Sabp P 013 PDF

Best Practice
SABP-P-013 13 January 2008

Electrical Design in Hazardous (Classified) Areas
Document Responsibility: Electrical Substations Equipment
Saudi Aramco DeskTop Standards

Table of Contents
1 Introduction.................................................................... 2
2 Definitions...................................................................... 3
3 Overview....................................................................... 3
4 Understanding the Basics............................................. 5
5 Probability of Explosion................................................. 6
6 Hazard Classification.................................................... 8
7 Electrical Equipment..................................................... 9
8 Comparison Between Zone and Division Systems..... 13
9 Role of the Standards.................................................. 15
Appendix A - EEx Protection Concepts............................ 16

Appendix B - IP Enclosure Classification System............ 17
Appendix C - FAQs.......................................................... 18
Previous Issue: New Next Planned Update: TBD

Page 1 of 18
Primary contact: Carlson, Ronald Wayne on 966-3-8746128
Copyright©Saudi Aramco 2007. All rights reserved.

Document Responsibility: Electrical Substations Equipment SABP-P-013
Issue Date: 13 January 2008
Next Planned Update: TBD Electrical Design in Hazardous (Classified) Areas
1 Introduction
1.1 Purpose
The purpose of this document is to provide an understanding of the basis of the

rules and regulations governing the selection and installation of electrical
equipment in electrically hazardous areas. This understanding will allow
designers to consider a wider variety of options while maintaining safety and
operational flexibility.
The focus is typical electrical installations in typical facilities within Saudi

Aramco. This means electrical (not instrumentation) applications in plants
processing/handling hydrocarbons (i.e., Class I installations).
This document is not intended as a tutorial however it does contain information

that will provide a basic understanding of what areas are hazardous areas, why
they are hazardous and design considerations for the selection and installation of
electrical equipment.
1.2 Disclaimer
This Best Practice (BP) is not mandatory. It is a supplement to existing

Mandatory Saudi Aramco Engineering Requirement (MSAERs) and provides
information that will maximize the opportunity for a successful electrical
installation.
Because this is not a mandatory document, in the event of a conflict between

this BP and MSAERs, the MSAER requirements take precedence.
1.3 References
The following is a summary of the documents mentioned in this BP:
Saudi Aramco References
Saudi Aramco Material Systems Specification

16-SAMSS-512 Switchracks & Factory Built assemblies-Low Voltage
Saudi Aramco Engineering Standards

SAES-B-068 Electrical Classified Areas
SAES-P-104 Wiring Methods and Materials
SAES-P-113 Motors and Generators
Page 2 of 18
Industry Codes and Standards

API RP 505 Recommended Practice for Classification of Locations
for Electrical Installations at Petrochemical Facilities
Class 1, Zone 0,1,2
NFPA 70 National Electrical Code (NEC)
IEEE Papers
“Conversion from Division to Zone electrical classification-why and how

the worlds largest oil company made the change”
This paper appears in: Petroleum and Chemical Industry Conference,

2000. Record of Conference Papers. Industry Applications Society 47th
Annual, Publication Date: 11-13 Sept. 2000, ISBN: 0-7803-6334-5
“Installation techniques and practices of IEC hazardous area equipment:

The nuts and bolts of a good installation”
This paper appears in: Petroleum and Chemical Industry Conference,

1999. Industry Applications Society 46th Annual, Publication Date:
13-15 Sept. 1999, ISBN: 0-7803-5601-2
2 Definitions
Text identified in bold font throughout this document is defined below.
BP: Best Practice
MSAER: Mandatory Saudi Aramco Engineering Requirements. These documents are

corporate mandatory documents. Examples of MSAERs are Saudi Aramco Materials
System Specifications (SAMSSs), Engineering Standards (SAESs) and Standard
Drawings (SASDs).
3 Overview
3.1 What is a Hazardous Area?
Hazardous areas (or locations) are areas where there is a reasonable risk that a
fire or explosion may occur because of the interaction of electrical equipment
and flammable gases or vapours, unless special design considerations are
followed with the electrical installation.
Page 3 of 18
The key phases to explain are:
“reasonable risk” – There needs to be a reasonable probability that there

will be an explosion caused by electrical equipment. Whether or not electrical
equipment is an ignition source at any point in time or whether an explosive
mixture is present, is dependant upon a wide variety of factors. Multiplied
together, the product is the probability of an explosion occurring. To cite an
extreme example, if the probability is one occurrence in 200 years, this isn’t a
risk worth spending money to prevent.
“because of the interaction of electrical equipment” – If there is a high

probability of an explosive gaseous mixture being present, but the probable
ignition sources would come from non-electrical sources (e.g., flames, hot pipes,
etc.), there is no point in classifying the area. In other words, there is no benefit
in eliminating electrical ignition sources if there are non-electrical ignition
sources that would be more likely to cause the explosion.
The probabilistic basis of electrical design in classified area is explained in

Section 5.
3.2 Who Determines the Hazardous Area?
Process Engineers and Loss Prevention experts determine the level and type of
classified area. The determination of the area classification requires a detailed
knowledge of the process conditions and the characteristics of the material
handled. Electrical engineers are in an advisory role to provide information on
the consequences to the electrical design when a particular classification is
established.
3.2 When is the Hazardous Area Drawing Developed?
It needs to be one of the first drawings developed during the detailed design
since it establishes the basis for the selection and installation of the electrical
equipment.
3.3 What Rules define the Hazardous Area?
Mandatory standard SAES-B-068 provide the rules and guidelines for classifying
a process area. This standard is based upon industry standard API RP 505.
3.3 Why is the Hazardous Area Drawing Important?
It identifies the areas in the process plant that will contain a flammable
atmosphere that could be ignited by electrical equipment. In this area, electrical
systems may need special design considerations.
Page 4 of 18
4 Understanding the Basics
4.1 The Hazard Triangle
For an explosion to take place, all three sides of the below triangle must be
present.
Fuel: There must be sufficient fuel present in the air to form an ignitable
mixture. This fuel may be in the form of gas, vapor or mist.
Oxygen: There must be sufficient oxygen present. The percentage required is

different for each type of fuel. Generally, the 21% oxygen in the air
is sufficient for most fuels.
Ignition Source: An ignition source from electrical equipment. It can be either

sparks, arcs, or surface temperature.
Proportions and combinations of each: Each type of fuel has unique

requirements as to the percentage of oxygen required and the temperature of the
ignition source.
4.2 Overall Objective
The design of the electrical equipment, and installation techniques in hazardous

areas are based upon ensuring that the probability of an uncontrolled explosion
of the atmosphere around the electrical equipment is so low so that in practice it
is not a concern (e.g., probabilities in the order of 1 event in 100).
Page 5 of 18
This objective is achieved by combinations of equipment and installation

techniques that ensure the fire triangle will only exist in very remote
circumstances. These techniques are explained in later sections of this BP.
5 Probability of Explosion
The probability of having an explosion is the product of the individual probabilities of

the three sides of the hazard triangle. The combination of fuel and oxygen are treated as
one and called “explosive atmosphere”. Therefore, the overall probability of an
explosion is:
Probability of explosion = (Probability of explosive atmosphere) x (Probability of

ignition source)
Probability of explosive atmosphere: Defined by the “Zone” classification.
Probability of ignition source: Defined by the function of the electrical equipment
Probability of Explosive Atmosphere
“Zones” establish the probability level of the an explosive mixture being

present (i.e., having two legs of the fire triangle). There are three
classifications:
Zone 0: Explosive mixture present continuously.
Zone 1: Explosive mixture present normally.
Zone 2: Explosive mixture present abnormally.
“Continuously”: always present (probability HIGH)
“Normally”: expected as part of the normal

operation of the facility but not
expected to be a routine occurrence.
(probability MEDIUM)
“Abnormal”: shouldn’t exist during normal plant

operation. (probability LOW)
Page 6 of 18
Probability of Ignition Source
The “Zone” establishes the probability of two sides of the fire triangle
being present. The probability of the complete triangle being present
depends upon the probably of the electrical equipment being an ignition
source.
An overall “LOW” probability of the fire triangle occurring is considered

an acceptable risk in the industry. This is generally the basis for the
rules in documents such as the National Electrical Code (NEC). The
NEC does not speak in these “probabilistic” terms but if the reader
understands this concept, the equipment installation rules in the NEC
will automatically be understood.
Electrical equipment can be assigned one of two probability levels of

being an ignition source depending upon the function of the equipment.
HIGH probability: if it is an ignition source during NORMAL

operation.
LOW probability: if it is an ignition source during

ABNORMAL operation.
“NORMAL" operation is when the equipment is

performing the function for which it was designed. For
example, when a motor is operating within its design
parameters, when a circuit breaker is operating to close or
open the power circuit, etc.
“ABNORMAL” operation is when the equipment is

experiencing an abnormal condition. For example, when
there is an electrical fault in the motor.
The “frequency” of the operating condition is not a factor in establishing

the probability that the equipment is an ignition source; only whether the
equipment is performing the function for which it was designed. For
example, a circuit breaker is a NORMAL ignition source because, when
it performs its function (i.e., clears a fault), the arc across the contacts are
an obvious ignition source. There is no consideration as to whether the
breaker is expected to operate once per day or once per decade.
An overall “probability of explosion" of LOW or higher is considered an unacceptable

risk and the electrical system design must be modified with special equipment and/or
installation techniques to bring it below the LOW probability.
Page 7 of 18
Consider a couple of examples:
Small motor installation in Zone 2:
Zone 2 has a LOW probability of having an explosive atmosphere. The

motor1 has a LOW probability of being an ignition source.
Probability of explosion = LOW x LOW = <LOW (i.e., LOW-).
Conclusion: A standard motor in a Zone 2 environment is acceptable.
If the classification had been Zone 1, the overall probability would be

>LOW (i.e., LOW+) which means the motor could not be installed.
1
squirrel cage induction motor per Saudi Aramco standards
Contactor in Zone 2:
The contactor is a NORMAL ignition source (HIGH probability)

because, when it performs its function, there is an arc (ignition source)
across the contacts.
Probability of explosion = LOW x HIGH = MEDIUM
Conclusion: A standard contactor can not be used in a Zone 2

environment.
This model can be applied to all electrical based equipment to determine

whether special equipment/designs are necessary in a hazardous area.
6 Hazard Classification
The “Zone” defines the probability of the explosive atmosphere being present. The type
of gas is also important since the characteristics of the explosions are different for
different gases (i.e., pressures and temperatures). These characteristics affect the type
of electrical equipment design.
Page 8 of 18
Gas Grouping
The Gas Grouping identifies groups of gases with similar explosive characteristics (i.e.,
similar oxygen requirements, explosive pressures, ignition temperatures, etc.). For IEC
groupings, they are Groups IIA, IIB & IIC with IIC being the most critical group. See
below table.
The hazardous area drawing will have areas designated by the “Zone” and the “Gas
Grouping”. For example “Zone 2, IIA”. The “II” designation is a “gas” reference.
In 2000, Saudi Aramco switched to the IEC based hazardous area system (based upon
Zones instead of Divisions). SAES-B-068 has the mandatory requirements for
establishing the hazardous locations. See Section 8 for discussion on the comparison
7 Electrical Equipment
“Standard” electrical equipment is equipment that is designed for a non-explosive

atmosphere. As explained above, standard equipment can be suitable in hazardous
areas providing it is obvious whether the equipment is a NORMAL or ABNORMAL
ignition source. Sometimes it is not obvious.
Ignition sources in electrical equipment comes from two sources: arcs and surface
temperature.
Arcs: Equipment which have mechanical contacts that make/break current.

For example, circuit breakers, contactors, relays, pushbuttons.
Surface temperature: Equipment that have components or general areas that get
hotter than ambient. For example, lamps, power resistors,
heating elements, motor enclosures.
Page 9 of 18
In the previous section, equipment with arcing components were obvious NORMAL
ignition sources since the energy in an arc is always enough to ignite an explosive
mixture of any gas. Note the exception to this are arcs in low energy/energy limited
systems which is outside the scope of this BP.
Whether there is a surface in the equipment at a temperature that will be an ignition

source, is not always obvious. If there is a temperature issue with the equipment, the
nameplate of the equipment has a “T” designation specifying the maximum temperature
of any surface that will be exposed to the atmosphere. See below table. With this, and
the “Gas Group” information from the classification drawing, it can be determined
whether the equipment is a NORMAL ignition source.
7.1 Selection
Once it has been determined that non-standard equipment is required, there is a

variety of equipment available. The techniques employed in the design of the
equipment are intended to ‘break” the hazard triangle so no explosion occurs.
To accomplish this, the design techniques are of the following types:
- Isolation
- Containment
Isolation:
Ensuring that the ignition source is isolated from the atmosphere.
Some examples:
-The electrical arcing contact is sealed in an enclosure so that the
exterior atmosphere will not be exposed to the arc.
-The equipment is installed in an enclosure that is continuously purged
with a fresh air supply.
Containment:
Allowing the explosion to occur in a controlled manner inside the
equipment. The ignition source is allowed to ignite the explosive
atmosphere within a specially designed flameproof/explosionproof
enclosure. The enclosure has engineered flamepaths so that the
explosive gas is cooled when it is relieved to the outside atmosphere.
The temperature of the gas exiting the enclosure is too low to ignite the
surrounding atmosphere.
Page 10 of 18
7.2 Labeling
Equipment that is of a special design for installation in a classified area is

labeled to provide the information necessary for proper application.
The basis of the labeling is different between North American and IEC based
equipment.
North American:
Labeling indicates the hazardous classification into which the equipment

can be installed.
IEC
Labeling indicates how the equipment is designed (i.e., the various

protective techniques employed). It is left up to the installer to
determine whether the protective techniques employed are suitable for
the area classification. Refer to Appendix A for the IEC protective
techniques.
Page 11 of 18
7.3 Installation
The equipment must be interconnected to make a functional system. This is

done either by conduits or cabling.
There are two main considerations when interconnecting equipment in classified

areas:
- Ensuring that the function of the equipment is maintained
- Ensuring the interconnecting equipment does not transmit the explosive

atmosphere to a device that is not designed for the classification
- Ensuring that the function of the equipment is maintained
With flameproof/explosionproof equipment, the explosion is allowed to

occur in a controlled manner in a confined space. When we connect a cable
or conduit to this equipment it must be ensured that the explosion is confined
to the space to which it was intended and not be transmitted into the conduit
or cable system. To accomplish this “seals” are used in the cable of conduit
close to the connection to the equipment. These provide a physical barrier to
the explosive forces ensuring that the explosion is confined inside the
device.
Some equipment is labeled as “factory sealed” which means the conduit or

cable connection to the equipment does not require an external seal. This
equipment has been designed so the explosion inside the equipment is
confined to a separate chamber from where the cable/conduit terminates.
- Ensuring the interconnecting equipment does not transmit the explosive

atmosphere to a device that is not designed for the classification.
The interior of conduit can act like a pipeline to transmit the explosive
atmosphere from one area to another. If equipment in a non-classified area
is connected to equipment in a classified area, the conduit would transmit the
explosive atmosphere from the classified area into the equipment in the non-
classified area. Since the equipment in the non-classified area is standard
equipment, it is not designed to control this explosion.
To eliminate this concern, the interior of the conduit is sealed when it passes
from the classified area to the unclassified area.
Cables are not a concern. There is minimal space in the cable interior and
gas transmission will not occur.
Page 12 of 18
Refer to IEEE paper “Installation techniques and practices of IEC

hazardous area equipment: The nuts and bolts of a good installation” for a
detailed discussion on equipment selection and installation.
8 Comparison between Zone and Division Systems
In 2000, Saudi Aramco changed the standards to require new facilities be classified to
the IEC “Zone” system. Previous to this the plants were classified to the “Division”
system.
Refer to IEEE paper Conversion from Division to Zone electrical classification-why and
how the worlds largest oil company made the change” for a detailed discussion on why
and how Saudi Aramco converted.
8.1 Zone vs. Division
The below table compares the two.
Page 13 of 18
8.2 Gas Grouping
8.3 Temperature Classification
Page 14 of 18
9 Role of the Standards
The Saudi Aramco standards that govern Hazardous Area Classification and equipment
selection/installation, are the following:
SAES-B-068 “Electrical Area Classification”
Rules and guidelines on how to classify a process facility
SAES-P-104 “Wiring Methods & Materials”
Mandatory requirements on equipment selection and installation techniques by

field contractor
SAES-P-116 “Switchgear & Control Equipment”
Directs designer/contractor on which standards to use for electrical equipment

selection.
16-SAMSS-512 “Switchracks & factory Built Assemblies-Low Voltage”
Requirements for selection and installation of equipment installed in classified

areas
Revision Summary
13 January 2008 New Saudi Aramco Best Practice.
Page 15 of 18
Appendix A
EEx Protection Concepts
Page 16 of 18
Appendix B
IP Enclosure Classification System
Page 17 of 18
Appendix C
FAQs
Is the Electrical Area Classification drawing an Electrical Drawing?
Yes and No. It is unique in that it is only used by the electrical (and instrumentation)
discipline, is usually given an electrical drawing number but it is not developed by electrical
people. It is developed by the process/loss prevention discipline.
Do we use the NEC to classify an area?

No. The NEC establishes the rules for installing the electrical equipment, assuming the area
classification already exists. The NEC describes, in general terms what the different
classifications mean, but there is not enough detail to actually develop the area
classification. Within Saudi Aramco, Loss Prevention standard SAES-B-068 are the rules
and instructions for establishing the area classification. The standard relies heavily on API
RP 505.
Is there a difference between a “Hazardous” and “Classified” location?

No. The terms are used synonymously.
Is explosionproof equipment automatically weatherproof?

No. The default explosionproof rating is only good for indoor installation. Depending on
the specific equipment, installation outdoors requires some optional features.
For explosionproof equipment to function they must have engineered “gaps” between the
inside and the outside to relieve the explosive pressure. These gaps mean water and dust can
get inside.
When did Saudi Aramco Change from Division to Zone classification?

The year 2000. Previous to this, Saudi Aramco used the Division concept.
What is the difference between Flameproof and Explosionproof?

Nothing, in concept. Both techniques allow an explosion to happen within a controlled
space (i.e., box enclosure) and relieve the hot gases in such a manner so when they reach the
outside atmosphere, the gas is not an ignition risk.
What does “Factory Sealed” mean?

This is a North American term. A device with this designation does not need a conduit or
cable seal to field installed. The techniques the manufacturer had used to accomplish this is
not always obvious.
Page 18 of 18

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Best Practice

SABP-P-013 13 January 2008

Saudi Aramco DeskTop Standards

Appendix A - EEx Protection Concepts............................ 16

Previous Issue: New Next Planned Update: TBD

Copyright©Saudi Aramco 2007. All rights reserved.

The purpose of this document is to provide an understanding of the basis of the

The focus is typical electrical installations in typical facilities within Saudi

This document is not intended as a tutorial however it does contain information

This Best Practice (BP) is not mandatory. It is a supplement to existing

Because this is not a mandatory document, in the event of a conflict between

The following is a summary of the documents mentioned in this BP:

Saudi Aramco References

Saudi Aramco Material Systems Specification

Saudi Aramco Engineering Standards

Industry Codes and Standards

“Conversion from Division to Zone electrical classification-why and how

This paper appears in: Petroleum and Chemical Industry Conference,

“Installation techniques and practices of IEC hazardous area equipment:

This paper appears in: Petroleum and Chemical Industry Conference,

Text identified in bold font throughout this document is defined below.

BP: Best Practice

MSAER: Mandatory Saudi Aramco Engineering Requirements. These documents are

3.1 What is a Hazardous Area?

The key phases to explain are:

“reasonable risk” – There needs to be a reasonable probability that there

“because of the interaction of electrical equipment” – If there is a high

The probabilistic basis of electrical design in classified area is explained in

3.2 Who Determines the Hazardous Area?

3.2 When is the Hazardous Area Drawing Developed?

3.3 What Rules define the Hazardous Area?

3.3 Why is the Hazardous Area Drawing Important?

4 Understanding the Basics

4.1 The Hazard Triangle

Oxygen: There must be sufficient oxygen present. The percentage required is

Ignition Source: An ignition source from electrical equipment. It can be either

Proportions and combinations of each: Each type of fuel has unique

4.2 Overall Objective

The design of the electrical equipment, and installation techniques in hazardous

This objective is achieved by combinations of equipment and installation

The probability of having an explosion is the product of the individual probabilities of

Probability of explosion = (Probability of explosive atmosphere) x (Probability of

Probability of explosive atmosphere: Defined by the “Zone” classification.

Probability of ignition source: Defined by the function of the electrical equipment

Probability of Explosive Atmosphere

“Zones” establish the probability level of the an explosive mixture being

Zone 0: Explosive mixture present continuously.

Zone 1: Explosive mixture present normally.

Zone 2: Explosive mixture present abnormally.

“Continuously”: always present (probability HIGH)

“Normally”: expected as part of the normal

“Abnormal”: shouldn’t exist during normal plant

Probability of Ignition Source

An overall “LOW” probability of the fire triangle occurring is considered

Electrical equipment can be assigned one of two probability levels of

HIGH probability: if it is an ignition source during NORMAL

LOW probability: if it is an ignition source during

“NORMAL" operation is when the equipment is

“ABNORMAL” operation is when the equipment is