Hazardous Area Classification Guide - Profound Engineering

HAZARDOUS AREA CLASSIFICATION
Presentation on the
methodology to be followed
when conducting
Hazardous Area
Classifications
Disclaimer: Profound Engineering (Pty) Ltd accept no liability for the use or interpretation of this guide .
Presented by: Johan van Zyl Pr. Eng., B. Eng. (Electrical & Electronics)
HAZARDOUS AREA
CLASSIFICATION
HAZARDOUS AREA CLASSIFCATION
GUIDE
2001 March 15th. Brazil, offshore Campos Basin: 3
explosions at the world's biggest offshore oil platform, a
40-storey rig owned by Petrobas and located in the
Roncador oil fields, 80 miles offshore, 10 people are
presumed dead.
HAZARDOUS AREA
CLASSIFICATION
GUIDE
HAZARDOUS AREA
CLASSIFICATION
GUIDE
HAZARDOUS AREA
CLASSIFICATION
GUIDE
October 19, 2004
A Springfield, Utah mother and her 5-year-old son are

lucky to be alive after the SUV Trooper she was filling up
with fuel caught fire and burned.
HAZARDOUS AREA
CLASSIFICATION
GUIDE
How do we as engineers prevent

this from happening?
HAZARDOUS AREA
CLASSIFICATION
GUIDE
Why do we require to classify

certain areas?
 Difference between the equipment
used in non classified areas to those
in classified areas
 Classified equipment is
substantially more expensive
 Engineers must protect the
workers and the environment
HAZARDOUS AREA
CLASSIFICATION
GUIDE
Standards to consult in order or

importance:
 SANS 60079-10
 Institute of Petroleum (IP) Part 15
 SANS 60108
 SANS 60079-20
 Calculations in support of IP 15
HAZARDOUS AREA
CLASSIFICATION
GUIDE
1. Analyze the MFD / PFD to

determine if there are any
potentially hazardous products
 Petrol
 Diesel
 Hydrogen
 Oxygen
 Listed in SANS 60079-20
HAZARDOUS AREA
CLASSIFICATION
GUIDE
2. Only analyze lines with

potentially hazardous products
GUIDE
3. Get the Material Safety Data

Sheets (MSDS) for each
potentially hazardous product
 Density relative to air
 Flash Point
 Ignition Temperature
 Temperature Class
 Temperature Group
GUIDE
4. Get the mechanical GAs and ISOs
and identify all possible sources of
release and number the points
 Seals on valve stems
 Seals on flanges
 Sampling points
 Drainage points
 Bursting disks
 Instruments
HAZARDOUS AREA
CLASSIFICATION
GUIDE
 Pump seals
 Compressors
 Pressure relief valves venting to
atmosphere or a drain
HAZARDOUS AREA
CLASSIFICATION
GUIDE
EXAMPLE NETWORK
General
Arrangement (GA)
2
3
4
1
GUIDE
5. Get the P&ID and Process Data

Sheets
 Create a table reflecting the
release point number
 Description of the element
 Location of the element
 Operating temperature and

pressure
HAZARDOUS AREA
CLASSIFICATION
GUIDE
Table C.2 - Hazardous area classification data sheet -
Part II: List of sources of release
Plant: Natref Sasolburg Project: Fuel Component Transfer Project
1 2 3 6
Source of release Flammable Material
No. Description Location Operating Temperature and Pressure
°C kPa (bar)
Next to bund at
1 Orifice Plate tank 29604 20 242 (2.42)
Isolation Valve & Next to bund at

2 Flanges tank 29604 20 242 (2.42)
Next to bund at
3 MOV 29575 tank 29604 20 242 (2.42)
Isolation Valve & Next to bund at

4 Flanges tank 29604 20 242 (2.42)
HAZARDOUS AREA
CLASSIFICATION
GUIDE
6. Determine the Grade of each
release
 Continuous
 Primary
 Secondary
HAZARDOUS AREA
CLASSIFICATION
GUIDE
Continuous
A release that is continuous or that
occurs frequently and for short
durations
Normally lead to a Zone 0
HAZARDOUS AREA
CLASSIFICATION
GUIDE
Primary
A release that is likely to occur
periodically or occasionally in normal
operations. Thus it is anticipated to
occur.
HAZARDOUS AREA
CLASSIFICATION
GUIDE
Secondary
A release that is unlikely to occur in
normal operations. Thus it is not
anticipated to occur.
HAZARDOUS AREA
CLASSIFICATION
GUIDE
FOR OUR EXAMPLE
 A release is not likely to occur at

the orifice plate thus a Secondary
Grade of release
HAZARDOUS AREA
CLASSIFICATION
GUIDE
7. Determine the Release
Frequency ‘LEVEL’
 Use a standard probability of
occupancy (Pocc) = 0.22
 Find the avg. number of release
sources
HAZARDOUS AREA
CLASSIFICATION
GUIDE
Find the avg. number of release
sources
HAZARDOUS AREA
CLASSIFICATION
GUIDE
 Calculate the exposure (Exp) =
Pocc x Nrange
 Determine the Probability of
ignition
HAZARDOUS AREA
CLASSIFICATION
GUIDE
 Now read off the ‘LEVEL’
HAZARDOUS AREA
CLASSIFICATION
GUIDE
FOR OUR EXAMPLE
 (Exp) = Pocc x Nrange = 0.22 x 1

= .22
 Pign = 0.01
 LEVEL = I
HAZARDOUS AREA
CLASSIFICATION
GUIDE
 FOR OUR EXAMPLE
HAZARDOUS AREA
CLASSIFICATION
GUIDE
8. Determine the product
Category
 A
 B
 C
 G(i)
 G(ii)
HAZARDOUS AREA
CLASSIFICATION
GUIDE
Category A
A flammable liquid that, on release,
would vaporise rapidly and
substantially
 Any LPG
 Any liquid at a temperature
sufficient to produce, on release,
more than about 40% vol
vaporisation with no heat input other
than from the environment
HAZARDOUS AREA
CLASSIFICATION
GUIDE
Category B
A flammable liquid, not in Category
A, but at a temperature sufficient for
boiling to occur on release.
HAZARDOUS AREA
CLASSIFICATION
GUIDE
Category C
A flammable liquid, not in Category A
or B, but which can on release be at
a temperature above its flash point,
or form a flammable mist or spray.
HAZARDOUS AREA
CLASSIFICATION
GUIDE
Category G(i)
A typical methane rich natural gas
HAZARDOUS AREA
CLASSIFICATION
GUIDE
Category G(ii)
Refinery hydrogen
HAZARDOUS AREA
CLASSIFICATION
GUIDE
HAZARDOUS AREA
CLASSIFICATION
GUIDE
For Unleaded Petrol

 Category C
 Handled below the boiling point of

38°C
 But can be upon release above the
Flash point of -20°C
 This Unleaded Petrol is a Class IC
product
HAZARDOUS AREA
CLASSIFICATION
GUIDE
9. Determine the Release Hole
Diameter
 With the release pressure (the
pressure in the pipeline)
 The Category
 The ‘LEVEL’
HAZARDOUS AREA
CLASSIFICATION
GUIDE
HAZARDOUS AREA
CLASSIFICATION
GUIDE
HAZARDOUS AREA
CLASSIFICATION
GUIDE
10. Determine the Maximum
Rate of Release at source
(dG/dt)max
HAZARDOUS AREA
CLASSIFICATION
GUIDE
HAZARDOUS AREA
CLASSIFICATION
GUIDE
FOR OUR EXAMPLE
 Category C
 Hole diameter for flanges is
0.6mm < 1mm
 Pressure is less than 5 bar
 Release flow rate is 0.01 kg/s
HAZARDOUS AREA
CLASSIFICATION
GUIDE
11. Calculate (dV/dt)min
(dV/dt)min=((dG/dt)max)/(k x LELm) x
T/293
LELm=Lower Explosion Limit (kg/m3)
k=0.25 for Continuous & Primary
Grades
k=0.5 for Secondary Grades
T=ambient temperature in Kelvin
LELm=0.416x10-3xMxLELv
HAZARDOUS AREA
CLASSIFICATION
GUIDE
For our example
LELm= 0.416x10-3x710x0.013
= 3.84x10-3
(dV/dt)min= (0.01)/(0.5 x 3.84x10-3)
x 293/293
= 5.2 m3
This is the actual physical gas vapour volume
(A cub of 1.8m in all directions)
HAZARDOUS AREA
CLASSIFICATION
GUIDE
12. Calculate hypothetical
volume Vz
Vz=f x (dV/dt)min /C
f = 1 for ideal and 5 for impeded air
flow
C = 0.03 in open air
C = 0.01 in restricted open air
Since you have to take wind direction
into account a safety factor is added
HAZARDOUS AREA
CLASSIFICATION
GUIDE
For our example
Vz =1 x 5.2/0.03
= 173 m3
≈ 5.6 x 5.6 x 5.6 m
HAZARDOUS AREA
CLASSIFICATION
GUIDE
13. Calculate Persistence Time
t = (-f/C)ln(LEL x k)
This is not used to determine the

zone but gives a good indication of
the extent of the release
HAZARDOUS AREA
CLASSIFICATION
GUIDE
For our example
t = (-1/.03)ln(3.84x10-3 x 0.5)
= 208.5 seconds
= 3.5 minutes
This means that once a leak in the flange has

been sealed off it will take another 3.5
minutes before the explosive atmosphere
would become safe.
HAZARDOUS AREA
CLASSIFICATION
GUIDE
14. Determine the degree of
ventilation
 VH = High ventilation if Vz<0.1 m3
 VL = Low ventilation if Vz>Vo
 VM = Medium ventilation if not VH

or VL
 Look at next table to decide if the
Zone can be reduced
HAZARDOUS AREA
CLASSIFICATION
GUIDE
For our example
Vz = 173 m3 (5.6 x 5.6 x 5.6) <

Surrounding area (Vo)
Thus Medium Ventilation
HAZARDOUS AREA
CLASSIFICATION
GUIDE
HAZARDOUS AREA
CLASSIFICATION
GUIDE
15. Determine the extent of the
Zone
HAZARDOUS AREA
CLASSIFICATION
GUIDE
15. Determine the extent of the
Zone (cont)
HAZARDOUS AREA
CLASSIFICATION
GUIDE
For our example
A Zone 2 area with a radius of 2m

from the possible source.
HAZARDOUS AREA
CLASSIFICATION
GUIDE
16. Finish the Report
 Complete table C1 and C2 of
SANS60079 – 10
 Create the Hazardous area
drawing
HAZARDOUS AREA
CLASSIFICATION
GUIDE
HAZARDOUS AREA
CLASSIFICATION
GUIDE
17. Specify the equipment
 SANS 600108 – The classification
of hazardous locations and the
selection of apparatus for use in
such locations
HAZARDOUS AREA
CLASSIFICATION
GUIDE
(cont)
 All the Electrical and Instrument
equipment within the boundaries of
the hazardous area must be classified
according to that zone
 A certificate is needed for as proof
for all such equipment
 Only a Master Electrician can issue
a COC for the installation work
HAZARDOUS AREA
CLASSIFICATION
GUIDE
(cont)
 Zone 0
❖ Only “Ex ia” apparatus (Intrinsically

safe)
HAZARDOUS AREA
CLASSIFICATION
GUIDE
17. Specify the equipment (cont)
 Zone 1 – Limited to the following
❖ Flameproof Ex d
❖ Specially protected Ex s
❖ Increased safety Ex e
❖ Encapsulated Ex m
❖ Powder filled Ex q
❖ intrinsically safe Ex ia or Ex ib
❖ Pressurized Ex p
HAZARDOUS AREA
CLASSIFICATION
GUIDE
17. Specify the equipment (cont)
 Zone 2 – Limited to the following
❖ Non sparking – Ex n
❖ Pressurized - Ex p
❖ All acceptable to Zone 1 or 0
HAZARDOUS AREA
CLASSIFICATION
GUIDE
REMEMBER
If you don’t know ask!

Do this at the beginning of the
project NOT at the end.
This presentation is not a

replacement for the standards, but
merely provides a guide.
HAZARDOUS AREA
CLASSIFICATION

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HAZARDOUS AREA CLASSIFICATION

October 19, 2004

A Springfield, Utah mother and her 5-year-old son are

How do we as engineers prevent

Why do we require to classify

Standards to consult in order or

1. Analyze the MFD / PFD to

 Listed in SANS 60079-20

2. Only analyze lines with

3. Get the Material Safety Data

5. Get the P&ID and Process Data

 Location of the element

 Operating temperature and

Plant: Natref Sasolburg Project: Fuel Component Transfer Project

Source of release Flammable Material

No. Description Location Operating Temperature and Pressure

Isolation Valve & Next to bund at

Isolation Valve & Next to bund at

Normally lead to a Zone 0

Normally lead to a Zone 1

Normally lead to a Zone 2

 A release is not likely to occur at

 (Exp) = Pocc x Nrange = 0.22 x 1

For Unleaded Petrol

 Handled below the boiling point of

This is not used to determine the

This means that once a leak in the flange has

 VL = Low ventilation if Vz>Vo

 VM = Medium ventilation if not VH

Vz = 173 m3 (5.6 x 5.6 x 5.6) <

A Zone 2 area with a radius of 2m

❖ Only “Ex ia” apparatus (Intrinsically

❖ All acceptable to Zone 1 or 0

If you don’t know ask!

This presentation is not a

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