Hazardous Area Process | Ensuring Hazardous Area Compliance: A Step-by-Step Guide

November 8, 2024

Introduction

Ensuring compliance with Australian Standards (AS/NZS 60079) in hazardous areas is crucial for the safety of personnel and the integrity of facilities. Hazardous Area (HA) works involve several stages, from classification to verification. From my experience, there is little to no awareness of this process unless you work in the field. This guide outlines the essential steps to help you understand the process.

1. Hazardous Area Classification (HAC)

The first step in HA compliance is to ensure that the hazardous area is properly classified. Typically, I first ask the organization if they have previously conducted a Hazardous Area Classification (HAC) report. This report determines the zones where explosive atmospheres are likely to occur. The material you handle plays a vital role in this classification, as different materials lead to different zoning requirements. For instance, gases like hydrogen will result in different zoning than dusts like milk powder. Correct zoning ensures the right equipment is chosen for the environment. If there is no report, I develop the HAC based on AS/NZS 60079.10.1 and/or AS/NZS 60079.10.2.

2. Hazardous Area Design

Once zoning is established, the next step is to design the electrical system to meet the safety requirements within the hazardous area. The zoning will define the constraints for equipment allowed in the area. This involves:

  • Speaking with manufacturers to source equipment that meets the needs of the client and the HA.
  • Performing necessary calculations to verify protection methods for the electrical system. Common calculations include electrical tripping of Direct Online Ex e motors (ensuring they don’t overheat) or ventilation needs for Exv artificially ventilated rooms.
  • Considering other relevant standards based on the materials or processes involved that may need to be incorporated into the design. Some examples are AS 19880.1:2023 for hydrogen generating and dispensing, AS 1940:2017 for distilleries handling flammable liquids, and AS/NZS 4745:2012 for handling combustible dusts, typically in dairy factories.
  • Drafting a drawing set for the site that captures all the necessary information for the electrician to install the equipment. This often undergoes a few reviews before the final revision is provided to the site.

3. Hazardous Area Installation

Once the design is finalized, the next step is installation. The installation phase is critical for ensuring that the designed system is implemented safely. It's essential that the electricians involved in the installation are competent in hazardous areas. There are a range of extra considerations that electricians need to be aware of when installing electrical equipment. One way to verify their competency is by checking if they have EEHA (Electrical Equipment for Hazardous Areas) certification. At Boschetti, we employ electricians with EEHA training, ensuring they have the necessary knowledge and skills for HA installations.

4. Develop an Inspection Routine

Now the system is in place, we need to ensure the equipment is maintained to continue providing the necessary protection to prevent an explosion. Regular inspections are required by AS/NZS 60079 to maintain safety and compliance. After the installation, I typically explain and develop and inspection routine to ensure that the site is aware of all equipment that upkeeped. Inspections should be documented and address wear, corrosion, and any faults that could compromise the integrity of the hazardous area.

Remember - Consistency always beats intensity. Set a routine and use this as a basis for continual improvement.

5. Hazardous Area Verification Dossier (HAVD)

Finally, all documentation related to the design, installation, and maintenance of hazardous area equipment must be compiled into a Hazardous Area Verification Dossier (HAVD). This dossier includes the HAC report, design drawings, certificates of equipment, inspection records, and any other relevant documents.

By following these steps — from classification and design to installation and documentation — your organization will be compliant with Australian Standards, safeguarding both people and your assets.

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