HAZARD

AREA

HAZARD AREA CLASSIFICATION

CLASSIFICATION
Ref: International Electrotechnical Commission

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 IEC 60079 Series
Hazardous Area
A location where flammable gases, vapors or combustible
dusts are present in quantities that can ignite.
It is also known as explosive atmosphere.

HAZARD AREA CLASSIFICATION

Why it matters ?
To prevent any catastrophic events such as fires and explosions.

IEC 60079 Series

IEC 60079 Series is a global reference for equipment used in
explosive atmospheres.
Provides a consistent
framework to
identify and mitigate
explosion risks.

Key parts of IEC 60079:

1. 60079-0: General requirements.
2. 60079-10-1: Explosive gas atmospheres – area classification.
3. 60079-10-2: Combustible dust atmospheres – area classification.
4. 60079-14: Selection and installation of equipment.
5. 60079-17: Inspection and maintenance.

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 Hazardous Substances
Flammable Gases/Vapors: Combustible Dusts:

HAZARD AREA CLASSIFICATION

Hydrocarbons,
These are fine
alcohols, hydrogen,
particles that can
acetylene, etc.
explode when
dispersed in air.
Explosive mists:
LEL (Lower Explosive Limit): The lowest
concentration of a combustible gas or
vapor in air at which ignition can occur.
Below this concentration, the gas-air
mixture is too lean to burn.
Aerosols of
flammable liquids UEL (Upper Explosive Limit): The
under certain highest concentration of a combustible
conditions. gas or vapor in air at which ignition can
occur. Above this concentration, the
gas-air mixture is too rich to burn.

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 IEC60079-10-1

HAZARD AREA CLASSIFICATION

Zone 0: Zone 1: Zone 2:
Explosive atmosphere Explosive substances are present Explosive substances are
present > 1000 during normal operation (10-1000 present for very short
hours/year. This hours/year). duration (less than 10
atmosphere requires hours/year).
equipment with highest
protections.

For example: Immediate Area For example: In areas

For example: Inside the Around the Tank/Vessel (inside where vapors might
tank, hydrocarbons are the pump cabinet or under the occasionally escape due
continuously present, nozzle area). Vapors are likely to to spillage, leaks, or
so this is a Zone 0 be present during normal venting – but not
environment. operation (e.g., fueling, venting), normally – it would be
making it Zone 1. classified as Zone 2.

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 IEC60079-10-2

Zone 20:
Continuous presence of dust clouds

Zone 21:

HAZARD AREA CLASSIFICATION

Dust clouds are present during normal operation.

Zone 22:
Rare, short duration presence of dust.

DUST CLOUDS CAN

CAUSE FIRE INCIDENTS

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 IEC60079-20-1
Gas Groups
• Hazardous gases and vapours are categorized into Gas
Groups.
• Gas Groups indicate the severity of explosion risk.
• This classification helps to select suitable equipment for
different environments.

HAZARD AREA CLASSIFICATION

• IEC Gas Group Categories : Group I and Group II.
• When an equipment is certified for a particular gas group under
IEC 60079 standards, it tells us the types of gases or gas
severities for which the equipment is safe to use.
• Group I: Equipment certified with Group I are mainly used in
underground coal mines or other mining environments where
methane gas and coal dust are primary danger.
For example: A battery-powered drill used in a coal mine must
be certified Group I, meaning it won’t ignite methane if it sparks
and gets hot.
• Group II: Equipment certified with Group II are mainly used in
all industries above ground such as refineries, petrochemical
plants, etc.
• It covers flammable gases, vapours or mists in air.
• It is divided into 3 sub-groups: Group IIA, Group IIB, Group IIC.

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 Gas Group I

HAZARD AREA CLASSIFICATION

Coal mines pose significant risks due to the presence of methane gas and coal dust,
both of which are highly explosive under the right conditions when mixed with air in
the right concentration and exposed to a heat source or spark.

Due to the explosion risks from methane and coal dust, all equipment used in coal mines
must meet Group I IEC/ATEX standards. This includes being robust, dust/gas-tight,
spark-proof, and temperature-controlled to prevent ignition. Certified protection
methods like intrinsic safety (Ex i), flameproof (Ex d), or pressurization (Ex p) must be
used. Non-compliance can lead to fatal explosions and major operational losses.

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 Gas Group II
Gas Group II covers equipment used in above-ground (surface) industries
where explosive gases, vapors, or mists may be present (e.g., oil & gas, chemical
plants, refineries).

Group IIA Group IIB Group IIC

Group II → Equipment Group II → Equipment is Group II → Equipment
designed for use in designed for surface (non- is designed for surface

HAZARD AREA CLASSIFICATION

surface industries mining) industries. industries (not
(not mining). underground mining).

Subgroup IIA → For Subgroup IIB → Equipment is Subgroup IIC →

use in atmospheres suitable for medium-risk Equipment is rated for
containing less flammable gases (more the most hazardous
hazardous hazardous than IIA, less than flammable gases
flammable gases. IIC).
Equipment designed
Equipment marked Equipment marked Group IIB is for Group IIC must
Group IIA is tested and built to safely contain or prevent withstand maximum
certified to safely ignition of IIB gases like explosion risk.
operate in ethylene or hydrogen sulfide.
environments where Example: Hydrogen,
IIA gases might be Acetylene Carbon
present. Example: Ethylene, disulfide, Ethylene
Hydrogen sulphide, oxide, etc
1,3-Butadiene,
Example: Propane, Tetrahydrofuran, etc
Methane, Butane,
Ethanol , Acetone,
Toluene, Ammonia,
etc
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 Gas Group II

Equipment Rating Can Be Used For

HAZARD AREA CLASSIFICATION

IIA IIA gases only

IIB IIB and IIA gases

IIC, IIB, and IIA gases

IIC
(most flexible)

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 Autoignition Temperature
Autoignition Temperature (AIT) is the lowest temperature at
which a substance (gas, vapor, or dust) will ignite
spontaneously in air, without any external ignition source such
as a flame or spark.

UNIT OF MEASUREMENT – Degree Celsius

HAZARD AREA CLASSIFICATION

It’s determined under Substance AIT (°C)
standardized laboratory
conditions using IEC test
Hydrogen ~560°C
methods.

Acetylene ~305°C
It varies by:
✓ Type of substance (e.g., Methane ~595°C
propane vs. hydrogen)
✓ Pressure
✓ Air concentration Propane ~470°C

Ethylene ~450°C
It is higher than the flash point,
because it doesn’t involve an
external ignition source.

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 TEMPERATURE CLASSES
IEC 60079-0
✓ It is defined by the maximum surface temperature of
equipment.
✓ It must be below the autoignition temperature of present
hazardous substance.

HAZARD AREA CLASSIFICATION

Maximum Surface Minimum Autoignition
Temperature Class Temperature of Temperature (AIT) of
Equipment Gas/Vapor

T1 ≤ 450 °C ≥ 450 °C

T2 ≤ 300 °C ≥ 300 °C

T3 ≤ 200 °C ≥ 200 °C

T4 ≤ 135 °C ≥ 135 °C

T5 ≤ 100 °C ≥ 100 °C

≥ 85 °C
T6 ≤ 85 °C

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 EQUIPMENT PROTECTION LEVEL
IEC 60079-0

✓ EPLs tell you how safe a piece of equipment is in a hazardous

area where explosive gases or dust might be present.
✓ Think of EPLs like safety ratings – the higher the rating, the safer
the equipment is, even if things go wrong (like a fault or failure).

HAZARD AREA CLASSIFICATION

Protection Gas How Safe
EPL Code Zone
Level Presence Is It?

Still safe
Gas present
Ga Very high Zone 0 even with 2
all the time
faults

Gas present Safe with 1

Gb High Zone 1
sometimes fault

Safe in
Gas present normal
Gc Normal Zone 2
rarely operation
only

Zone 0 (Gas always present): We must use equipment with EPL Ga.
Zone 1 (Gas sometimes): We need at least EPL Gb.
Zone 2 (Gas rarely): We can use EPL Gc.

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 EQUIPMENT PROTECTION LEVEL
IEC 60079-0

EPL Fault Tolerance Zone Use

Safe even if 2
Ga Zone 0
things fail

HAZARD AREA CLASSIFICATION

Safe if 1 thing
Gb Zone 1
fails

Safe only if
Gc Zone 2
nothing fails

EPLs for Dust Atmospheres

EPL Code Zone Dust Presence

Dust always
Da Zone 20
present

Dust sometimes
Db Zone 21
present

Dust rarely
Dc Zone 22
present

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 ALL TOGETHER
EPL

ZONES Gas Groups

T-Rating Autoignition

HAZARD AREA CLASSIFICATION

LET’S CLEAR THE CONFUSION WITH
A SIMPLE EXAMPLE

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 EXAMPLE
• Suppose we are selecting a motor for a chemical plant.

• When we choose equipment for hazardous areas then we

really need to answer three questions:

1. What type of gas is present ?

HAZARD AREA CLASSIFICATION

2. How often is the gas present ?
3. How hot can the equipment get ?

What type of gas is present ?

This tells us how explosive is:
Needed
Explosion
Gas Group Examples Equipment
Risk
Rating

Propane, Easiest to
IIA Low
methane protect against

Needs better
IIB Medium Ethylene, H₂S
protection

Needs best
Hydrogen,
IIC High possible
acetylene
protection

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 EXAMPLE
How often is the gas present ?
This tells you how likely an explosion could happen.

Presence of Meaning of
Zone EPL Needed
Gas EPL

HAZARD AREA CLASSIFICATION

Gas is always Must be safe
Zone 0 or long Ga even if 2 faults
periods happen

Gas is likely Must be safe if

Zone 1 during Gb 1 fault
operation happens

Safe only
Gas is rare or
Zone 2 Gc under normal
for short time
operation

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 EXAMPLE
How hot can the equipment get ?
This tells you whether the equipment could get hot enough to
ignite the gas.
Max Surface
Can Be Used If
T-Class Temp of
Gas AIT ≥

HAZARD AREA CLASSIFICATION

Equipment

T1 ≤ 450°C ≥ 450°C

T2 ≤ 300°C ≥ 300°C

T3 ≤ 200°C ≥ 200°C

T4 ≤ 135°C ≥ 135°C

T5 ≤ 100°C ≥ 100°C

T6 ≤ 85°C ≥ 85°C

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 EXAMPLE
We are selecting a motor for a chemical plant where:
✓ Gas present: Hydrogen (very explosive → Group IIC)
✓ Location is Zone 1 (gas is sometimes present)
✓ AIT (autoignition temp) of hydrogen = ~560°C

HAZARD AREA CLASSIFICATION

Requirement What to Look For

Gas group Equipment rated IIC

Zone EPL Gb or better (i.e., Ga)

At least T1 (≤ 450°C), but safer

Temperature class would be T4 or better to keep
equipment cool

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 LAYER OF FILTERS

GAS GROUP IIA, IIB, IIC (How dangerous?)

HAZARD AREA CLASSIFICATION

Ga, Gb, Gc (How often is it
EPL dangerous?)

T1 to T6 (How hot can

T-RATING equipment get?)

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 Alot to know !!!!!!!!!!!!

HAZARD AREA CLASSIFICATION

A lot to discuss !!!!!!!!!

Comment down if you have

more to share !!

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