Hazardous Area

Classification

Prepare by: Yuliya Loginova

Supervised by: Erwana Rahayu Mohamad Sharip
- 2020 -
This presentation has been prepared for the purpose of study and reference
All Table and Figures supported by relevant literature

- 2020 -
 CONTENT
• OBJECTIVE
• INTRODUCTION
• AREA CLASSIFICATION
• IDENTIFICATION OF POINT SOURCES
• DETERMINATION GRADE OF RELEASE
• DEFINING FLUID CATEGORY
• ESTABLISH ZONE CLASSIFICATION
• DETERMINE HAZARD RADII OF HAZARDOUS AREA
• VENTILATION
• REQUIRED DATA AND DOCUMENTATION
• APPROACHES
• DIRECT EXMAPLE APPROACH
• POINT SOURCE APPROACH
• RISK-BASED APPROACH

• CALCULATIONS AND REFERENCES (RELATED TABLES, FIGURES)

OBJECTIVE

To understand the importance of Hazardous area classification.

To familiarize with minimum requirements and recommended

practices for the Determination of hazardous areas and its
classifications.
WHAT IS AREA CLASSIFICATION?

It is a method to analyze the location environment where there is a

potential risk of fire or explosion due to their containment of volatile
gases or dust.

Hazardous area classifications are a grouping system that recognizes the

risk associated with various volatile materials and determines the
appropriate protection measures needed to mitigate that risk.
WHY IT IS IMPORTANT TO CLASSIFY THE AREA?

Avoid an explosion by earlier identification

of ignition sources

Provides sufficient precaution

Ensure safe operation

Safe personnel

No property damage
WHERE TO APPLY HAC?

 Oil & gas production and processing plants :

-onshore
-offshore : platforms, FPSO (Floating Production Storage Offloading vessels)
 Oil and gas tankers, drilling ships
 Oil refineries
 Petrochemical and Chemical processing plants
 Gas pipelines and distribution centers
 Re-fuelling stations or petrol stations

 Underground coal mines

 Printing industries, paper and textiles
 Hospital operating theatres
 Surface coating industries
 Sewerage treatment plants
 Grain handling and storage and processing (flour-milling industry)
 Sugar refineries
 Light metal working, where metal dust and fine particles can appear
 Woodworking areas
FAILURE AND CAUSE OF HAZARDOUS AREA CLASSIFICATION
INDUSTRY: COAL MINES
PROBLEM STATEMENT: SPARK (often generated by electrical apparatus) leading to those
catastrophic accidents
FAILURE AND CAUSE OF HAZARDOUS AREA CLASSIFICATION
INDUSTRY: OIL & GAS, CHEMICAL AND PETROCHEMICAL INDUSTRIES
PROBLEM STATEMENT: FAILURE OF DESIGN AND USE OF ELECTRICAL APPARATUS IN
HAZARDOUS AREAS
AREA CLASSIFICATION

Area classification is the assessed division of a facility into hazardous

areas and nonhazardous areas, and the subdivision of the hazardous
areas into zones. Area classification is dependent upon its degree of
ventilation and mode of release.

AREA CLASSIFICATION

HAZARDOUS NON-HAZARDOUS

* Subdivision of hazardous areas divided into zones.

AREA CLASSIFICATION FLOWCHART (IP CODE PART 15, 2015)
 IDENTIFICATION OF
POINT SOURCES

TYPICALLY INCLUDES: Valve, Flanges, Vents,

Sampling And Drainage Points, Instrument
Connections, Rotating Machinery (Pumps,
Compressors, Area Where Spillage Can Be
Collected)
 DETERMINATION
GRADE OF RELEASE

CONSIDER ALL ACTUAL AND POTENTIAL

SOURCES OF FLAMMABLE RELEASE.
SOURCE AND GRADE OF RELEASE WITH DRAWING SHADING
CONVENTION

GRADE OF RELEASE FREQUENCY AND DURATION

release is continuous or nearly so, or occurs

Continuous frequently for short period (present >1000 hrs/year)

release occurs periodically or occasionally in normal

Primary opt. (present 10 and 1000 hrs/year)

release unlikely to occur during normal opt., or

Secondary infrequently for short periods (present 1 to 10
hrs/year)
 DEFINING FLUID
CATEGORY

Fluid Classes The class of fluid relates to their

flash point and handling temperature.
CLASSIFICATION AND CATEGORISATION OF PETROLEUM AND
FLAMMABLE FLUIDS
IP Petroleum Classes:

Categorization of Flammable Fluids:

ESTABLISH ZONE
CLASSIFICATION
REQUIREMENTS AND APPLICATION OF AREA CLASSIFICATION
(IP CODE PART 15, 2015)

• LIMITS: If hazard radius, R > 30 m, consider to modify the facility to minimize the
size of release

• MISTS & SPRAY – flammable fluids handled below its flash point (non-hazardous),
treated as ‘hazardous’ when pumped or under pressure & capable of producing
mist/spray if release from small leak – category C fluid

• CAPACITY THRESHOLDS above which hazardous area classification is required:

AREA ZONING
Zones – based on Pocc and t flammable atmosphere
Zone 0 : An area where flammable atm. continuously
present/present for long time;
Zone 1 : An area where flammable atm. is likely to occur in normal
opt.
Zone 2 : An area where flammable atm. is not likely to occur in
normal opt, if it occurs, only for short period
Non-hazardous : Areas that do not fall into any of the above
SOURCE AND GRADE OF RELEASE WITH DRAWING SHADING
CONVENTION

GRADE OF RELEASE FREQUENCY AND DURATION RELATION TO ZONE CLASS SHADING

CONVENTION
release is continuous or nearly
Continuous so, or occurs frequently for leads to Zone 0
short period (present >1000
hrs/year)
release occurs periodically or
Primary occasionally in normal opt. leads to Zone 1
(present 10 and 1000 hrs/year)

release unlikely to occur during

Secondary normal opt., or infrequently for leads to Zone 2
short periods (present 1 to 10
hrs/year)
DETERMINE HAZARD
RADII OF
HAZARDOUS AREA
HAZARD RADIUS

“Is the extent at which the concentration of flammable vapor in air has fallen to
the lower flammable limit”, but the distance might be increased due to the
ground effect.

HAZARD RADII CONVENTION APPLICATION

R1 in situation where the Zone is defined by a

SINGLE parameter.
• To pressurized releases that do not touch
the ground
• To liquid pools

in situation where the Zone is defined by To pressurized releases that touch the ground
TWO parameter. resulting in the `ground effect`.
R1 & R2

*Radius in free air

*Radius resulting from the ground effect
HAZARD RADIUS
Procedure For Determining The Hazard Radii For Primary And Continues Release
HAZARD RADIUS
Procedure For Determining The Hazard Radii For Secondary Release
VENTILATION

“Is comprises the movement of air within and through a volume to achieve the
introduction of fresh air into, and removal of contaminated air from, the volume
and the mixing of air and contaminants within the volume.”

wind or convection effects,

NATURAL VENTILATION
wind speed > 5 m/s
VENTILATION AND AREA

air purge or mechanical

ARTIFICIAL VENTILATION
assistance, enclosed area

outdoor, no stagnant
OPEN AREA regions, wind speed rarely <
0.5 m/s, frequently 2 m/s

SHELTERED/OBSTRUCTED natural ventilation less than

AREA in a true open area

building, room or enclosed

ENCLOSED AREA
space
PROCEDURE OF ASSESSING TYPE AND DEGREE OF VENTILATION
SHAPE FACTORS AND HAZARD RADII FOR PRESSURIZED RELEASES

Shape factor – depends upon the height and orientation of the release and hazard radius

- Releases below a height of 1 m are influenced by the ground and have a hazard
radius R2

- Releases above 1 m, but at heights < R1+1 m are influenced by the ground if
release is directed downward and passes below 1 m

- Releases at a height above the hazard radius R1+1 m are independent of the
ground
SHAPE FACTORS AND HAZARD RADII FOR PRESSURIZED RELEASES
 1. PFD & P&ID with flows, temperatures &
pressures

2. Flash points, boiling ranges or other physical

REQUIRED DATA AND characteristics of the fluids handled

DOCUMENTATION 3. Layout drawings

4. Knowledge of equipment features and mode

IN ORDER TO SUFFICIENTLY ANALYZE AND of operation
IDENTIFY HAZARDOUS AREA, IT IS
5. Consideration of ventilation
IMPORTANT TO HOLD RELEVANT
DOCUMENTATION FOR REFERENCES. 6. MSDS for material identification
 Direct Example Approach

• Arrangement of generic industrial

equipment handling common flammable
APPROACHES materials i.e. drilling, tank storage

Point Source Approach

• Installations or processes (due to variability

SHOLD BE SELECTED ACCORDING TO of temp., pressure & ventilation) the extent
of vaporization on release may vary greatly
SITUATION making individual assessment necessary

Risk-based Approach

• Release rate is unknown, this approach is to

determine the hole size to be used for a
secondary grade release (not be anticipated
to occur during normal opt.)
DIRECT EXMAPLE APPROACH
• Chapter 3 & 4 of IP Code Part 15, operate in an open area & material handled can
be classified from typical examples.
• The distances shown may be modified if justified by specific release & dispersion
calcs.
• Examples: All types of Storage Tank, Road & Rail loading & discharge facilities,
marine loading & discharge facilities, drum filling, retail dispensing on filling
station forecourts and tankage for high volatility/vapor pressure stocks

EXAMPLE: STORAGE TANK

POINT SOURCE APPROACH

• Chapter 5 of IP Code Part 15, typical hazard radii results of

dispersion modelling published in IP Calculations in support of IP15
– open area natural ventilation

• Release rate (hole size & pressure) unknown – Risk-based

Approach, Annex C Part 2

• Release sources – ‘point sources’ i.e. vents, drains & sample points
and assembly of several individual point sources e.g. pumps
POINT SOURCE APPROACH

Typical pumps
hazard drains & sample points
radii
compressors
(R1)for:
vents
piping systems
(i)
receivers & launchers Vaporizing
potential of
spillage pools fluid release

sumps/interceptors/separators
pits/depressions

Factors

(iii) rate or (ii) degree

volume of of
release ventilation

* Refer Tables C9(a) and C9(b) Annex C Part 3 if conditions e.g. opt. pressure, equipment size different
 METHODOLOGY
POINT SOURCE APPROACH

IDENTIFY POINT SOURCES AND DETERMINE GRADE OF RELEASE

ASSOCIATED RELEASE
CONDITIONS
• frequency and duration, controlled
& uncontrolled release) and fluid
DETERMINE
• grade of release, duration of
flammable atm., degree of
category – fluid’s vapor-producing
potential, Table 1.2 & A3
FLUID
ventilation CATEGORY

ESTABLISH ZONE DETERMINE HAZARD

CLASSIFICATION RADII AND HAZARDOUS
• grade of release, duration of AREA
flammable atm., degree of • dependent upon grade of release
ventilation

*Where appropriate, combine the hazardous areas from different point sources
POINT SOURCE APPROACH
Procedure For Determining The Hazard Radii For Primary And Continues Release (EI 15,
2015 Figure 3.1, pg. 31)
Point Source Approach – Methodology
(DAR Energy, Erwana Rahayu Mohamad Sharip, 2020)

• Primary & Continuous Grade Release

Does the fluid fall into one

of the following No
categories: A, B, C, G(i) or
G(ii)?
Yes

Are the hole size and Carry out dispersion

process cond. for the modeling using specific
No
characteristics of the fluid &
equipment covered in release rate (hole size &
Sect. 5.4 or in Tables pressure) to establish the
C9(a) & (b)? extent of hazardous area
Yes
Read-off hazard radius
(R1) from the app.
Table in Sect. 5.4 or
from Tables C9(a) and
(b)

• Determine Hazardous Area – various ventilation situations

Risk-based Approach
(DAR Energy, Erwana Rahayu Mohamad Sharip, 2020)

Release rate unknown, methodology to determine the hole

size to be used for a secondary release

Concept of ‘Release frequency LEVEL’ – ensure individual

risk (IR) < 10-5/year
‘LEVEL’ – based on exposure of the most exposed
individual to flammable releases & the probability of
ignition

‘LEVEL’ is used to determine hole size

CALCULATIONS
 CALCULATION -EXPOSURE FOR PLANT AREA (TABLE C2)
(EI 15, 2015 Table C9, pg. 79-80)

Determination of Exposure (Exp)

• Probability of Occurrence, Pocc – proportion of time individual spends on site exposed to at
least one potential release source
• Pocc = No. of hrs spends in hazardous area per year divided by no. of hrs in a year
CALCULATION
AVG. NUMBER OF RELEASE OF SOURCES IN RANGE (N range )

• Nrange – no of secondary grade release source within range

CALCULATION
Probability of Ignition, Pign
Calculation
Probability of Ignition, Pign (Table C4 )
Release frequency `LEVEL` to achieve IR criterion (Figure C2 )

Determination of ‘LEVEL’
Equivalent hole sizes for a range of release frequencies
(Table C6; EI15 - Table C13 )
Hazard Radius (R1) (Table C9(a) )
Hazard Radius at Ground Level (R2) (Table C9(b) )
Hazard Radii R1 and R2 for pressurised release
(EI 15, 2015 - Table C4 )

NOTES:

1. At the fluid storage temp of 20 oC the nominal

discharge of 5 bar(a) is below the saturated vapour
pressure of Fluid category A. the saturated vapour
pressure (6, 8 bar(a)) was used to calculate the
discharge rate and dispersion.
2. Distance of LFL for LNG release at 5m height.
These distances have been modelled as methane,
with typical LNG compositions varying between
93%-90%. Typical rundown, storage and loading
temp. for LNG are in the range – 170 oC to – 160 oC;
therefore release from a storage temp. of – 165 oC
have been modelled.
3. No data are available for gasoline blends with
ethanol; however, for blends with small quantities of
ethanol, these could be treated as category C. it is
recommended that modelling is carried out.
4. Release pressure should be taken as the maximum
allowable operating pressure.
Recommended Apparatus Sub-group & Temp. class (Table 7.2 )
Temperature Class & Max Surface Temperature
( HAC IN PETROLEUM AND CHEMICAL PLANTS, 2014-Table 2.4, pg.71)

Maximum Surface Temperature for Group II Electrical

Apparatus
Problems & Solutions

RELATED INFO/BOOKS
Battery room ventilation – normal 12 ACH

Living Shelter located in hazardous area – pressurized to

minimum 50 Pa
AIT of equipment – NFPA 30 or other standards
To Be Continue…..