HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

 Doc. No: HSE – TSTR – 17 - 5412 2
Area Classification & Electrical Safety
This training module has been prepared based on current KNPC Safe Work Practices,
other HSE Procedures and other resources. Employees are advised to periodically
update themselves by referring to the KNPC website.

02 19/04/2017 Amended based on Competency Level based Training matrix

01 This is made inline with relevant KNPC Safe Work Practices and
other Maintenance Work procedures and Manuals
Rev Date Description

Prepared by Reviewed & Approved by

Name: Vijayakumar Krishnan, HSE Training Engineer Deven Kotecha, A/Sr. Engineer, HSE Training

Signature:

Date: Nov 2017 Nov’ 2017

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

FACILITATOR

Your Trainer Today…….

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

IMPORTANT Housekeeping Instructions
• Emergency Response

• Confirm the Participation with Training Nomination List

• Refresher Duration is 3 Years – (System will not Accept the Attendance within 3
Years of Last Participation)

• Course Duration is 3 Hours

– 10 Minutes Snacks Break after 1 Hour 15 Minutes

• Sanitary Facilities

• Smoking Policy

• No Entry Policy to Other Offices

• SWITCH OFF the MOBILE or at least in “SILENT MODE”

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

COURSE OBJECTIVES
To familiarize the participants about:
• Basics of Area Classification
• Types of Area Classification
• Selection of Electrical Equipment for Different Areas
• Method of Protection
• Hazards of Electricity
• Safe Work Practices

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

TERMS AND DEFINITIONS
Flash Point, Fire Point, Boiling Point & Ignition Temperature

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

TERMS AND DEFINITIONS
Flash Point
Minimum Temperature at which Liquid gives off < 100°F : Flammable
Sufficient Vapor in sufficient Concentration to form
Ignitable Mixture to create MOMENTARY FLASH when ≥ 100°F : Combustible
source of Ignition is Introduced.

Fire Point
Minimum Temperature at which Liquid gives off Sufficient Vapor in sufficient
Concentration to form Ignitable Mixture to create SUSTAINED FIRE when Source of
Ignition is Introduced.
Boiling Point
Temperature at which Liquid transforms its phase to Vapor.
Ignition Temperature
Temperature at which the Flammable Vapor or Gas activates the Fire EVEN
WITHOUT ANY SOURCE OF IGNITION like Spark or Flame

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

TERMS AND DEFINITIONS
Explosive (Flammable) Limits

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

TERMS AND DEFINITIONS
Lower Explosive Limit Upper Explosive Limit
LOWEST Concentration (Percentage by HIGHEST Concentration (Percentage by
Volume of Air) of a Gas or Vapor capable Volume of Air) of a Gas or Vapor capable
of producing a flash or fire in presence of of producing a flash or fire in presence of
Ignition Source. Ignition Source.
Lower Explosive Limit Upper Explosive Limit
5 Hydrogen (H2) 75
3 Acetylene (C2H2) 92
2.2 Propane (C3H8) 9.5
12.5 Carbon Monoxide (CO) 74
4 Hydrogen Sulfide (H2S) 44
1.2 Benzene & Toluene 7.8
15 Ammonia 28

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

TERMS AND DEFINITIONS
Vapor Density
Ratio of Mass of a Volume of Vapor to the Mass of an Equal
Volume of Air.
Air is combination of 21% of Oxygen and 78% of Nitrogen
Mol. Weight of 21% of Oxygen 0.21 * 32 = 6.72
Mol. Weight of 78% of Nitrogen 0.78 * 28 = 22.12
Mol. Weight of Air = 6.72 + 22.12 = 28.84 (i.e.≈ 29)
Mol. Weight of Gas (or Vapor)
Vapor Density = ----------------------------------------
29 (Mol. Weight of Air)
Vapor Density Comparison with Air Presence of Vapor/Gas
Less than 1 Lighter than Air Elevated Areas
Equal to 1 Same as Air All Areas
More than 1 Heavier than Air Lower Areas

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

HIERARCHY OF RISK MANAGEMENT
1. Prevent Explosive Atmosphere IF NOT
2. Avoid Source of Ignition IF NOT
3. Special Construction & Erection of Equipment to Prevent any
Hazard

WHY AREA CLASSIFICATION?

Helps to:
• Identify Extent of Protection
• Select Electrical Apparatus, Equipment, Instruments, etc.
• Locate Equipment like Heaters, Boilers (Source of Heat)

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

STANDARDS, CODES AND REFERENCES
• IEC International Electro-Technical Commission
• NEC National Electrical Code
• NEMA National Electrical Manufacturer’s Association
• API-RP-500
• IP Model Code of Safety
• CENELEC/ ATEX
• UL/FM/BASEEFA (For Equipment Certification)
• ANSI American National Standards Institute
• NFPA National Fire Protection Agency

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

ELECTRICAL AREA CLASSIFICATION

BASIS
Nature of Hazard
Gas, Vapor, Dust, Fiber

Likelihood of Hazard
Normal, Abnormal

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

ELECTRICAL AREA CLASSIFICATION

DIVISION CLASS

DIVISION 1 DIVISION 2 CLASS 1 CLASS 2 CLASS 3

Normal Abnormal Gas & Liquids Dust Fibers

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

NEC CLASSIFICATION - DIVISION
Division Description Example

1 Areas immediately surrounding

Explosive mixtures may
to vents.
be present under
NORMAL operating
Open transfer of flammable
conditions materials.

2 Explosive mixtures may

be present under Loss of containment due to
ABNORMAL operating equipment leakage or failure
conditions

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

NEC CLASSIFICATION – CLASS GROUPING
Class Description Group List
A Acetylene (C2H2)
B H2 & Gas/ Vapor with Equivalent Hazards
Flammable Gases, C Ethyl Ether, Ethylene
1
Vapors & Liquids
Gasoline, Naphtha, Benzene, Butane,
D Propane, Alcohol, Acetone, Benzol,
Lacquer Solvent Vapor, Natural Gas
E Metal Dust (Aluminum, Magnesium, Alloy)
Asphalt, Bitumen, Carbon Black, Coke of
F
2 Combustible Dusts Coal Dust
Flour, Starch, Wood, Sugar, Combustible
G
Plastics
3 Fibers N.A. All Combustible Fibers

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

ELECTRICAL AREA CLASSIFICATION

Gas & Vapor Dust

ZONE 0 ZONE 1 ZONE 2 ZONE 20 ZONE 21 ZONE 22

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

IEC CLASSIFICATION – ZONE
Zone Description Example
Explosive Gas-Air Mixture is
0 CONTINUOUSLY Present or Present for
Vapor Space of Process Vessels
Long Periods.
or Storage Tanks
≥ 1000 Hours Per Year

Explosive Gas-Air Mixture MAY Occur in

1 Normal Operations.
Sampling Point, Vent, Drain, etc.
10 ~ 1000 Hours Per Year

Explosive Gas-Air Mixture is NOT LIKELY &

2 if it occurs will exist only for SHORT TIME Process Plant Area, Tank Area,
etc.
0.1 ~ 10 Hours Per Year

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

METHODS OF PROTECTION
Maximum
Methods of Lowering
Experimental
Ignition Hazards
Safe Gap

Minimum
Limit the Energy Contain the Ignition
Ignition
(Intrinsically Safe) (Explosion Proof)
Energy

Eliminate Air Entry

Restrict the
(Oil Immersion,
Temperature of
Pressurized,
Components
Hermetically Seal)

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

CLASSIFYING THE LOCATIONS
STEP 1: Classification is Required if the answer to either of the following
questions is YES:
Does the Area Need
1. Is presence of flammable liquid or gas likely?
to be Classified 2. Are combustible liquids (flash point ≥100°F) likely to be
handled, processed or stored at temperatures above their
STEP 2: flash points?
Determine the
Division & Class Classify based on:
1. Presence of the Hazard – Either Flammable or Combustible
2. Frequency of the Hazardous Atmosphere Present
STEP 3:
Decide the Extent of
Applying Good Engineering Judgment
Classified Area
1. Selected, Tested & Approved
STEP 4: 2. Specific FLAMMABLE ATMOSPHERE Involved
Select the Electrical 3. Details of Flammable Atmosphere to be specified in the
Equipment Purchase Order

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

METHODS OF PROTECTION
• Explosion Proof or Flame Proof

• Intrinsic Safety

• Increased Safety

• Pressurization/ Purging

• Encapsulation

• Dust-Tight

• Oil Immersion

• Powder Filling

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

 BREAK
10 Minutes
HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

BASICS OF ELECTRICITY
1. Electricity means FLOW of
Current
2. Complete LOOP Beginning
at Source & Returning to
the Source
3. Always RETURNS to the
Source
4. INTERRUPTION in the
Current Flow will Lead to
Electrical Hazards
HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

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TERMS
1. FAULT: Partial or Total Failure of
Continuity of Conductor
2. SHORT CIRCUIT: Unintended
current path between 2 points of
different potential
3. GROUND FAULT: Short Circuit
between a Conductor & Ground
or Grounded Conductor
4. ARC: Luminous Discharge of
current that is formed when a
strong current jumps a gap in a
circuit or between 2 electrodes

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

ELECTRICAL HAZARDS..........

FIRE
ELECTROCUTION
(Electric Shock)

SECONDARY INJURIES

ELECTRIC BURN EXPLOSION

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

FACTORS FOR SEVERITY OF INJURIES
• Current & Circuit Voltage

• Area of Body Contact

• Physical Size of Person

• Age & Health Condition

• Duration of Current

• Body Resistance

• Wet and/or Damp Location

• PPE Used

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

DOSAGE & RESPONSE
RESPONSE
CARDIAC & BREATHING
ARREST
VENTRICULAR FIBRILLATION

LET GO THRESHOLD

THRESHOLD OF PERCEPTION

DOSE
0.5 mA 10 mA 500 mA

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

RISK FACTORS
• Dose-Duration Factors
– 500 mA for 0.5 Seconds may be fatal

– 100 mA for 2 Seconds may lead to

death

– 3 mA may lead to painful shock

• Frequency
– High Frequency – Serious Internal
Burns

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

INJURY TYPES
• ELECTRICAL BURNS – Flow of Electricity
through Body Tissues – Non-fatal
Injury – Occurs on the Hands
• ELECTRO-THERMAL BURNS – HV
Conductor
• Involuntary Muscle CONTRACTIONS
• STOPPAGE of Breathing
• VENTRICULAR FIBRILLATION (Irregular
Heart-Beat)
• CARDIAC ARREST - Leading to Paralysis
• PULMONARY ARREST (Inability to
Breath) Oxygen Supply to Brain may
Stop leading to Death
HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

RECOGNIZING THE CASUALTY
• Asphyxia

• No Apparent Pulse

• Pallid Blue Color

• Muscular Contraction

• Contact Burns

• Thrown Away by Shock

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

INITIAL ACTION
• Isolate from the Power Source
– Turn Off the LV Connection

– Dislodge the Victim with Non-

conducting Prop

• Never Attempt to Rescue the Victim

from HV Connection without
Switching the Power Off

• Check for Circulation (Pulse/

Breathing)

• First Aid – Including CPR by

Authorized Person

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

CONTROL OF ELECTRICAL HAZARDS
1. Physical Controls 1. Design of Component

2. Selection of Component

3. Materials for Construction

4. Physical Location of Site

5. Shielding & Enclosure

6. Double-Insulation for Tools & Cables

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

CONTROL OF ELECTRICAL HAZARDS
1. Physical Controls ++++
++++
2. Grounding & Bonding

++++ ++++

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

CONTROL OF ELECTRICAL HAZARDS
1. Physical Controls Over-Current Protection
Devices will Protect only the
2. Grounding & Bonding Equipment; not the Personnel

3. Over-Current Protection Devices

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

CONTROL OF ELECTRICAL HAZARDS
1. Physical Controls Fault Current Protection
Devices will Protect BOTH
2. Grounding & Bonding Equipment AND Personnel

3. Over-Current Protection Devices

4. Fault Current Interrupters

Ground Fault Current Interrupters (GFCI) Arc Fault Current Interrupters (AFCI) Earth Leakage Circuit Breaker (ELCB)

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

CONTROL OF ELECTRICAL HAZARDS
1. Physical Controls

2. Grounding & Bonding

3. Over-Current Protection Devices

4. Fault Current Interrupters

5. Procedures

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

PROCEDURES
• Competent & Authorized Personnel
• Electrical Power Isolation
• No-Voltage Testing
• Excavation Works
• Crane & Mobile Equipment
• Water/ Steam Cleaning
• Energy Discharge in CP Transformer
• Pre-Start Up Review
• Work Permit System
HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

INGRESS OF PROTECTION (IP)

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

MANAGEMENT OF PORTABLE APPLIANCES
• Should be Intrinsically Safe or Explosion Proof

• Hand Lamp Voltage shall be limited to 24 V

• All Tools shall be Insulated

• 240 V NOT Permitted. Use of any electrical
equipment above 24V shall have earth leakage
tripping device. Electrical fittings exceeding 24V
and connections inside confined space (including
ELCB) shall be inspected and approved by KNPC
Electrical Maintenance (or equivalent in projects
department) before starting the job.
• Screened Cables shall be used

• Fixed Equipment (Wood/ Rebar Cutter) shall be

installed with Dead-Man Switch

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

STATIC ELECTRICITY
• Generation of Static
• Accumulation of Static
• Spark
• Spark of Sufficient Energy
• Presence of Flammable Atmosphere
SOURCES OF STATIC ELECTRICITY
• Flow of Light Hydrocarbon
• Passage of Dry Powder Materials (e.g. Sulphur)
• Charging of Non-Conductive Clothing
• Loading and Unloading of Liquid Hydrocarbons
• Spray Painting and Sand Blasting
• Moving Parts of Mechanical/ Electrical
Equipment

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

CONTROL OF HAZARDS FROM STATIC ELECTRICITY
• Earth the Mechanical/ Electrical
Equipment

• Wear Anti-Static PPE

• Control the Flow Rate

• Add Anti-Static Additives

• Bond the Components (e.g. Flexible

Hose in the Loading Station)

• Avoid Spilling/ Splashing

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

FREQUENT VIOLATIONS/ OBSERVATION
• Faulty or Damaged Wire or Equipment
• Loose Connections
• Use of Under-Rated Wiring or Poor Quality Fittings
• Lack of Earthing/ Grounding/ Bonding
• Lack of Protective Safety Devices
• Use of Over-Rated Fuses or Jumpers
• Working on Live Equipment
• Water Seepage or Handling with Wet Body Parts
• Poor Housekeeping
• Handling of Electrical Equipment by Incompetent Person
• Lack of Awareness and Training
• Lack of Safe Working Procedures and Poor Communication
• Failure to Use Appropriate PPE & Tools
• Lack of Warning Signs
• Lack of Proper Identification

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

REMEMBER…..

• Electricity can Turn You OFF.

• Electricity is a REAL BUT DEADLY Friend.

• DEAL this Friend with Due Care and Respect.

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02

HSE Training Center - 2017 HSE – 203 : Area Classification & Electrical Safety

Doc. No : HSE – TSTR – 17- 5412/Rev 02