Hazardous Area Classification (HAC) for a Global FMCG Manufacturing Facility

Case Study

HAC for a Global FMCG Manufacturing Facility to helps in proper selection and installation of electrical apparatus to be used safely in hazardous environment.

Background

A leading global FMCG manufacturer operating a large production facility engaged Sigma-HSE to conduct a comprehensive Hazardous Area Classification (HAC) study. The facility handled a variety of combustible powders, flammable liquids, perfumes, solvents, diesel fuel, LPG cylinders, and hydrogen-generating battery charging systems.

The objective was to identify areas where explosive gas, vapor, or dust atmospheres could occur and establish appropriate hazardous zones for safe selection and installation of electrical equipment.

Key Challenges

The facility included multiple operations with potential ignition and explosion risks:

1. Powder charging and dispensing operations
2. Mixing vessels handling flammable fragrances and solvents
3. Flammable liquid storage and transfer systems
4. Tank farms and tanker unloading facilities
5. Warehouses storing combustible powders
6. Battery charging stations generating hydrogen gas
7. Laboratory solvent storage and handling areas
8. Diesel storage tanks and DG fuel systems

In addition, several locations had ordinary electrical fittings installed close to potential release sources, requiring a detailed review of hazardous area requirements.

Approach

Sigma-HSE conducted:

1. Detailed site inspections and process reviews
2. Assessment of flammable gas, vapor, and dust release sources
3. Evaluation of ventilation effectiveness
4. Identification of hazardous zones (Zone 0, 1, 2, 20, 21 and 22)
5. Review of ignition sources and electrical equipment suitability
6. Development of area classification drawings and recommendations
7. Compliance assessment against international standards such as IEC/EN 60079

Key Findings

The study identified hazardous zones associated with:

1. Flammable powder charging hoppers and screw feeders
2. Mixing vessels and perfume handling rooms
3. Solvent and chemical storage cabinets
4. Diesel storage tanks, vents and transfer pumps
5. Hydrogen battery charging areas
6. Tank farm vent systems and unloading operations
7. Warehousing areas containing combustible powders

Several improvement opportunities were identified, including enhanced ventilation, grounding and bonding systems, hazardous-area-rated electrical equipment, spill control measures, dust management practices, and gas detection systems.

Benefits Delivered

The HAC study enabled the client to:

✔ Identify and classify all hazardous locations across the facility

✔ Select appropriate explosion-protected electrical equipment

✔ Reduce ignition risks associated with flammable gases, vapors and combustible dusts

✔ Improve compliance with international hazardous area standards

✔ Strengthen process safety and operational reliability

✔ Support future facility modifications and audits with a documented HAC basis

Outcome

The project provided a clear hazardous area classification framework for the entire facility, helping management implement appropriate engineering and operational controls while ensuring the safe installation and operation of electrical equipment in potentially explosive atmospheres.

Sigma-HSE continues to support industries worldwide with Hazardous Area Classification (HAC), Dust Hazard Analysis (DHA), HAZOP, LOPA, QRA, ATEX Compliance, Explosion Safety, and Process Safety Management studies.