Hazspec 00676094

DOCUMENT NO:
60-0000-B-PHL-0010
DOCUMENT TITLE:
HAZARDOUS AREA CLASSIFICATION

PHILOSOPHY
ДОКУМЕНТ №
XXX-A-XXX
НАИМЕНОВАНИЕ
XXXXX
TENGIZCHEVROIL
PFD Project No. 571500
TCO Project No.
ТЕНГИЗШЕВРОЙЛ
Проект № 571500
0 31/10/02 13 APPROVED FOR DESIGN NPCA NPCA/ NPCA RDV

/PAP DA
C2 25/04/02 13 RE-ISSUED FOR APPROVAL BV / NPCA
PAP
C1 10/09/01 12 ISSUED FOR APPROVAL BV NPCA
C Not Issued
B Not Issued
A 17/05/01 12 ISSUED FOR CLIENT NW NPCA

COMMENT/APPROVAL
REV DATE PAGES DESCRIPTION BY CHKD APPR CLIENT

ИЗМ. ДАТА СТР. ПОЯСНЕНИЯ ИСП. ПРОВ. УТВ. ЗАКАЗЧИК
\\fdcbdn02\data6\66571500\225\General\Process Philosophy Updates\Hazardous Area Classification\Latest Rev\Rev 0 Haz Area Classification Philosophy.docPage 1 of
13
TENGIZCHEVROIL ASSET DEVELOPMENT PROJECTS PFD
CONTRACT №. 571500
HAZARDOUS AREA CLASSIFICATION PHILOSOPHY DOC №. : 60-0000-B-PHL-0010
Rev.0
REVISION DESCRIPTION SHEET
REV. PARA. REVISION DESCRIPTION

A ISSUED FOR CLIENT COMMENT/APPROVAL
C1 ISSUED FOR APPROVAL
C2 RE-ISSUED FOR APPROVAL
0 APPROVED FOR DESIGN
13
Rev.0
TABLE OF CONTENTS
1. SCOPE .......................................................................................................................... 4
2. CODES AND STANDARDS ........................................................................................... 4
3. ABBREVIATIONS .......................................................................................................... 4
4. INTRODUCTION............................................................................................................ 5
5. DEVELOPMENT OF DOCUMENTATION ...................................................................... 5
5.1 Phase 3 (FEED) ......................................................................................................... 5
5.2 Phase 4 (Detailed Engineering) .................................................................................. 6
6. APPROVALS ................................................................................................................. 7
7. DESIGN PHILOSOPHY ................................................................................................. 7
8. EQUIPMENT SELECTION............................................................................................. 8
8.1 General....................................................................................................................... 8
8.2 Equipment within Substations and Control Rooms.................................................... 10
8.3 Analyser Houses....................................................................................................... 10
8.4 Fired Equipment ....................................................................................................... 10
8.5 Diesel Engines.......................................................................................................... 10
9. ATTACHMENTS .......................................................................................................... 10
9.1 Hazardous Area Classification Data Sheet - Part 1: Flammable Material List ..............
and Characteristics, Doc. No. DS-60-B-0001............................................................ 10
9.2 Hazardous Area Classification Data Sheet - Part 2: List of Sources of Release, ..........
Doc. No. DS-60-B-0002. ........................................................................................... 11
10. APPENDIX: DEFINITIONS ....................................................................................... 11
10.1 PUE, Rules for the Arrangement of Electrical Installations .................................... 11
10.2 Pue Classification and Marking of Explosion - Protected Electrical Equipment...... 11
10.3 IEC 60079 & IP Model Code of Safe Practice ( Part 15), 1990 .............................. 12
13
Rev.0
1. SCOPE
This document is developed to outline the Hazardous Area Classification Philosophy
which is to be used during the design, selection of equipment and materials and the
construction of the Tengizchevroil Asset Development Projects.
The Tengizchevroil Asset Development Projects involve the expansion of an existing

oil and gas production facility located at Tengiz, to the north east of the Caspian Sea
in the Republic of Kazakhstan. They currently comprise the Second Generation
Project (SGP) and the Staged Sour Gas Injection Project (SGI) Stages 1 and 2.
These projects will mainly be separate from and have few tie-ins to the existing plant.
They will be provided with their own dedicated utilities.
This document will be reviewed and updated, as required, during Phase 4 which
involves detailed design, procurement and construction.
2. CODES AND STANDARDS

The Hazardous Area Classification will be carried out in accordance with PUE,
“Rules for the Arrangement of Electrical Installations”, and the codes and standards
referenced therein. For aspects of Hazardous Area Classification not covered by
PUE, the criteria given in the Institute of Petroleum, Model Code of Safe Practice in
the Petroleum Industry, Area Classification Code for Petroleum Installations Part 15
1990 will be used.
Power generation vendor’s drawings are expected to be in accordance with API 505
and thus shall be reviewed for compliance with PUE, with PUE requirements
superimposed where necessary.
For vendors who are unfamiliar with PUE and the codes and standards referenced
within it, the international code IEC 60079-10: 1995 Electrical Apparatus for
Explosive Gas Atmospheres - Part 10: Classification of Hazardous Areas may be
used for guidance purposes only.
3. ABBREVIATIONS
The following abbreviations are used in this document;
AFD Approved for Design

AFC Approved for Construction
CPDEP Chevron Project Development and Execution Process
FEED Front End Engineering Design
GID Gas Injection Development
HIL Highly Inflammable Liquid
IP Institute of Petroleum
LEL Lower Explosive Limit
PFD Process Flow Diagram
P&ID Piping and Instrument Diagrams
PUE Rules for Arrangement of Electrical Installation
SGP Second Generation Project
SGI Staged Sour Gas Injection with Oil Production Facility
SGI Stage 1 Sweet Gas Injection
SGI Stage 2 Sour Gas Conversion
TCO Tengizchevroil
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Rev.0
4. INTRODUCTION
This philosophy sets out the codes, standards and procedures which will be followed
to establish the Hazardous Area Classification of the new facilities which in turn will
form the basis of the certification requirements of electrical equipment. This
document also contains the Hazardous Area Classification data sheets, Part 1
(Flammable Material List and Characteristics) and a pro forma Part 2 (List of Sources
of Release) as detailed in Section 5 of this document.
The new facilities will handle a variety of fluids including crude oil, natural gas and
LPG and, owing to the hydrocarbon feed being very sour, they will also produce
elemental sulphur in liquid form which will be sent to the existing sulphur forming
facilities. In addition, a number of chemicals will be used.
5. DEVELOPMENT OF DOCUMENTATION
The final documentation for Hazardous Area Classification shall consist of:
• Hazardous Area Classification Philosophy, Document No. 60-0000-B-PHL-

0010 (this document).
• SGP Hazardous Area Classification Data Sheet - Part 1: Flammable Material

List and Characteristics (Attachment 1 of this Philosophy, document no. DS-
60-B-0001).
• SGP Hazardous Area Classification Data Sheet - Part 2: List of Sources of

Release. (Blank form DS-60-B-0002 provided as Attachment 2 of this
document. Completed forms will be presented separately and given area
specific document numbers.).
• Overall Hazardous Area Classification Key Plan.
• Hazardous Area Classification Layouts and Elevations.
5.1 Phase 3 (FEED)

(Note that this phase of the Project is now complete)
The objective of the Hazardous Area Classification at the Pre-Engineering

phase is to:
• Verify preliminary general plot layouts from a safety and operability

point of view.
• Identify restricted and unrestricted roads.
For the Pre-Engineering phase of SGP and SGI projects, the Hazardous Area
Classification Data Sheet - Part 1: Flammable Material List and
Characteristics is prepared in detail but the Data Sheet - Part 2: List of
Sources of Release, is only completed in sufficient detail to give a preliminary
guide to likely zoning to assist in equipment selection.
Hazardous Area Zones will be assigned as per the definitions given in PUE,
Rules for the Arrangement of the Electrical Installations, Sections 7.3.40 to
13
Rev.0
46. The Zone dimensions will be allocated in accordance with PUE and the
standards referenced therein.
Hazardous Area Classification Layouts and Elevations are prepared for each
new area based on the Hazardous Area Classification Data Sheets (Parts 1 &
2), the AFD Plot Plans and the Standards listed in Section 2.
Where modifications are made in existing plant areas, or a hazardous area

zone from new plant extends into an existing plant area, the existing
Hazardous Area Classification for that area, will be checked and updated if
required.
In addition, if an existing plant area changes from non-hazardous to

hazardous or the zone category becomes more severe, then the certification
of any equipment within that area will be checked to confirm its suitability. If
the certification of any existing equipment is found to be inappropriate this will
be highlighted so that the best course of action may be determined to resolve
the situation. Such action may range from the revision of the layout of the
relevant section of new plant to replacement of the unsuitable existing
equipment. (Note: Replacement / relocation of existing equipment is to be
avoided unless there is a strong safety and economic justification)
A single, multi-discipline conference review of the preliminary Hazardous

Area Classification drawings will be held which will include TCO and PFD and
be based on the following documents:
• Hazardous Area Classification Philosophy including data sheets for SGP

and SGI projects:
Part 1 – Flammable Material List and Characteristics
Part 2 – List of Sources of Release
• Plot Plans
• AFD PFDs
• Preliminary P&IDs
• Equipment List
• Applicable codes and standards
The deliverables from the review will be as follows:
• Completed check lists from each discipline.

• Report.
• List of actions, which must be tracked to close out.
Updates to Plot Plans as Phase 3 develops will not be formally reviewed, but
the AFD Hazardous Area Classification drawings will reflect the AFD plot
layouts and incorporate general comments as applicable.
5.2 Phase 4 (Detailed Engineering)

The Hazardous Area Classification Data Sheets will be updated as
necessary, and Data Sheet Part 2 will reflect any additions or deletions of
equipment, and will incorporate equipment details as they are received, e.g.
pump and compressor seal types.
13
Rev.0
The Hazardous Area Classification Layouts and Elevations will also be

updated to incorporate these changes and any relevant revisions to the Plot
Plans. The Hazardous Area Classification drawings will be issued as
Approved for Construction following the AFC issue of the Plot Plans and
Hazardous Area Classification Data Sheets.
6. APPROVALS
Hazardous Area Classification approvals will follow the requirements of the Activity
Quality Plan with regard to conference reviews.
Final Hazardous Area Classification drawings and data sheets will be submitted to
the Client for formal approval by the regulatory authorities in the Republic of
Kazakhstan.
Any plot and equipment changes after formal approvals will be recorded and
transmitted to TCO for re-approval by the regulatory authorities.
7. DESIGN PHILOSOPHY
All continuous releases of flammable material, solvents and dusts will be eliminated
and there is to be no routine flaring, including prolonged periods of flaring in order to
keep the plant producing when a section or unit is off line. In addition, the objective
will be to reduce flaring to a minimum (preferably zero) during start up. Primary
grades of release will be minimised by identification and the introduction of mitigating
measures.
In order that primary grade releases can be minimised the following typical examples
of design and operation philosophies will be adopted:
• Under normal operation, all charges, transfers and discharges within the process
trains will be made using closed systems. The use of closed systems means that
any release of flammable or combustible material will be of a secondary nature.
• Transport of chemicals and catalysts in secure bulk containers or drums, etc

• Use of closed sampling systems
• Use of closed relief and venting systems
• Imposition of strict operating procedures with regard to the handling, transport
and clean up of potentially flammable solvents.
• Nitrogen or fuel gas blanketing as appropriate will be provided on the storage
tanks which have a vapour space and contain hazardous liquids and the vents
on these tanks will be connected to appropriate facilities, e.g. flares or absorber
systems. These measures will be taken in order to prevent the release of
flammable or toxic vapours to atmosphere during normal operation. The tanks
will therefore be a secondary source of release.
13
Rev.0
8. EQUIPMENT SELECTION
8.1 General
The definitions used in this document are shown in the Appendix (Section
10).
Wherever possible, electrical equipment shall be located in non-hazardous

areas. Where it is impractical to install electrical equipment in non-hazardous
areas, electrical equipment shall be selected for use in hazardous areas in
accordance with PUE, Rules for the Arrangement of Electrical Installations
and the codes and standards referenced therein.
All electrical apparatus that is located in a hazardous area shall as a minimum

be suitable for gas group IIB and temperature class T3.
Any equipment which is expected to operate in an emergency condition shall

be suitable for Zone B-1 or B-1a if equipment is indoors, or Zone B-1г if
equipment is outdoors even if the emergency equipment is not within a
hazardous area. This includes the following items unless the equipment is
located in a control room, local equipment room or otherwise protected
against gas entry:
• Emergency shutdown system.

• Fire and gas detection system.
• Fire protection system.
• Emergency lighting.
• Alarm and emergency communication system(s).
• Turbine emergency lubrication systems.
All electrical equipment for use in hazardous areas shall be certified in

accordance with the requirements of the relevant authorities in the Republic
of Kazakhstan.
Hot or potentially hot equipment shall be considered as a potential ignition

source including the following:
• Hot pipes operating above auto-ignition temperatures.
• Rotating equipment bearings.
• Hot exhausts of static equipment and vehicles.
13
Rev.0
Electrical equipment installed in hazardous areas shall be certified in

accordance with the table below.
Zone Zone Type of Equipment Permissible

(PUE) (IEC 60079) Explosion Protection Level (Note 4) and Type
See Note 3 Zone 0 (a) Level: 0 – Specially Explosion Proof
Type: Intrinsically Safe Exia
B-1 Zone 1 (a) Level: 0 – Specially Explosion Proof
(Indoors) (Indoors) Type: Intrinsically Safe Exia or Exib
(b) Motors only:-
Level: 1 – Explosion Proof
Type: Flameproof Exd, or
Increased Safety Exe, or
Pressurised Exp
(c) All other equipment:-
Level: 0 – Highly Explosion Proof
Type: Flameproof Exd, or
Increased Safety Exe, or
Pressurised Exp
B-1a Zone 1 All equipment suitable for use in Zone B-1
(Indoors) (Indoors)
B-1б Zone 1 All equipment suitable for use in Zone B-1
(Indoors) (Indoors)
B-1г Zone 1 and All equipment suitable for use in Zone B-1
(Outdoors) Zone 2
(Outdoors)
Non- Non- Electrical equipment for installation in non-hazardous
Hazardous Hazardous areas shall be of the standard industrial design
suitable for the environmental conditions. Equipment
described above for Zone B-1 applications may be
used in non-hazardous areas to facilitate equipment
standardisation.
Notes:
1. Refer to PUE, Rules for the Arrangement of Electrical Installations, Sections
7.3.40 - 43, for definitions of hazardous zones. The Russian characters shown
shall be used on all drawings and documentation to identify the hazardous zones.
2. The approximately equivalent hazardous area classification in accordance with
IEC 60079-10 is shown for guidance.
3. Zone 0, as defined in IEC 60079-10, has no equivalent in PUE.
4. Refer to PUE, Section 7.3.32 for definitions of explosion protection levels.
Equipment and motors of the non-sparking Exn type shall not be used.
For the purposes of equipment standardisation, all electrical equipment, which will be
installed in a hazardous area, shall be certified for a Zone B-1 area (equivalent to
Zone 1 according to IEC 60079-10).
13
Rev.0
8.2 Equipment within Substations and Control Rooms

Electrical substations and control rooms shall be located in non-hazardous
areas. Equipment and installations within and major equipment around the
electrical substations and control rooms can be standard, industrial type.
Rooms containing batteries shall be classified as non-hazardous, since
batteries are gas recombination, sealed lead acid type and so do not give rise
to a flammable atmosphere.
8.3 Analyser Houses
The analyser house interior will be classified as for an enclosed, inadequately
ventilated building. Any ventilation purging to the interior of the building will be
considered as an additional benefit, but will not affect the classification.
8.4 Fired Equipment

Fired equipment is considered non-hazardous whilst operating. However all
electrical equipment and installations supplied with the equipment shall be
certified for use in a Zone B-1 area. Fired equipment is to be purged before
start-up and gas detection installed in air inlet. Hydrocarbon lines to fired
equipment shall be all welded as far as practicable with a minimum number of
fittings in the vicinity in order to minimise leaks.
Fired equipment will be located in accordance with plant spacing

requirements. Gas turbine driven process gas compressors shall incorporate
special design features for the gas turbine enclosure. Air intakes for the gas
turbines shall be located in safe areas with gas detectors installed in the inlet.
The ventilation vent location shall be such that it ensures no recirculation to
either the ventilation or combustion air inlet.
The whole of the gas turbine enclosure shall be classified as Zone B-1a.
The power plant Heat Recovery Steam Generator is classified as a safe area
with localised classified areas as per the code meeting IIB, T3. The power
plant gas turbines are classified to API 505 enclosure zone 1 to IIA, T2.
8.5 Diesel Engines

Air intakes and exhausts from diesel engines shall be located in safe areas,
with gas detection installed in the air inlet or the generator enclosure as
appropriate.
9. ATTACHMENTS
9.1 Hazardous Area Classification Data Sheet - Part 1: Flammable Material

List and Characteristics, Doc. No. DS-60-B-0001.
See attached document.
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Rev.0
9.2 Hazardous Area Classification Data Sheet - Part 2: List of Sources of

Release, Doc. No. DS-60-B-0002.
Currently only the blank form is provided as an attachment to this document.
Completed forms will comprise a separate document.
10. APPENDIX: DEFINITIONS
10.1 PUE, Rules for the Arrangement of Electrical Installations
The following definitions have been used within this document. Definitions of
Zones B-1, B-1a, B-1б and B-1г are summaries only and full definitions may
be obtained by referring to PUE, Rules for the Arrangement of Electrical
Installations, Sections 7.3.40 to 43, for definitions of hazardous area
classifications.
Zone B-1 Zone inside an enclosure where explosive mixtures of

combustible gases or HILs may be released during
normal modes of operation.
Zone B-1a Zone inside an enclosure where explosive mixtures of

combustible gases or HILs will not be released during
normal operation but may be released in an emergency
or as a result of a failure.
Zone B-1б Zone inside an enclosure where explosive mixtures of

combustible gases or HIL will not be released during
normal operation but may be released in an emergency
or as a result of a failure and are characterised by one
of the following features:
1. Combusible gases have inflammable limit of 15%
and higher and have a sharp odour in threshold
concentration.
2. Buidlings involving hydrogen conversion process
units where explosive miixture formed cannot
exceed 5% of the empty space of the enclosure.
Zone B-1г Zone outside near units processing combustible gases

or HILs (excluding ammonia compression units).
For the purpose of Hazardous Area Classification HIL will be defined as all IP
fluid categories A, B & C.
10.2 Pue Classification and Marking of Explosion - Protected Electrical

Equipment
Explosion protection “Levels” of electrical equipment are specified as follows:
Level 2 (Lowest Level)

Electrical Equipment of
High Explosive Safety:
13
Rev.0
Electrical equipment protected against possible

explosion wherein this protection is secure only in the
specified normal operation conditions.
Level 1
Explosion-Free Electrical
Equipment:
Electrical equipment protected against explosion,
wherein explosion protection is secure both in normal
operation conditions and in conditions of recognised
possible damages which are determined by the
conditions of use, except damages to the explosion
protection means.
Level 0 (Highest Level)

Specially Explosive-Free
Electrical Equipment:
Electrical equipment protected against explosion,
wherein additional measures of explosion protection
have been taken as compared to the “Explosion-Free
Electrical Equipment”, as stipulated by standards on
types of explosion protection.
10.3 IEC 60079 & IP Model Code of Safe Practice ( Part 15), 1990
Continuous grade of release

a release which is continuous or is expected to occur for long periods.
Primary grade of release

a release that can be expected to occur periodically or occasionally during
normal operation. (1)
Secondary grade of release

a release which is not expected to occur during normal operation and, if it
does occur, is likely to do so only infrequently and for short periods. (2)
Adequate ventilation
the achievement of a uniform ventilation rate of at least twelve air changes
per hour with no stagnant areas.
Inadequate ventilation
not adequate ventilation, as defined above. (3)
Zone 0
an area in which an explosive gas atmosphere is present continuously or for
long periods or frequently.
Zone 1
an area in which an explosive gas atmosphere is likely to occur in normal
operation occasionally.
13
Rev.0
Zone 2
an area in which an explosive gas atmosphere is not expected to occur during
normal operation and if it does occur is likely to do so only infrequently and
will exist for a short period only.
(1) Examples of machinery and plant which can give rise to a primary
grade release are:
• pump seals.
• vents on tanks without inert cushions.
• safety valves or vents releasing to surrounding atmosphere.
• sample/valve outlets releasing to the surrounding atmosphere,
operated frequently.
(2) Examples of machinery and plant which can give rise to a secondary
grade release are:
• flanges, connections and pipe fittings.

• glass gauges
• seals of pumps where a release of flammable liquid is not expected.
• glands of pumps etc. designed and maintained to prevent leakage.
• valves having glands.
• sample/valve outlets releasing to the surrounding atmosphere,
operated infrequently.
(3) IP Model Code of Safe Practice (Part 15) states that location of a
primary source of release within an inadequately ventilated enclosed
area is not an acceptable practice and should be avoided.
13

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DOCUMENT NO:

HAZARDOUS AREA CLASSIFICATION

0 31/10/02 13 APPROVED FOR DESIGN NPCA NPCA/ NPCA RDV

A 17/05/01 12 ISSUED FOR CLIENT NW NPCA

REV DATE PAGES DESCRIPTION BY CHKD APPR CLIENT

REVISION DESCRIPTION SHEET

REV. PARA. REVISION DESCRIPTION

The Tengizchevroil Asset Development Projects involve the expansion of an existing

2. CODES AND STANDARDS

AFD Approved for Design

• Hazardous Area Classification Philosophy, Document No. 60-0000-B-PHL-

• SGP Hazardous Area Classification Data Sheet - Part 1: Flammable Material

• SGP Hazardous Area Classification Data Sheet - Part 2: List of Sources of

• Overall Hazardous Area Classification Key Plan.

• Hazardous Area Classification Layouts and Elevations.

5.1 Phase 3 (FEED)

The objective of the Hazardous Area Classification at the Pre-Engineering

• Verify preliminary general plot layouts from a safety and operability

• Identify restricted and unrestricted roads.

Where modifications are made in existing plant areas, or a hazardous area

In addition, if an existing plant area changes from non-hazardous to

A single, multi-discipline conference review of the preliminary Hazardous

• Hazardous Area Classification Philosophy including data sheets for SGP

The deliverables from the review will be as follows:

• Completed check lists from each discipline.

5.2 Phase 4 (Detailed Engineering)

The Hazardous Area Classification Layouts and Elevations will also be

• Transport of chemicals and catalysts in secure bulk containers or drums, etc

Wherever possible, electrical equipment shall be located in non-hazardous

All electrical apparatus that is located in a hazardous area shall as a minimum

Any equipment which is expected to operate in an emergency condition shall

• Emergency shutdown system.

All electrical equipment for use in hazardous areas shall be certified in

Hot or potentially hot equipment shall be considered as a potential ignition

Electrical equipment installed in hazardous areas shall be certified in

Zone Zone Type of Equipment Permissible

8.2 Equipment within Substations and Control Rooms

8.4 Fired Equipment

Fired equipment will be located in accordance with plant spacing

8.5 Diesel Engines

9.1 Hazardous Area Classification Data Sheet - Part 1: Flammable Material

See attached document.

9.2 Hazardous Area Classification Data Sheet - Part 2: List of Sources of

10. APPENDIX: DEFINITIONS

10.1 PUE, Rules for the Arrangement of Electrical Installations

Zone B-1 Zone inside an enclosure where explosive mixtures of

Zone B-1a Zone inside an enclosure where explosive mixtures of

Zone B-1б Zone inside an enclosure where explosive mixtures of

Zone B-1г Zone outside near units processing combustible gases

10.2 Pue Classification and Marking of Explosion - Protected Electrical

Level 2 (Lowest Level)

Electrical equipment protected against possible

Level 0 (Highest Level)

Continuous grade of release

Primary grade of release

Secondary grade of release

• flanges, connections and pipe fittings.