Common Hazardous Area Compliance Failures

Industrial environments where flammable gases, vapours, or combustible dust are present require strict compliance with the SANS 60079 series and SANS 10108 to prevent ignition risks. These standards guide the classification of hazardous locations, the selection of suitable electrical equipment, and the inspection of installations.

Despite clear regulatory frameworks and engineering standards, many facilities still experience hazardous area compliance failures that increase operational risk and legal exposure.

Understanding the most common compliance issues can help organisations improve safety, maintain regulatory compliance, and prevent costly incidents.

1. Incorrect Equipment Selection for the Hazardous Zone

One of the most common compliance failures is installing electrical equipment that is not suitable for the classified hazardous area.

Hazardous locations are classified according to SANS 10108, which defines zones such as:

• Zone 0, Zone 1, Zone 2 (flammable gases and vapours)

• Zone 20, Zone 21, Zone 22 (combustible dust environments)

Each zone requires equipment with the correct Equipment Protection Level (EPL) and temperature classification.

Common issues include:

• Equipment installed without Ex certification

• Incorrect temperature class (T-rating)

• Equipment unsuitable for the gas group

• Incorrect protection type selection

Improper equipment selection significantly increases the risk of ignition.

2. Improper Cable Glands and Entry Sealing

Cable entries play a critical role in maintaining the explosion protection integrity of electrical enclosures.

Common failures include:

• Non-certified cable glands used in hazardous areas

• Incorrect barrier gland installation

• Damaged or missing seals

• Incorrect thread engagement

Poor cable entry practices can compromise the integrity of flameproof or increased safety enclosures.

3. Poor Earthing and Bonding

Earthing and bonding systems are essential to prevent ignition caused by electrical faults or static discharge.

Typical issues include:

• Missing equipotential bonding connections

• High earth resistance values

• Poor continuity of bonding conductors

• Inadequate grounding of metallic structures

In hazardous environments, inadequate earthing may allow dangerous potential differences that can produce sparks.

4. Lack of Periodic Inspections

Hazardous area installations must be inspected periodically in accordance with SANS 60079-17, which defines inspection grades including:

• Visual inspection

• Close inspection

• Detailed inspection

Many facilities fail to implement structured inspection programmes, resulting in:

• Undetected equipment deterioration

• Corrosion or mechanical damage

• Uncorrected non-conformities

Routine inspections are critical for maintaining long-term compliance.

5. Incomplete Hazardous Area Documentation

Proper hazardous area management requires comprehensive documentation.

Common documentation failures include:

• Missing hazardous area classification drawings (SANS 10108)

• Incomplete Ex equipment registers

• Missing equipment certificates

• Lack of inspection and maintenance records

Without proper documentation, demonstrating compliance during regulatory or insurance audits becomes difficult.

6. Unauthorized Modifications to Explosion-Protected Equipment

Explosion-protected equipment must never be modified without proper engineering control.

Typical violations include:

• Drilling additional holes in Ex enclosures

• Replacing certified components with non-certified parts

• Improper repair of flameproof joints

• Modification of cable entries

Such modifications can invalidate equipment certification and create serious ignition hazards.

7. Lack of Competent Personnel

Hazardous area installations require specialised knowledge of standards such as SANS 60079 and SANS 10108.

Compliance failures often occur when:

• Personnel lack training in explosion protection techniques

• Maintenance teams are unfamiliar with Ex equipment requirements

• Installations are performed without proper inspection

Competent personnel are essential for maintaining safe hazardous area installations.

Conclusion

Hazardous area compliance is not simply a regulatory requirement—it is a critical component of industrial risk management. Standards such as SANS 10108 for hazardous area classification and SANS 60079 for equipment installation and inspection provide the framework for safe operations in explosive environments.

By addressing common compliance failures such as incorrect equipment selection, poor earthing, inadequate documentation, and lack of inspections, organisations can significantly reduce the risk of ignition and ensure long-term regulatory compliance.

Maintaining structured inspection programmes and proper technical oversight is essential for protecting personnel, equipment, and operational continuity in hazardous locations.