1. How to Manage Hazardous Areas effectively by using Gas Monitors
EXECUTIVE SUMMARY
Hazardous areas are those locations that could have hazardous levels of
explosive gas, vapor or dust mixtures present that could potentially ignite
and cause fires or explosions. Such locations are normally found in oil &
gas processing, chemical & petrochemical plants, shipping terminals,
warehouses , aircraft fuelling depots and similar locations. Electrical
equipment that is to be installed in such locations is different from general
purpose electrical equipment. It has to be explosion protected and
certified for the area in which it is to be used.
Thus Electrical equipment installed in hazardous areas, necessarily has to
conform to the area classification for that area. However, frequently,
practical problems arise, where the specified equipment may not be easily
available. For example, an area classified as Zone 1 under the IEC
system, theoretically can accept only Zone 1 equipment. However
sometimes, especially in case of specialized equipment, Zone 1 certified
equipment of that type may not be available.
In such cases what could be done? This paper presents the background of
such situations, possible solutions and current international practices
regarding this issue.
Introduction
Places containing combustible or flammable mixtures of vapors, gases
and dusts are generally classified according to the likelihood of the
flammable mixture being present and the nature of the mixture so
present. Hence these areas are known as Hazardous Areas (Classified
locations). Typically these locations would be chemical plants, oil
refineries, gas processing plants, tank farms, grain storage silos, etc.
These places are generally classified on the basis of two widely applied
systems, one is the North American system ( Class, Division & Group
based) and the other one is the European/ IEC system (based on Class,
Zone, Group). Various National as well as International standards follow
either one of these two systems.
Area Classification
Based on the location of your plant or facility, either one of the two
systems above would be used to do the area classification. This holds true
all over the world. This means, that though each country would have its
own national standard ( and a law that basically says that the particular
national standard has to be adhered to), in principle, all of the national
standards follow either one or the other of the two systems.
Now let us take an example of an upcoming petrochemical manufacturing
plant in Happyville. The entire plant is supposed to process

2. petrochemicals and has several areas classified as hazardous. The plant is
presently under the engineering design stage. During this stage, it is
classified by the engineering and safety gurus/ consultants and the local
authorities as "hazardous". It has been agreed by the owners and the
engineering consultants, to use the IEC system for Hazardous Areas.
Thus, various markings on engineering layout drawings now show the
various locations as Zone 1, Zone 2 and so on. Then during the next
stage of the project, suitable equipment is ordered, the plant is
constructed and commissioned and starts producing petrochemicals
safely.
What next?
The fairy tale ending of "Everyone lived happily ever after" does not
happen.
Why? Let us move a little further ahead in the lifecycle of this plant, say
two years, after it has been commissioned.
Zone 2 equipment in Zone 1 areas? Sacrilege !?
Suppose there is an equipment in this plant that is certified for Zone 1
and which is installed, also in an area designated as Zone 1. Now after
two years of running, it has a major failure and needs replacement. You
are the Plant Engineer and are assigned the task of replacing it. You look
up the spec sheet and try to contact the original equipment manufacturer.
You learn that the manufacturer has stopped producing that kind of
equipment because of tough competition and no longer can supply it. He
however, helpfully gives you the name of another manufacturer, who
makes similar equipment. You are glad to get the information and contact
the new guy.
Whew! What a relief! You learn that he can supply his model which will
suit your purposes admirably well, except for one (minor?) detail. The
equipment is not certified for use in Zone 1, but only for use in Zone 2.
Thus , it can only be installed in Zone 2.
You now have a problem. You understand that you cannot install an
equipment that has been certified as suitable for Zone 2, into a Zone 1
classified area, as it would be violating the law, good engineering
practice, safety standards and so on. So what do you do?
Let us examine your options
a) Install it anyway!-Not recommended at all, as it would not only violate
the law, it could cause a disaster.
b) Re-classify it, until you get an answer you like!
(Try to get the area re-classified by another expert, to check if the area
really merits a Zone 1 designation, or you can get it designated as Zone
2, or even better, a safe area!)
This option is also not recommended, since if the original design engineer
has done the job well, there is no reason why he would have been wrong.
You will waste time, money and energy on a futile project.

3. c) Look for another less-taxing job?-Not necessary, there is a fourth
option, read on below!
Installing Zone 2 equipment in a Zone 1 area-Your options
Yes, you guessed right. You can install a Zone 2 certified equipment, in an
area reserved for only Zone 1 equipment, legally in many countries,
provided certain conditions are met. What are these conditions? Before
proceeding further, let us go back to basic concepts. What is really the
difference between a Zone 1 and a Zone 2 area? If you remember your
fundamentals of area classification, recollect that the only difference, is in
the probability of an explosive mixture of vapor/gas/dust being present.
In Zone 1, it is more probable, in Zone 2, it is less probable. It is as
simple as that.
Option 1
You can try to reduce the classification of the hazardous area from Zone 1
to Zone 2, by changing certain environmental conditions, like improving
ventilation in the area. Improving ventilation will ensure that enough
dilution air is always present at all times, so that explosive limits of
vapors/ dust concentrations are never reached. This would reduce the
classification itself to Zone 2, so the problem gets solved.
You may now think, that this is exactly what was offered as an option in
the previous section, where we ruled it out, why repeat it now?
This is not so. Note, that in order to really change the classification of the
area, we cannot merely study it again and again and hope to get a
different answer every time. We will have to change the nature of that
area, by reducing the hazards present. In the option that we are
discussing now, we are not merely studying the classification again, we
are going to physically change the characteristics of the classified area to
make it safer.
In this case by having better ventilation of fresh air into the area.
For studying the second option, let us first study the basic idea behind
area classification. The idea was to segregate areas, that were at risk of
having explosive vapor or gas mixtures for longer periods of time, from
other non hazardous areas. Again, further sub-dividing the hazardous
areas into zones (Zone 0, Zone 1 and Zone 2) gives us finer choices, for
selecting certain methods of protection over others, in a cost effective
way. This is in keeping with the general principles of risk reduction, using
ALARP (As Low As Reasonably Possible). This basically means, that we
can spend truckloads of greenbacks on installing explosion protected
equipment everywhere, even in safe areas, (to really really protect
ourselves), but then the cost of doing so would drive us out of business.
Thus we follow the ALARP principle.

4. For example, Increased Safety (Ex-e) as a method of protection, is
allowed in Zone 2, but not in Zone 1. Thus we can have equipment that is
appropriate for use in the area without overdesign or being unsafe.
However, what if we could continuously measure the so called hazardous
area and check if there really are explosive gases or vapors present? Of
course, we can and to do this correctly, we can install a fixed (not
portable) combustible gas detector(s) in the hazardous area and monitor
it in real time, if hazardous levels of vapors are present.
Option 2
You could install a combustible gas detector, that will detect the presence
of combustible gas or vapor in the area and give warning alarms, or shut
off the equipment immediately, in case flammable gas is detected.
Is this allowed? Yes of course, provided certain conditions are met. This
protection method is known as "Combustible gas detector method of
protection"
Conditions under which this method of protection may be used
Of course this method of protection is only allowed under certain
conditions and not always, as it would completely defeat the very purpose
of area classification. It would also dilute the safety of the installation if
used recklessly. Broadly speaking, this method of protection should be
used only under the following conditions:
1. If the area to be so protected has an area classification of a higher
level (like Zone 1) only because of a lack of ventilation.
2. If the area is part of an industrial or work area which would have very
little public access.
3. If fixed type combustible gas detectors are used to detect the presence
of combustible mixtures of gas or vapors, in the same area, near which
the equipment is sought to be installed.
4. The fixed combustible gas detector is itself certified to be used in the
hazardous area under the same classification.
5. The fixed combustible gas detector is selected, installed and mounted
as per prevailing standards and regulations.
6. The fixed combustible gas detector is regularly calibrated and tested
for correctness of its indication, which means its integrity is never in
question at any time.
7. The fixed combustible gas detector is capable of giving out a high level
alarm signal (audio/visual) on detecting explosive levels of gas or vapor

5. mixtures in the surroundings and this alarm or trip signal should also
switch off the power to the equipment in the area.
8. The gas detector should cover the entire area which is sought to be
protected.
The above are just broad guidelines and you should consult the
appropriate national or international standards (or legal regulations), that
apply to your installation.
Why not use it throughout the plant?
This method of protection cannot be used all over the plant. The reasons
are many, but we enumerate a few below:
a) Modern plants may cover large land tracts. To cover this entire area
(even just the hazardous areas) would require probably hundreds of fixed
gas detectors. The costs of doing this would be huge. Again remember
the ALARP principle.
b) The total cost of ownership also has to be considered. Each detector
would have to have itself subject to periodic calibration & inspection,
maintenance & repair.
c) It may not be practical to shut down entire plants just because of some
gas leakages in certain portions of the plants.
d) Some equipment requires itself to be up and running, even in case of
leakages or in presence of explosive gases or vapors. For example, alarm
hooters, scrubber pumps, etc.
Conclusion
Merely having a higher level of area classification does not automatically
preclude you from installing equipment of a lower area classification. A
workaround for this situation is now available and consists of installing a
suitable fixed type combustible gas detector, which continuously monitors
the ambient air for any explosive or flammable levels of gas or vapor and
takes adequate automatic alarm and trip actions to safely shut down the
equipment in the hazardous area.
Further information
For further information on Hazardous Areas or Gas Monitors, please take
a look at some excellent e-learning courses on these topics by us. These
courses can be taken online at anytime and are very comprehensive.
Please visit our Gas Detectors training course page and Hazardous Area
Instrumentation training course page for more details.

6. E-learning course on Gas Monitors
E-learning course on
Hazardous Area Instrumentation
For an excellent guide to Area Classification,
please download the Practical Guide to
Hazardous Area Classification now!
If you have any comments or questions, or you would like to know
something more about e-learning, please send us an email to
mail@abhisam.com
We will be glad to assist you!
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