 OISD Accident compilation (1996-1999):

◦ Out of the total 71 accidents (5 lakh property loss/fatality/loss

of 500MH/led to plant SD ), 66% were fire accidents

◦ 47% accidents happened during operational jobs

◦ Causes of accidents:
 71% human error
 11% Failure of plant
 18% Presence of ignition source

Is the above ‘accident cause’ grouping correct?

 Petroleum Rules, 1976
 An area shall be deemed to be a hazardous area, where:
◦ petroleum having FP below 65 deg C or any inflammable gas
or vapour in concentration capable of ignition is likely to be
present
◦ petroleum or any inflammable liquid having FP above is likely
to be refined, blended or stored at or above its FP

 IS 5572
◦ Hazardous area is an area in which an explosive gas
atmosphere is present, or likely to be present, in quantities
such as to require special precautions for the construction,
installation and use of electrical apparatus.
 In the 1700's, certain gases or the lack of oxygen were detected
with various hit and miss types of detection. The candles on
miners caps, or if carried by the miner, would either go out from
the lack of oxygen or the flame would get larger with a different
coloring of the flame if certain gases were in the area.
 Of course, in some instances these open flames caused fires or
explosions. By 1815, the Davy's Safety Lamp came into use in the
mines. This certainly changed the way for miners to check for
certain gases.
 They took these canaries in small cages with them down the coal
mines where they worked. The canaries were the miners alarm
signal to show them when the coal-gas levels got too high. The
canary stopped singing and was most likely to be laid feet up on
the bottom of the cage, poisoned by the mine gas.
 HAC is a method of analyzing and classifying the environment
where explosive gas atmospheres may occur to allow the proper
selection of electrical apparatus to be installed in that
environment.
 Ignition sources not considered
◦ ESD
◦ Sparks
◦ Lightning
◦ Flames/Fires
◦ Hot surfaces

 IS 5572
◦ HAs are classified in zones based on the frequency of the
appearance and the duration of an explosive gas atmosphere.
 Leak Potential & Presence of Ignition Sources

 Hazardous properties of hydrocarbons

 Safe selection (& optimization) of Electrical Equipment

 How many Zones as per Indian standards?

 European & American classifications (Zones and Divisions)

 Why not ‘blanket’ zoning?

 Is the 4th Zone really a ‘safe’ zone?

 Who should do HAC-Electrical or Process Engineer?

 Mining applications
 Explosive manufacturing
 Areas where ignitable dusts & fibers are present
 Catastrophic failures
 Ignition sources other than electrical apparatus
 Vapour space above:

◦ closed process vessels,

◦ storage tanks

◦ closed containers,

◦ areas containing open tanks of volatile, flammable liquid

 (Primary grade)

• Flammable gas or vapour concentration is likely to exist in the air under

normal operating conditions
• Flammable atmospheric concentration is likely to occur frequently because
of maintenance, repairs or leakage
• Flammable liquid or vapour piping system (containing valves, meters, or
screwed or flanged fittings) is in an inadequately ventilated area
• The area below the surrounding elevation or grade is such that flamamble
liquids or vapours may accumulate therein
 Imperfectly fitting peripheral seals on floating roof tanks

 Inadequately ventilated pump rooms for flammable gas or for

volatile, flammable liquids
 Oily waste water sewer / basins
 Loading / unloading gantries of hazardous products
• The system handling flammable liquid or vapour is in an adequately ventilated
area and is so designed and operated that the explosive or ignitable liquids,
Vapours or gases will normally be confined within closed containers or closed
systems from which they can escape only during abnormal conditions such as
accidental release of a gasket or packing

• The flammable vapours can be conducted to the location as through trenches,

pipes or ducts

• Locations adjacent to Zone 1 areas

• Pressurized rooms where flammable gas / vapour can enter in the case of
failure of positive mechanical ventilation
The following locations are considered safe from the point of view
of electrical installation:
 Areas where the piping system is without valves, fittings, flanges

or similar appurtenances
 Areas where flammable liquids or vapours are transported only in

suitable containers or vessels

 Areas where permanent ignition sources area present like area

where combustion gases are present, for example flare pits, tips,
other open flames 7 hot surfaces
 DG shed room / shed having adequate ventillation

 GT installation meeting the ventilation (12 ACPH) , pressurization

(0.5 mbar )and flange (not more than one pair of flanges inside
the turbine room) requirements
 North America (NFPA / API/ NFPA 70E or NEC)
◦ Hazardous Areas:
 Division I- Z0 + Z1
 Division II- Z2
◦ Hazardous Locations
 Class I-Flammable Gases / Vapour
 Class II- Combustible dust
 Class III- Combustible fibres or flyings
◦ Gas / vapour grouping
 A, B, C, D, E, F & G
 Japan
◦ Hazardous Areas
 Classes 1, 2 & 3
◦ Gas / vapour groups
 G1, G2, G3, G4, G5 & G6
 Flash Point - A, B, C

 Ignition Temperature

 Explosive Limits (based on MIE)

◦ LEL

◦ UEL
 Factors to be considered (IS 5572)
 Vapour / Gas Density

 Effect of Air Current

 Identification of leak scenarios

 In the absence of walls, enclosures, etc. & air currents,
vapour/gas dispersion will depend on density & velocity. Denser
gas/vapour will disperse downward and outward, lighter gases
upward & outward.HA for a single leak source would be a circle.

 Vapours / gas released(high density releases) at or near ground

level, will be found below ground, thus altering the shape of HA.
 Winds alter the shapes of hazardous areas

 A mild breeze may extend the HA and a strong wind could dilute
the flammable concentration,making it non-hazardous

 But what are logically to be considered are the most unfavourable

conditions
 Open -Air Situations (freely ventilated Process Areas)
◦ Figures 1 ,2)
◦ Figures 3 & 4

◦ In case of petroleum pipelines (where well-maintained valves,

fittings, and meters and in well-ventilated areas or in a pit),
Zone 2 A/G shall be 4m in all directions, from the potential
leak source. Pit will be considered as Zone 1.

◦ Zone 1
Zones 1 or 2
(unless
separated by
a fire wall)
 ◦ Vapour density of 0.75 is considered as the boundary between
lighter and heavier gases / vapours as a safety measure

HA of a leak source located in air

Source of 4.5 m
hazard

8.0 m

R 4.5 m

H<4.5m

Zone 2
 Mark in elevation and plan drawings

 Separate identification (hatching) for various zones

◦ Zone 0

◦ Zone 1

◦ Zone 2

 Frequency of HAC?
An experienced process engineer’s judgement in visualizing
leak scenarios and classifying hazardous areas is the
most CRUCIAL factor in the HAC exercise
 Adequacy of ventilation

 Accident record of the plant / business group / industry

sector/maintenance standard adopted in the plant

 Sound judgement & Experience of the engineer who carries out

HAC
 Perceived Limitations on the present HAC approach:
◦ Ignition sources not considered
◦ Reduction of zone areas & relaxation of zone designations not
considered
◦ Blinkers -On Approach , High cost, blanket zoning, narrow &
easy approach

or in short, the full potential of HAC is not utilized at present

 EXTENDING HAC PROCEDURE

◦ Additional steps
 After applying the present HAC procedure, assess all ignition
sources
 Assess the grade of release using
HAC-based risk assessment matrix
 Assessing the ventilation & evaporation aspects of the
chemicals considered

◦ Applying the new HAC procedure

 Grade of Ignition

Grade of Release Continous Frequent Infrequent Very Infrequent

Continous Unacceptable Unacceptable Acceptable

unless low (e.g. Ex i
consequences apparatus)
Primary Unacceptable Unacceptable Risk Assessment Acceptable (e.g.
required-look at Ex d apparatus )
consequences
Secondary Risk Assessment Risk Assessment Acceptable Acceptable
required-look at required-look at (E.g. Ex n
consequences but consequences but apparatus)
probably
unacceptable
Non-Hazardous Acceptable but Acceptable but Acceptable Acceptable
examine examine
catastrophic catastrophic
releases releases
CONCLUSION

 A logical extension of the present HAC methodology & not a

radical approach

 New European legislation, ATEX 118a Directive will be on similar

lines

 The new focussed & practical HAC approach will make HAC
exercise more cost-effective
 A SAFE APPROACH?
 Classified Time that haz. gases are Estimated % Estimated % (Z)
present in ignitable (Divisions)
area

Z0 Continuously <2%

D1 Normally present <5%

Z1 Occasionally in >60%
normal operations

Z2 <40%
D2 Not normally present >95%
C
L
A Z2
S
S
I
F
I
E
Z1
D

A Z0
R
E
A O 10 20 30 40 50 60 70 80 90
S 100
HAC- A RECAP
 API RP 500- Area Classification of Petroleum Installations
 IEC 79-10 :1995 -Electrical Apparatus for Explosive Gas
Atmospheres, part 10 Classification of hazardous areas
 IP Part 15, 1990- Area Classification Code for Petroleum
Installations
 BS EN 60079-10, : 1996 -Electrical Apparatus for Explosive Gas
Atmospheres, part 10 Classification of hazardous areas
 BS 5345, 1983-Selection, installation and maintenance of
electrical apparatus for use in potentially explosive atmospheres
(other than mining applications or explosive manufacturing), part
2, Recommendations for particular industrial situations
 Classification of Hazardous Locations,I.Chem. E. Cox, A.W., Lees,
F.P. and Ang, M.L, 1990
 IP Model Code of Safe Practice, 1990, Part 15, Area Classification
Code for Petroleum Installations
 NFPA 69, 1992, Explosion Prevention Systems
 ICI/RoSPA, 1972, ICI Electrical Installations Code
 NFPA 325M, Properties of Flammable Liquids, gases and solids
 Electrical Safety in Hazardous Locations, William Calder & Ernest
C. Magison
SELECTION OF ELECTRICAL EQUIPMENT IN HAZARDOUS AREAS
 How to select equipment for various zones?

 Selection Criteria

◦ Gas Grouping (based on ignition energy)

◦ Temperature Classification

◦ Classified Zones
T Class Max. Surface Temperature
(Deg. C)

T1 450
T2 300

T3 200

T4 135

T5 100

T6 85
 Gas group I
◦ Methane
 Gas group II A
◦ Ammonia, CO, Propane, Butane, Benzene, Acetone, Methanol
 Gas group II B
◦ Butadiene, Ethylene, Ethylene Oxide, Diethyl Ether
 Gas group II C
◦ Hydrogen
Which is the most hazardous group ?
S No Name of the Minimum Flash point Iignition Flammable limit
chemical Ignition Deg. Cen. temperatur LEL UEL
Curre nt e
(MIC) mA (Deg C)
1 Methane I, 85 - 595 5% 15%
T1
2 Ammonia - - 630 105 mg/l 200 mg/l
II A T1
3 Ethylene 45 - 425 2.7% 34%
II B T2
4 Propane 70 - 470 2% 9.5%
II A T1
5 Acetylene 24 - 305 1.5 % 100%
II C T2
Gas Representative Gas Ignition Energy
Group (mj)

I Methane 280

II A Propane 260

IIB Ethylene 95

IIC Hydrogen 18
 No electrical equipment should be allowed. When this is not
practicable, Ex ‘ i ‘ (ia or ib) apparatus or circuits to be used

• No transformers, motors, lights, switch gear or control gear

 Motors- Ex d, Ex p
Transformers & Capacitors - Ex d
Control & Instrument Transformers - Ex i
Lighting Fitting - Ex d
Switch Gear & Control Gear - Ex d
Communication/ Telephone equipment/Meters - Ex i
Portable Hand Lamps- Ex i

*Ex o, Ex q type equipment are also allowed for use as per IS 5571
 Motors- Ex d, Ex p, Ex n, Ex e,
Transformers & Capacitors - Ex d, Ex p (auxiliary devices to be
located in pressurized room/hermetically sealed / intrinsically
safe)
Control & Instrument Transformers - Ex i
Lighting Fitting - Ex d, Ex e, Ex n
Switch Gear & Control Gear - Ex d, Ex o, Ex
Communication/ Telephone equipment/Meters - Ex i
Portable Hand Lamps- Ex i

* Minimum IP 55 (for UN-insulated parts) and IP 44 (for insulated parts)

if Ex e protection is used for outdoor applications
 Ex
EXPLOSION-PROTECTION EQUIPMENT
 Flameproof (EX d)

 Increased Safety (Ex e )

 Non-Sparking (Ex n )

 Pressurization (Ex p )

 Intrinsically Safe (Ex i )

 Powder filled Ex ‘q’ type

 Oil immersed Ex ‘o’ type

 Special Ex ‘s’ type

 Definition as per IS 2148:

US- Explosion-Proof, UK- Flame-Proof, GERMANY - Pressure-Proof

A type of protection in which the parts can ignite

an explosive atmosphere are to be placed in an
enclosure, which can withstand the pressure
developed during internal explosion of an
explosive mixture, and which prevents the
transmission of the explosion to the explosive
atmosphere surrounding the enclosure

FLAMEPROOF EQUIPMENT- A MISNOMER?

Assumptions based in IS 2148 are:

• Flammable gases / vapours, if present in atmosphere will enter the enclosure

• The apparatus will be selected, installed, operated and maintained within the
acceptable ratings. The maintenance and use of FLP equipment shall be so
that its safety will not be impaired, is the responsibility of the user

• The electric circuit of the FLP equipment will have all required protection
devices

• Sparking which will ignite a flammable gas or vapour, may occur at any part of
the equipment contained in the enclosure in normal operation due to an
internal fault due to insulation failure, etc.
 FLAME PATH - Width of Joint
◦ Minimum

 GAP - Diametrical Clearance

◦ Maximum
 Maximum gaps and flame path for gas groups depends on ignition
energies of the gas / vapour and the volume of the enclosure

 For example, for IIB gas group, for 100 Cubic cm volume, for flanged
joints:
◦ Flame Path - 6 mm
◦ Maximum Gap - 0.3 mm

 For II C Hydrogen, 100 cubic cm volume, for flanged joints:

◦ Flame path - 9.5 mm
◦ Maximum Gap - 0.1 mm
 USE OF APPROVED MATERIAL WITHOUT THE USE OF INCENDIVE FRICTIONAL
SPARKING
 EQUIPMENT SHOULD WITHSTAND ROUGH USAGE
 EQUIPMENT SHALL BE ADEQUATELY STRONG TO WITHSTAND ALL REQUIRED TESTS
 THE EFFECTIVE THREADED METAL TO METAL JOINTS SHALL HAVE A MINIMUM OF 5
FULL UNINTERRUPTED ENGAGED THREADS & A MINIMUM EFFECTIVE
UNINTERRUPTED DIRECT AXIAL LENGTH OF THREADED ENGAGEMENT OF 9 mm
 THERE SHALL BE NO INTENTIONAL GAP BETWEEN JOINT SURFACES
 NO PACKING MATERIAL SHALL BE USED BETWEEN OPPOSED SURFACES TO FORM A
FLAMEPROOF JOINT
 IF COMPRESSIBLE PACKING MATERIAL OR A GASKET IS NECESSARY TO SEAL A JOINT
(eg. IP) THE PACKING SHALL BE APPLIED AS A SUPPLMENT TO, BUT SHALL NOT BE
INCLUDED IN THE FLAMEPROOF JOINT
 ANY DISPLACEMENT, DAMAGE, INTEGRATION OR OMISSION OF THE PACKING SHALL
NOT RESULT IN THE FLAMPROOF NATURE OF THE JOINT BEING ADVERSELY
EX d typical marking: EEx d IIB T5
A type of protection which a circuit or part of the circuit
is intrinsically safe when any spark or thermal effect
produced normally is incapable, under prescribed
test conditions, of causing ignition of prescribed gas
or vapour
 Only electrical protective measure (protection technology by way
of power limitation), the other protective techniques use
mechanical means to prevent ignition from electrical faults (max.
30 volts or 50 mA)

 Ex ‘i’ apparatus is the one which has all the circuits within
intrinsically safe
 Ex ‘i’ circuit is the one which has intrinsically safe barriers with
Zenner diodes for power limitation

 Minimum IP 20 ingress protection

 Ex ib equipment shall be incapable of causing ignition in normal
operation, with a single fault and with the following safety
factors:

◦ 1.5 in normal operation and with one fault

◦ 1.0 with one fault, if the equipment contains no unprotected

switch contacts in parts likely to be exposed to a potentially
explosive atmosphere and the fault is self-revealing

EX i typical marking: EEx ia IIC T5

 Cell phone explosion accident in an offshore platform

 Fuel outlets- restricted cell phone usage?

Definition as per IS 6381

A type of protection by which measures are applied so

as to prevent with a minor degree of security, the
possibility of excessive temperature and the
occurrence of arcs or sparks in the interior and the
external parts of electrical apparatus which does not
produce them in normal service
Stringiest construction methods to ensure that no sparks, excessive
temperature are produced
• Careful terminal design
• Use of good quality insulation material
• Use of special materials to protect the enclosure against impact, ingress
of dust & moisture
• Can be used for I, II A, B, C gas groups
• Permitted for us in T1, T2, T3 classes only
• Terminal with minimum IP 54 ingress protection

EX d typical marking: EEx e IIA T3

A type of protection by which the entry of surrounding
atmosphere into the enclosure of the electrical
apparatus is prevented by maintaining inside the
said enclosure, a protective gas at a higher than that
of the surrounding atmosphere
 Dynamic Pressurization (DP) or pressurization by continuos
circulation of protective gas (purging)

◦ DP is a method of maintaining pressure in an enclosure in which

after purging the protective gas is passed continously through the
enclosure at a pressure above that of the specified minimum and
discharged to the outside atmosphere

◦ Static Pressurization or pressurization with leakage compensation

 Air supplied & pressurized continously from a non-hazardous
area to avoid ingress of flammable gases / vapour inside the
enclosure
Pressurized Equipment
 Ingress protection minimum IP 4X

 Over pressure 1.5 times or 0.2 kPa

 Material of construction should be flame retardant, self-

extinguishing and should not be affected by protective gas

Pressurized Equipment / Panels
 A minimum overpressure of 0.2 kPa (2mbar) with reference to

external atmospheric pressure

 Air intake from a safe area

 Exhaust duct outlet to be located in safe area

 Zone 1- can be used if there is no spark in normal service

 Zone 1 or 2 -if ejection of spark is prevented by effective device

and rapid suction of external atmosphere is prevented

Area Enclosure does Enclosure
not contain contains I-C
Ignition-capable Apparatus
apparatus
Zone 2 No Action Alarm
required
Zone 1 Alarm Alarm with trip
 ◦ Definition as per IS 8289

A type of protection applied to electrical apparatus

such that , in normal operation it is not capable of
igniting a surrounding atmosphere and a fault
capable of causing ignition is not likely to occur

EX n typical marking: EEx n II T5

 Equipment construction in such a way that in normal operation, it
is incapable of igniting a surrounding explosive atmosphere and
a fault incapable of causing ignition
 Hermetically sealed type
 Restricted breathing type
 Careful design of terminals

 SUBSTANTIAL COST SAVING

 Applications
◦ Tools
◦ Equipment
• Equipment enclosure filled with quartz /sand so that in normal operating
condition, any arc occurring within the enclosure of electrical equipment will not
ignite the surrounding atmosphere

• No ignition shall be caused either by flame or by excessive temperature of the

surfaces of the enclosure

• Enclosure constructional features:

• High mechanical strength
• Ingress protection
• Powder filled
• Insulation of enclosed equipment
 Protection technique in which the equipment or its parts are
immersed in oil in such a way that an explosive atmosphere
which, may be above the oil or outside the enclosure cannot be
ignited.

 Oil used shall be mineral oil confirming to relevant standards

 Constructional features:
◦ Fully enclosed, leak-proof enclosure
◦ Oil level indicator
 Transformers, Switch gears, Control gears
 This is a concept that has been adopted to permit the
certification of those types of equipment which by their nature,
do not comply with the constructional or other requirements
specified for equipment with established types of protection but
which, nevertheless, can be shown, wherever necessary, by test
to be suitable for use in hazardous areas in prescribed zones
 This concept permits flexibility on the part of certifying and
assessment authorities in their approach to applications for
certification of equipment the use of which would otherwise not
permitted in hazardous areas on account of non-compliance with
the requirements of standards for established types of
protection. This allows flexibility of approach to innovative ideas
and new designs, the development of which otherwise be
obstructed.
 Examples:
◦ Factory sealed hand lamps, Encapsulation (Ex ‘m’ type), Gas
detection apparatus
INGRESS PROTECTION (IP)
 Ingress of Liquid

IP XY

Degree of Protection of persons

against contact with or
moving parts inside the
enclosure & Protection Of
Equipment against Solid
ingress
 FIRST NUMERAL SECOND NUMERAL
0 No protection 0 No protection
1 Objects greater than 50 mm 1 Vertically dripping
2 Objects greater than 12 mm 2 Angular dripping
3 Objects greater than 2.5 mm 3 Sprayed water
4 Objects greater than 1.0 mm 4 Splashed water
5 Dust - protected 5 Water jets
6 Dust tight 6 Heavy seas
7 Effects of immersion
8 Indefinite immersion
 IS 5571 Guide For Selection Of Electrical Equipment For Hazardous Areas
 IS 5572 –Part I Classification of Hazardous Areas for Electrical Installations
 IS 13408 Part I, II, III Code of Selection, Installation and Maintenance of Electrical
Apparatus for Use in Explosive Atmospheres
 IS 8239 Classification of Maximum Surface Temperature of Electrical Equipment for Use
In Explosive Atmospheres
 IS 6381 Construction and testing of Electrical Apparatus with type of protection
‘e’
 IS 2148 Flameproof Enclosures of Electrical Apparatus
 IS 13346 General Requirements for Electrical Apparatus for Explosive Gas Atmospheres

 IS 5780 Specification For Intrinsically Safe Electrical Apparatus and Circuits

 IS 8240 Guide for Electrical Equipment for Explosive Atmospheres
 IS 2147 Degrees of Protection Provided by Enclosures For Low Voltage Switch Gear & Control
Gear
 IS 4691 Degrees of Protection Provided by Enclosures For Rotating Electrical
Machinery
 IS 8241 Methods of Marking for Identifying Electrical equipment for Explosive
Atmospheres
 IS 8224 Specification for Electric Lighting fitting for Explosive Atmospheres
 IS 8289 Electrical Equipment with Type of Protection ‘n’
 IS 7389 Specification for Pressurized Enclosures
 IS 2206 (PART I,III)Specification for Flame proof Electric Light Fixtures
 Adequate precautions to avoid ESD & Lightning to be
implemented

 Use of light alloy (Mg, Al, Ti, ) material to be assessed critically in

HAs due to its incendive properties

 Where reasonably practical, electrical apparatus generally and

switch & control apparatus should be installed outside the
Hazardous Areas

 Electrical apparatus may be installed in open air in a non-

hazardous area
 Equipment designed for higher gas groups can be used for less
hazardous gas groups ( for e.g., Equipment certified for II C can
be used for II A, B or I)
 Portable hand-lamps, communication equipment and other test
equipment shall be Ex i type
 All equipment shall be installed so as to avoid mechanical
damage
 Earthing shall be carried out as per IS 3043
 Bonding of all pipeline flanges should be carried out so as to
avoid Electro-static discharges
 Internal earthing to be provided for all FLP equipment in addition
to external earthing
 All circuits and apparatus in Hazardous Areas should be provided
with means to ensure quick disconnection in the event of any
fault (O/C, S/C or E/F)
 Protection & Control apparatus shall be normally located in non-
HAs but if unavoidable, they may be of the right protection type
 All electrical apparatus (for every apparatus or sub-groups)
should be provided with an effective means of isolation, including
neutral
 Metal conduits, armoured cables
 Correct terminations using proper sized cable glands (double-
compression, FLP type)
 Unused cable openings of all electrical apparatus shall be closed
with plugs suitable for the type of protection
 Copper or Aluminium (above 16 sq. mm only) conductors can be
used

 FLP plugs & sockets should have preferably PUSH-IN, TWIST-ON

type to avoid ignition while insertion or removal
 Adequacy of IP equipment

 Test equipment
◦ Insulation Resistance megger shall be Ex i type
◦ Earth Megger shall be Ex i type
◦ Hotspot Detection equipment
 FLP Equipment
◦ All bolts in place
◦ All openings closed
◦ No site modification / alteration
◦ Internal & external earthing
◦ Double-Compression, FLP cable glands
◦ No physical damage
◦ No damage to Flame path
◦ All threaded connections-minimum 5/ 6 threads engagement
◦ Flange faces to be smooth & original (to be careful while
opening stuck covers)
 Light alloy paint even for the purpose of maintenance must not
be applied on any external surface of the equipment to prevent
inscendve frictional sparking
 Equipment shall not be tampered to open covers, etc.
 No components shall be added or removed or even replaced. This
has to be done after getting re-certified by the OEM
 A scheme of regular inspection & maintenance of the items
should be made on the basis of guidelines / standards. Any
equipment which is originally flameproof may loose its integrity if
not maintained properly
 The equipment should be de-energized before attempting any
repair
 Drawings /Records
◦ Updated SLD
◦ Updated HAC drawing
◦ Drawing with various equipment installed in various identified
zones
◦ Certification / re-certification records
◦ IR / ER records
 Sufficient Spare stock of critical equipment (various Ex types)
 Solid obstruction(steel structures, walls, other electrical
equipment) effects (close to equipment flanges)
◦ IIC - 40 mm clearance
◦ IIB - 30 mm
◦ II A - 10 mm
◦ I - no clearance envisaged
 Integrity of IP equipment
◦ Use of gasket is permitted if certified as part of the equipment
◦ No sealing of flange faces (this could affect the ability of the
enclosure to withstand the maximum explosion pressure)
◦ Application of non-setting grease or anti-corrosive agent is
permissible
◦ Non-hardening tape can be used in II A gas groups, II B tape is
to be avoided and no use of tape in II C gas groups
 Insulation integrity to be periodically tested and maintained
 Maintenance personnel
◦ Inspection, Maintenance, testing, replacement and repair in
HAs shall be carried out by trained personnel only
◦ Refresher training for them is essential
 Periodic examination of flange gaps and flange faces for any
effects of corrosion / damage, etc.
 Maintenance Tests (at an interval not exceeding 3 years)
◦ IR measurements
◦ Earth electrode resistance measurements
◦ Earth loop resistance measurements
◦ Operation & Setting of Protection devices
• Ex i - No addition / alteration of circuit components / power limitation barriers,
etc.
• Check Ex p equipment / panels / rooms for low pressure interlock operations,
periodic review of air in take stack location
• Terminations in Ex e, n types equipment
• Use of non-sparking tools

“ELECTRICAL EQUIPMENT USED IN HAZARDOUS ARAES ARE

SPECIAL AND THEY NEEDS TO BE TREATED SPECIAL”
 CMRI (Central Mining Research Instituite), Dhanbad, BIHAR

 CCoE (Chief Controller of Explosives), Nagpur

 BIS (Bureau Of Indian Standards)

 DGMS (Director General Mine Safety), Dhanbad, BIHAR

 DGFASLI (Director General of Factory Advice Service and Labour

Instituites), Mumbai
  Petroleum Act, 1884
◦ Petroleum Rules, 1976
 Explosive Act, 1934
◦ Explosive Rules, 1983
◦ Gas Cylinder Rules, 1981
◦ Static & Mobile pressure Vessel (Unfired) Rules, 1981

CCoE, Department of Explosives is entrusted with the responsibility of

administration of the above statutory rules in India
 Petroleum Rules, 1976 (Chapter IV)

 Static & Mobile Pressure Vessels (U) Rules, 1981 ( Rule 31)

 Gas Cylinder Rules, 1981 (Rule 21)

 Hazardous Area- Definition
◦ An are shall be deemed to be an hazardous area, where:
◦ i) petroleum having FP below 65 deg. C or any other flammable
gas or vapour in concentration capable of ignition is likely to
be present
◦ ii) petroleum or any inflammable liquid having FP above 65 deg
centigrade is likely to be refined, blended, handled or stored at
or above its FP
 HAC- Zones 0, 1, 2
 Earth resistance values:
◦ 4 ohm for electrical systems
◦ 10 ohms for non-current carrying metallic parts
◦ all joints in pipelines, valves, etc. shall be bonded and the earth
resistance between each joint shall be 1 ohm
 Hazardous Areas as per 4th Schedule:
◦ -In-line with IS 5571
 Tables 1 & 2 (as per Form XIII)
◦ Inter-Distances between tanks (with Classes A, B, C products)
◦ Distance between tanks and tankers, offices, motors
 Equipment testing and approvals (for all gas groups- I, II A, IIB,
IIC)
 Testing and approval required for modified equipment
Drawing and prototype
submittal to CMRI

Tests by CMRI

Approval by CMRI

ISI Certification (Tests by

CMRI) as per applicable
Indian Standards

Approvals by:
• DGFASLI
• CCoE
 Original HAC drawings (IS 5572)
 Plant additions / alterations
 Installation of electrical equipment in hazardous areas (IS 5571)
 Valid applicable statutory approvals (CCoE)
 Maintenance of Electrical Equipment
◦ FLP
◦ Pressurized equipment
◦ Earthing (internal & external)
 Advantages include CLEAR Zone marking, stringent quality
requirements, very user-friendly
 Products will have to be re-certified as per the new harmonized
ATEX standards
 CAT 3 (Zone 2) products will not require approval from a notified
body (could be self-certified, if in-house test facilities are
available)
 Use Directive ATEX137 ‘Protection of workers at Risk from
Potentially Explosive Atmospheres’
◦ Another directive for user industries
◦ Will be mandatory under EU laws in 2003
◦ Requirements
 Documented evidence of analysis, HAC, inspections carried
out
 Use of ATEX certified (E & M) equipment & safety systems
 OISD 145 (Section 9)

 IS 5571

 IS 5572

 IS 13408 Part I, II, III (Code of practice for selection, installation &
maintenance of Electrical equipment in potentially Explosive
atmospheres)
 Periodic examination of flange gaps and flange faces for any
effects of corrosion / damage, etc.
 Maintenance Tests (at an interval not exceeding 3 years)
◦ IR measurements
◦ Earth electrode resistance measurements
◦ Earth loop resistance measurements
◦ Operation & Setting of Protection devices
 HAC

 EQUIPMENT SELECTION

 VARIOUS EXPLOSION PROTECTION TECHNIQUES

 INSTALLATION , MAINTENANCE & AUDITING GUIDELINES

 STATUTORY REQUIREMENTS
 ATEX Directive 94/9/EC is adopted by the EU members & is
concerning technical & legal requirements applicable for
potentially explosive atmospheres
 CE marking is a pre-requisite if products are to be used in EU
nations
 ATEX directive 100a will become mandatory on July 1, 2003
 Equipment groups (non-mining)
◦ CAT 1 (Zone 0)
◦ CAT 2 (Zone 1)
◦ CAT 3 (Zone 2)