Hazardous Area Design (HAD)

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Hazardous Area Design (HAD)

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Hazardous Area Design (HAD) is Ideal for EPC design phases, brownfield upgrades and compliance remediation.

Once the hazardous zones are defined the design must translate those zones into a buildable solution. We help asset owners and EPCs select compliant Ex equipment and protection techniques, define installation requirements, and produce the documentation needed for construction, commissioning, and ongoing inspection/maintenance.

Key outcomes

Correct Ex equipment for the zone (EPL, gas group, temperature class, dust/IP requirements) — without over-specifying
Installation detail that stands up to commissioning pressure (glands, sealing, segregation, earthing/bonding, mechanical protection)
Documentation that supports inspection, maintenance, and future upgrades

What we do (scope inclusions)

Review HAC outputs (or validate existing zones) and confirm design basis
Develop an Ex Equipment Selection Schedule (EPL/protection technique, gas group, temp class, certificates, ‘X’ conditions)
Engineering support for protection techniques (e.g., Ex d, Ex e, Ex i, Ex p, Ex n, Ex t) and IS loop design where required
Define installation requirements: cable/gland selection, sealing, segregation, ingress protection, earthing/bonding, labeling
Vendor package review (motors, lighting, instruments, skids) to confirm certification and suitability
Audit/verification readiness planning: inspection checklists, ITP/ITC, evidence requirements

Typical deliverables

HAD Philosophy / Basis of Design (assumptions + verification approach)
Ex equipment register + selection schedule (certificates + conditions of use)
Installation requirements/spec for contractors (glands, sealing, conduits, segregation, terminations)
Drawing markups/updates (as required) + construction notes
Hazardous-area ITP/ITCs and commissioning checklists
Handover dossier structure to support ongoing inspection and maintenance

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Call our Team about
your HAD requirements Today!

1300 15 66 85

Other HADC Services

Hazardous Area Classification

Hazardous Area Audits

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Hazardous Area Classification FAQs

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Can you work alongside our EPC/design house?
Yes, we slot in as Ex SMEs and provide design assurance through targeted reviews (e.g., 30/60/90% design), helping keep the project compliant without slowing delivery.
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Can you review vendor skid packages?
Yes, before installation we check Ex certification, EPL/gas group/temp class, any “X” conditions, and practical items like cable entries, glands, sealing and documentation completeness.
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Do you provide intrinsic safety loop calculations?
Yes, we develop or verify IS loop calculations (barrier/isolator selection, device parameters, cable limits) and package it into documentation that’s easy to maintain through future changes.
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Can you help make us “audit ready” before commissioning?
Yes, we run an audit readiness check: document pack review + targeted walkdown + a prioritised punch list. This reduces late findings and protects commissioning dates.
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Why RelyOn?

• Led by industry-recognised HACD engineers

• Independent, defensible engineering advice

• Deep experience across renewables, BESS, hydrogen & industrial assets

• Integrated with broader electrical safety & compliance services

Speak to our Hazardous Areas Team