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Fmds 0501 Electrical Equipment in Hazardous (Classified) Locations
Fmds 0501 Electrical Equipment in Hazardous (Classified) Locations
Table of Contents
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5-1 Equipment in Hazardous (Classified) Locations
Page 2 FM Global Property Loss Prevention Data Sheets
List of Figures
Fig. 1. Areas near indoor hazardous processes or equipment handling heavier than air vapors
where special types of electrical equipment are needed. .................................................................. 5
List of Tables
Table 1. Area Classification of Locations Containing Flammable Gas or Vapor Atmospheres (Class I) ...... 4
Table 2. Classification Guidelines Based on Depth of Dust Accumulations ................................................. 6
Table 3. Protected Types of Electrical Equipment for Class I Locations per the NEC or
Comparable Hazardous Locations per IEC or CENELEC Standards ............................................. 7
Table 4. T Codes (Temperature Identification Numbers) ............................................................................... 8
Table 5. Equipment Recommended for Locations Containing Flammable Gases or Vapors (Class I)* ....... 9
Table 6. Surface Temperature Limits ........................................................................................................... 11
Table 7. Equipment Recommended for Locations Containing Combustible Dusts (Class II)* ................... 11
Table 8. Group Classifications for Flammable Gas and Vapor Atmospheres ............................................. 20
Table 9. Group Classifications of Dust Atmospheres per NEC Article 500 ................................................. 20
Table 10. Ignition Characteristics of Selected Gases ................................................................................. 22
Table 11. Minimum Ignition Energy of Selected Dusts1 .............................................................................. 23
1.0 SCOPE
This loss prevention data sheet provides recommendations for preventing electrical systems or equipment
from igniting flammable gases, flammable vapors and combustible dusts that may be released into the
atmosphere, or that may be normally present in or near processing equipment.
The following FM Global loss prevention data sheets should be consulted for specific guidance at specific
occupancies: Data Sheet 7-1, Fire Protection for Textile Mills (locations involving combustible fibers or flyings
in textile processes); Data Sheet 7-9, Dip Tanks, Flow and Roll Coaters and Oil Cookers; Data Sheet 7-13,
Mechanical Refrigeration; Data Sheet 7-27, Spray Application of Flammable and Combustible Materials;
Data Sheet 7-30N, Solvent Extraction Plants; Data Sheet 7-32, Flammable Liquid Operations; Data Sheet
7-55/12-28, Liquefied Petroleum Gas.
This data sheet does not address Class III (easily ignitable fibers and flyings) hazardous locations.
1.1 Changes
September 2006. Added information on the acceptability of portable electronic products to Appendix C.
2.1 Introduction
Example 1:
Small quantities of low flash point flammable liquids are handled in equipment or containers such that the
maximum ignitable quantity in the event of electrical ignition would not exceed 5 gallons (19 liters), and the
ignition of that quantity would not cause a rapid escalation of fire events. Approved containers should be
used where transporting or dispensing of the liquid is involved.
Example 2:
Small quantities of flammable gas are used on a regular basis in a given area, such as in a 1 lb (0.5 kg)
cylinder of propane used in a workshop brazing torch.
Example 3:
Larger quantities of flammable gas are used as fuel for mobile equipment, such as propane or natural gas
to power a forklift truck, or as part of a portable acetylene welding kit. The mobile equipment may be brought
to areas that would not normally require hazardous location electrical equipment.
Example 4:
Fine combustible dust is produced and accumulates, but in relatively small quantities, and without producing
a potential explosion hazard, such as at a sanding machine in a woodworking shop.
2.2 Occupancy
Table 1. Area Classification of Locations Containing Flammable Gas or Vapor Atmospheres (Class I)
Standards Flammable Material Flammable Material Flammable Material
Organizations Present Continuously Present Intermittently Present Abnormally
IEC/CENELEC Zone 0 Zone 1 Zone 2
NFPA NEC Article 505 Zone 0 Zone 1 Zone 2
NEC Article 500 Division 1 Division 2
Note: The IEC and CENELEC do not use the Class I designation for areas where flammable gases or vapors may be present. That is,
the corresponding area designations would be Class I, Zone 1 (NEC Article 505) and simply Zone 1 (IEC/CENELEC) for example.
unless communication is prevented by adequate positive ventilation from a source of clean air and effective
safeguards against ventilation failure are provided. Locations where flammable gases or vapors are present
continuously or for long periods of time (i.e., typically 1000 hours or more per year) are considered Class
I, Zone 0 hazardous locations. See C.2.1 for examples of Class I, Zone 0 hazardous locations.
2.2.1.1.2 Locations in which flammable gases or vapors are or may be present should be classified as Class
I, Division 2 hazardous locations if the following conditions exist: 1) volatile flammable liquids or flammable
gases are handled, processed, or used, but in which the liquids, vapors or gases will normally be confined
within closed containers or closed systems from which they can escape only in case of accidental rupture or
breakdown of such containers or systems, or in case of abnormal operation of equipment; 2) ignitible
concentrations of gases or vapors are normally prevented by positive mechanical ventilation, and which might
become hazardous through failure or abnormal operation of the ventilating equipment; or 3) that are adjacent
to a Class I, Division 1 location, and to which ignitible concentrations of gases or vapors might occasionally
be communicated unless such communication is prevented by adequate positive-pressure ventilation from a
source of clean air, and effective safeguards against ventilation failure are provided. The definition for a Class
I, Zone 2 hazardous location is essentially identical to the above definition for a Class I, Division 2 hazardous
location (i.e., simply replace the word ‘‘Division’’ with the word ‘‘Zone’’).
2.2.1.1.3 Figure 1 should be used to determine the degree of hazard at various distances from a typical
indoor vapor source expected to have a Division 1 area (e.g., open equipment or process). Figure 1 should
assist in the selection and location of equipment in Class I areas. When other applicable FM Global data
sheets provide distances for classified (hazardous) areas related to specific hazards and occupancies, refer
to them rather than to Figure 1.
Fig. 1. Areas near indoor hazardous processes or equipment handling heavier than air vapors
where special types of electrical equipment are needed.
2.2.1.1.4 Figures in NFPA 497 may be used to help determine the extent of a Class I, Division 2 or Zone
2 area for leakage sources located outdoors, in closed containers or systems (e.g., pipes, process equipment)
with or without adequate ventilation or in other closed installations that are not expected to have Division I
or Zone 1 areas. Since NFPA documents normally recommend what are considered minimum criteria,
considerable judgement may still be needed in the evaluation of a specific situation.
2.2.1.1.5 Adequate mechanical ventilation may be provided to reduce the extent of a hazardous location
or to reduce the classification level. A ventilation system can significantly reduce or even eliminate a Division
1 or Zone 1 area. Exceptions to completely eliminating a Division 1 or Zone 1 area would include the
immediate vicinities where the release of ignitable concentrations of vapor are expected under normal
conditions. (See Appendix C for examples.) Adequate ventilation requires a ventilation rate of 1 ft3/min/ft2
(0.3 m3/min/m2) of room or process area to ensure that flammable vapor concentrations do not exceed 25%
of the lower explosive limit. In addition, effective safeguards against the failure of the ventilation system
should be provided.
Based on these accumulations, good housekeeping can reduce the classification from Division 1 to Division 2.
However, housekeeping should not be used as a primary method of dust control but should rather be used
to supplement control and elimination of dust at its source.
2.2.1.2.4 Guidelines in NFPA 499 may be used as an aid in applying judgement to determine the extent of
Division 1 and Division 2 areas for a Class II location. Since NFPA documents normally recommend what
are considered minimum criteria, considerable judgement may still be needed in the evaluation of a specific
situation.
Note: Paragraph A-3-1.2 of NFPA 499-1997 with dust layer thickness criteria based on a 24-hour
accumulation period should not be used. It could lead to underclassifying areas that may be hazardous.
2.3.1 General
2.3.1.1 If available, Approved equipment should be recommended. When Approved equipment is not
available, equipment listed, labeled, or approved by another recognized testing laboratory is acceptable.
Note: FM Approvals can conduct testing to satisfy both the ‘‘Division’’ and ‘‘Zone’’ hazardous location
classification methods, and also has reciprocal interlaboratory testing agreements with other testing agencies
worldwide.
Table 3. Protected Types of Electrical Equipment for Class I Locations per the NEC or
Comparable Hazardous Locations per IEC or CENELEC Standards
Method of Protection
Protection Code Permitted Use Standard Principle
Increased Safety AEx e Class I, Zone 1, 2 FM 3619*(ISA S12.16.01) No arcs, sparks or hot
EEx e Zone 1, 2 EN 50119 surfaces
Ex e Zone 1, 2 IEC 79-7
Non-Incendive (NI) Class I, Division 2 FM 3611
Non-Sparking Ex nA Zone 2 IEC 79-15
Explosionproof (XP) Class I, Division 1, 2 FM 3615 Contain the explosion
Flameproof AEx d Class I, Zone 1, 2 FM 3618*(ISA S12.22.01) and quench the flame
EEx d Zone 1, 2 EN 50018
Ex d Zone 1, 2 IEC 79-1
Powder Filled AEx q Class I, Zone 1, 2 FM 3622*(ISA S12.25.01)
EEx q Zone 1, 2 EN 50017
Ex q Zone 1, 2 IEC 79-5
Enclosed Break Ex nC Zone 2 IEC 79-15
Intrinsic Safety (IS) Class I, Division 1, 2 FM 3610** Limit energy of sparks
AEx ia Class I, Zone 0,1, 2 FM 3610** and surface temperature
AEx ib Class I, Zone 1, 2 FM 3610**
EEx ia Zone 0, 1, 2 EN 50020/39
EEx ib Zone 1, 2 EN 50020/39
Ex ia Zone 0, 1, 2 IEC 79-11
Ex ib Zone 1, 2 IEC 79-11
Limited Energy Ex nA Zone 2 IEC 79-15
Pressurized Type X Class I, Division 1 FM 3620 Keep flammable gas out
Type Y Class I, Division 1 FM 3620
Type Z Class I, Division 2 FM 3620
EEx p Zone 1 EN 50016
Ex p Zone 1 IEC 79-2
Restricted Breathing Ex nR Zone 2 IEC 79-15
Encapsulation AEx m Class I, Zone 1, 2 FM 3614*(ISA S12.26.01)
EEx m Zone 1, 2 EN 50028
Ex m Zone 1, 2 IEC 79-18
Oil Immersion AEx o Class I, Zone 1, 2 FM 3621*(ISA S12.26.01)
EEx o Zone 1, 2 EN 50015
Ex o Zone 1, 2 IEC 79-15
*Also shall comply with ISA S12.0.01
**Based on ISA S12.2.01
Note: Where non-incendive electrical equipment is provided in Class I, Division 2 hazardous locations, a special enclosure is not needed,
just a general purpose enclosure.
2.3.2.1.2 Equipment approved and used in Class I hazardous locations also should be approved for the
specific group (A, B, C or D per NEC Article 500) or (IIC, IIB or IIA per NEC Article 505 or the corresponding
IEC or CENELEC standard) of the gas or vapor that will be present.
Note: Needed electrical equipment protective features are based on the degree or severity of hazard
exposure. Different flammable gases and vapors represent such a wide range of degree or severity of hazard
that further grouping (subdivision) is necessary to facilitate testing and approving/listing of appropriately
designed hazardous location electrical equipment. See Section C.3 for further explanation of group
classifications.
2.3.2.1.3 Heat producing equipment (i.e., motors and lighting fixtures but not equipment such as junction
boxes, conduit and electric wiring fittings) should be marked to show the class, group and operating
temperature. Temperature identification numbers (T codes) marked on the equipment should be in accordance
with Table 4 below. The surface temperature of the equipment (see Table 4) should not exceed the ignition
temperature of the specific gas or vapor to be encountered. Ignition temperatures for many gases and vapors
are provided in NFPA 497.
The ignition temperature for which existing equipment was approved in past years (prior to the establishment
of T codes in NFPA 70 — 1971) should be assumed to be as follows:
Group A, B, D: 280°C (536°F)
Group C: 180°C (356°F)
2.3.2.1.4 Where unclassified areas exist at elevations directly above a Division 1 or Zone 1 area, and ordinary
electrical equipment is located within that unclassified area, provisions should be made to ensure that failure
or foreseeable mechanical damage to that equipment would not allow parts or fragments hot enough to
cause ignition to fall into the Division 1 or Zone 1 area.
Example 1: Metal halide or mercury lamps, which are known to rupture in the event of a defect, should
be located within a fixture able to contain fragments of hot quartz or glass.
Example 2: Ordinary incandescent light bulbs, which are easily broken by impact, should be enclosed within
substantial guards or globes.
2.3.2.1.5 Electrical equipment and wiring recommended for locations containing flammable vapors or gases
should be provided per Table 5. Refer to Article 501 of the NEC or IEC 60079-14 Ed. 2.0: Electrical apparatus
for explosive gas atmospheres — Part 14: Electrical installations in hazardous areas (other than mines),
for additional requirements.
Table 5. Equipment Recommended for Locations Containing Flammable Gases or Vapors (Class I)*
Division 1 Division 2
Wiring Threaded rigid metal conduit or Type MI Threaded rigid metal conduit, threaded
cable. Explosionproof boxes and fittings. steel intermediate metal conduit, enclosed
Use seals to prevent passage of gases, gasketed wireways, enclosed gasketed
vapors, or flames through conduit from one busways, or Type MI, MC, PLTC, MV, TC,
portion of electrical installation to another. or SNM cable. No seals required except
Threaded joints must have at least 5 where explosionproof equipment is
threads engaged. Avoid tensile stress at necessary and conduit leaves hazardous
termination fittings. Use approved flexible area. Wiring, which under normal conditions
fittings for Class I locations. cannot release sufficient energy to ignite a
specific hazardous atmospheric mixture,
can be accepted using any of the methods
suitable for wiring in ordinary locations.
Switches, circuit Install in an enclosure approved as a Same as Division 1, unless general
breakers, and motor complete assembly for Class I, Division 1 enclosures are provided and the
controllers locations. (Enclosures approved for Class I, interruption of current occurs in hermetically
Division 1 locations include explosionproof sealed chambers, the contacts are oil-
and purged and pressurized enclosures.) immersed, or interruption occurs in an
approved explosionproof chamber. (General-
purpose enclosures are acceptable for
isolating or disconnecting switches without
fuses and not intended to interrupt current.)
Fuses Install in an enclosure approved as a Install in an enclosure approved for Class I,
complete assembly for Class I, Division 1 Division 1 locations, for fuses protecting
locations. (Enclosures approved for Class I, motors, appliances, and portable lamps.
Division 1 locations include explosionproof General purpose enclosures are acceptable
and purged and pressurized enclosures.) for these fuses if the operating element of
the fuse is oil-immersed or in hermetically
sealed chamber. (General-purpose
enclosures are acceptable for fuses on
circuits to fixed lamps.)
Receptacles and Polarized type approved for Class I Same as Division 1.
attachment plugs locations, having provision for connection to
grounding conductor of flexible cord.
Motors and generators Approved for Class I locations, or totally Enclosure approved for Class I locations for
enclosed type supplied with positive rotating electrical machines employing
pressure ventilation from a source of clean sliding contacts, centrifugal or other
air, or totally enclosed inert gas filled type switches or integral resistors, unless such
supplied with a source of inert gas to contacts, switches, and resistors have
pressurize the enclosure, or a type enclosures approved for Class I, Division 1
designed to be submerged in a liquid that is locations. Open polyphase squirrel-cage
flammable only when vaporized and mixed induction motors without brushes or
with air. The different types should be switches are acceptable. (Enclosed
arranged to automatically de-energize the polyphase squirrel-cage induction motors
equipment when the supply of liquid, gas or are preferable for new installations.)
vapor fails.
Division 1 Division 2
Lighting fixtures Fixed and portable units approved as Fixed enclosed gasketed globes or other
complete assembly for Class I, Division 1 effective protective means where
locations. Fixtures should have guards (a) flammable liquids are in the open, or
surrounding the globes or be located so as (b) sparks or hot metal from lamps or
not to be subject to physical damage. fixtures might ignite local concentrations of
Pendant fixtures should be suspended by flammable vapors or gases. Use lamps of a
threaded rigid metal conduit or threaded size or type that do not reach surface
steel intermediate conduit stems or by other temperatures in excess of 80 of the ignition
approved means. Supports should be temperature (°C) of the gas or vapor
approved for Class I locations. involved; or use fixed fixtures approved as
complete assembly for Class I, Division 1
locations. Other fixed lighting units may be
ordinary open type without switches,
starters, or control equipment.
Fixtures for fixed lighting should have
guards or be located so as not to be
subject to physical damage.
Portable lamps to be approved as complete
assembly for Class I, Division 1 locations.
Pendent fixtures per Division 1.
Transformers and Install units containing either flammable or Install according to rules of sections 450-21
capacitors nonflammable liquid in approved vaults to 450-27 of NEC for nonhazardous
having no openings to hazardous areas.** locations.
Use units approved for Class I locations for
those that do not contain a liquid that will
burn.
Meters, relays, and Provide enclosure approved for Class I, Equipment containing make-and-break
instruments Division 1 locations, or intrinsically contacts should have enclosures approved
safe equipment. (Enclosures approved for for Class I, Division 1 locations. General
Class I, Division 1 locations include purpose enclosures are acceptable if current-
explosionproof and purged and pressurized interrupting contacts are (a) oil-immersed,
enclosures.) or (b) hermetically sealed, or (c) in circuits
that under normal conditions do not release
sufficient energy to ignite a specific
hazardous atmospheric mixture, i.e., are
non-incendive.
Equipment such as transformer windings,
solenoids, and other windings that do not
contain sliding or make-and-break contacts
is acceptable in general purpose
enclosures.
* Wherever possible, locate electrical equipment outside of hazardous areas. More specific details are given in Article 501 of the NEC.
Also see Article 501 of the NEC for details on equipment not covered in Table 5.
** Units containing flammable liquid must have ample ventilation, vent openings or ducts leading to a safe location outside the building
and vents and ducts of sufficient area for explosion relief. Ducts within buildings shall be of reinforced concrete construction.
2.3.2.2.3 The surface temperature markings in Table 4 should be less than the ignition temperature of the
specific dust encountered. Ignition temperatures of many common dusts are provided in NFPA 499. The
ignition temperature for which existing equipment was approved in past years (prior to the establishment
of T codes in NFPA 70-1971) should be assumed to be as shown in Table 6.
2.3.2.2.4 Electrical equipment and wiring recommended for locations containing combustible dusts should
be provided per Table 7. Refer to Article 502 of the NEC or IEC 61241-1-1 Ed. 1.0: Electrical apparatus for
use in the presence of combustible dust — Part 1: Electrical apparatus protected by enclosures — Section 1:
Specifications for apparatus, and IEC 61241-1-2 Ed. 1.0: Electrical apparatus for use in the presence of
combustible dust — Part 1: Electrical apparatus protected by enclosures — Section 2: Selection, installation
and maintenance, for additional requirements.
Table 7. Equipment Recommended for Locations Containing Combustible Dusts (Class II)*
Division 1 Division 2
Wiring Threaded rigid metal conduit, threaded Rigid metal conduit, electric metallic tubing,
steel intermediate metal conduit or Type MI intermediate metal conduit, dust-tight
cable with termination fittings. Use units wireways or Type MI, MC, SNM cable with
approved for Class II locations for boxes or approved termination fittings, or Type MC,
fittings containing taps, joints, or terminal PLTC or TC cable in ventilated channel
connections, or in locations where dusts are type cable trays in a single layer with a
combustible and electrically conducting. space not less than the larger cable
Seals are needed in conduit connecting dust- diameter between the two adjacent cables.
ignitionproof and non-dust-ignitionproof Same as Division 1 for sealing.
enclosures.
Switches, circuit breakers, Install in an enclosure approved as a Install in a tight metal enclosure with close
and motor controllers complete assembly for Class II, Division 1 fitting cover to minimize entrance of dust,
locations for devices that normally interrupt and to prevent escape of sparks or burning
current or where dusts are combustible and material.
electrically conducting. (Enclosures
approved for Class II, Division 1 locations
include dust-ignitionproof and purged and
pressurized enclosures.) Isolating or
disconnecting switches without fuses and
not subject to the above conditions should
have tight metal enclosures and covers to
minimize entrance of dust, and to prevent
escape of sparks or burning material.
Locations having metal dusts should have
approved enclosures.
Fuses Same as for other spark-producing devices Same as for other spark-producing devices
above. above.
Receptacles and Polarized type approved for Class II Polarized type with grounding connection
attachment plugs locations, having provision for connection to and so designed that connection to the
grounding conductor of flexible cord. supply circuit cannot be made or broken
while live parts are exposed.
Division 1 Division 2
Motors and generators Approved for Class II locations or totally Totally enclosed nonventilated, totally
enclosed pipe ventilated meeting any enclosed fan cooled, dust-ignitionproof or
temperature limitations. totally enclosed pipe ventilated, for which
maximum surface temperature does not
exceed the ignition temperature of the
specific dust (see Table 4) and shall have
no external openings. Where moderate
accumulations of nonconducting
nonabrasive dust occur and equipment is
accessible for cleaning, it is acceptable to
use (a) self-cleaning textile-type squirrel-
cage motors, or (b) standard open motors
without sliding contacts, switches, or
resistance devices or (c) with contacts,
switches or resistance devices, enclosed in
dust tight housings.
Lighting fixtures Fixed and portable units approved as For fixed lights, provide enclosures to
complete assembly for Class II, Division 1 minimize dust deposits, prevent escape of
locations. Provide guards or locate to sparks or burning material, and maintain
prevent physical damage. Pendant fixtures exposed surface temperature less than the
should be suspended by threaded rigid ignition temperature of the specific dust.
metal conduit or intermediate metal conduit Provide guards or locate to prevent physical
stems or by other approved means. damage. Portable units approved for Class
Supports should be approved for Class II II, Division 1 locations. Pendent fixtures as
locations. in Division 1.
*Capacitors and Install units containing flammable liquid in Install units containing flammable liquid in
transformers approved vaults. Any openings to approved vaults. Install dry-type
hazardous areas should be protected by transformers in vaults or tight metal
double, tight-fitting, self-closing fire doors. housings without openings, and do not
Ventilating and pressure-relief openings operate at voltages above 600 volts. Install
should communicate only to outside air. askarel transformers rated in excess of
Install units that do not contain a liquid that 25 kVA in accordance with rules for
will burn in approved vaults, or use those nonhazardous locations. Locate these
approved as a complete assembly for Class transformers so that there is an air space of
II locations. Transformers/capacitors may not less than 6 in. (15.2 cm) between the
not be installed in locations containing transformer cases and any adjacent
metal dusts combustible material. Transformers should
be provided with pressure-relief vents and
have means of absorbing any gases inside
the case or venting gases to outside the
building.
Meters, relays, and Enclosure approved for Class II, Division 1 Tight metal enclosures and covers to
instruments locations, or intrinsically safe equipment. minimize entrance of dust, and prevent
(Enclosures approved for Class II, Division escape of sparks and burning material.
1 locations include dust-ignitionproof and
purged and pressurized enclosures.)
* Wherever possible, locate electrical equipment outside of hazardous areas. More specific details are given in Article 502 of the NEC.
Also see Article 502 of the NEC for details on equipment not covered in Table 7.
2.3.3 Purged and Pressurized Enclosures for Electrical Equipment in Class I and Class II Hazardous
(Classified) Locations
2.3.3.1.1 Pressurized enclosures may be used to locate electrical equipment in hazardous locations for which
the equipment would otherwise be unsuitable. The three types of pressurization generally used for electrical
equipment enclosures are Types X, Y, and Z. Type X pressurizing should be used to reduce the classification
inside the protected enclosure from Division 1 to nonclassified. Type Y pressurizing should be used to reduce
the classification within the protected enclosure from Division 1 to Division 2. Type Z pressurizing should
be used to reduce the classification inside the protected enclosure from Division 2 to nonclassified.
2.3.3.1.2 During operation of the protected equipment, the protected enclosure should be maintained at a
positive pressure of not less than 25 Pa (0.1 in. water) above the surrounding atmosphere.
2.3.3.1.3 An alarm should be provided to indicate the loss of the protective gas supply. However, an alarm
on the supply is unnecessary if individual alarms are provided for each protected enclosure, or if Type X
pressurization is used. Alarms on either the gas supply or protected enclosures should sound at a constantly
attended location.
2.3.3.1.4 Acceptable protective gases include air of normal instrument quality, nitrogen or other
nonflammable gases. Compressed air is acceptable if the compressor intake is located in a nonclassified
location.
2.3.3.1.5 The protective gas should be discharged from the enclosure to a nonclassified location.
2.3.3.1.6 Temperatures or T codes should be marked on the enclosures, and should indicate the highest
of the following: a) the hottest external surface temperature, b) the hottest internal component surface, or
c) the temperature of the protective gas leaving the enclosure. The T code marking is not necessary if the
hottest temperatures cannot exceed 100°C (212°F).
2.3.3.1.7 A permanent label should be mounted on the purged and pressurized enclosure and should state
that the enclosure should not be opened unless the area is known to be nonhazardous or unless power has
been removed from devices in the enclosure.
2.3.3.1.8 The area classification for the enclosure and pressurization type should be marked on the
enclosure.
2.3.3.1.9 Type Z Pressurization
a) An alarm or indicator should be provided to detect the loss of positive pressure in individually protected
enclosures. The protected equipment does not need to be de-energized.
b) If provided, an indicator should be located for convenient viewing and should indicate pressure or flow.
2.3.3.1.10 Type Y Pressurization
a) The features indicated for Type Z pressurizing systems should be provided.
b) Equipment inside the enclosure should be Approved for Division 2 locations.
c) Where the flow of protective gas provides needed equipment cooling as well as pressurization, the
equipment should be interlocked to de-energize when the flow of gas is stopped.
2.3.3.1.11 Type X Pressurization
a) Circuits should be de-energized automatically using a flow or pressure actuated cutoff switch upon
failure of the protective gas supply.
b) Equipment that could be overloaded (e.g., motors, transformers) should be provided with temperature
measurement devices, and should be interlocked to automatically de-energize upon detection of any
increase in temperature beyond the equipment design limits. Alternatively, the flow rate of protective gas
should provide sufficient cooling even during overload conditions.
3.1 General
Following the recommendations in this loss prevention data sheet is needed to minimize the potential for
electrical ignition of flammable gases, flamable vapors and combustible dusts within areas or equipment
where they are handled.
4.0 REFERENCES
4.1 FM Global
Data Sheet 7-1, Fire Protection for Textile Mills.
Data Sheet 7-9, Dip Tanks, Flow Coaters and Roll Coaters.
Data Sheet 7-13, Mechanical Refrigeration.
Data Sheet 7-27, Spray Application of Flammable and Combustible Materials.
Data Sheet 7-30N, Solvent Extraction Plants.
Data Sheet 7-32, Flammable Liquid Operations.
Data Sheet 7-55/12-28, Liquefied Petroleum Gas.
4.3 Others
CSA Standard C22.1-98, Canadian Electrical Code, Part 1.
IEC 60079-10:1995 or EN 60079-10:1996, Electrical apparatus for explosive gas atmospheres — Part 10:
Classification of hazardous areas.
IEC 60079-14 Ed. 2.0: Electrical apparatus for explosive gas atmospheres — Part 14: Electrical installations
in hazardous areas (other than mines).
IEC 61241-1-1 Ed. 1.0: Electrical apparatus for use in the presence of combustible dust — Part 1: Electrical
apparatus protected by enclosures — Section 1: Specifications for apparatus.
IEC 61241-1-2 Ed. 1.0: Electrical apparatus for use in the presence of combustible dust — Part 1: Electrical
apparatus protected by enclosures — Section 2: Selection, installation and maintenance.
IEC 61241-3:1997, Electrical apparatus for use in the presence of combustible dust — Part 3: Classification
of areas where combustible dusts are or may be present.
LeBlanc, J. A. and Lawrence, W. G., ‘‘The Three-Zone Classification System and the National Electric Code,’’
Paper 5b, presented at AIChE 34th Annual Loss Prevention Symposium, Atlanta (March 5–9, 2000).
C.1 General
The NEC divides hazardous locations into three ‘‘classes’’ according to the nature of the hazard: Class I,
Class II, and Class III. The locations in each of these classes are further classified by ‘‘divisions’’ (or ‘‘zones’’
for Class I locations only) according to the degree of hazard. Class I and II locations and their divisions (or
zones for Class I locations) are described in Section C.2 of this appendix.
It is sometimes possible to avoid the use of special hazardous location electrical equipment and wiring by
locating the equipment and wiring outside the hazardous location. For example, lights may be located outside
a room, illuminating the inside through transparent panels. Motors may be located outside hazardous
locations with properly sealed shafts extending into the hazardous location to drive mechanical equipment.
Power equipment and control instruments may be located in remote, nonhazardous locations or in
pressurized rooms that are suitable for general purpose equipment.
Considerable judgement is required to properly classify an area as a hazardous location. Unnecessarily
expensive installations can be avoided by not over-classifying an area or by using expensive, explosionproof
equipment that is sometimes rated for a higher classification.
should be used again. Factors to consider in exercising judgment include the magnitude and location of
potential material releases or accumulations, as well as the potential distances that the released material
may drift
C.2.4.1 Terminology
Purging: the process of supplying an enclosure with a protective gas at a sufficient flow and positive pressure
to reduce the concentration of any flammable gas or vapor initially present to an acceptably safe level.
Pressurization: the process of supplying an enclosure with a protective gas with or without continuous flow
at sufficient pressure to prevent the entrance of a flammable gas or vapor, a combustible dust or an ignitible
fiber.
Protective Gas: the gas used to maintain pressurization or to dilute a flammable gas or vapor.
Protective Gas Supply: the compressor, blower, or compressed gas container that provides the protective
gas at a positive pressure. The supply includes inlet (suction) pipes or ducts, pressure regulators, outlet pipes
or ducts, and any supply valves not adjacent to the pressurized enclosure.
The NEC and other corresponding IEC and CENELEC standards recognize intrinsically safe electrical
equipment and its wiring. The intrinsically safe apparatus is safe for use in the specified atmosphere without
the special enclosures or physical protection that would otherwise be needed.
Industrial applications of intrinsically safe electric circuits are increasing considerably. There is a greater use
of intrinsic safety to supplement or substitute for the other forms of protection in hazardous locations. Overall,
the principal of intrinsically safe equipment and circuits can be considered for any equipment that operates
at very low voltages and very low amperages. Intrinsically safe equipment is thus ideal for process monitoring
or controlling applications in chemical plants and petroleum refineries.
The ability of an electrical circuit or equipment to produce ignition is determined by the energy available and
the manner in which such energy is released. The energy may be released by arcing (a spark), by high
temperature, or by a combination of arcing and temperature. The energy released by an arc or spark discharge
can be by: a) the discharge of a capacitive circuit, b) the interruption of current in an inductive circuit, c) the
make-and-break of a resistive circuit, or d) a combination of these three mechanisms.
FM Global Research and other recognized laboratories examine electrical devices to determine, by analysis
and/or actual tests, the ignition capability of the particular equipment. The laboratories determine whether
or not the device is intrinsically safe for a specific hazardous location. Electrical equipment approved as
intrinsically safe is listed in the Approval Guide.
Oil Immersion ‘‘o’’ is a type of protection in which the electrical equipment or parts of the electrical equipment
are immersed in a protective liquid in such a way that an explosive atmosphere that may be above the liquid
or outside the enclosure cannot be ignited.
Increased Safety ‘‘e’’ is a type of protection applied to electrical equipment that does not produce arcs or
sparks in normal service and under specified abnormal conditions, in which additional measures are applied
so as to give increased security against the possibility of excessive temperatures and of the occurrence of
arcs and sparks.
Encapsulation ‘‘m’’ is a type of protection in which the parts that could ignite an explosive atmosphere by
either sparking or heating are enclosed in a compound in such a way that this explosive atmosphere cannot
be ignited.
Powder Filling ‘‘q’’ is a type of protection in which the parts capable of igniting an explosive atmosphere are
fixed in position and completely surrounded by filling material (glass or quartz powder) to prevent the ignition
of an external explosive atmosphere.
C.5 FM Approvals
Electrical equipment is Approved by FM Approvals for either Class I or Class II locations, or both, and for
one or more atmosphere groups (A, B, C, D or IIC, IIB, IIA) for Class I hazardous locations or (E, F, or G)
for Class II hazardous locations. Surface temperatures of Approved equipment do not exceed the ignition
temperature of the specific gas, vapor, or dust for which the equipment is Approved. Electrical equipment
is marked to show the class, division or zone, group as applicable, and operating temperature or temperature
range for which it is Approved. Electrical equipment also can be specifically Approved and marked for Division
1 and 2 or Zone 0, 1 and 2 applications or for Division 2 or Zone 2 only. Electrical equipment that has been
Approved for a Division 1 or Zone 0 and Zone 1 location may be permitted in a Division 2 or Zone 2 location
of the same class and group as applicable.
There are types of electrical equipment which the NEC allows to be used in Class I, or II, Division 1 or 2
classified locations that do not require any special protection mechanisms, special markings or specific
listings. This type of equipment is commonly referred to as ‘‘nonsparking’’. Tables 5 and 7 (Section 2.3.2)
indicate many of the specific equipment types that need not be Approved or listed to be acceptable. Some
examples of frequently used non-Approved equipment include:
1. Some attachment plugs and receptacles which are not completely explosionproof and yet have been tested
and designed to be safe for use in Class I, Division 1 locations.
2. Electrical lighting fixtures in Class I, Division 2 locations with the exception of portable lighting equipment.
(Note that it must still be ensured that surface temperatures will not exceed 80% of the autoignition
temperature of the gas or vapor involved.)
3. Open squirrel cage or totally enclosed motors, fan cooled or not, are acceptable in Class I, Division 2
locations provided that they do not produce ignition-capable sparks or arcs under normal equipment operating
conditions.
4. Dust-tight enclosures in Class II, Division 2 locations are permitted for fuses, switches, motor controllers,
circuit breakers, push buttons, solenoids, control transformers, relays and other small devices. (See
Section C.4 for an enumeration of enclosures considered to be dust tight.)
5. Totally enclosed, pipe-ventilated motors for Class II, Division 2 locations.
6. ‘‘Simple apparatus’’ which will neither generate nor store more than 1.2 volts, 0.1 amps, 25 milliwatts or
20 microjoules need not be approved (e.g., thermocouple, LED).
There are various kinds of general purpose equipment that can be used in hazardous locations. The above
is just a guide and not a complete listing. The many exceptions can be found in the NEC.
C.6.1 General
The required energy for ignition of any flammable gas or vapor mixture primarily depends on the flammable
material, its concentration in air, its temperature and pressure just prior to ignition, and the prevailing electric
circuit ignition characteristics. Each vapor air mixture has a minimum value of energy that is required for
ignition. The minimum amounts of energy required to ignite some common flammable gases (i.e., Minimum
Ignition Energy or MIE at their most easily ignitable concentration) are given in Table 10 below. Below this
minimum, ignition of the mixture does not occur.
Electric spark ignition energy may be expressed in joules or millijoules. In a capacitive circuit, the energy
of a spark may be expressed as W = 1⁄2 CV2. W is the energy available in joules, C is the effective capacitance
in farads, V is the capacitance voltage in volts. MIE values for specific gases or vapors are determined using
a capacitive spark discharge. In an inductive current, W = 1⁄2LI2. W is the energy available in joules, L is
the effective inductance in henrys and I is the inductive current in amperes. MIC (Minimum Igniting Current)
values are determined using an inductive spark discharge. The MIC ratio is the ratio of the MIC value for
the specific gas or vapor of concern compared to the MIC value for methane when evaluated in the same
test apparatus. MIC values for Groups A through D and corresponding Groups IIC, IIB and IIA are given in
Table 8. MIC values for many other flammable gases and vapors are also provided in NFPA 497.
The Maximum Experimental Safe Gap (MESG) assumes the basic principle that ignition of a flammable
atmosphere can be prevented by separating an unburned flammable atmosphere from an ignition source
by a slit, screen or gauze material with very small openings. In general, the more ignitable a gas, the smaller
the openings are required to prevent a flame (or explosion) from passing through. Using this principle,
electrical equipment such as motors with commutators and switches can be made non-incendive by enclosing
the equipment in such a way that openings for shaft and switch operating mechanisms are very small.
Flat joints having a very small gap between mating surfaces in comparison to their width, present a flame
path along which an explosive mixture could travel. A flammable mixture ignited inside the enclosure would
be prevented from propagating flame through the gap to the outside of the enclosure. The amount of heat
absorbed from the hot gases by the flame path is dependent on the length of the flame path and the tightness
of the joint. The MESG for Groups A through D and corresponding groups IIC, IIB and IIA are given in Table
8. Typical values of the MESG for a 25 mm wide flame path that will not propagate an explosion through
a flameproof joint also are given for some flammable gases in Table 10. MESG values for many other
flammable gases and vapors also are also in NFPA 497.
The minimum ignition energy of most flammable gases and vapors as shown in Table 10 and NFPA 497 is
typically less than 1 mJ. In comparison, the minimum ignition energy for combustible dusts is considerably
higher, as illustrated by the few representative values shown in Table 11. On the other hand, the autoignition
temperatures (AITs) of many typical hydrocarbon solvent vapors are in the 450-500°C (850-950°F) range,
whereas the AITs of some typical dusts are below 250°C (500°F). The AIT ignition hazard of dusts is further
increased by the accumulation of deposits on equipment, leading to the possibility of smoldering due to
thermal instability. For this reason, the surface temperature requirements of equipment suitable for Class II
locations are based not only on the dust cloud ignition temperature, but also the dust layer ignition
temperature. Layer or cloud ignition temperatures for many common dusts are given in NFPA 499.
The practical implication of the comparison between dust and gas ignition properties is that the risk of ignition
from hot surfaces is much greater for dusts, while the risk of ignition from sparks is much greater for gases
and vapors. These very different ignition properties result in different designs for Class I and Class II
equipment. Unless Approved or listed for both classes, equipment Approved or listed for one class should
be assumed to be inappropriate for the other class.
1. The symbol AEx, Ex or EEx which indicates that the electrical equipment corresponds to the applicable
ANSI, IEC or CENELEC test standards as noted in Table 3.
2. The sign to identify the method of protection:
o — oil immersion
p — pressurized apparatus
q — powder filling
d — flameproof enclosure
e — increased safety
ia — intrinsic safety, category a
ib — intrinsic safety, category b
m — encapsulation
3. The symbol of the group of the electrical apparatus: I (IEC and CENELEC only) for electrical apparatus
for mines susceptible to firedamp (gas mixture primarily methane) and II, IIA, IIB or IIC for electrical apparatus
for locations with a potentially explosive atmosphere other than mines susceptible to firedamp. The chemical
formula or name of the gas will follow the symbol II when the electrical apparatus is certified for use in only
a particular gas.
4. For Group II electrical apparatus, the symbol indicating the temperature class (i.e., T codes given in
Table 4) or the maximum surface temperature in °C, or both. The temperature class will be given last in
parenthesis if the marking includes both. For Group II electrical apparatus where the maximum surface
temperature is greater than 450°C, only an inscription of the temperature will appear.
The order of the markings will correspond to the order in which they are given above. Some examples of
markings are as follows:
• electrical apparatus in flameproof enclosure for Group IIC:
AEx d IIC (NEC Article 505)
Ex d IIC (IEC)
EEx d IIC (CENELEC)
Note: See Code column in Table 3 for other examples of different methods of protection.
• electrical apparatus in flameproof enclosure for Groups IIC, temperature class T3:
AEx or Ex or EEx d IIC T3
• increased safety electrical apparatus and a pressurized enclosure for group II with a maximum surface
temperature of 125°C:
AEx or Ex or EEx ep II 125°C (T4) or
AEx or Ex or EEx ep II 125°C
• flameproof enclosure for ammonia:
AEx or Ex or EEx d II(NH3)
Portable, low-voltage, battery-operated devices meeting the requirements of ISA (The Instrumentation,
Systems and Automation Society) recommended practice (RP) 12.12.03 - 2002, can be used in Class I or
II, Division 2 or Zone 2 hazardous locations where FM Approved or listed devices are not available.
APPENDIX D BIBLIOGRAPHY
1. Electrical Installations In Hazardous Locations, Peter J. Schram and Mark W. Early, National Fire
Protection Association, 1991.
2. Hazardous Locations — Guide for the Design, Construction and Installation of Electrical Equipment in
Explosive Atmospheres, John Bossart, Canadian Standards Association, 1994.
3. ELECTRICAL SAFETY a guide to the causes and prevention of electrical hazards, J. Maxwell Adams,
The Institution of Electrical Engineers, 1994.
4. NFPA 497 (1997), Recommended Practice for the Classification of Flammable Liquids, Gases, or Vapors
and of Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas, National Fire
Protection Association, Quincy, MA.
5. NFPA 499 (1997), Recommended Practice for the Classification of Combustible Dusts and of Hazardous
(Classified) Locations for Electrical Installations in Chemical Process Areas, National Fire Protection
Association, Quincy, MA.
6. NFPA 496 (1998), Purged and Pressurized Enclosures for Electrical Equipment, National Fire Protection
Association, Quincy, MA.
7. Various publications of IEC TC 31, Electrical Apparatus for Explosive Atmospheres, as listed in the current
IEC Yearbook.
APPENDIX E THE THREE-ZONE CLASSIFICATION SYSTEM AND THE NATIONAL ELECTRIC CODE
The following paper was presented at the American Institute of Chemical Engineers 34th Loss Prevention
Symposium, Atlanta, March 5–9, 2000. This paper provides a description of the ‘‘Zone’’ classification system,
compares the ‘‘Zone’’ system to the traditional ‘‘Division’’ system and provides some discussion on the
application of the ‘‘Zone’’ system.
To be published in Chemical Engineering Progress, December 2000. Copyright © 2000 American Institute
of Chemical Engineers. All rights reserved. Not to be uploaded to any other site without permission from the
AIChE.
AIChE shall not be responsible for statements or opinions contained in papers or printed in its
publications
INTRODUCTION
The National Electrical Code® (NEC®), ANSI/NFPA 70, published by the National Fire Protection Association
(NFPA) is a set of uniform electrical installation rules written in a form that can be adopted into law. The federal
Occupational Safety and Health Administration (OSHA), all fifty states, and many local jurisdictions have
adopted, at least in part, the NEC® for electrical installation requirements. In addition to its applicability to
ordinary locations (unclassified), the NEC® provides the framework for approval, by jurisdictions, of electrical
equipment installations in hazardous (classified) locations and serves as the basis for the product standards
used by Nationally Recognized Testing Laboratories (NRTLs) to list equipment for approval by jurisdictions.
The NEC® allows two distinct approaches to classifying and installing electrical equipment in hazardous
locations containing flammable gases, vapors, or liquids. The original approach utilized the two-Division
classification system for hazardous locations. That system has been in use for many years and is generally
well understood. The 1996 edition of the NEC® provided the framework for the introduction of a three-Zone
classification system based on the International Electrotechnical Commission (IEC) 60079 series of
standards. This classification system only applied to flammable gases, vapors, and liquids. US deviations
were introduced into the appropriate product standards to align these IEC standards with NEC® and US
practice. The 1999 edition of the NEC® further refined the new “Zone” system.
The “Zone” system has been used in much of the world for many years Electrical equipment listed in
accordance with the new “Zone” system is now available in the US but availability remains limited. The lack
of acceptance is based on a lack of understanding and the requirements of the NEC®. The NEC® requires
that hazardous areas must be classified under either the “Division” system or the new “Zone” system. Since
many existing installations were based on the “Division” system, “Zone” designed equipment could not be
introduced. The NEC® does, however, permit the use of “Division” equipment in similar “Zone” areas.
Reclassifying an area using the “Zone” system increases the number of available options since both “Zone”
and “Division” equipment may be used. An understanding of the similarities and differences between
“Division” equipment and “Zone” equipment is needed to effectively use these systems to protect facilities
against unwanted electrical ignition sources.
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from the AIChE.
©2006 Factory Mutual Insurance Company. All rights reserved.
5-1 Equipment in Hazardous (Classified) Locations
Page 28 FM Global Property Loss Prevention Data Sheets
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from the AIChE.
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from the AIChE.
Protection Techniques
The specific rules for applying the “Division” and “Zone” classification systems must be clearly understood.
The differences in application are driven by the differences in protection techniques used on the electrical
equipment. Table 3 provides a listing of the allowed protection techniques for both systems. They each have
their own methodology for accomplishing the general equipment protection principle. In many cases, the
methodologies differ significantly and cannot be directly compared.
Intrinsic Safety.
Electrical equipment that is built using intrinsic safety is designed to be unable to ignite a flammable
atmosphere, even under specific fault conditions. This is accomplished by limiting the amount of electrical
energy used by or delivered to the device. Only equipment that uses the intrinsic safety protection scheme
is permitted in Zone 0 areas. However, caution must be used since there are two levels of intrinsic safety
that can be used. Electrical equipment that is specifically intended and tested for Zone 0 areas is identified
by using the letter “a” in the type of protection code for intrinsic safety (i.e., “ia”). Electrical equipment that
is specifically intended and tested for Zone 1 areas is identified by using the letter “b” in the type of protection
code for intrinsic safety (i.e., “ib”).
Flameproof.
“Flameproof” is a protection technique in the “Zone” system that is similar to “Explosionproof” under the
“Division” system. Equipment that is designed to be flameproof will resist an internal deflagration of a
flammable atmosphere without causing the ignition of an external flammable atmosphere. The ability to
contain an explosion and prevent ignition of a surrounding flammable atmosphere depends on the ability to
extinguish or cool an escaping flame front before it exits the equipment. Flame extinction is accomplished
by cooling the burning gases. The equipment designs to accomplish this cooling of the flame are tied to
specific flammable gases, vapors or liquids. As discussed in the next section of this paper, flammable vapors,
gases, and liquids are subdivided into Groups. “Zone” listed equipment is always marked with the acceptable
Group.
Increased Safety.
The increased safety protection technique was developed in Germany. It focuses on eliminating the potential
sources of ignition such as sparking, arcing or hot surfaces. The increased safety protection approach is
not directly comparable to any of the “Division” system protection schemes. Increased safety employs
increased creepage and clearance for electrical insulation, generously dimensioned contact surfaces, and
highly reliable connections to greatly reduce the likelihood of an ignition capable spark occurring. All increased
safety connections must be protected by an enclosure to reduce the possibility of contamination of the
electrical insulation that could result in a failure of the insulation. The enclosure must have a minimum degree
of protection of IP54 per IEC 60529 which provides a dust tight and water tight enclosure. This protection
is most commonly employed for connection terminals but also has applications in motor windings.
A Benefit of “Zone” Listed Equipment.
The combination of Zone 1 protection techniques allows the construction of small, light-weight, electrical
devices that can be readily combined into control panels without the need for the entire panel to be flameproof.
This allows the use of the best engineering approach to protect against any potential ignition source.
An example of how this approach can benefit an end user follows:
A Class I Division 1 fluorescent light fixture designed to be explosionproof has all of the electrical components
enclosed in an explosionproof case. A Class 1 Zone 1, fluorescent light fixture has each of its electrical
components individually protected using one of the “Zone” types of protection. The ballast is housed in its
own flameproof case with its wire terminals increased safety. The isolation switch is also flameproof with its
wire terminals increased safety. The bi-pin fluorescent lamps are connected using special sockets that meet
the requirements for increased safety. All of the fixture components are housed in a lightweight shatterproof
plastic case that provides degree of protection IP54 to reduce the likelihood of contamination of the electrical
insulation. This example demonstrates the significant reduction in the size and cost of electrical equipment
possible for Zone 1 locations in contrast to that required for Division 1 locations.
Copyright © 2000 American Institute of Chemical Engineers. All rights reserved. Not to be uploaded to any other site without permission
from the AIChE.
Table 3. Electrical Protection Techniques for the “Division” and “Zone” Systems
Permitted Zone/
Protection Technique Designation Division Standard Protection Principle
General Requirements AEx Zone 0, 1, & 2 ANSI/ISA S12.0.01
Division 1, 2 FM 3600
Explosion Proof (XP) Division 1, 2 FM 3615 Contain the
Flameproof d Zone 1, 2 ANSI/ISA S12.22.01 explosion and
Powder Filling q Zone 1, 2 ANSI/ISA S12.26.01 quench the flame
Increased Safety e Zone 1, 2 ANSI/ISA S12.16.01 No arcs, sparks, or
Non-sparking Equipment nA Zone 2 ISA S12.12.01 hot surfaces
Sparking Equipment nC Zone 2 ISA S12.12.01
w/protected contacts
Non-Incendive (NI) Division 2 FM 3611
Intrinsic Safety ia Zone 0, 1, 2 ISA S12.2.01 Limit energy of
Intrinsic Safety ib Zone 1, 2 ISA S12.2.01 sparks and surface
Intrinsically Safe Associated [ia] Non-Hazardous ISA S12.2.01 temperature
Apparatus
Intrinsically Safe Associated [ib] Non-Hazardous ISA S12.2.01
Apparatus
Intrinsic Safety (IS) Division 1, 2 FM 3610
(based on ISA
S12.2.01)
Restricted Breathing nR Zone 2 ISA S12.12.01 Keep flammable
Enclosure gas or vapor out.
Purged or Pressurized p Zone 1, 2 ANSI/NFPA 496
Type X, Y, Z Division 1, 2
Oil Immersion o Zone 1 ANSI/ISA S12.25.01
Encapsulation m Zone 1 ANSI/ISA S12.23.01
Group
There are other similarities between the two classification systems. Both systems provide an additional rating
that subdivides flammable gases and vapors into several Groups. Table 4 lists the “Zone” and “Division”
system Groups. As shown in Table 4, the Groups are quite similar in how the various gases or vapors are
subdivided. The largest difference is how acetylene and hydrogen are handled. Under the “Division” system,
each gas has its own Group, acetylene is in Group A, and hydrogen is in Group B. In the IEC “Zone” system,
both gases are in the same Group, acetylene and hydrogen are in Group IIC. In addition to the grouping
difference, Group IIC does not allow the use of flanged joints in flameproof equipment where as Group B
explosion proof equipment allows the use of flanged joints. In order to resolve these differences and continue
to allow the use of flanged joints, Group IIB equipment is also tested with hydrogen. This permits its use
in Group IIB atmospheres and also in hydrogen atmospheres. This equipment is marked IIB+H2.
Temperature Class
The last electrical equipment rating is temperature class. A comparison of the “Zone” and “Division”
temperature classes is presented in Table 5. The only real difference between the temperature classes in
the two systems is that the “Division” system allows for additional subdivision of temperatures.
Equipment Use
The use of electrical equipment in a “Zone” classified location is more limited by the NEC® than the equipment
for application in a “Division” classified location. Under the traditional “Division” system, apparatus only has
to be approved. Under the “Zone” system, apparatus has to be listed although there are exceptions for Zone
2 to allow the apparatus to be approved instead of listed. The NEC® differences between approved and listed
are important to understand.
The NEC® defines Approved as follows:
Approved — Acceptable to the authority having jurisdiction.
The NEC® defines Listed as follows:
Listed — Equipment, materials, or services included in a list published by an organization that is acceptable
to the authority having jurisdiction and concerned with evaluation of products or services, that maintains
periodic inspection of production of listed equipment or materials or periodic evaluation of services, and whose
listing states that either the equipment, material, or services meets identified standards or has been tested
and found suitable for a specified purpose.
With few areas classified using the “Zone” system, the market for apparatus using the IEC-based types of
protection in “Zone” classified areas remains limited and apparatus manufacturers continue to focus on the
“Division” system types of protection. In reality, the NEC® rules should not be a major limitation for apparatus
manufacturers or users. The NEC® permits “Division” apparatus to be used in similar “Zone” areas (see Table
6). Intrinsically Safe apparatus listed for Division 1 is permitted in Zone 0 locations, apparatus approved for
Division 1 is permitted in Zone 1 locations, and apparatus approved for Division 2 is permitted in Zone 2
locations. The requirement here for listed Intrinsically Safe Apparatus is not a penalty as almost all Intrinsically
Safe apparatus is indeed listed.
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from the AIChE.
This allowance provides additional equipment options for users if they reclassify existing hazardous
(classified) locations using the “Zone” system. In addition to having additional equipment choices, electrical
equipment that was designed using the Increased Safety “e” and Powder Filling “q” protection techniques
can offer significant size, weight, and cost reductions. These newly available “Zone” protection techniques
cannot be used in “Division” classified locations.
Marking Hazardous Area Electrical Equipment
Because of the potential for confusion with the introduction of the alternate “Zone” area classification system,
some changes were made to the marking detailed in IEC 60079-0 for use in the NEC®. The driving force
is that under the traditional “Division” system, the apparatus marking advises the installer which areas the
equipment can be installed in. A typical “Division” system apparatus marking is provided in Figure 1. Under
the IEC-based “Zone” system, the apparatus marking advises the installer what the type of protection is,
but does not detail where it can be used. The marking requirements introduced in Article 505 of the NEC®
combine the two methods of marking. In addition to the IEC-based marking, which is modified with the addition
of an “A” prefix before the “Ex” marking, the permitted Class and Zone are also added. A typical NEC®-based
“Zone” apparatus marking is provided in Figure 2.
Since “Division” apparatus is permitted in areas classified using the “Zone” classification system, a
supplemental “Zone” marking was also allowed. The marking consisted of the Class, Zone, Group, and
temperature class (T-Code) corresponding to the Class, Division, Group, and temperature class (T-Code)
of the “Division” system. The difference is the absence of the AEx and type of protection marking.
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from the AIChE.
Wiring Methods
Although the IEC types of protection for electrical equipment have been introduced into the US, it is critical
to note that the wiring methods permitted for this equipment remains the traditional US wiring method of
conduit with some limited application of cable. Many of the deviations introduced into the apparatus standards
are directly related to the need to interconnect with these traditional US wiring methods.
For wiring in NEC®-based Zone 0 locations, any of the wiring methods permitted for ordinary locations may
be used. Typical wiring methods employed are various types of non-armored cable, not unlike those used
in Europe. The apparent lack of requirements for Zone 0 wiring is based on the fact that all Zone 0 equipment
is intrinsically safe (i.e., low energy).
Beginning with the 1996 NEC®, some limited cable wiring methods were introduced for Division 1/Zone 1
locations. Metal-clad cable, Type MC, and Instrument Tray Cable, Type ITC, are both armored cable designs
with limited flexibility. However, they represent the first US application of other than conduit in a Division 1/
Zone 1 fixed applications.
For wiring in Division 2/Zone 2 locations, there are again some types of non-armored cable used, but for
most applications, the traditional conduit system is the most common wiring method.
CONCLUSION
Using the “Zone” system to classify hazardous areas increases the choices of electrical equipment available
for use in hazardous (classified) locations since both “Zone” and “Division” listed equipment is acceptable.
The added choices will can also reduce the overall cost of electrical installations in hazardous (classified)
locations since the protection techniques allowed in the “Zone” system can permit smaller, lighter, and less
costly equipment designs. The only way to utilize the advantages of the “Zone” system is to reclassify existing
hazardous (classified) locations in accordance with Article 505 of the NEC®.
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from the AIChE.
As more areas are classified using the “Zone” system and more electrical equipment is certified to meet
the US requirements for IEC-based “Zone” types of protection, US apparatus and installations will migrate
towards the IEC-based “Zone” system. As the users prepare by classifying new installations and reclassifying
existing installations to take advantage of the new “Zone” apparatus, the manufacturers are also preparing.
Most of the major US companies manufacturing or marketing hazardous area electrical apparatus have
1)international operations producing IEC-based “Zone” apparatus, 2) alliances with international companies
producing IEC-based “Zone” apparatus, or 3) have purchased international operations to provide a source
of IEC-based “Zone” electrical apparatus. Unfortunately, moving to the “Zone” classification system will not
provide compatibility of equipment from other countries also using the IEC-based “Zone” system. There are
still numerous differences between the US system and the IEC systems for equipment. Because of all the legal
ramifications involved in national certifications, equipment that is certified to meet the IEC-based requirements
of other countries will need to be re-certified to meet the US requirements.
ADDITIONAL READING
1. ANSI/NFPA 70, “National Electrical Code®,” National Fire Protection Association, 1999 Edition
2. Earley, M. W., Sheehan, J. V., Caloggero, J. M., “National Electric Code Handbook,” National Fire Protection
Association, 1999 Edition
3. NFPA 497, “Recommended Practice for the Classification of Flammable Liquids, Gases, or Vapors and
of Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas,” National Fire
Protection Association, 1997 Edition.
4. API Recommended Practice 500 (RP500), “Recommended Practice for Classification of Locations for
Electrical Installations at Petroleum Facilities Classified as Class I, Division 1 or Division 2,” American
Petroleum Institute, November 1997, Second Edition.
5. ANSI/API RP505, “Recommended Practice for Classification of Locations for Electrical Installations at
Petroleum Facilities Classified as Class I, Zone 0, Zone 1 or Zone 2,” American Petroleum Institute, 1998,
First Edition.
6. FM Global Property Loss Prevention Data Sheet 5-1, “Electrical Equipment in Hazardous (Classified)
Locations.”
7. “Approved Product News — In the Zone with FMRC,” Factory Mutual, 1998, Volume 14, Number 3.
http://www.fmglobal.com/pdfs/apn14_3.pdf
8. “Approved Product News – Interlaboratory Agreements – International Hazardous Location Standards,”
FM Global, 1999, Volume 15, Number 3. http://www.fmglobal.com/pdfs/apn15_3.pdf
Copyright © 2000 American Institute of Chemical Engineers. All rights reserved. Not to be uploaded to any other site without permission
from the AIChE.