in air which
can cause explosion.
• Upper Explosive limit-Maximum concentration of gas in air beyond
which no explosion can take place.
• Ignition Temperature- Lowest temperature which will cause the
mixture to explode.
• Ignition source has two essential characteristics
• Temperature
• Source of energy: Catagaries are Flames, Sparks, Hot Surfaces.
• Minimum Ignition Energy: In order to ignite a given flammable
atmosphere sufficient energy has to be applied to raise the
temperature of gases locally to their ignition temperature.
 Types of Hazardous situations

• The zone classification for gases is divided into

three zones, namely Zone 0, Zone 1 and Zone 2
and for dusts Zone 20, Zone 21 and Zone 22.
 Types of Hazardous situations
Zone 0 – Zone in which explosive mixture is continuously
present/is present for long periods.
Such as vapour space of closed process vessels, storage tanks or
containers. In zone 0, any arc /spark would lead to fire or
explosion.
It is recommended to avoid installing electrical equipment in zone
0 area to the extent possible.
Zone 0 condition is rarely encountered and is limited mainly to
confined spaces (such as the vapour space of closed process
vessels, closed storage tanks and closed containers), although it
can occur in larger rooms, such as chemical plants.

Description of Explosion Protection Technique

Zone 0 – Limited to the Following explosion protection techniques
Intrinsically Safe Ex ia(IS:5780-1980)
Intrinsic Safety-A technique whereby electrical energy is limited such
that the heat generated by the electrical equipment is sufficiently low as
to not ignite an explosive atmosphere.
An exposure exceeding 1000 hours per year is often used.
 Types of Hazardous situations

.
Zone 1 – Zone in which explosive mixture of gas, vapour
or dust is likely to be present in normal operation. In zone
1, hazard is likely to occur any time .
Flame proof enclosure.

Classification usually includes locations where volatile

flammable liquids or liquefied flammable gasses are
transferred; gas generator rooms; inadequately ventilated
pump rooms for flammable gases or for volatile flammable
liquids; and most other locations where hazardous
concentrations of flammable vapors or gases can occur in
the course of normal operations.

An exposure between 10 hours and 1000 hours per year.

• Zone 1 – In addition to Zone 0 techniques
the following methods are acceptable
• Intrinsically Safe Ex i
• Encapsulated Ex m
• Increased Safety Ex e
• Ventilation Ex v
• Powder or Sand Quartz Filling Ex q
• Flameproof Ex d
• Oil Immersion Ex o
• Pressurised rooms and enclosures
• Special Protection Ex s
• Flameproof Ex d- An enclosure when subjected to house electrical equipment ,
which when subjected to an internal explosion will not ignite a surrounding
explosive atmosphere.
• Enclosures must be sufficiently strong to withstand the internal explosion,so that
internal explosion is not transmitted to the surrounding atmosphere

• Intrinsically Safe Ex i - A technique whereby electrical energy is limited such

that the heat generated by the electrical equipment is sufficiently low as to not
ignite an explosive atmosphere.

• Increased Safety Ex e -Equipment is so desined as to eliminatesparks and hot

surfaces capable of igniting an explosive atmosphere.

• Encapsulated Ex m –A method of exclusion of the explosive atmosphere by

fully encapsulating the electrical components in an approved material.

• Powder or Sand Quartz Filling Ex q – Equipment is surrounded with a fine

powder , which does not allow the surrounding atmosphere to come into contact
from any sparks or hot surfaces.

• Oil Immersion Ex o
• Pressurised rooms and enclosures
• Special Protection Ex s
• Ventilation Ex v
 Types of Hazardous situations
.

Zone 2 – Zone in which explosive mixture is not likely to be

present in normal operation and if it does occur, it will exist for a
short time only.
Increased Safety. (IS 8224,IS6381)

Minimum requirements for the area:

a) the area is so well ventilated that if an abnormal conditions arises,
ignitable
concentrations of the gas or vapour are rapidly dispersed; and
b) complete segregation from Zone 1 locations is ensured.

Special Protection Ex s
Ventilation Ex v
Pressurised rooms andenclosures Ex p
Non-sparking Ex n spaking contacts are sealed against ingress of the
surrounding atmosphere,; hot surfaces are eliminated.

An exposure less than 10 hours per year

• It is a common misconception that explosion protected apparatus
suitable for a Zone 1area such as Flameproof (Ex d) apparatus is
automatically suitable for all Zone 1
• locations.
• Electrical apparatus is certified for use in a given location is not
only based on the zone classification, but on the selection of the
gas group and the temperature for the flammable atmosphere

• The gas group of the environment also needs to be considered.

• Electrical equipment for hazardous gas areas is grouped as

follows:
• a) Group I – electrical equipment for mines susceptible to
methane, and

• b) Group II – electrical equipment for all places with an explosive

gas atmosphere, other than mines susceptible to methane.

• Group II is then further divided into subgroups IIA, IIB or IIC

according to their volatility.
• Classification criteria of gas grouping

• MESG – Maximum Experimented Safe Gap

• MIC _ Minimum Ignition current
• Ignition characteristics – gas groups
• Gas / Vapour Group Representative Gas
• I Methane
• IIA Propane
• IIB Ethylene
• IIC Hydrogen
Surface temperature applicable to the flammable material
• Hot surface can ignite explosive atmospheres.So electrical equipment
intended for use in a potentially explosive atmosphere is classified according
to the max. surface temperature it will reach in service.This temperature is
compared to the ignition temperature of the gas which may come in contact
with the equipment and a judgement reached as to the suitability of the
equipment to be used in that area.

• The temperature rating of the apparatus is found on the Explosion Protection

Certificate issued by the testing authority and on the Explosion Protected
identification plate on the apparatus identified T1 to T6.

• Once the ignition temperature of flammable liquids, gases and volatile solids
is determined, the electrical apparatus must be selected so that the
maximum surface temperature that could cause in ignition of the flammable
product is not exceeded.

• Class Maximum Surface TemperatureºC

• T1 450
• T2 300
• T3 200
• T4 135
• T5 100
• T6 85
• Ignition characteristics of the
flammable substance
• Gas group and temperature class for
product X.

Reference Gas or Vapour Ignition Temp Temp Class Group

112 Diisobutylamine 256 °C T3 IIA
136 Ethane 515 °C T1 IIA
184 Methane 537 °C T1 IIA
272 Tetrahydrofuran 224 °C T3 IIB
• Area Not Classified
In General, the following locations are considered safe from
the point of view of electrical installations:

a) Areas where the piping system is without valves, fittings,

flanges or similar appurtenances.
b) Areas where flammable liquids or vapours are transported
only in suitable containers or vessels.
c) Enclosed premises in which a plenum or purging steam of
safe atmosphere is continuously maintained, so that no
opening therein may be a point of ingress of gases or
vapours coming from external source of hazard.
d) Diesel generators room/ shed having adequate ventilation.
 Determine the type of inspection

• Ensure that the installations are maintained in a satisfactory condition

for
• continued use within a hazardous area. In terms of this standard, the
area shall be subject
• to either:
• a) Regular periodic inspections; or
• b) Continuous supervision by competent personnel and, where
necessary,
• maintenance.
• The periodic inspection interval shall be based upon the expected rate
of deterioration.

• Initial inspection - An initial inspection shall be performed for all

new installations
• before the plant is brought into service.
• Periodic inspection
 Establish the grade of inspection

• There are three grades of inspection identified:

• Visual inspection - A visual inspection is an inspection which

identifies, without the use of access equipment or tools, those
defects, e.g. missing bolts, which are apparent to the eye.

• Close inspection - A close inspection is an inspection which

encompasses thoseaspects covered by a visual inspection and, in
addition, identifies those defects, e.g. loose bolts, which will become
apparent only when access equipment, e.g. steps (where necessary)
and tools are used. Close inspections do not normallyrequire the
enclosure to be opened or the equipment to be de-energized.

• Detailed Inspection - A detailed inspection is an inspection which

encompasses those aspects covered by a close inspection and, in
addition, identifies thosedefects, e.g. loose terminations, which only
become apparent when the enclosureis opened up, or by the use of
tools and test equipment.
 Frequency of periodic inspections

• Flameproof Equipment (Ex d), Inspection periods shall not exceed four
years, without seeking expert advice”.

• Increased Safety (Ex e),

• The interval betweeninspection periods shall not exceed three years, without
seeking expert advice.

• Intrinsic Safety (Ex i) In extremely adverse conditions, the interval between

Periodic Inspections may be as low as three months but should not normally
exceed two years

• The minimum requirement of a visual inspection of all equipment be carried out

at least every two years. Depending on the rate of equipment deterioration
(based on the results of the visual
• inspection) the interval between inspections periods may need to be reduced.
• EEHA inspection interval of three or fours

• The design, construction, maintenance, testing and inspection of installations

covering electrical equipment in hazardous areas is to be carried out only by
competent persons
 Visual Inspection

S.No Description Remarks

1 Equipment is appropriate to area classification  

2 Equipment gas group is correct  

3 Equipment temperature class is correct  

4 Equipment is clearly marked  

Enclosure, glasses, glass-to-metal sealing

5  
satisfactory.
6 There are no unauthorized modifications  

7 Bolts, glands, drain/entry plugs are complete  

8 Earthing / equipotential bonding are satisfactory  

9 No visible damage to equipment or cables  

10 Equipment protected against environmental cond.  

11 No undue accumulation of dust or dirt  

12 Electrical installation is clean and dry  

Sealing of trunking, ducts, pipes & conduits

13  
satisfactory.
14 Glands certified Ex e or Ex d  
 Maintenance schedule guidelines

S.No Description

1 A light alloy paint even for the purpose of maintenance must not be applied  

Cable conductors must not be subjected to any tensile stress during use.
2  

The equipment must not be tampered during its normal conditions of

3 operations.  

Any kinds of alterations or modifications to the tested product must not be

4 done during its service in the users premises.  

Any discrepancies or defects of electrical or mechanical nature observed in the

equipment during their functioning must be brought to the notice of the
5  

manufacturer.

No component should be added or removed or even replaced without prior  

intimation to the manufacturer

A scheme of regular inspection and maintenance of the items should be made on
6 the basis of the directives made.  
 Testing & Certifying authorities
• Testing Laboratories

• CIMFR, Dhanbad

• ERTL, Kolkata

• CPRI, Bangalore

• Approving Statutory Authorities

• PESO, Nagpur

• DGFASALI, Mumbai

• Licensing authority
BIS
 Guidelines for Enquiry Details

Type of Explosion proof Protection

1.1 Flame-proof – Type Ex ‘d’
1.2 Increased Safety – Type Ex ‘e’
1.3 Non-Sparking – Type Ex ‘n’
1.4 Flame-proof & Increase Safety (Hybrid Protection) Type- Ex ‘de’
2. Applicable Indian Standards
3. Zone Classification whether Zone 0, Zone1, Zone 2
4. Group of Gases / Temperature Classification
(Only for FLP Motors) (For FLP as well as Increased Safety /
Non-Sparking Motors)
Note : Whether for
Gas Group I - U/G Coal Mine Application
Gas Group II A/IIB/IIC – other than U/G Coal Mine Application
 Guidelines for Enquiry Details

5. Type of Inpress Protection : IP55/56/65 or any other.

6. Connection Details : Whether DOL/ Star – Delta –
3leads/6leads
(Please Indicate whether Shortening Links Required)
5.1 A copy of DGMS Approval for U/G Coal Mine
Applications
7. Requirements of Documents / Approvals
5.2 A copy of DGMS Approval for Oil Mine Applications
5.3 A copy of PESO Approval – IIA
5.4 A copy of PESO Approval – IIC
(Note : Now a days IIB is not appearing in PESO Approval)
 Guidelines for Enquiry Details
8. Any other specific Requirements.
8.1 Please Specify Cable size & Connection Details whether
fix installation or portable installation
8.2 Whether FLP plug-socket required
If required please mention trailing cable size.
8.3 Type of cable gland
9. Rating Details – HP/KW, Shaft Details RPM, Mounting
(Foot/Flange/Face/Rod) Details of Voltage & Frequency.
10. Ambient: 400
450
500
Any Other (Lower/Higher)
 Guidelines for Enquiry Details
11. Insulation Class : B, F, H
12. Temperature Restrictions if any – Generally we offer class ‘F’
temperature restricted to class B for a std. ambient temperature of 40 0C
13. Specific Environmental Conditions : Sandy/Dusty/ Corrosive
Indoor – Outdoor - - whether canopy required.
14. Pre-Sales Service – Whether an expert – should call on you for technical
discussion ?
15. Training - Can be provided on request.
16. Maintenance Training – Can be provided.
17. General Note : Please call on us for any non-standard requirement of
voltage/frequency/mounting/international standards.