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Introduction to Hazardous Areas and

HA Classification (repeat)
Thursday, 9 February 2023 | Technical Engineering Webinar

Presented By
Ms. Alexandra Gregory | EIT Lecturer and AECOM Principal Engineer
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Introduction - Presenter

Alexandra Gregory
EIT Lecturer & AECOM Principal Engineer

• Chartered Professional Engineer (CPEng) with Engineers

Australia
• Registered Professional Engineer (RPEQ) in QLD
• National Engineering Register (NER)
Agenda

1 Welcome and Introduction

2 Introduction to Hazardous Areas
3 Classification Terminology
4 Properties of Hazardous Materials
5 Hazardous Area Classification Process
6 Conclusion and Q&A
Introduction to Hazardous Areas

What is a 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 potential ignition sources

Can be caused by • Refuelling or petrol stations

• Metal surface grinding (especially aluminium dusts)
• Gases/Liquids
• Aircraft refuelling and hangars
• Dusts • Hospital operating theatres
• Mining (Methane) • Processing plants
• Sewerage treatment plants
What are some examples? • Gas pipelines
• Woodworking areas
• Sugar refineries
Introduction to Hazardous Areas

Hazardous Classification Standards (Australia)

• AS/NZS 60079.10.1:2022 – Gas/Vapour/Mist
(IEC 60079-10-1:2020 (ED.1.0) MOD)
• AS/NZS 60079.10.2:2016 – Combustible Dusts
(IEC 60079-10-2:2015 (ED.2.0) MOD)
• AS/NZS 60079.14:2022 – Design selection, erection and initial inspection
(IEC 60079-14:2013 (ED.5.0) MOD)
• AS/NZS 60079.20.1 – Material properties
(IEC 60079-20-1:2010, Ed. 1.0 (Withdrawn) )
Introduction to Hazardous Areas

The above hazardous areas do not include Explosive Hazardous Areas (EHAs) which are
covered under a separate set of regulations (eg eDEOP for Defence)

Dangerous Goods are substances that are corrosive, flammable, explosive, spontaneously
combustible, toxic, oxidising or water reactive.

Classification of dangerous goods is described in the Australian code for the Transport of
Dangerous Goods by Road and Rail, which is closely aligned with international requirements
of the United Nations Recommendation on the Transport of Dangerous Goods, and relevant
state legislation, which may provide additional guidance on specific materials.
Introduction to Hazardous Areas

Causes of Explosions

Infernal Triangle Dust Pentagon Dust Explosion

2012 Gas Plant Explosion – Mexico
Classification Terminology – Overview
Classification Terminology - Zones

Probability of a hazardous area being forming within

certain areas and the duration it exists ( 0 is most likely - 2
less likely, NH no risk). • Zone 0
• Zone 0 – an area in which explosive gas atmosphere is present Gas • Zone 1
continuously, or is expected to be present for long periods of time • Zone 2
** this is the most onerous**
• Zone 1– an area in which explosive gas atmosphere is likely to • Zone 20
occur in normal operation occasionally
• Zone 2 – an area in which explosive gas atmosphere is not likely to
Dust • Zone 21
occur in normal operation and if it does it will exist for short period • Zone 22
only or abnormal conditions
Classification Terminology – Material Group

In addition to the probability of an explosive atmosphere being present (as defined by the
Zone), the properties of the material causing the hazard are also considered.

Groups are related to the hazard.

• Group I = Coal Mines (Methane) and Coal Dust
• Group II = Explosive Gas Atmospheres
• Group III = Combustible Dust Atmosphere
Classification Terminology - Sub-Groups

Sub-groups are defined by energy levels

For Group II (GAS), there are three subgroups

• Group IIA = Methane and Propane
• Group IIB = Ethylene
• Group IIC = Hydrogen and Acetylene *** this is the most onerous***

DUST - Combustible Dust Atmosphere

• Group IIIA: Large particles (flyings) - requires IP5X
• Group IIIB: Non-conductive (> 1kOhm) - requires IP5X
• Group IIIC: Conductive (< 1k Ohm) - requires IP6X *** this is the most onerous***
Classification Terminology

Putting it all together

Group I
• Methane/Coal dust
Underground
• Group IIA
Group II Gas • Group IIB
• Group IIIC

• Group IIIA
Group III Dust • Group IIIB
• Group IIIC
Properties of Hazardous Materials

Flammable Verse Combustible

< 61 degrees – flammable
> 61 degrees - combustible (high flash point) --> No zones required for combustible
You need EX rated equipment for Flammable material as it is considered ‘Hazardous’. You do
not need Ex rated equipment for Combustible.

Gas v Vapour V Mist

At normal temperature:
Gas – does not occur in liquid form
Vapour – may be in contact with its liquid form
Mist - Cloud of condensed vapour
Properties of Hazardous Materials

Auto Ignition Temperature determines the likelihood of an explosion occurring without an

ignition source, for example, as a result of a hot surface. Dust has different temperatures for
‘layer’ versus ‘cloud’

Minimum ignition energy is energy in Joules (watt-sec) required to ignite a substance. A

certain minimum energy required is for an explosion to occur.

Flashpoint is an indication of whether a flammable mixture mix of vapour and air is likely to
occur above a liquid at a given temperature.
Properties of Hazardous Materials

UEL – Upper Explosive Limit

LEL – Lower explosive limit

→ lower the flashpoint the more

dangerous the vapour is!
→ Gases do not have a flashpoint
because they are already vapours
Properties of Hazardous Materials

Example of Flammable Liquids and

Gases and their properties from AS/NZS
60079.20.1
→ Always refer to the safety data sheet
for the specific product
Properties of Hazardous Materials

Temperature Class
The hazardous area will have an Auto-Ignition Temperature (AIT) - where by the
temperature can ignite the flammable gases/vapour without a spark.

Any equipment located within the defined hazardous area must be prevented from
reaching the AIT.
Properties of Hazardous Materials

Temperature Class • Hydrogen (560deg)

Example
• Ethylene (425deg)

• Ethyl ether (160deg)

• Acetylene (305deg)
Hazardous Area Classification Process

Hazardous Areas – Why Classify?

Identify where there is a high probability than an explosive atmosphere may exist so that control measures
can be implemented

We can reduce the risk through Hierarchy of Controls

• Substitution
• Control
• Mitigation
Hazardous Area Classification Process

Hazardous Areas – Defined by Who?

The standard requires that Hazardous Areas are classified by a competent person.
In this instance, a competent person is someone who is qualified (through formally
recognised training program)

You must also be deemed competent to

• Select equipment for installation within Hazardous Areas
• Conduct Audits / Inspections of the Hazardous Areas

Competency defined by AS/NZS 60079.14 Explosive atmospheres (IEC 60079-14:2013 (ED.5.0)

Hazardous Area Classification Process

1. Define the Hazard

2. Assess the probability of an explosive atmosphere occurring
3. Produce Documentation
Hazardous Area Classification Process

1. Define the Hazard

Consider Personnel (External) influences

• What maintenance operations impact safety
• Operation procedures
• Processes nearby
• Evacuation procedures

Understand process conditions

• Ambient temperatures
• Process pressures
• Storage / handling
Hazardous Area Classification Process

2. Assess the Probability

Identify source of release / grade of release

• Continuous / intermittent release
• Normal or only during failure

Define Ventilation
• Adequate / not adequate

Define Hazardous ‘Zones’

• Zone is the frequency and duration of a release
• E.g Zone 0 / 1 / 2 for Gas or Zone 20 / 21 / 22 for Dust
Hazardous Area Classification Process

Example Classification
Hazardous Area Classification Process

3. Document

Classification Report
• Report background and captures client comments
• Explanation of assumptions
• Information used (SDS, temperature, pressure, location etc)
• Basis of certification relating to Type, Zone etc

Drawings
• Type and extent of zones
• Temperature class
• Gas Group designation
Hazardous Area Classification Process

Examples
Summary

• Hazardous Areas may be present in existing or new installations and involve Flammable
liquids, vapours, gases or dusts
• Flammable is different to Combustible
• Dangerous goods can include Hazardous materials, but also are separate
• Gas Groups are IIA, IIB and IIC and can be Zone 0, 1 or 2
• Dust Groups are IIIA, IIIB or IIIC and can be Zone 20, 21, 22
• Classification Process: Define the Hazard, Assess the probability, Document

Whenever a hazardous area is encountered seek advice from a “Competent Person”

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