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9661B 000 JSD 1900 911 - RC
9661B 000 JSD 1900 911 - RC
9661B 000 JSD 1900 911 - RC
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HAZARDOUS AREA CLASSIFICATION REPORT (FIRST OIL)
CONTENTS
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1. SCOPE OF DOCUMENT
The purpose of this document is to determine the extent of the hazardous areas
expected to be created by process facilities to be provided in artificial islands (Central,
North, South and West) as part of the First Oil (FO) phase of the Project.
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MP Medium Pressure
MSL Mean Sea Level
NI North Island
NSP North Satellite Platform
OTL Oil Trunk Line
PBU Production Build-Up
Pocc Probability of Occupancy
PPM Parts Per Million
SI South Island
SP Sustainable Phase
SPC Supreme Petroleum Council
SSP South Satellite Platform
UAE United Arab Emirates
UZ Upper Zakum
UZFFD Upper Zakum Full Field Development
VENDOR / SUPPLIER / Firm or company to whom the Purchase Order
MANUFACTURER is issued to supply the goods
WI West Island
WP Work Package
WSP West Satellite Platform
ZADCO Zakum Development Company
ZCC Zakum Central Complex
3. REFERENCE DOCUMENTS
Codes, standards and other documents generally applicable to this Project have been
listed as below.
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Central Island
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South Island
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Summer
West Island Heat & Material Balance Sheet First Oil -
9661B-230-PFD-0010-602 Winter
4.1 GENERAL
The flow diagram below shows the procedure for determining the hazardous area
around a source of release. Sections 4.2 to 4.7 give the basic definitions for each
parameter of the hazardous area classification process; further definitions can be
found in the IP-15.
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Determine ventilation & define zone requirement Determine ‘level’ of release frequencies
Three grades of release are defined in terms of their likely frequency and duration.
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The Institute of Petroleum (IP) Class of any liquid hydrocarbon is based on its flash
point and handling temperature at actual storage or process conditions.
Categories of fluid condition, as per IP-15, are listed below and are distinguished in
order of their vapourising potential.
Fluid category A: A Flammable liquid that, on release, would vapourise rapidly and
substantially. This category includes:
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Ventilation is a general term to indicate air movement and air changes by fresh air.
The level of ventilation is an important factor to determine the extent of any hazardous
area and must always be assessed according to the following definitions:
Open Area: An area that is open-air without stagnant regions where vapours are
rapidly dispersed by wind and natural convection. Typically air velocities will rarely be
less than 0.5 m/sec and will frequently be above 2 m /sec.
Sheltered Area: An area within or adjoining an open area (which may include a
partially open structure) where, owing to obstruction, natural ventilation may be less
than in a true open area but is adequate to avoid persistence of a flammable
atmosphere.
Enclosed Area: Any building, room or enclosed space within which in absence of
artificial ventilation, the air movement will be limited and any flammable atmosphere
will not be dispersed naturally.
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Area classification is the assessed division of a facility into hazardous areas and non-
hazardous areas, and the subdivision of the hazardous areas into zones.
Hazardous areas are subdivided into four zones based on the likelihood of occurrence
and duration of a flammable atmosphere, as follows:
Zone 2: That part of a hazardous area in which a flammable atmosphere is not likely
to occur in normal operation, and if it occurs, will exist only for a short period.
Non-hazardous areas: Areas that do not fall into any of the above are non-
hazardous.
The ‘Zone’ for a release is determined based on the grade of release, area of release
and ventilation in the area.
The area classification technique assumes that the facilities to which it is applied are
designed, constructed, maintained and operated in accordance with good industry
practice so as to reduce releases to a minimum. Equipment and piping should be
designed to international standards or national equivalents. The recommendations of
the IP Model Codes of safe practice (Annex I of IP-15) or their equivalents, regarding
good operational and maintenance practice should also be followed.
As per IP-15, 3rd Edition, a risk-based approach has to be applied to determine the
extent of the hazardous radius around a secondary source of release.
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purpose, in IP-15, an individual risk acceptance criteria of 1x10-5 per year has been
considered. To assign a LEVEL to an installation the probability of occupancy (Pocc),
number of secondary grade release sources within range (Nrange), vulnerability and
ignition probability (Pign) at the Zone 2 outer boundaries have to be determined based
on the guidelines presented in Annex C–Part 1 of IP-15. A brief description of these
parameters is presented below. The detailed calculation for determination of release
frequency level for artificial islands is provided in Appendix -2
Workers within Zone 2 hazardous area are exposed to multiple ignition sources of
release. In order to take multiple ignition sources into account a parameter called
Exposure (Exp) is used as follows (IP-15):
Where:
Pocc is calculated by estimating the proportion of time the individual spends on site
exposed to at least one potential release source (i.e. within a hazardous area). This is
simply the ratio of the number of hours spent by the worker in the hazardous area in a
year and the total number of hours in a year (IP-15).
Plant workers are exposed to a wide variety of potential secondary grade release
sources depending on the type of plant and schedule. To take account of these
situations it is necessary to calculate the average number of release sources, which
could affect the individual (taken as the average number of Zone 2 radii which the
individual is within during their time in the hazardous area).
The following table presents suggested values for average number of release sources
within range (IP-15):
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Average
Number Of
Activity Description Release
Sources In
Range
General Hazard radius from flages/valves is
patrol in typically 1.5 - 3.0m and therefore only
1
‘open’ large radius release sources will affect
plant the worker for large proportion of time
General As above, however allows for
patrol in congestion and proximity to multiple
5
congested release sources
plant
Inspection Inspection of items of equipment such
of area as pumps, compressors, manifolds
with many etc. Observation of typical onshore
30
release plant shows groups of 30 release
sources sources (within 3 m range to be
typical)
The probability of ignition to be considered for varying ignition strength has been
defined in IP-15 based on historic data and is summarised below:
Ignition Description Probability of
Source Ignition Given
Release
Controlled Where control of ignition sources
extends beyond Zone 2 (e.g. offshore 0.003
facilities)
Weak Ignition sources within Zone 2
0.01
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The appropriate value of Pign to use in calculating the individual risk (IR) of the most
exposed worker is a function of the proportion of the time the worker spends in areas
of various ignition source strengths (IP-15).
Values of Pign which do not contain “Strong” and/or “Medium” components are mainly
applicable to offshore facilities (IP-15).
The release frequencies are banded into the following three LEVELS to achieve an
individual risk level of 1x10-5 (or lower) per year based on the estimated worker
Exposure (Exp) term and ignition probability (Pign).
LEVEL Frequency of Release per Leak Sources - yr
LEVEL I Greater than 1.0 E-2 / release source-yr
It should be noted that increase in the LEVEL increases the extent of the hazard
radius i.e. hazard radius is smallest for LEVEL I and largest for LEVEL III. This
relation essentially defines the conditions for acceptable level of individual risk in the
facility, i.e.
These release levels are plotted in the Figure 4.0 below for various values of ‘Exp’ and
‘Pign’. Figure 4.0 may therefore be used to select the appropriate release frequency
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(LEVEL I, II or III) to use for a given Pign at the Zone 2 boundary and a given level of
exposure (Exp) of an individual to secondary grade release sources (IP-15).
1
IGNITION PROBABILITY ON ZONE 2
LEVEL III
BOUNDARY (Pign)
0.1
LEVELII
0.01
LEVEL I
0.001
0.1 1 10 100
EXPOSURE (Exp.)
Not all flammable fluids are equally easy to ignite and the different properties are
usually measured as minimum ignition temperature and minimum ignition energy.
Electrical equipment standards recognise these differences by subdividing the
equipment categories into subgroups and temperature classes.
Since ignition of flammable atmosphere can occur by hot surface contact, maximum
surface temperatures that can be permitted for electrical apparatus are defined.
Listed below are the main categories considered for artificial island facilities :
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As the subgrouping becomes more severe in going from IIA to IIB to IIC, sub-group B
apparatus may used in place of sub-group A apparatus and sub-group C can be used
in place of apparatus from both sub-groups A and B, but the converse is not true.
Even though the fluid handled during First Oil phase does not contain H2S, subgroup
llB has been conservatively selected due to the presence of H2S in the future gas
injection and gas lift facilities.
Since ignition of a flammable atmosphere can occur by hot surface contact, maximum
surface temperatures that can be permitted for electrical apparatus are defined.
For purpose of apparatus selection, the ignition temperature has been standardised
and defined as being:
The lowest temperature of a heated surface at which under the specified test
conditions, the ignition of a flammable substance, in the form of a gas or vapor mixture
with air, will occur.
The following table provides the relationship between temperature class and
maximum surface temperature of the apparatus(*).
Temperature Class Maximum Surface Temperature(°C)
T1 450
T2 300
T3 200
T4 135
T5 100
T6 85
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temperature class may be used in place of that having a higher maximum surface
temperature (lower T Class), but not conversely.
6. GENERAL NOTES
Based on the fluids being handled in the artificial islands, the following flammable
materials have been considered for area classification of the facilities to be installed
during the FO phase of the Project :
♦ Well Fluid
♦ Diesel
Well fluid will be handled above its flash point and below its boiling point, and can be
released as mist. Therefore based on Table A3 of IP 15, the fluid category ‘C’ has
been considered for well fluid.
Diesel will be handled at ambient conditions (max. ambient temperature is 43ºC) in the
artificial islands and has a flash point of 65ºC (at ambient conditions). Since the diesel
is handled at more than 5ºC below its flash point at atmospheric pressure and cannot
form mist or spray on release, it is considered as non-hazardous.
Where the release is a liquid having components with different flash points,
designation of the flash point of the mixture has been considered conservatively as
the flash point of that component in the mixture having the lowest flash point. Based
on the same flash point of Methane (i.e. – 222.6oC) has been considered for the
released liquid.
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The release frequency ‘LEVEL’ for the artificial islands has been determined as
‘LEVEL I’. The details of the release frequency LEVEL calculations are provided in
Appendix – 2.
♦ All outdoor electrical equipment i.e. located outside the pressurised building
rooms, shall be labelled, listed, or certified for Zone 2, Sub-Group IIB and
Temperature Class T3, as a minimum, unless shown otherwise on HAC
schedules and drawings .
♦ The indoor of the buildings / enclosures located in potentially hazardous area and
provided with air locks will be classified as safe area.
♦ As per IP-15, generally the three (3) – dimensional envelope of the hazard zone
created by a release will be in form of a sphere with a hazard radius equal to the
hazard distance i.e. R1. The relationship between the hazard radius R1 and the
full three (3) dimensional envelope of the hazard zone is determined using Figure
5.6, IP-15 and is attached in Appendix – 1. The shape factor depends upon the
height and orientation of the release and the hazard radius. The key features are :
♦ Releases below a height (H) of 1m are influenced by the ground and have a
hazard radius R2. A ground effect radius R2 is calculated to determine the
shape of the hazard zone [Table 5.8 and /or Table C9 (b). Annex C (Part 3),
IP-15].
♦ Releases above 1m, but at heights below the hazard radius R1+1m are
influenced by the ground if the release is directed downward and passes
below 1m.
♦ Releases at a height above the hazard radius R1+1m are independent of the
ground.
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♦ As a conservative case, the vertical extent of the hazardous area for the
equipment provided on the riser platforms has been extended downwards upto
sea level and the vertical extent of hazardous area for equipment provided in
piperack has been extended downward upto ground level.
Even though artificial adequate ventilation will be provided in the battery room, to
assist in the dispersion of hydrogen released during high rate battery charging / boost
charging, as a conservative case the electrical equipments in the battery room
required to operate post gas detection shall be classified as Zone 1, Group llC and
Temperature Class T3, as a minimum.
♦ The gases will be vented from CPI separators at a rate of less than 250 Nm3/hr.
♦ These vents have been considered as tank vent and thus Table 5.4 of IP-15 has
been used for area classification for the same.
♦ For pumps, the seal, in addition to the other point sources i.e. vents, drains,
piping flanges and filters / strainers, as applicable, have been considered as point
sources for area classification. As per IP-15, pump seals form secondary grade
point source of release.
♦ Area Classification around pig launcher /receiver opening has been considered as
Zone 1 limited to a radius of 1.5 meters as per IP Part 15. This is due to the
following considerations:
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♦ Also the design of the pig launcher will be such that it cannot be opened
while under pressure. This will be achieved by mechanical key interlocking
between the pig launcher door with the vent & drain system.
The drip pans or the skid drains have been provided for the vessels, pig
launcher/receiver and pump skids to contain the flammable hydrocarbons, in event of
any major leakage or during major maintenance. For the hazardous area classification
purposes, the drip pans have been considered as sump with secondary grade source
of release.
During FO phase of the Project, only the MP flare at CI will be operational. For other
Islands (NI, SI and WI), the flare system will remain offline during the FO phase.
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APPENDIX – 1
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APPENDIX – 2
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A. Since the facilities to be provided at CI, NI, SI and WI during the FO phase of the
Project are identical, the release frequency ‘LEVEL’ for CI is applicable to NI, SI
and WI
2) Based on the above it has been estimated that an individual (i.e. plant personnel)
will spend 437 working hours (i.e. 7 shifts per week * 8 hours per shift * 52 weeks
per year * 0.5 * 0.3) in the hazardous area per year. Considering a maximum
number of 8760 hours per year (i.e. 24 hours per day * 365 days per year) this
corresponds to a maximum Pocc of 0.0498 (i.e. 437 hours / 8760 hours).
4) The average number of release sources in the range have been calculated based
on the assumption that while visiting the island the plant personnel in the process
i.e. hazardous area will spend hundred (100) percent of his time in areas having
many release sources i.e. typically having thirty (30) average release sources in
range. Refer Section 4.7.1.2 for the details of the typical average release sources
in range.
D. Exposure, Exp:
O:\9661B\Secretaries\PROJECT DOCUMENTS\000\JSD\1900-911\Rev.C\9661B-000-JSD-1900-911_RC.doc
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TECHNIP PROJECT No. 9661B
HAZARDOUS AREA CLASSIFICATION REPORT (FIRST OIL)
7) Since CI is provided with fire and gas detection systems, it is considered that the
control of ignition sources extends beyond Zone 2. Thus probability of ignition
given release has been considered as 0.003 (refer Section 4.7.3).
F. Using the above estimated values for Exp, Pign and the graph presented as
Figure 4 in Section 4.7.4, the release frequency ‘LEVEL’ for CI has been
determined as ‘LEVEL I’.
O:\9661B\Secretaries\PROJECT DOCUMENTS\000\JSD\1900-911\Rev.C\9661B-000-JSD-1900-911_RC.doc
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TECHNIP PROJECT No. 9661B
HAZARDOUS AREA CLASSIFICATION REPORT (FIRST OIL)
APPENDIX – 3A
O:\9661B\Secretaries\PROJECT DOCUMENTS\000\JSD\1900-911\Rev.C\9661B-000-JSD-1900-911_RC.doc
Appendix 3.A
HAZARDOUS RADIUS
DETERMINATION OF HOLE HAZARDOUS RADIUS
OPERATING ELECTRICAL (R2) FROM POINT
PROCESS EQUIPMENT ITEM SIZE (ACCORDING TO TABLE (R1) FROM POINT
CONDITION FLUID CLASS APPARATUS SOURCE IN ‘m’
STATE C6. IP-15) SOURCE IN ‘m’
OR / AND IP – 15, 2005
PRODUCT S/L/V LOCATION VENTILATION COMMENTS / REMARKS
CATEGORY REFERENCE
(NOTE 1) HOLE
TEMP PRESS SUB TEMP SOURCE OF GRADE OF
No TAG No. DESCRIPTION SIZE Zone 0 Zone 1 Zone 2 Zone 0 Zone 1 Zone 2
(º C) (bar a) GROUP CLASS RELEASE RELEASE
(mm)
Wellhead
3 - Water - - - - - - - - - - - - - - - - -
(Injection)
NOTES :
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TECHNIP PROJECT No. 9661B
HAZARDOUS AREA CLASSIFICATION REPORT (FIRST OIL)
APPENDIX – 3B
O:\9661B\Secretaries\PROJECT DOCUMENTS\000\JSD\1900-911\Rev.C\9661B-000-JSD-1900-911_RC.doc
Appendix 3.B
HAZARDOUS RADIUS
DETERMINATION OF HOLE SIZE HAZARDOUS RADIUS
OPERATING ELECTRICAL (R2) FROM POINT
PROCESS EQUIPMENT ITEM (ACCORDING TO TABLE C6. IP- (R1) FROM POINT
CONDITION FLUID CLASS APPARATUS SOURCE IN ‘m’
STATE 15) SOURCE IN ‘m’
OR / AND IP – 15, 2005
PRODUCT S/L/V LOCATION VENTILATION COMMENTS / REMARKS
CATEGORY REFERENCE
(NOTE 1) HOLE
TEMP PRESS SUB TEMP SOURCE OF GRADE OF
No TAG No. DESCRIPTION SIZE Zone 0 Zone 1 Zone 2 Zone 0 Zone 1 Zone 2
(º C) (bar a) GROUP CLASS RELEASE RELEASE
(mm)
Wellhead
3 - Water - - - - - - - - - - - - - - - - - -
(Injection)
Primary - - 1.5 - - -
Door - Pip launcher / receiver will
i) Section 5.4.5 be purged with nitrogen
Secondary 0.6 - - 2.5 - - - ii) Section 5.4.6 before opening.
OTL Pig Well 75 35
4 2109-V-1001 L/V C llB T3 Open Natural iii) Table C6 - Pig launcher door has been
Launcher Fluid (HOLD) (HOLD)
Flanges Secondary 0.6 - - 2.5 - - - iv) Table C9(a) considered as a flange for
& (b) determining release hole
size.
Valves Secondary 0.1 - - 2.5 - - -
Primary - - 1.5 - - - -
Door - Pip launcher / receiver will
i) Section 5.4.5 be purged with nitrogen
Secondary 0.6 - - 2.5 - - - ii) Section 5.4.6 before opening
LP WF / OTL Well 55 8
5 2109-V-1006 L/V C llB T3 Open Natural iii) Table C6 - Pig launcher door has been
Pig Trap Fluid (HOLD) (HOLD)
Flanges Secondary 0.6 - - 2.5 - - - iv) Table C9(a) considered as a flange for
& (b) determining release hole
size.
Valves Secondary 0.1 - - 2.5 - - -
Water
Injection PIG
6 2109-V-1008 Receiver Water - - - - - - - - - - - - - - - - - - -
Storm Water
11 2114-S-1003 Water - - - - - - - - - - - - - - - - - - -
Basin
2114-P-1001 Storm Water
12 Water - - - - - - - - - - - - - - - - - - -
A/B Basin Pumps
Diesel - Refer Section 6.1 of main
13 - Diesel - - - - - - - - - - - - - - - - - -
Generator document
NOTES :
1. S = SOLID, L = LIQUID, V = VAPOUR/GAS
ZADCO DOCUMENT NUMBER TECHNIP DOCUMENT NUMBER
Work Ref. Doc Type Unit No. Discipline Chrono No. Rev. Project Nº. Unit Document Type Material Code Serial N°. Rev.
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TECHNIP PROJECT No. 9661B
HAZARDOUS AREA CLASSIFICATION REPORT (FIRST OIL)
APPENDIX – 3C
O:\9661B\Secretaries\PROJECT DOCUMENTS\000\JSD\1900-911\Rev.C\9661B-000-JSD-1900-911_RC.doc
Appendix 3.C
HAZARDOUS RADIUS
DETERMINATION OF HOLE SIZE HAZARDOUS RADIUS
OPERATING ELECTRICAL (R2) FROM POINT
PROCESS EQUIPMENT ITEM (ACCORDING TO TABLE C6. IP- (R1) FROM POINT
CONDITION FLUID CLASS APPARATUS SOURCE IN ‘m’
STATE 15) SOURCE IN ‘m’
OR / AND IP – 15, 2005
PRODUCT S/L/V LOCATION VENTILATION COMMENTS / REMARKS
CATEGORY REFERENCE
(NOTE 1)
TEMP PRESS SUB TEMP SOURCE OF GRADE OF HOLE
No TAG No. DESCRIPTION Zone 0 Zone 1 Zone 2 Zone 0 Zone 1 Zone 2
(º C) (bar a) GROUP CLASS RELEASE RELEASE SIZE (mm
- During drilling /
Bell Nipple Primary - - 3 15 - - - wirelining
- 46”size bell nipple has
i) Section 4.2.1 been considered
ii) Section 5.4.5 - Zone 1 around the bell
Wellheads Well 173 Flanges Secondary 0.6 - - 2.5 - - 3 iii) Section 5.4.8 nipple is based on
2 - 75 L/V C llA T3 Open Natural
(Producer) Fluid (HOLD) iv) Table 5.7 Section 4.2.1, Section
v) Table C6 5.4.8 and Table 5.7 of
vi) Table C9(a) & (b IP-15
Valves Secondary 0.1 - - 2.5 - - 3 Zone 2 around the bell
nipple is based on
Section 5.4.8.
Wellhead
3 - Water - - - - - - - - - - - - - - - - - -
(Injection)
Primary - - 1.5 - - - -
- Pip launcher / receiver
Door will be purged with
i) Section 5.4.5
Secondary 0.6 - - 2.5 - - - nitrogen before
ii) Section 5.4.6
OTL Pig Well 75 35 opening.
4 2209-V-1001 L/V C llA T3 Open Natural iii) Table C6
Launcher Fluid (HOLD) (HOLD) - Pig launcher door has
Flanges Secondary 2 - - 2.5 - - - iv) Table C9(a)
been considered as a
& (b)
flange for determining
release hole size.
Valves Secondary 0.1 - - 2.5 - - -
Primary - - 1.5 - - -
Door - Pip launcher / receiver
Secondary 0.6 - - 2.5 - - - i) Section 5.4.5 will be purged with
ii) Section 5.4.6 nitrogen before opening
LP WF / OTL Well 55 8
5 2209-V-1006 L/V C llA T3 Open Natural iii) Table C6 - Pig launcher door has
Pig Launcher Fluid (HOLD) (HOLD)
Flanges Secondary 2 - - 2.5 - - - iv) Table C9(a) been considered as a
& (b) flange for determining
release hole size.
Valves Secondary 0.1 - - 2.5 - - -
Water
Injection PIG
6 2209-V-1004 Receiver Water - - - - - - - - - - - - - - - - - - -
Storm Water
11 2214-S-1003 Water - - - - - - - - - - - - - - - - - - -
Basin
2214-P-1001 Storm Water
12 Water - - - - - - - - - - - - - - - - - - -
A/B Basin Pumps
Diesel - Refer Section 6.1 of
13 - Diesel - - - - - - - - - - - - - - - - - -
Generator main document
NOTES :
1. S = SOLID, L = LIQUID, V = VAPOUR/GAS
ZADCO DOCUMENT NUMBER TECHNIP DOCUMENT NUMBER
Work Ref. Doc Type Unit No. Discipline Chrono No. Rev. Project Nº. Unit Document Type Material Code Serial N°. Rev.
UPPER ZAKUM
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PROJECT No.: 8383 Page
FEED SERVICES
CONTRACT NO. CTE UZ083210 31 / 31
TECHNIP PROJECT No. 9661B
HAZARDOUS AREA CLASSIFICATION REPORT (FIRST OIL)
APPENDIX – 3D
O:\9661B\Secretaries\PROJECT DOCUMENTS\000\JSD\1900-911\Rev.C\9661B-000-JSD-1900-911_RC.doc
Appendix 3.D
HAZARDOUS RADIUS
DETERMINATION OF HOLE HAZARDOUS RADIUS
OPERATING ELECTRICAL (R2) FROM POINT
PROCESS EQUIPMENT ITEM SIZE (ACCORDING TO TABLE (R1) FROM POINT
CONDITION FLUID CLASS APPARATUS SOURCE IN ‘m’
STATE C6. IP-15) SOURCE IN ‘m’
OR / AND IP – 15, 2005
PRODUCT S/L/V LOCATION VENTILATION COMMENTS / REMARKS
CATEGORY REFERENCE
(NOTE 1) HOLE
TEMP PRESS SUB TEMP SOURCE OF GRADE OF
No TAG No. DESCRIPTION SIZE Zone 0 Zone 1 Zone 2 Zone 0 Zone 1 Zone 2
(º C) (bar a) GROUP CLASS RELEASE RELEASE
(mm)
Water Injection
5 2309-V-1003 PIG Receiver Water - - - - - - - - - - - - - - - - - - -
NOTES :