Australia’s National

Science Agency

Managing Hazardous
Areas (HA) Technical
Guide

Revision 1.8

07 Feb 2024
Contents
Managing hazardous areas – Overview and navigating this guide ......................................... 3
1 Introduction ............................................................................................................................. 1
2 Identifying Hazardous Areas .................................................................................................... 2
2.1 Potentially Explosive Atmospheres ............................................................................ 2
2.2 Ignition Sources .......................................................................................................... 3
2.3 Elimination of Risk ...................................................................................................... 4
2.4 Hazardous Zone Classification .................................................................................... 4
2.5 Hazardous Area Report .............................................................................................. 5
3 Managing Hazardous Areas ..................................................................................................... 8
3.1 Mitigation of Risk........................................................................................................ 8
3.2 Removal of Ignition Sources ....................................................................................... 8
3.3 Relocation of Equipment ............................................................................................ 8
3.4 Hazardous Area Rated Equipment ............................................................................. 9
3.5 Other Risk Controls................................................................................................... 18
3.6 Hazardous Area Drawings ........................................................................................ 19
4 Hazardous Area Verification Dossier ..................................................................................... 20
5 Maintaining Hazardous Area Equipment .............................................................................. 22
5.1 Documentation ......................................................................................................... 22
5.2 Maintenance & Inspection ....................................................................................... 22
5.3 Signage ..................................................................................................................... 24
5.4 Regular Review ......................................................................................................... 24
Appendix A – Hazardous Area Classification for Potentially Explosive Atmospheres ....................... 25
Appendix B – Key Legislation, Codes & Standards............................................................................. 27
Appendix C – Examples ...................................................................................................................... 28
Glossary .............................................................................................................................................. 47
 Managing hazardous areas – Overview and navigating this guide
A “hazardous area” (HA) is a location where an explosive atmosphere could develop, whether it be within a
process, piece of equipment, apparatus or in a room. Consider: flammable gases, vapours, dusts.

Identify You must: If there is a risk of explosion: i.e. an ignition

source is in a hazardous area.
Hazardous 1. Consult (pg. 2) – with those
familiar with the work. 1. Eliminate the risk (pg. 4). If this
Areas 2. Locate (pg. 3) – ignition cannot be done, then:
(pg. 2) sources. 2. Manage HA. (pg. 8) – see next section.
3. Risk Assess (pg. 3) – 3. Develop a HA Report (pg.
i.e. could an explosive
atmosphere be present? likelihood of explosive Hazardous Area Report5) -
atmosphere in contact with where elimination and substitution are not
ignition sources. possible.

Manage Minimise risk by one or a If the HA still exists:

combination of: (pg. 8)
Hazardous 1. Remove ignition sources
(pg. 8) – most effective, least cost.
Areas (pg. 8) • Substituting the
2. Use Certified HA Rated
flammable material.
If a hazardous area is Equipment (pg. 9) – consult
identified… • Reducing the quantity of licensed electrical inspector with
flammables. HA qualifications.

• Isolating the process from 3. Ensure adequate

ignition sources. ventilation (pg. 18)
4. Install flammable gas
• Engineering controls.
detection systems (pg. 18) –
• Administrative controls, required if the concentration could
e.g., SOPs. exceed 5% of the gas’ LEL

• Providing personal 5. Control static electricity (pg.

19) – consult a specialist.
protective equipment 6. Create and keep HA
(PPE). drawings (pg. 19) – available as
part of HA dossier.

Develop a ➢ Must be kept where HA rated equipment is located.

Hazardous ➢ This is a “live” document.
➢ It is a set of documents showing compliance of electrical
Area
equipment and installations.
Verification ➢ Produced in consultation with area occupiers and specialists.
Dossier (pg. 20) ➢ See page 20 of the HA guide for all elements of the dossier.

Maintain You must: Maintenance work must:

Hazardous 1. Keep records (pg. 22) – using ➢ Use a Permit to Work
a HA Verification Dossier.
Area 2. Engage licensed electrical
system that includes (pg. 22):
- Job Safety Analysis
Equipment inspectors with HA (JSAs)
(pg. 22) Using the qualifications (pg. 22) – to
Hazardous Area Dossier.
- Safe Work Method
conduct maintenance and
Statement systems
inspections.
3. Install signage (pg. 24) – on (SWMS)
area hazard posters and ➢ Apply Work Permits to HA
within/close to HAs. equipment maintenance
4. Regularly review HA AND general maintenance
conditions, equipment activities.
and maintenance (pg. 24)
1 Introduction
This document is intended to provide technical guidance for CSIRO employees working in research
facilities in Australia, to enable them to identify and manage hazardous area related risks in their
operations where flammable materials are used and stored. It includes information that will allow
them to determine if electrical installations will require special hazardous area protection and the
requirements for maintaining the equipment. Where hazardous areas are identified, additional
induction or training may be necessary for staff working in those areas.

The term “hazardous area” refers to locations where a potentially explosive atmosphere may
occur, whether it be within a process, piece of equipment, apparatus or in a room.

In this context, the term “hazardous area” does not refer to locations where human exposure to
hazardous chemicals (e.g., toxic substances) may occur, or where other hazards, such as from
slips, trips and falls, may exist.

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2 Identifying Hazardous Areas
2.1 Potentially Explosive Atmospheres

2.1.1 Hazard Identification

The first step in identifying a hazardous area is determining if there is likely to be a potentially
explosive atmosphere present.

This requires a good knowledge of the process, the equipment or apparatus used, the
chemicals used, and the materials produced or generated.

All these factors will help identify where an explosive atmosphere is likely to occur. Some
questions to ask are:
• Do the chemicals used in the process give off flammable vapours?
• Are flammable gases used or produced in the process?
• Will powders or dust be released during the process, or are large volumes of powders or dusts
stored?
• Will heating be used in the process or will heat be involved or be created during the process?
• Is the apparatus designed to contain the results of the process or will material be released?
• Is the apparatus’ materials of construction compatible with the process? Especially worth
considering for repurposed equipment.
• If new equipment is used in an experiment, will it be operating within the bounds of the
manufacturer’s certified operating condition limits?
• Does the process involve the re-use or upscaling of existing apparatus? If so, will the
apparatus still be operating within its original safe working conditions, e.g., with respect to
pressure and temperature?
• Is any existing or new pipework mechanically jointed (e.g., joined by screwed couplings or
flanges) or continuously welded? Has the pipework been pressure tested?
• Does the by-product of the process give off flammable vapours?
• Is there oxygen or other oxidisers present?
• Is the area well ventilated? Is the ventilation appropriate for the size of the area and the
materials that are likely to be present?
• What happens if there is an accidental release or spill of material? What likely form will the
spill take, e.g., gas, vapour or liquid?
The answers to these and similar questions that are appropriate to the actual process will help
identify if there is the potential for an explosive atmosphere to exist.
You may also want to consider using a HAZOP study to identify hazardous areas. This process is
best done at the design stage and can be time consuming.

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2.1.2 Likelihood of Explosive Atmosphere

The next step would be to assign a probability or likelihood to the various ways an explosive
atmosphere may be produced. This will assist with determining if it is necessary to proceed with
identifying potential ignition sources or whether, if there is such an extremely low likelihood of an
explosive atmosphere occurring, further assessment is not necessary.

This can be done by conducting a risk assessment to establish the frequency of occurrence of
the events that may lead to an explosive atmosphere.

This can be based on statistics relating to previous incidents or manufacturer data, if available, and
knowledge of the components that make up the process. It may be quantitative or qualitative.
If there is any doubt, or the likelihood is not easily quantifiable, it must be assumed that an
explosive atmosphere is likely to be present.

2.2 Ignition Sources

Generally, unless a self-reacting, pyrophoric or other spontaneously combustible substance is
involved, there are three conditions necessary for a fire or explosion to occur. A flammable or
combustible material must be present; an oxidant (e.g., oxygen) must be present and the resulting
mixture must be within the material’s flammability or explosive range; and an ignition source must
be available to ignite the mixture.
The assessment of the existence of a potentially explosive atmosphere will have established if a
flammable or combustible material is present and if a flammable or explosive mixture is likely to
occur. The next step is therefore to establish if there is a potential ignition source available to
ignite the mixture (e.g., flammable vapour or gas and air; a dust cloud and air).
There are several potential ignition sources that may be present in a laboratory, including:
• Open flames
• Hot surfaces
• Sparking or arcing parts of electrical equipment including electric motors (e.g., vacuum pumps
and compressors, refrigerators and freezers), light switches and light fittings
• Mechanical sparking due to friction between parts
• Electrostatic discharge (e.g., due to static charge build-up on clothing).

To achieve ignition of a potentially explosive atmosphere, the ignition source must have
sufficient energy to ignite the mixture. There are other factors involved in the process of
ignition, but a discussion of these is beyond the scope of this guide.

In most circumstances, ignition sources will be present. If there is potential for an explosive
atmosphere to encounter the source of ignition, a risk assessment must be undertaken to
establish the level of risk.

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If the risk is sufficient to require action, then action must be taken in accordance with the
hierarchy of risk controls. That is, in descending order of effectiveness:

Elimination
Substitution
Reduction – isolation, engineering controls
Administrative controls – management procedures, PPE

A combination of these risk control methods may be necessary.

2.3 Elimination of Risk

Once a hazardous area has been identified and the level of risk assessed, you must first try to
eliminate the risk.
Consider:
• Replacing the flammable materials with non-flammable alternatives,
• Altering the process, preventing a flammable atmosphere occurring, or
• Terminating the process in its current form if the risk is too great.
In most cases it will not be possible to eliminate the risk completely using these methods.

An alternative elimination strategy is to relocate all ignition sources outside the hazardous
area (See Section 3.2 below for more details). In this case the hazardous area should still be
documented for future understanding of where equipment or ignition sources cannot be
located. If the risk assessment identifies that elimination controls cannot be used to control
the risk, a Hazardous Area Report must be undertaken.

2.4 Hazardous Zone Classification

Hazardous zones for flammable gases and vapours are classified into three levels that are
equivalent to the relative level of risk. From higher to lower risk these are: Zone 0, Zone 1 and
Zone 2. Simply put, these zones cover a range of likelihoods that there will be an explosive
atmosphere present, as follows:
a. Zone 0 – nearly always present,
b. Zone 1 – normally present occasionally,
c. Zone 2 – not normally present, but if it is, for short periods only.
Similarly, for explosive dust atmospheres, the zones are; Zone 20, Zone 21 and Zone 22. Refer to
Appendix A for more detail.

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 Although explosive dust atmospheres may be encountered in laboratory operations, it is far
more common that where explosive atmospheres occur, they will be due to flammable gases
and vapours.

As such, most of the following discussions and examples will relate directly to the latter. Many of
the general considerations, however, will also apply to explosive dust atmospheres.
Where ignition sources cannot be excluded from the hazardous area, the type of Zone applying to
a hazardous area will govern the level of explosive (Ex) rating required for the potential ignition
source, e.g., electric motors. This Ex rated equipment generally becomes considerably more
complicated and expensive as the Zone rating moves higher (i.e., Zone 0 equipment is more
expensive than Zone 2 equipment). Refer to Section 3.4 for further discussion of Ex rated
equipment.

2.5 Hazardous Area Report

The purpose of a Hazardous Area Report is to document the inputs and outcomes of a hazardous
area assessment and provide the basis for the classification of hazardous zones.

Hazardous Area Reports for a particular installation may be developed internally by the
organisation only if those involved have the required expertise and understanding of the
relevant AS 60079 series. Alternatively, it can be produced by specialists in consultation with
the work area users.

An understanding of the process, equipment, materials and location of the works are
important considerations. This will assist in identifying the sources of release and extent of
the hazardous areas.

An essential part of this process is to identify the properties of the flammable material/s present
so the risk level of each material can be assessed. These material properties typically consist of
parameters such as ignition temperature, density and lower explosive limits, etc. An example of a
data sheet containing flammable material properties is shown in Appendix C of this guide. The
group and temperature class of the flammable material is an aid to selecting appropriate
hazardous area rated equipment that may be required to operate in these areas.
The outcomes of the hazardous area assessment as documented in the report will be information
on the type and extent of the hazardous areas pertaining to the process or facility. This
information will consist of the extent and type of hazardous zones (e.g., Zone 1 or Zone 2) in the
form of drawings and data sheets. An example of a data sheet containing a list of sources of
release and hazardous zones type and extent is shown in Appendix C of this guide.
The extent and type of hazardous zones due to flammable vapours and gases for a number of
typical situations are shown in the relevant illustrative examples described in AS/NZS IEC
60079.10.1 Supplement 1: 2022. Where applicable, these illustrative examples can be used to
define the hazardous zones for a particular situation (category of occupancy) and will form the
basis of the hazardous area documentation. If the actual situation departs significantly from the

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typical examples, the type and extent of the hazardous zones must be defined by the fundamental
principles as discussed in AS/NZS IEC 60079.10.1. A useful schematic approach to classifying
hazardous areas is shown in the form of a flowchart (Annex F) in AS/NZS IEC 60079.10.1.
Below is a typical example of a hazardous area drawing:
Figure 1 – Laboratory hazardous areas – Example from AS/NZS 60079.10.1
Laboratory bench and floor level

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 Figure 2 – Fume cupboard hazardous areas – Example from AS/NZS 60079.10.1 Sup. 1
F.1.3 - Fume cupboard not complying with AS/NZS 2243.8 and laboratory floor level

0.6 m

Fume
3.0 m Min

Cupboard

0.6 m
Exhaust
Fan

Roof Line

0.6 m
Wall

PLAN
Fume Cupboard not
complying with
AS/NZS 2243.8
0.3 m

Floor Level

ELEVATION
LEGEND:
ZONE 1 ZONE 2
(AS/NZS IEC 60079.10.1) (AS/NZS IEC 60079.10.1)

Figure F.1.3
Fume cupboard not complying with AS/NZS 2243.8. Note as of 2021, fume cabinets
complying with AS/NZS 2243.8 are not automatically considered hazardous areas.

Hazardous area drawings for installations, in addition to the above figures, will generally include
more detailed floor plan layouts, sections and elevations showing the extent and type of zoning
based on architectural floor plans of the facility. These may also include detailed zoning in and
around apparatus and equipment, as well as around pipe fittings, valves and in pits and conduits.
Detailed manufacturer’s equipment drawings and mechanical services drawings would normally
be required for the latter details.

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3 Managing Hazardous Areas
3.1 Mitigation of Risk
Where elimination of risk is not possible, it is necessary to reduce the risk so far as is reasonably
practicable. This can be done, for example, by:
• substituting the flammable material with a less flammable material,
• reducing the quantity of flammable materials used,
• isolating the process from personnel and ignition sources,
• applying engineering controls such as local ventilation,
• applying administrative controls such as safe operating procedures and training, and/or
• providing personal protective equipment.
A combination of some or all of these initiatives may be used to reduce the risk when elimination
is not possible.

3.2 Removal of Ignition Sources

If the source of release cannot be eliminated and a hazardous area will exist, the most
effective ways to manage the risk, with generally least cost, is to ensure that no ignition
sources are present within the hazardous area.

This means that all potential ignition sources (e.g., non-rated electrical equipment such as
compressor motors, general power outlets (GPOs), etc.) must be located outside of the hazardous
area. With a new building design or fit-out this can be achieved by good planning and design. With
an existing facility, potential ignition sources will need to be removed (see below).
A very important consideration when controlling the hazardous area risk through the removal of
ignition sources is to ensure that strict operating procedures are in place that prevent unrated
fixed or portable ignition sources being installed or brought into the hazardous area. These
procedures must be communicated to all personnel involved in the laboratory operations,
including cleaning staff and contractors.

3.3 Relocation of Equipment

A survey must be undertaken of all equipment in existing facilities that are being converted into
one where there is a risk of a hazardous area being introduced. This will require all non-rated
ignition sources and equipment to be relocated out of the hazardous area or replaced with
hazardous area rated equipment.

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3.4 Hazardous Area Rated Equipment

3.4.1 Types of Protection

Multiple explosion protection techniques, or types of protection, are available for hazardous area
rated electrical equipment. These techniques are identified by the prefix Ex (meaning Explosion-
protected) followed by a letter corresponding to the type of protection. The following table
summarises the various types of protection grouped by their principal method of protection.
Table 1 – Types of Explosion Protection

Method Symbol Type of Protection

Exclusion Ex t Dust ignition protection
Ex m and Ex mD Encapsulation
Ex n Non-sparking (hermetically sealed devices, sealed devices and restricted
breathing)
Ex o Oil-immersion
Ex p and Ex pD Pressurised enclosure
Ex q Powder filled (sometimes called ‘sand filled’)
Explosion containment Ex d Flameproof enclosure
Ex n Non-sparking (enclosed-break devices)
Energy limitation Ex i and Ex iD Intrinsic safety
Ex n Non-sparking (non-incendive components and energy limitation)
Dilution Ex v Ventilation
Avoidance of ignition source Ex e Increased safety
Ex n Non-sparking (inherently non-sparking)
Other techniques shown to Ex s Special protection
be suitable by test

Discussion of the applicability of the various techniques is beyond the scope of this guide,
however, for Zone 1 areas the most common protection techniques are Ex d (flameproof) or Ex i
(intrinsic safety); and for Zone 2 areas Ex n (non-sparking) is commonly used. Generally, within
each Method grouping (e.g., Exclusion), any Type of Protection can be used (e.g., Encapsulation or
Pressurised enclosure) to achieve the aim of that method, subject to the limitations of applicability
imposed by the specific application. For non-electrical equipment, an Ex h marking will indicate it
is suitable for hazardous areas in accordance with the ISO/IEC 80079 series of standards as
modified in Australia (AS/NZS 80079 suite).
In addition to the type of protection chosen, other parameters which relate to the selection of
electrical equipment for hazardous areas include the apparatus Group and the apparatus
Temperature classification. These parameters will be discussed further in Section 3.4.2 below.
Hazardous area rated equipment suitable for a higher risk zone is acceptable for lower risk zones,
e.g., Zone 1 rated equipment is suitable for use in a Zone 2 hazardous area. However, the reverse
is not true; that is, Zone 2 rated equipment is not suitable for use in a Zone 1 or Zone 0 hazardous
area.
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When it is not possible to provide suitable hazardous zone rated equipment for certain areas, the
method of dilution ventilation control may be used to minimise the possibility of an explosive gas
or vapour mixture forming. The methodology used is based on that described in Appendix A of AS
14821 “Electrical equipment for explosive atmospheres - Protection by ventilation - Type of
protection v”. This methodology provides a means to calculate the rate of dilution air flow
required to control the concentration of a vapour or gas emitted into the air to no more than 25%
of the vapour or gas’s Lower Explosive Limit (LEL). Another related method is described in Annexe
B of AS/NZS 60079.10.1. This calculation procedure assesses the degree and availability of
ventilation that will assist in controlling the dispersion and persistence of an explosive gas or
vapour atmosphere and it can be used to estimate the extent of the hazardous zones.

3.4.2 Selection of Equipment

The selection of electrical apparatus for use in a hazardous area generally requires the following
key information to be considered:
a. The classification of the area, i.e., Zone 0, 1 or 2. As discussed in Section 2.4.
b. Where applicable, the Group or the characteristics of the gas or vapour involved in relation
to:
i. igniting current or minimum ignition energy for installations of intrinsically safe
apparatus; or
ii. safe gap data in the case of installations for flameproof enclosures.
c. The temperature class or ignition temperature of the gas or vapour involved.
d. Other considerations, such as protection from mechanical damage, the relevant ambient
temperature, non-electrical ignition sources, the control of static electricity, ingress
protection (IP rating), etc. must be taken into account in the apparatus selection process.
The Equipment Grouping (Group) is a classification system of equipment related to the explosive
atmosphere for which the equipment is intended to be used. This data is derived from
experiments involving the subject gas or vapours. The three Groups are as follows:
• Group I - equipment for mines susceptible to firedamp (a gas that occurs naturally in coal
seams and is primarily coalbed methane);
• Group II - equipment for all places with an explosive gas atmosphere other than mines
susceptible to fire damp (this Group is divided into three sub-groups; A, B and C);
• Group III - equipment for all places with an explosive dust atmosphere other than mines
susceptible to fire damp (this Group is divided into three dust-type sub-groups; A, B and C).
Group II is the group relevant to most laboratory operations involving flammable vapours and
gases. Group III applies to combustible dust hazards which may be applicable in some laboratory
situations. Group I is generally only relevant to the mining industry.

1 Note: AS 1482 Appendix A has been incorporated in Appendix H of AS/NZS IEC 60079.10.1 Supplement 1

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Equipment belonging to Group II is subdivided according to the nature of the explosive gas
atmosphere for which it is intended. Group II subdivisions are as follows:
• IIA, a typical gas is propane
• IIB, a typical gas is ethylene
• IIC, typical gases are hydrogen and acetylene.
The Group subdivisions are based on the Maximum Experimental Safe Gap (MESG) or the
Minimum Igniting Current ratio (MIC ratio) of the explosive gas atmosphere in which the
equipment may be installed. Either or both of these parameters are used to define the correct
subdivision. (For further information on the derivation of the MIC and MESG values and for
tabulated data of many gases and vapours, refer to AS/NZS 60079.20.1).
In simple terms of the risk of a gas or vapour being ignited, IIC is a higher risk than IIB, and IIB is a
higher risk than IIA. Hence, equipment marked IIB is suitable for applications requiring Group IIA
equipment. Similarly, equipment marked IIC is suitable for applications requiring Group IIA or
Group IIB equipment. This is shown in the table below.
Table 2 – Allowable Apparatus & Gas Group II Subdivisions

Group of Gas Allowable Group of Apparatus

IIA IIA, IIB, IIC
IIB IIB, IIC
IIC IIC

The Temperature Class is a classification system of Ex equipment, based on its maximum surface
temperature, related to the specific explosive gas atmosphere for which it is intended to be used.
This data is again derived from experiments involving the subject gas or vapours. The table below
shows the different Temperature Classes in relation to Group II electrical equipment.
Table 3 – Relationship between Temperature Class, Surface Temperature & Ignition Temperature

Temperature Class of Maximum Surface Auto Ignition Allowable Temperature

Electrical Apparatus Temperature of Electrical Temperature of Gas Or Classes of Equipment
Apparatus (°C) Vapour (°C)
T1  450  450 T1 to T6
T2  300  300 T2 to T6

T3  200  200 T3 to T6

T4  135  135 T4 to T6
T5  100  100 T5 to T6

T6  85  85 T6

When considering the Temperature Class and an item of electrical equipment located in a
hazardous area containing a flammable gas or vapour, for auto-ignition to occur, the surface
temperature of the equipment needs to be sufficient to cause the gas or vapour to ignite without
the presence of a spark or flame. (The mixture of gas or vapour with air would also need to be

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between the gas or vapour’s lower explosive limit (LEL) & upper explosive limit (UEL)). To prevent
ignition due to hot equipment surfaces, the maximum surface temperature of the equipment
must be below the auto-ignition temperature of the gas or vapour. For example, propane has an
auto-ignition temperature of 450°C. From the table above, the minimum applicable Temperature
Class of apparatus would therefore be T2 (300°C). T3 to T6 rated apparatus would also be suitable
for use with this gas. For another example, diethyl ether has an auto-ignition temperature of
175°C. The minimum applicable temperature class of apparatus would therefore be T4 (135°C). T5
to T6 rated apparatus would also be suitable for use with this vapour.
The Temperature Class rating of the hazardous area equipment always corresponds with a
temperature less than the auto-ignition temperature of the gas or vapour for which it is intended
to be used.
The above Zone, Group and Temperature Class information will be marked on the hazardous area
apparatus and the related certification documents.
An alternative (risk-based) designation system for equipment suitable for installation in explosive
atmospheres is the Equipment Protection Level (EPL) system. The EPL will sometimes be listed on
equipment certificates and markings. The relationship between hazardous zones and EPLs for
explosive gas (G) and dust (D) atmospheres are shown in the table below.
Table 4 – Equipment Protection Levels & Hazardous Zone Assignments

Zone Equipment Protection Level

(EPL)
0 Ga
1 Ga or Gb
2 Ga, Gb or Gc
20 Da
21 Da or Db
22 Da, Db or Dc

3.4.3 Interpretation of Equipment Ex Markings

All hazardous area electrical equipment must be appropriately labelled with markings defining the
hazardous area/s where the equipment can be safely used, as well as other identifying
information. The marking shall include the following:
a. the name of the manufacturer or its registered trademark
b. the manufacturer's type identification
c. a serial number
d. the name or mark of the certificate issuer and the certificate reference
e. any specific conditions of use
f. the specific Ex marking for explosive gas (refer to Table 5 below) or dust atmospheres
g. any additional marking prescribed in the specific standards for the types of protection
concerned.

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 Table 5 – Summary of Required Equipment (Group II) Marking for Common Techniques

Manufacturer’s name or trademark

Manufacturer’s identification/model number
The following symbols:
Explosion Type of Apparatus Temperature Degree of ingress protection (where applicable)
protection protection group (or class (or actual
Code 1st Numeral 2nd Numeral
symbol specific gas) temperature)
Ex d IIA T1 IP 1 1
e IIB T2 2 2
ia or (ia) IIC T3 3 3
ib or (ib) T4 4 4
ic or (ic) T5 5 5
m T6 6 6
n 7
o 8
p
q
s
v

The following figures show typical markings on hazardous area rated equipment.
Figure 3 – Example of a Hazardous Area Rated Equipment Markings – Example 1 - Switch

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Example 1: The markings relevant to an Australian context are the IECEx (see Section 3.4.4 below)
text. This includes the following information:
“IECEx PTB 06 0090” This is the Certificate of Conformity number which certifies the
equipment as complying with the IECEx Scheme.
“Ex de IIC T6 Gb” This is the explosive gas atmosphere the apparatus is rated to
operate within. Ex de indicates the type of protection is a
combination of Flameproof (d) and Increased Safety (e). The Gas
Group is IIC and the Temperature Class is T6. The EPL is Gb.
Generally, this means that the apparatus is suitable for installation in
a Zone 1 or Zone 2 hazardous area that may contain, for example,
hydrogen (IIC, T1 gas group).
“Ex tD A21 IP66 T80°C Db” This is the explosive dust atmosphere the apparatus is rated to
operate within. Ex tD indicates the type of protection is by Enclosure.
A21 indicates that the Type of Practice is A (A or B, refer to AS/NZS
61241.1:20052 Electrical apparatus for use in the presence of
combustible dust Part 1: Protection by enclosures ‘tD’) and the
explosive dust Hazardous Zone is 21. IP66 is the Ingress Protection
rating (first 6 = complete protection against entry of dust; second 6 =
protection against a strong jet of water from all practicable
directions). T80°C indicates that the maximum surface temperature
of the apparatus is 80°C. The EPL is Db.
“Ta = -20°C … +55°C” This is the temperature range the apparatus can operate within.

2 Now obsolete. Refer to AS/NZS 60079.31:2014. (tD protection is more recently known as ta, tb or tc).

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 Figure 4 – Example of a Hazardous Area Rated Equipment Markings – Example 2 - Aspirating Smoke Detector

Example 2: The IEC Ex text includes the following information:

“Ex ic nA IIC T5 Gc IP54” This is the explosive gas atmosphere the apparatus is rated to
operate within. Ex ic and nA indicates the type of protection is both
Intrinsically Safe (ic) and Spark Proof (nA). The Gas Group is IIC and
the Temperature Class is T5. The EPL is Gc. IP54 is the Ingress
Protection rating. Generally, this means that the apparatus is suitable
for installation only in a Zone 2 hazardous area that may contain, for
example, acetylene (IIC, T2 gas group).
“IECEx ITS 12.0008X” This is the Certificate of Conformity number which certifies the
equipment as complying with the IECEx Scheme.
Where “X” appears in the Certificate of Conformity number, it indicates that the equipment has a
specific condition of use associated with it and caution must be observed in ensuring the
equipment is only used within the limitations of the conditions of use stated in the Certificate of
Conformity documents.

3.4.4 Certification of Equipment

All electrical equipment or apparatus that will be installed or brought into a hazardous area
must be appropriately hazardous area rated for operation in the particular hazardous zone in
which it will be located. To ensure equipment complies with this requirement, it must be
tested and certified to operate in the proposed environment. A Certificate of Conformity
must accompany all such equipment and it must be marked with the appropriate information
indicating the limitations of its use.

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In Australia, the International Electrotechnical Commission (IEC) Ex Scheme has largely been
adopted for the certification of equipment for explosive atmospheres. Local certification is
administered by the Australian National Ex Certification Scheme (ANZEx Scheme). Under this
scheme: the installation standards for electrical equipment to be installed in a Hazardous Area
require ‘Proof of Compliance’ according to a Type 53 scheme in AS/NZS [ISO/IEC]17067 and the
related Standards. Either a Certificate of Conformity within this ANZEx Scheme or an IECEx
Certificate of Conformity is deemed to comply with this requirement. The Australian Standards
covering explosive atmospheres are now largely based on the equivalent IEC Standards.
In the European Union (EU) an alternative certification scheme is the ATEX scheme. The ATEX
scheme operates under two EU Directives and uses European (EN) Standards. While the IECEx
scheme is applicable internationally, the ATEX scheme is limited to the EU. Although there are
some small differences between each certification, ATEX and IECEx are very similar. In Australia,
however, equipment that carries only an ATEX certification is not accepted and would require
approval for its use from the appropriate regulatory authority in each state. Other international
certification schemes, e.g., from the USA (UL and FM) or Canada (CSA), are generally not accepted
in Australia. A Conformity Assessment Document is required for all equipment that does not have
an ANZEx or IECEx certification to provide justification for its use and to establish that the
equipment protection provides an equivalent level of safety.
An example of a typical certificate for a luminaire assembly is shown in the figure below. This is an
extract from the full certificate which also includes other pages of supporting information, for
example: references to test reports, compliance standards, drawings, operating conditions, etc.

3 The ANZEx and IECEx Schemes are both ISO Type 5 Schemes which involve three basic elements: Type Test, Quality Assurance and Ongoing
Surveillance of manufacturers.

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 Figure 5 – Example of a Certificate of Conformity for a Luminaire

3.4.5 Inspection

All new hazardous area rated equipment installed in a workplace requires an initial inspection by
qualified personnel prior to commissioning and use. This is required to ensure that the selected
type of protection and its installation are appropriate. The initial inspection is required to be
carried out in accordance with the requirements for detailed inspections in AS/NZS 60079.14.

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 Under all state and territory legislation, electrical equipment installed in a hazardous area is
considered to be prescribed electrical installation work. As such, the equipment must be
inspected by a licensed electrical inspector who has the required level of competency with
respect to a detailed understanding of safety in electrical installations in hazardous areas. A
Certificate of Electrical Safety issued for the installation must include the details of the
inspection of all hazardous area electrical equipment relating to the installation.

For ongoing maintenance and inspection requirements refer to the discussion in Section 5.2.

3.5 Other Risk Controls

3.5.1 Adequate Ventilation

Adequate ventilation as defined by the various codes and standards is a fundamental

engineering control for laboratory facilities and must be provided to a laboratory at all times
the facility is occupied and operated.

Adequate ventilation is an important component in the prevention and control of hazardous areas
since diluting flammable gases and vapours to concentrations below their explosive limits when
mixed with air is a very effective risk management control.
In laboratories and hazardous chemical stores, mechanical ventilation is usually relied upon to
provide adequate ventilation. Alarms and interlocks should be provided to ensure the laboratories
are not operated during periods when the ventilation system is not operational as per the
intended design. Consideration should be given to providing the mechanical ventilation system
with an emergency power provision to maintain adequate ventilation to laboratory areas.
Natural ventilation may be provided to provide adequate ventilation in some situations; however,
these situations are usually limited to outdoor locations or separate stores buildings that have an
abundance of high and low ventilation openings (e.g., air louvres and vents).

3.5.2 Flammable Vapour/Gas Detection

A method of providing early warning of the dangerous build-up of flammable vapours or a

flammable gas leak in an enclosure is to provide flammable gas/vapour sensors linked to audible
and visible alarms.

If it is determined that there is a risk that the concentration of flammable gas could exceed
5% of the gas’ LEL, these detection systems must be installed and be interlocked with gas
shut-off devices (solenoid valves) and a method of isolating the electrical supply. See the
Reticulated Gas Installations and Maintenance Guide for more information.

The mounting height of these sensors will depend on the density of the flammable vapour or gas.
Most flammable liquid vapours are heavier than air and a sensor mounted near the floor would be

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appropriate. Lighter than air flammable gases such as hydrogen would require a sensor mounted
near the highest internal points of the enclosure.
Gas sensors for Flammable Gas/Vapour sensing must be designed in accordance with AS/NZS
60079.29.2:2009 “Electrical apparatus for explosive gas atmospheres: Part 29.2: Gas detectors -
Selection, installation, use and maintenance of detectors for flammable gases and oxygen”.

3.5.3 Control of Static Electricity

Where practices in the facility may involve the use or generation of flammable vapours, gases or
combustible dusts and there is a risk of spark ignition due to an electro-static discharge causing a
fire or explosion, static electricity may be controlled in accordance with the equipotential bonding
and earthing requirements of AS/NZS 1020 – “The control of undesirable static electricity” and
Clause 9.2.7.4 of AS 1940. A personnel earth bonding method to avoid static electricity may be
applicable. The method may consist of an anti-static earthed wrist strap and flexible lead, and may
be supplemented by earthed anti-static bench covers, floor mats, chair covers, humidity control
and ionized air sources.

The control and management of static electricity is often a complex subject and specialist
consultants and electrical engineers may be required to assist with the provision of
appropriate techniques depending on the complexity of the situation.

3.6 Hazardous Area Drawings

Hazardous area drawings for the facility that show the extent and type of zoning must be kept
by the facility management to inform the laboratory users of the risks associated with each
process.

These drawings must be readily available as separate documents or as part of the Hazardous Area
Report and the Hazardous Area Verification Dossier (see section 4 of this guide) relating to the
facility. A management process must be in place to communicate to all laboratory users, both
existing and new, that the area they will be working in is subject to a hazardous area risk
management process.
The drawings must be kept up to date to reflect any changes in equipment, processes or materials
used.
Examples of typical hazardous area drawings are included in Appendix C of this guide.

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4 Hazardous Area Verification Dossier

A Hazardous Area Verification Dossier must be kept at each facility where Hazardous Area
rated equipment is located.

A Hazardous Area Verification Dossier (Dossier) is a set of documents showing the compliance of
electrical equipment and installations. The production of the Dossier will normally require the help
of specialists in consultation with the occupiers of the facility.
A Dossier must contain:
• Hazardous area classification documents (e.g., a Hazardous Area Report), with drawings
showing the classification (zones) and extent of the hazardous areas. Include details of any
hazard identification and operability analyses and risk assessments.
• As installed, drawings of hazardous area equipment.
• Details of the method of assessment, including any relevant calculations.
• The applicable equipment group or subgroup for the flammable or combustible material.
• The temperature class or ignition temperature of the flammable material.
• Safety Data Sheets for the flammable or combustible material.
• Instructions for erection and connection of hazardous area rated equipment.
• Certificates of Conformity (including conditions of use) for all hazardous area rated
equipment, electrical accessories, electrical conduit and connections installed in the
hazardous zones.
• Descriptive system documents for any intrinsically safe systems. The document shall specify
the items of electrical equipment and the electrical parameters of the system, including those
of interconnecting wiring. (Refer to AS/NZS 60079.25 for detailed requirements).
• Details of any uncertified apparatus including manufacturer’s name, its type number and the
justification for its use. Include Conformity Assessment Documents for all equipment that does
not have an ANZEx or IECEx certification.
• Manufacturer’s instructions for the equipment, e.g., Operation and Maintenance manuals.
• Information necessary for inspection and maintenance, e.g., schedules, checklists, list and
location of equipment, spares, technical information and manufacturer’s maintenance
instructions.
• Information necessary for the repair of the electrical equipment.
• Records of selection criteria for cable entry systems.
• Drawings and schedules relating to circuit identification.
• Copies of inspection records including details of the initial inspection and all subsequent
inspections.
• Copies of defect reports and corrective actions undertaken.
• Copies of maintenance records.

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 • Any other material that is relevant to the hazardous area classification and the selection,
inspection, maintenance and repair of the hazardous area rated equipment.
Further information describing what is expected to be included in a Dossier is contained in
Australian Standards AS/NZS 60079.14:2009 and AS/NZS 60079.17:2009.

The Dossier is a “live” document and the details of any alterations to the facility which effect
the hazardous areas defined therein, or the hazardous area rated equipment used in those
areas, must be incorporated in the Dossier by way of updating the document in a timely
manner.

The sole responsibility for updating the document shall rest with the occupier or the authorised
representative/s of the facility, or the person conducting the business or undertaking. A copy of an
up-to-date Dossier must be kept on the premises at all times, and made available to the personnel
who will be working in the hazardous area, and to all maintenance and electrical contractors who
will be undertaking work in, or associated with, the hazardous area.

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5 Maintaining Hazardous Area Equipment
5.1 Documentation
The minimum documentation required to maintain hazardous area equipment is that contained in
the Hazardous Area Verification Dossier. Refer to Section 4 above for the general requirements.
Different hazardous area protection concepts have different maintenance requirements, and it is
imperative that the details of the protection techniques used for all the equipment is well
documented.

A continuous record of all inspections, defects, repairs and maintenance activities shall be
kept and included in the Dossier. Sample maintenance and repair certificates and forms are
included in Appendix C of the Standards Australia Handbook HB 239.

5.2 Maintenance & Inspection

Ongoing inspection, testing and maintenance are essential to ensure the continued satisfactory
performance and safety of the hazardous area rated equipment and systems.

The inspection and maintenance of hazardous area installations shall be carried out only by
experienced personnel with the necessary level of competency, whose training has included
instruction about the various types of protection and installation practices, the requirements
of the relevant standards and regulations applicable to the installation and the general
principles of hazardous area classification.
In general, this will require an external qualified person4 to undertake inspection or
maintenance of equipment rated for use in hazardous areas.

The following types and levels of inspections shall be undertaken throughout the life of the
hazardous area equipment, as appropriate to the type and complexity of the installed equipment,
the standard’s provisions and the manufacturer’s requirements. The frequency of inspections will
vary with the type of equipment and should be based on the manufacturer’s recommended
inspection and maintenance intervals, as well as specific requirements of the installation and good
maintenance practice.
Types of inspections:
a. Initial inspections used to check that the selected type of protection and its installation are
appropriate. The initial inspection shall be in accordance with the requirements for detailed
inspections in AS/NZS 60079.14.

4 Qualified person as per clause 4.2 of AS 60079.17 – 2017. The person may also need to demonstrate the relevant qualifications as required by the
local state electrical safety regulator.

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 b. Periodic inspections which may be visual, close or detailed in accordance with AS/NZS
60079.17.
c. Sample inspections which may be visual, close or detailed in accordance with AS/NZS
60079.17. Sample inspections should not be expected to reveal faults of a random nature,
such as loose connections, but should be used to monitor the effects of environmental
conditions, vibration, inherent design weakness, etc.
Three levels of inspection:
a. visual inspection - inspection which identifies, without the use of access equipment or tools,
those defects, such as missing bolts, which will be apparent to the naked eye.
b. close inspection - inspection which encompasses those aspects covered by a visual
inspection and, in addition, identifies those defects, such as loose bolts, which will be
apparent only by the use of access equipment.
c. detailed inspection - inspection which encompasses those aspects covered by a close
inspection and, in addition, identifies those defects, such as loose terminations, which will
only be apparent by opening the enclosure, and/or using, where necessary, tools and test
equipment.
If any faults or defects are identified during the inspections, it shall be immediately brought to the
attention of the responsible person or persons managing the facility. All faults or defects that may
compromise the performance of the hazardous area equipment and the safety of the facility shall
require the immediate cessation of the activities in the area that may lead to an explosive
atmosphere forming. The fault or defect shall be fully rectified before the hazardous area
operation can recommence.
Faulty or defective hazardous area rated equipment shall be repaired or replaced as necessary.
Where the repairs involve hazardous area rated electrical equipment, they shall be undertaken
only by a hazardous area qualified electrician with the required level of competency and may
require inspection by a licensed electrical inspector.

A Permit to Work system (e.g., hot works permit), Job safety Analysis and Safe Work Method
Statement systems must be employed for all maintenance work carried out in the hazardous
area to ensure that maintenance personnel are aware of the risks and importance of not
compromising the safety of the hazardous area during the works. This applies to both work
related to the hazardous area equipment, and to general maintenance activities. No
unauthorised modification shall be made to any apparatus installed in a hazardous area.

Repair and overhaul of Ex rated equipment shall comply with the relevant requirements of AS/NZS
3800 - Electrical equipment for explosive atmospheres - Repair and overhaul (IEC 60079-19:2015
(ED. 3.1), MOD). Further guidance is provided in Standards Australia Handbook HB 239 - Guidance
on the repair and overhaul of electrical equipment for explosive atmospheres.

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5.3 Signage
In addition to the mandatory labelling of all hazardous area rated equipment installed in the
facility (refer to Section 3.4.3 above), signage must be provided within or close to the identified
hazardous areas. This signage must alert occupants to the presence of a hazardous area due to a
potentially explosive atmosphere. The signage may also indicate the type of hazardous zone/s
present and should refer to the location of the Hazardous Area Verification Dossier and contact
details of a responsible person. A suggested hazardous area sign is as follows:

WARNING: HAZARDOUS AREA

There is an explosive atmosphere risk in: Room/Area/Apparatus.
The type of hazardous area is: Zone 1 (for example).
Equipment installed in this room may be hazardous area rated.
For further information refer to the Hazardous Area Verification Dossier located at: xxxxxxxx.
For all enquiries contact: xxxx xxxx.

This signage can be incorporated into other room signage indicating hazards in the area. See
Appendix C Figure 9 for an example of how the hazardous area signage could be incorporated with
a CSIRO area hazard poster template.

5.4 Regular Review

The inspection, testing and maintenance of hazardous area equipment in a facility will require
regular review to capture any changes to the operations, materials, condition of equipment or the
types of equipment installed. These regular reviews and upkeep of the Hazardous Area
Verification Dossier for the facility should form part of the ongoing management (e.g., an area
housekeeping inspection).

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Appendix A – Hazardous Area Classification for
Potentially Explosive Atmospheres

Background
A hazardous area can be defined as an area in which an explosive atmosphere (due to flammable
gas, vapour or combustible dust) is present, or may be expected to be present, in quantities such
as to require special precautions for the construction, installation and use of apparatus.
Hazardous area classification is a method of analysing and classifying the location where explosive
atmospheres may exist. From this the facility management team can implement appropriate
control procedures. One of these is the proper selection and installation of electrical apparatus for
that location.
The hazard can be due to flammable liquids, vapours, mists, gases, combustible dusts, fibres or
flyings (waste fibres generated through carding, drawing, spinning or similar).
Workplace safety and dangerous goods storage and handling legislation requires a hazardous area
classification assessment to be carried out where workplace hazards involve the risk of explosion
due to gases and vapours and dusts. The ‘area classification’ must be carried out before any
apparatus can be installed.
The nature of the hazard, in particular the relevant properties of the hazardous material, must be
considered as part of the analysis. For gases, vapours, mists and flammable liquids the area
classification establishes the zone, gas classification, temperature classification, the extremes of
ambient temperature that may be encountered and any specific requirements of the location.

Zone Classifications
AS/NZS 60079.10.1 defines three zones for flammable vapours and gases as follows:
Zone 0 – an area in which an explosive gas atmosphere is present continuously or is present for
long periods or frequently. Examples would be the vapour space of vented vessels, vapour space
of vented storage tanks and immediately adjacent to a continuous source of release.
Zone 1 – an area in which an explosive gas atmosphere is likely to occur in normal operation
occasionally. Examples would be where pumps are liable to leak under normal conditions, or
where vents, relief valves or sample points are likely to release vapour to the atmosphere.
Zone 2 – an area in which an explosive gas atmosphere is not likely to occur in normal operation
but, if it does occur, it will exist for a short period only. Examples would be where vessels, pumps,
compressors and pipes containing flammable gases and liquids are constructed and maintained to
prevent leakage under normal operating conditions.

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The preferred symbols for hazardous zones relating to flammable vapours and gases that would be
displayed on hazardous area diagrams or drawings are shown in Figure 6 below. Different symbols
are used for explosive dust atmospheres (refer to AS/NZS 60079.10.2 Clause 8.2.2, Figure 1).
Figure 6 – Symbols for Flammable Gas or Vapour Hazardous Area Zones as per AS/NZS 60079.10.1:2009

AS/NZS 60079.10.2 similarly, but with some differences due to the nature of the material, defines
three zones where explosive dust atmospheres may exist (defined as Zones 20, 21 and 22). These
zones are defined as follows:
Zone 20 – a place in which an explosive dust atmosphere, in the form of a cloud of dust in air, is
present continuously, or for long periods or frequently. The dust will be in sufficient quantity to be
capable of producing an explosive concentration of combustible dust mixed with air, and/or where
layers of dust of uncontrollable and excessive thickness can be formed. Examples include dust
containment areas where dust can form explosive mixtures frequently or for long periods of time.
This occurs typically inside apparatus.
Zone 21 – a place in which an explosive dust atmosphere, in the form of a cloud of dust in air, is
likely to occur in normal operation occasionally. The dust will be in sufficient quantities to be
capable of producing an explosive concentration of combustible dust mixed with air. Examples
include areas in the immediate vicinity of powder filling or emptying points and areas where dust
layers occur and are likely in normal operations to give rise to an explosive concentration of
combustible dust mixed with air.
Zone 22 – an area in which an explosive dust atmosphere, in the form of a cloud of combustible
dust in air, is not likely to occur in normal operation but, if it does occur, will persist for a short
period only. This may also occur when accumulations or layers of combustible dust may be
present under abnormal conditions and give rise to combustible mixtures of dust in air. Examples
include, amongst others, areas in the vicinity of apparatus containing dust in which dust can
escape from leaks and form deposits (such as milling rooms in which dust can escape from the
mills and then settle).

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Appendix B – Key Legislation, Codes & Standards
• Commonwealth Work Health and Safety Act 2011 and Regulations 2011.
• Managing Risks of Hazardous Chemicals in the Workplace - Code of Practice – Safe Work
Australia.
• State and Territory Work Health and Safety (or Occupational Health and Safety etc.) Acts and
Regulations.
• State and Territory Dangerous Goods (or Hazardous Chemicals etc.) – Storage and Handling
Acts and Regulations.
• National Construction Code – Building Code of Australia Volume 1.
• AS/NZS 1020: 1995 – The control of undesirable static electricity.
• AS 1482: 1985 – Electrical equipment for explosive atmospheres – Protection by ventilation -
Type of protection v.
• AS 1940: 2017 – The storage and handling of flammable and combustible liquids.
• AS/NZS 2243 Series – Safety in laboratories.
• AS/NZS 2982:2010 – Laboratory design and construction.
• AS/NZS 3800 – Electrical equipment for explosive atmospheres – Repair and overhaul (IEC
60079-19:2015 (ED. 3.1), MOD).
• AS 4332:2004 – The storage and handling of gases in cylinders.
• AS/NZS 4745:2012 – Code of practice for handling combustible dusts.
• AS/NZS IEC 60079.10.1:2022 – Explosive gas atmospheres: Classification of areas – explosive
gas atmospheres.
• AS/NZS IEC 60079.10.1:2022 Sup 1: 2022 - Explosive gas atmospheres: Classification of areas –
explosive gas atmospheres – Commentary (Supplement 1 to AS/NZS IEC 60079.10.1:2022.
• AS/NZS 60079.10.2:2016 – Explosive gas atmospheres: Classification of areas – explosive dust
atmospheres.
• AS/NZS 60079.14:2017 – Explosive atmospheres: Design selection, erection and initial
inspection (IEC 60079-14:2013 (ED.5.0) MOD).
• AS/NZS 60079.17:2017 – Explosive atmospheres: Electrical installations inspection and
maintenance (IEC 60079-17:2013 (ED.5.0) MOD).
• AS/NZS 60079.20.1:2012 – Explosive atmospheres: Material characteristics for gas and vapour
classification – Test methods and data.
• AS/NZS 60079.29.2:2009 – Electrical apparatus for explosive gas atmospheres: Gas detectors –
Selection, installation, use and maintenance of detectors for flammable gases and oxygen.
• HB 13—2007 – Handbook – Electrical equipment for hazardous areas.
• HB 239 – 2011 – Handbook – Guidance on the repair and overhaul of electrical equipment for
explosive atmospheres.
• https://www.iecex-certs.com/#/home -database of certification documentation

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Appendix C – Examples
Table C.1 − Hazardous area classification data sheet – Part I: Flammable material list and
characteristics.
Table C.2 − Hazardous area classification data sheet − Part II: List of sources of release.
Figure 7 – Examples of typical Hazardous Area Drawings.
Figure 8 – Closed vessel hazardous areas – Example Fig. D.4.2.2 from AS/NZS 60079.10.1 Supp. 1.
Figure 9 – Example of a CSIRO Area Hazard Poster containing the hazardous area signage.
Example of Hazardous Area Risk Assessment – Chemical Storage Cabinets

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Table C.1 − EXAMPLE of Hazardous area classification data sheet – Part I: Flammable material list and characteristics
Sheet: 1/1
Plant: Flammable liquid & gas process plant Reference drawings:
Haz. Area Zone Diag.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Flammable material LEL Volatilitya

Vapour Polytropic index

Any other relevant
Flash-point 3 pressure Melting Boiling point of adiabatic Relative density Ignition Temp.
No. Name Composition kg/m vol. % Group information and
°C 20 °C point °C °C expansion gas/air temp. °C class
remarks
kPa g

1 Ethanol C2H6O 12 0.060 3.1 5.950 -114 78 n/a 1.600 400 IIB T2
2 Methanol CH4O 9 0.080 6.0 13.020 -98 65 n/a 1.113 440 IIA T2
3 Isopropanol C3H8O 12 0.050 2.0 4.320 -88 83 n/a 2.087 399 IIA T2
4 Acetone C3H6O -20 0.061 2.5 24.530 -95 56 n/a 2.017 539 IIA T1
5 Ethyl acetate C4H8O2 -4 0.073 2.0 9.700 -83 77 n/a 3.059 470 IIA T1
6 Toluene C7H8 4 0.038 1.0 2.800 -95 111 n/a 3.199 530 IIA T1
7 Xylene C8H10 25 0.044 1.0 2.400 -48 139 n/a 3.686 465 IIA T1 M-Xylene
8 Acetonitrile C2H3N 2 0.051 3.0 9.864 -45 82 n/a 1.425 523 IIA T1
9 MEK C4H8O -10 0.045 1.5 9.500 -86 80 n/a 2.504 404 IIB T2 Methyl ethyl ketone
10 MIBK C6H12O 16 0.050 1.2 2.000 -80 116 n/a 3.478 475 IIA T1 Methyl isobutyl ketone
11 THF C4H8O -14 0.045 1.5 17.000 -108 64 n/a 2.504 230 IIB T3 Tetrahydrofuran
12 MTBE C5H12O -27 0.055 1.5 27.900 -109 55 n/a 3.061 385 IIA T2 Methyl tert-butylether
13 DMF C3H7NO 58 0.055 1.8 0.360 -61 153 n/a 2.538 440 IIA T2 N,N-Dimethyl formamide
14 Hydrogen H2 gas 0.003 4.0 gas -259 -253 1.405 0.070 560 IIC T1

a
Normally, the value of vapour pressure is given, but in the absence of that, boiling point can be used (4.4.1d).

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Table C.2 − EXAMPLE of Hazardous area classification data sheet − Part II: List of sources of release
Sheet: 1/1
Plant: Flammable liquid & gas process plant Reference drawings:
Area: Reactor Rooms, Ventilated Cabinets, General Laboratory, Exhaust Fan Room. Chemical Store. DGs Spill Containment Tank. Hazardous Area Zone Diagrams
1 2 3 4 5 6 7 8 9 10 11 12 13
Source of release Flammable material Hazardous area
Operating
Zone Zone extent
temperature Ventilation
Grade of Reference c type m Any other relevant information
No. Description Location and pressure [1] State Reference
release a b
and remarks
°C kPa Type d Degree e Availabilitye 0-1-2 Vertical Horizontal
1 Flow Reactors Reactor Rooms 1, 2 & 3 S 1 - 13 220 4200 L A Medium Good 2 0.3* ** SK01, *Above floor & below ceiling.
SK05 & **Extent of room.
SK06 Outside Zone - Protection by
ventilation, Type v.
2 Flow Reactors Reactor Rooms 1, 2 & 3 S 14 25 3000 G A Medium Good 2 0.3* ** SK01, *Below ceiling.
SK05 & **Extent of room.
SK06 Outside Zone - Protection by
ventilation, Type v.
3 Spill Reactor Rooms 1, 2 & 3 S 1 - 13 25 0 L A Low Poor 1 * * SK03, *Extent of pit: 0.45m x 3m x 0.46m
containment pit SK05 & deep.
SK06
4 Exhaust Fan Reactor Rooms 1, 2 & 3 S 1 - 14 25 0.06 L, G A Medium Good 2 * * SK05 & *Sphere of radius 3m from exhaust
Flue Discharges SK06 fan flue discharge.
5 Flow Reactors Ventilated Cabinets S 1 - 13 220 4200 L A Medium Good 2 0.3* ** SK03, *Above floor.
SK04 & **Extent of ventilated cabinet.
SK05 Outside Zone - Protection by
ventilation, Type v.
6 Flow Reactors Ventilated Cabinets S 14 25 3000 G A Medium Good * * * SK03, *Extent of ventilated cabinet -
SK04 & Protection by ventilation, Type v.
SK05
7 Chemical spill General Laboratory S 1 - 13 25 0 L A Medium Good 2 0.3* ** SK04, *Above floor.
SK05 & **Extent of laboratory.
SK06
8 Spill General Laboratory S 1 - 13 25 0 L A Low Poor 1 * * SK03, *Extent of drain trench.
containment SK04 &
drain trench SK06
9 Duct leak Exhaust Fan Room S 1 - 14 25 0.20 L, G A Medium Good * * * SK02 & *Protection by ventilation, Type v.
SK05
10 Exhaust Fan Ventilated Cabinets & S 1 - 14 25 0.06 L, G A Medium Good 2 * * SK04, *Sphere of radius 3m from exhaust
Flue Discharges Fume Cupboards SK05 & fan flue discharge.
SK06
11 Chemical Fume Cupboards S 1 - 13 25 0 L A Medium Good NH* * * SK03, *Non-hazardous subject to fume
experiment or SK04 & cupboards being fully compliant
spill SK05 with AS/NZS 2243.8.

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Table C.2 − EXAMPLE of Hazardous area classification data sheet − Part II: List of sources of release
Sheet: 1/1
Plant: Flammable liquid & gas process plant Reference drawings:
Area: Reactor Rooms, Ventilated Cabinets, General Laboratory, Exhaust Fan Room. Chemical Store. DGs Spill Containment Tank. Hazardous Area Zone Diagrams
1 2 3 4 5 6 7 8 9 10 11 12 13
Source of release Flammable material Hazardous area
Operating
Zone Zone extent
temperature Ventilation
Grade of Reference c type m Any other relevant information
No. Description Location and pressure [1] State Reference
release a b
and remarks
°C kPa Type d Degree e Availabilitye 0-1-2 Vertical Horizontal
12 Leak/spill from Flammable Liquids S 1 - 13 25 0 L A Low Poor 1 * * ZA.5.2.3(c) *Interior of flammable liquids
stored Storage Cabinet AS/NZS storage cabinet.
chemicals 60079.10.1
13 Leak/spill from Flammable Liquids S 1 - 13 25 0 L A Medium Good 2 1* 3* ZA.5.2.3(c) *Exterior of flammable liquids
stored Storage Cabinet AS/NZS storage cabinet.
chemicals 60079.10.1
14 Gas Leak Gas Cylinder Store S 14 25 13700 G A Medium Good 2 * * SK01 *Extent of gas store.
15 Chemical spill Bldg 208 - DGs Store S 1 - 13 25 0 L A Medium Good 2 * * SK07 *Extent of DGs store.
16 Spill Bldg 208 - DGs Stores S 1 - 13 25 0 L A Low Poor 1 * * SK07 *Extent of pit: 3m x 1m x 0.5m
containment pit deep.
17 Exhaust Fan Bldg 208 - DGs Stores S 1 - 13 25 0.06 L A Medium Good 2 * * SK07 *Sphere of radius 3m from exhaust
Flue Discharge fan flue discharge.
18 Inlet & Exhaust Bldg 208 - DGs Stores S 1 - 13 25 0.20 L A Medium Good 2 * * SK07 *Interior of inlet & exhaust ducts.
ducts Refer Figure ZA.36, AS/NZS
60079.10.1.
19 Vent Outlet DGs Spill Containment S 1 - 13 25 0 L N Medium Good 2 * * SK07 *Sphere of radius 1.5m from vent
Tank. outlet.
20 Underground East of Bldg 206 & 208 S 1 - 13 25 0 L A Low Poor 1 * * SK07 & *Extent of pit.
Collection pits SK08
21 Underground East of Bldg 206 & 208 S 1 - 13 25 0 L A Medium Good 2 * * SK07 & *Above pit opening from ground
Collection pits SK08 level: 0.3m vertically and 0.5m
horizontally.
22 Vent Pipe From Underground S 1 - 13 25 0 L N Low Poor 1 * * SK07 & *Interior of vent pipe.
Collection pits SK08
23 Vent Outlet From Underground S 1 - 13 25 0 L A Medium Good 2 * * SK07 & *Elongated hemisphere of
Collection pits SK08 horizontal radius 0.5m from vent
outlet and 0.3m high.
24 Interior of Tank - DGs Spill Containment S 1 - 13 25 0 L N Low Poor 1 * * SK07 *Interior of Tank - Extent of
Air/vapour space Tank. air/vapour space.

25 Dip point, hatch DGs Spill Containment S 1 - 13 25 0 L N Medium Good 2 * * SK07 *Hemisphere of radius 0.5m from
etc. Tank. dip point, hatch etc. (For large
openings, e.g. man holes,
measured from edge of opening).

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a
C – Continuous; S – Secondary; P – Primary.
b
Quote the number of list in Part I.
c
G – Gas (Flammable); L – Liquid (Flammable Vapour); LG – Liquefied gas; S – Solid.
d
N – Natural; A – Artificial.
e
See AS/NZS 60079.10.1 Annex B.
[1]
Maximum values from PFDs unless at ambient T & P. Gauge pressure.

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 Figure 7 – Examples of typical Hazardous Area Drawings

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CSIRO Australia’s National Science Agency Managing Hazardous Areas (HA) Technical Guide | 36
 Figure 8 – Closed vessel hazardous areas – Example Fig. D.4.2.3 from AS/NZS IEC 60079.10.1 Sup 1:2022 Appendix D

1.0 m

1.0 m
Flammable
Liquid

1.0 m
Ground Level
3.0 m

ZONE 0 ZONE 2
(AS/NZS IEC 60079.10.1) (AS/NZS IEC 60079.10.1)

Figure D.4.2.3
Closed vessel, up to 20 L
Batch type processes

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 Figure 9 - Example of a CSIRO Area Hazard Poster containing the hazardous area signage

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Example of Hazardous Area Risk Assessment
Scope
This example of a hazardous area risk assessment provides guidance on the appropriate hazardous
zone surrounding chemical storage cabinets containing “flammable chemicals” (Classes 3, 4.3, 5.1
and 5.2 dangerous goods or those with a subsidiary risk of Class 3). The assessment is limited to a
typical laboratory situation and applies to a laboratory room enclosed by bounding walls that may
be part of a larger laboratory containing other laboratory rooms.

Chemical Storage Cabinets – Hazardous Zones

Australian Standard’s Requirements
The following edited excerpts from the relevant Australian Standard’s summarise the hazardous
area requirements applying to chemical storage cabinets in a laboratory when they contain
chemicals that may lead to the formation of a hazardous area.
The Safety in laboratories standard AS 2243.2:2021 – Part 2: Chemical aspects and storage, states
that where flammable vapours may be present as part of normal or abnormal operations, the
areas shall be classified in accordance with AS/NZS IEC 60079.10.1. AS 2243.2, Clause 6.3.4 also
states that cabinets shall be constructed in accordance with AS 1940.
The Explosive atmospheres standard AS/NZS 60079.10.1-2009 - Classification of areas - Explosive
gas atmospheres Supplement 1 Appendix F, Clause F.1.2 states that a laboratory may be
considered non-hazardous if it meets the criteria of Clause F.1.1. These criteria include container
sizes of flammable liquids being limited to ≤ 1 L, or ≤ 2.5 L in spill-proof containers; spill control
measures such as bunded tubs and spill clean-up processes and equipment are in use; adequate
ventilation to mitigate these small volumes creating a hazardous vapour cloud; and that there are
procedural controls in place to minimize the total quantities of flammable liquids present.
The Explosive atmospheres standard AS/NZS 60079.10.1-2009 - Classification of areas - Explosive
gas atmospheres Supplement 1 Appendix C, Clause C.4.3(c) states that for the storage of small
(≤20 L) containers, storage cabinets as defined by AS 1940, irrespective of the ventilation of the
storage area:
(i) The interior of the cabinet is a Zone 1 hazardous area;
(ii) For cabinets that contain packages which are always closed, the exterior of the cabinet
together with any vent provided on the cabinet, from ground level to 0.5 m above and
0.5 m laterally shall be a Zone 2 hazardous area;
(iii) For cabinets which contain closed packages >500 mL for occasional decanting, the exterior
of the cabinet together with any vent provided on the cabinet, from ground level to 0.5 m
above and 1 m laterally shall be a Zone 2 hazardous area;
(iv) The area within 0.5 m above the floor and 3 m forward laterally from the cabinet shall be a
Zone 2 hazardous area to account for minor spills which may occur while handling
flammable liquids.

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The storage and handling of flammable and combustible liquids standard AS 1940:2017, Clause
4.9.7 states that where flammable liquids are stored, ignition sources shall be excluded from the
area outside the cabinet to a distance of 3 m measured laterally, and from floor level to a height of
1 m above any opening in the cabinet, including the door, or a distance determined in accordance
with AS/NZS 60079.10.1.
Table 6: Threshold for being considered “small” quantities –AS/NZS 60079.10.1 Supp. 1 Appendix C

Flammable Liquid Storage Quantity in Laboratory Room

100 L or kg in containers that remain unopened;

25 L or kg for infrequent decanting purposes;
5 L or kg in open containers that may be opened for regular use

AS/NZS 60079.10.1 Supplement 1 Appendix C limits the scope of its examples of hazardous area
classification for flammable liquids by stating that the classifications given are not representative
examples of the storage and use of flammable liquids for quantities exceeding the above (Table 6).
Note - these small quantities are almost identical to the quantities listed in AS 1940 Clause 2.3.3,
and as 60079.10.1 was updated more recently, we will use these quantities.
All chemicals must be in closed containers when stored in a chemical storage cabinet.

Risk Assessment
Based on the provisions of the Australian Standards discussed above, it is reasonable to assess the
level of hazardous area risk relating to a chemical storage cabinet on the basis of whether the
quantity of flammable chemicals stored are less, or more than, the small quantities listed above.
The small quantities are considered to include all the flammable liquids stored and used within the
laboratory room.
The risk can therefore be considered lower for situations where the quantity of flammable
chemicals contained in the laboratory room are less than or equal to the small quantities,
especially where some or all criteria for excluding a laboratory from being a hazardous area are
met (see above regarding Appendix F of the Supplement to the Standard).
Although the risk will be lower, it will not be eliminated and it is therefore necessary to apply a
minimum level of hazardous zoning to these chemical storage cabinets. The rationale for adopting
this minimum hazardous zone around flammable chemical storage cabinets, even though only up
to small quantities are stored, is supported by AS 1940 which states in Clause 2.3.3 that:
“There shall be no uncontrolled sources of ignition in any space in which a flammable
mixture of vapour and air could be present.
WARNING: EVEN SMALL QUANTITIES OF FLAMMABLE LIQUID, IF SPILT, CAN
CREATE A VAPOUR CLOUD THAT CAN TRAVEL CONSIDERABLE DISTANCES AND
FLASHBACK.”
and; AS/NZS 60079.10.1 Supplement 1 which notes in Clause C.1 that:
“Under some circumstances, particularly in confined spaces, caution should be taken with
small quantities of flammable liquids as these may give rise to hazardous areas.”

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In this assessment we consider:
(a) Whether some or all risk control measures are in place within the laboratory (see the
criteria listed in AS/NZS IEC 60079.10.1 Supp.1 Appendix F)
(b) Whether the quantities in the flammable liquid cabinet are less than those considered
small quantities (see Table 6)
(c) Whether the types and quantities of flammable liquids warrant special precautions despite
being below the threshold quantities considered small (e.g. PG I flammable liquids).

Clause C.4.3(b) of AS/NZS IEC 60079.10.1 Supplement 1 requires that ignition sources must be at
least 300 mm distant from flammable liquids packages (cabinets in this case). Within this distance
a Zone 2 hazardous area exists. This zone also extends 300 mm above the floor of the rest of the
laboratory room, where not all criteria listed in Appendix F of Supp. 1 are met.
For quantities greater than the small quantities, the prescriptive requirements of Clause C.4.3(c)
will apply, provided all requirements are met (e.g. container size within cabinet). Where we
identify that the quantities, container sizes or types of flammable liquids pose a higher risk of a
flammable or explosive atmosphere forming, the 3 m exclusion zone referred to in AS 1940 must
be considered.

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Summary of Hazardous Areas
In this example summary, the hazardous areas applying to flammable chemical cabinets in the
laboratory room can be defined by the relative risk, as shown in the table below.
Table 7: Hazardous Area - Flammable Chemical Storage Cabinets

Flammable Chemical Storage Quantity in Laboratory Room

Extent of Hazardous Area
(L or kg)

Up to threshold of small quantities Zone 1 – Interior

Zone 2 – Exterior 300 mm from all sides.

Over threshold of small quantities, but containers remain Zone 1 – Interior

unopened, or are limited to 500 mL Zone 2 – Exterior 0.5 m above and laterally around the
cabinet. Additionally, 3 m laterally from the front of the
cabinet to a height of 0.5 m.
Over threshold of small quantities and containers >500 mL Zone 1 – Interior
which are opened occasionally for decanting Zone 2 – Exterior 0.5 m above the cabinet and 1 m laterally
around the cabinet. Additionally, 3 m laterally from the
front of the cabinet to a height of 0.5 m.
Over threshold of small quantities and higher risks Zone 1 – Interior
identified, such as containers >20 L; PG I flammable liquids Zone 2 – Exterior 3 m laterally, and from floor level to a
>500 mL height of 1 m above any opening in the cabinet, including
the door5.

The above requirements are illustrated, respectively, in Figures 10-13 below. Note in all these
cases, the laboratory floor has been retained as a hazardous area to a height of 300 mm as it has
been determined containers >1 L will be held.

5 Note that were only flammable chemicals that have vapour densities heavier than air are stored in the cabinet, the 1 metre height above the
openings in the cabinet may be measured from the floor, subject to a further risk assessment of this concession which takes into account the height
of the cabinet and other relevant considerations.

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Figure 10. Chemical Storage Cabinet Hazardous Areas – Up to threshold of small quantities

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Figure 11. Chemical Storage Cabinet Hazardous Areas – Containers <500 mL or only unopened containers

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Figure 12. Chemical Storage Cabinet Hazardous Areas – Containers < 20 L and not high risk flammable liquids.

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Figure 13. Chemical Storage Cabinet Hazardous Areas – Large containers or high risk flammable liquids

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Glossary
Combustible With respect to hazardous areas, combustible may refer to
combustible dusts and combustible liquid vapours which can form
a potentially explosive atmosphere.

Combustible dust Dusts which are combustible or ignitable in mixtures with air.
These may include dust, fibres and flyings of materials as diverse as
grain, sugar, wood, starch, coal, aluminium, and polypropylene,
etc.

Combustible liquid Typically any liquid that gives off a flammable vapour and has a
flash point >60°C.

Ex An abbreviation for Explosion and used as a prefix denoting

explosion protected.

Ex rated equipment Explosion protected equipment using one or more techniques so

that the equipment is suitable for use in a specified hazardous
area.

Explosive atmosphere A mixture with air, under atmospheric conditions, of flammable

substances in the form of gas, vapour or dust, which, after ignition,
permits self-sustaining propagation. For flammable gases and
vapours, the mixture with air needs to between the upper and
lower explosive limits to form an explosive atmosphere.

Firedamp Methane, especially as forming an explosive mixture with air in

coal mines.

Flammable With respect to hazardous areas, flammable may refer to

flammable liquid vapours, flammable gases, and flammable solids
that give off flammable vapours, that can form a potentially
explosive atmosphere.

Flammable liquid Typically any liquid that gives off a flammable vapour and has a
flash point <=60°C.

Flash point The lowest temperature, at atmospheric pressure, at which

application of a test flame causes the vapour of the test portion to
ignite under the specified conditions of test (typically a closed-cup
test, refer to AS/NZS 2106 Methods for the determination of the
flash point of flammable liquids (closed cup) series).

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Group classification Classification system of equipment related to the explosive
atmosphere for which the equipment is intended to be used, e.g.
Group II:- all places with an explosive gas atmosphere other than
mines susceptible to fire damp.

Hazardous area An area in which an explosive atmosphere is present, or may be

expected to be present, in quantities such as to require special
precautions for the construction, installation and use of
equipment.

Lower Explosive Limit (LEL) Also known as Lower Flammable Limit (LFL). The concentration of
flammable gas, vapour or mist in air, below which an explosive
atmosphere will not be formed.

Pyrophoric substance A substance that ignites spontaneously on exposure to air (e.g.,

phosphorus, silane gas) or water (e.g., potassium or sodium).

Source of release A point or location from which a gas, vapour, mist or liquid may be
released into the atmosphere so that an explosive gas atmosphere
could be formed.

Temperature classification A classification system of Ex equipment, based on its maximum

surface temperature, related to the specific explosive gas
atmosphere for which it is intended to be used.

Upper Explosive Limit (UEL) Also known as Upper Flammable Limit (UFL). The concentration of
flammable gas, vapour or mist in air, above which an explosive
atmosphere will not be formed.

Zone Hazardous areas are classified into hazardous Zones based upon
the frequency of the occurrence and duration of an explosive gas
atmosphere. (Refer to Appendix A herein for a description of the
different zones).

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