Common Hazardous Area Mistakes

November 12, 2024

What are the Top 3 Biggest Things Hazardous Area (HA) Guys Miss?

When it comes to Hazardous Areas (HA) – explosive atmospheres – ensuring safety and compliance is paramount. However, despite the rigor involved, several critical mistakes are often made in the industry due to ignorance or misunderstandings. Here are the top three mistakes I commonly see:

1. Misunderstanding of Zones

A common issue in HA work is a misunderstanding of zoning. Zones are defined based on the likelihood of an explosive atmosphere being present, yet many professionals mistake the nature of the material for the zone it falls under. For instance, a sales representative once tried to sell a Zone 1 IIB motor for a hydrogen application. The problem? Hydrogen is not a Zone 1 material, and it belongs to Group IIC, not IIB. This mix-up could lead to serious safety risks if the equipment is not properly rated for the zone in question. Always ensure the zone and material group are correctly matched to avoid potentially hazardous oversights.

2. Misunderstanding of Certificates

Another major pitfall is a poor understanding of equipment certification. HA environments require specialized equipment certified for specific conditions. These certificates must be recognized in Australian Standards and meet the requirements of the hazardous area. It’s not uncommon for professionals to overlook important details on the certification. Some common mistakes include using equipment with certificates not recognized in Australia (e.g., ATEX), relying on outdated certificates, not recognizing the installation requirements for a valid device (such as the "X" at the end of certificates), or even using equipment with the wrong certificate. For example, a sales representative once assured that a device had a specific IECEx certificate, but on arrival, the nameplate showed a different marking. Certificates must always be verified for accuracy and current compliance with standards.

3. Misunderstanding of Inspection Requirements

While it is fantastic when organizations take proactive steps to address HA requirements during development, it is devastating when they neglect to inspect their equipment. Routine inspections are a vital part of ensuring the ongoing safety of any hazardous area, yet they are often overlooked. Many installations are completed without any follow-up inspections or maintenance plans. Australian Standards, like AS/NZS 60079, require regular inspections, maintenance, and documentation to ensure that systems continue to meet safety criteria. Ignoring these requirements can lead to non-compliance and an increased risk of failure in hazardous areas. I have witnessed many devices that have worn down, rusted, or have loose connections that make the electrical system a potential ignition source. One such case involved a light fitting; the enclosure began to crack, allowing flammable gas to seep inside — an explosion waiting to happen.

Conclusion

These three areas — misunderstanding zones, certificates, and routine inspections — are critical for ensuring safety in hazardous areas. Avoiding these common mistakes will protect both personnel and infrastructure, ensuring long-term compliance and safety. Always ensure you consult a Hazardous Area-qualified expert to meet your obligations.

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