Hazardous Area Classifications (HAC) consultancy

INTRODUCTION

Chemical industries are widely recognized for their high risk of explosions and fires due to the hazardous substances they routinely process. However, this same level of risk awareness is often lacking in general industries, even though flammable liquids, gases, and combustible dusts are also present. In chemical plants, these substances are overt and widespread, while in general industrial settings, they are typically used in smaller quantities and confined to specific areas, making the associated risks less visible but no less significant.

Explosions and fires involving flammable liquids, gases, and combustible dusts are rare but typically severe, leading to major property damage, financial loss, environmental harm, and risks to human life. While international and many national standards—especially in Europe and North America—are aligned and reflect the current state-of-the-art in hazardous substance management, standards in some developing countries remain outdated. A key concern is electrical safety, where non-compliance with requirements for Hazardous (Classified) Locations is still frequently observed.

Enterprise to operating level

We help companies achieve and sustain business resilience by focusing on the most material risks across the overall value chain as well as specific risks in different operating environments, geographies, etc.

Flexible and responsive

Our teams are available whenever and wherever they are needed, and can respond immediately in the event of an emergency or major loss.

Practical, realistic and cost-effective

Our technical expertise is coupled with deep business experience; we understand that risk management necessarily involves trade-offs, and look at risk in the context of the specific business situation – not the theoretical “ideal”.

Global reach

We have experience in all regions of the world and are specifically knowledgeable about internationally and local regulatory requirements in numerous countries around the world.

WHY CHOOSE US

WHY JASP & GLOBAL RISK EXPERTS?

Global Risk Experts is a Swiss-based risk management consultancy with a branch office in Malaysia. It is led by a group of highly experienced professionals who provide independent, unbiased risk management services.

Our objective is to help companies identify the various risks they face, assess their operational vulnerabilities across the organization, and provide practical, cost-effective solutions for minimizing or mitigating those risks.

STUDY BASICS

In many industries, flammable materials can release gases, vapours, mists, or dust that, when mixed with air, may form explosive atmospheres. Preventing explosions in such areas involves two key measures: avoiding the formation of explosive atmospheres and eliminating potential ignition sources.

Prevent the formation of potentially explosive atmosphere
Prevent the ignition of potentially explosion atmosphere

Restrict the effects of an explosion to a negligible level

Judging from the strengths and weaknesses, most students choose mixed methods because they can be more varied and deeper.

Various international and national standards were defined and are in place. The current main international guidelines and standards are:

National Electric Code (NEC)

NFPA 70 – Chapter 5
NFPA 30 / 33 /496 / 487 / 654 / etc.

ATEX 94/9/EC

EN 60079-x
EN 61241-x

IEC

IEC 60079-x
IEC 61242-x

Identification of hazardous substances

Flash point / Minimum ignition energy
Lower / Upper Explosion Limit (LEL/UEL)
Gas/Dust Group (IIA / IIB / IIC | IIIA /
IIIB / IIIC)
Temperature Class (T1 – T6)
Group classification (Group A – G) (NEC / NFPA compliance)

Identification of hazardous classified locations

Class I (flammable liquids and gases)
Class II (combustible dust)
Class III (combustible fibres)

Development of Zones at classified locations

Flash point / Minimum ignition energy
Lower / Upper Explosion Limit (LEL/UEL)
Gas/Dust Group (IIA / IIB / IIC | IIIA /
IIIB / IIIC)
Temperature Class (T1 – T6)
Group classification (Group A – G) (NEC / NFPA compliance)

Identification of existing electrical equipment within the identified zones

Equipment classification (e.g. Ex d
IIBT3)
Adequate installation (location /
conduit)

Development of corrective actions (reporting)

Equipment classification (e.g., Ex d IIB T3)
Adequate installation (e.g., correct location, certified conduit use)
Compliance verification (e.g., documentation and marking checks)

Daily close-out meetings and written summaries

Conduct daily close-out meetings to review progress, issues, and next steps.
Document key discussion points and agreed actions.

Prepare and distribute written summaries to all relevant stakeholders.

STUDY SCHEDULE

Compliance

One aim of the study is to ensure that the analysed site complies with the most stringent requirements of international standards (NFPA / IEC / ATEX) and respective local regulations. Compliance with the latest international standards guarantees state-of-the-art installations—an essential prerequisite for preventing accidents, property damage, financial losses, reputational harm, and legal actions. It also minimizes disputes and costly retrofitting measures driven by the demands of authorities and insurance companies.

Occupational Health & Safety Improvement

The purpose of a Hazardous (Classified) Location Study is to eliminate the risk of igniting explosive gas, vapour, or dust atmospheres through electrical equipment.

Reducing or eliminating the probability of an explosion leads to a direct and immediate improvement in health and safety within the plant, ensuring that personnel, visitors, and third parties are not exposed to potential hazards.

Moreover, protecting people from the impact of explosions is a mandatory requirement. Any violation can result in severe legal and financial consequences.

Higher Level of Asset / Business Interruption Protection

Inappropriate electrical equipment is a well-known ignition source for fires and explosions, especially in areas with ignitable gases, vapours, or dust. Eliminating such equipment as a potential ignition source significantly reduces the risk of explosions and fires. While this lowers direct physical damage, the reduction in consequential financial losses is often even more substantial.

Optimizing Capital Expenditure

The Hazardous (Classified) Location Study clearly specifies the type of electrical equipment required for each hazardous zone. Since the zones determine equipment requirements, the common practice of installing explosion-protected equipment over wide areas “just to be safe” can be avoided. Understanding the zones and their boundaries helps optimize the purchase and installation of costly explosion-protected equipment.

DIRECT BENEFITS

COMPREHENSIVE REPORT

The final report will detail each hazardous location, zone classification, existing electrical equipment, any deviations, and required corrective actions for compliance with international and national standards.

DRAWING WITH ZONES (HORIZONTAL AND VERTICAL)

For each hazardous location, a drawing will show zone types and their horizontal and vertical extent. If needed, zones can be added as a layer to the master CAD drawings.

DELIVERABLES

A Hazardous (Classified) Location Study is only the first step toward compliance. Equally important is the implementation of the recommended risk improvement measures. Upon request, our team can support this process—from recommending qualified contractors and identifying suitable explosion-protected equipment, to evaluating proposals, overseeing remedial work, approving modified installations, and ultimately verifying compliance.

FOLLOW UP SUPPORT

Hazard Identification & Risk Assessment

Identify the types of hazardous substances present.
Assess environmental conditions, such as temperature and humidity.
Categorize the risk of explosive atmospheres (e.g., gas, dust)

Classification of Hazardous Locations

Class I – Areas with flammable gases and liquids.
Class II – Areas with combustible dust risks

Zoning of Classified Locations

Zone 0 / 1 / 2 (for flammable gases and vapors).
Zone 20 / 21 / 22 (for combustible dust atmospheres).
Defining horizontal & vertical zone extensions for precise safety mapping

Assessment of Electrical Equipment in Hazardous Zones

Reviewing installed electrical equipment (e.g., Ex d IIBT3 classification).
Evaluating proper installation (location, conduit, sealing methods, etc.)

Identification of Compliance Deviations

Checking for non-compliant or outdated electrical installations.
Highlighting risks related to inadequate grounding, shielding, or sealing.

Corrective Action Recommendations

Developing site-specific corrective measures for non-compliant areas.
Providing guidance on upgrading installations to meet global safety norms.

The study focuses on three core principles to prevent explosions and fires:

Primary Explosion Protection Prevent formation of ignitable atmospheres
Secondary Explosion Protection Prevent ignition sources from triggering an explosion
Tertiary Explosion Protection Minimize explosion impact through containment & mitigation strategies

Comprehensive Risk Assessment Report

Detailed documentation of hazardous areas, existing equipment, safety gaps, and non
compliance findings.
Recommended corrective actions for compliance

Hazard Zone Mapping & Drawings

Customized hazard maps illustrating zones (horizontal & vertical spread).
CAD integration for seamless facility safety planning

Implementation & Compliance Support

Assisting in contractor selection, equipment procurement, and safety retrofits.
Evaluating corrective work
proposals and overseeing final compliance approvals

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