HAC Report of Megafine Pharma (P) LTD, Nashik

HAZARDOUS AREA CLASSIFICATION STUDY
MEGAFINE PHARMA (P) LTD
Nashik, Maharashtra
January 2020
Conducted by:
Cholamandalam MS Risk Services Limited
Chennai, India
(An ISO 9001:2008 Certified Organisation)
(A JV between Murugappa Group and Mitsui Sumitomo Insurance Group)

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DOCUMENT HISTORY
Revision
S.No. Document Identification Comments / Nature of Changes
No Date
00 23.02.2020 Draft report
Revision comments
1 HAC/SR/MPPL/19-20/166 01 03.03.2020 incorporated
Final Report With Comments

02 03.03.2020 Incorporated
Prepared By Reviewed By Approved By
Mr. Hari Kiran M Mr. Gopala Krishnan AM Mr. Gopala Krishnan AM

Manager – Electrical Safety AGM – Electrical Safety AGM – Electrical Safety
Cholamandalam MS Risk Services Limited, Chennai (India)
Megafine Pharma (P) Ltd, Nashik

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EXECUTIVE SUMMARY
The management of Megafine Pharma (P) Ltd, Nashik had approached Cholamandalam MS Risk Services
Ltd. (hereinafter referred as Chola MS Risk) to conduct Hazardous area classification study for their
facilities located at Nashik, Maharashtra. Accordingly, Consultants from Chola MS Risk visited the plant
and carried out site study from 28th to 30th January, 2020.
The hazardous zone classifications of various production blocks are summarized below
Predominant area classification for the particular location is listed in the below table. Recommended to
verify the detailed report to find out other hazardous zones for the particular mentioned location
REQUIRED
ZONE GAS TEMPERATURE
S.NO BLOCK Location EQUIPMENT
CLASSIFICATION GROUP CLASSIFICATION
SPECIFICATION
1 PB - A 1st Floor Zone 1 IIA/IIB T3 Ex d IIA/IIB T3
Ground Floor Zone 1 IIA/IIB T3 Ex d IIA/IIB T3

GF – Sifter, Zone 22 IIA/IIB T* Ex d IIA/IIB T*
Milling,
Blending
GF – Tray Zone 2 /Zone 22 IIA/IIB T3 Ex d IIA/IIB T3
Drier (or)
Ex “e” IIA/IIB T3
GF – Zone 1 IIA/IIB T3 Ex d IIA/IIB T3
Washing
Room
Terrace Zone 2 IIA/IIB T3 Ex d IIA/IIB T3
(or)
2 PB - B 4th Floor Zone 2 IIA/IIB T3 Ex d IIA/IIB T3
(or)

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REQUIRED
SPECIFICATION
3rd floor Zone 1 IIC T3 Ex d IIC T3
2nd Floor Zone 1 IIA/IIB T3 Ex d IIA/IIB T3
3 PB - F 1st Floor Zone 1 IIA/IIB T2 Ex d IIA/IIB T2
4 PB - D First Floor Zone 1 IIA/IIB T3 Ex d IIA/IIB T3
Sifter & Zone 22 IIA/IIB T* Ex d IIA/IIB T*

Miller Room
5 PB - C VTD Zone 2 /Zone 22 IIA/IIB T3 Ex d IIA/IIB T3
(or)
RCVD Zone 1 IIA/IIB T3 Ex d IIA/IIB T3
Multimiller, Zone 22 IIA/IIB T* Ex d IIA/IIB T*

Sifter
Wash and Zone 1 IIA/IIB T3 Ex d IIA/IIB T3

Anciliary
room
6 PB - I 2nd Floor Zone 1 IIA/IIB T3 Ex d IIA/IIB T3
1st Floor Zone 1 IIA/IIB T3 Ex d IIA/IIB T3
Sifter, Zone 22 IIA/IIB T* Ex d IIA/IIB T*

Multimiller

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REQUIRED
SPECIFICATION
7 PB - K 1st Floor Zone 1 (2m IIA/IIB T3 Ex d IIA/IIB T3
from the
reactor
manhole) &
Zone 22 (2m
from manhole,
if dust is
combustible)
1 (2m from the
reactor bottom
adapter)
8 PB - J 2nd Floor Zone 1 IIA/IIB T3 Ex d IIA/IIB T3
1st Floor Zone 1 IIA/IIB T3 Ex d IIA/IIB T3
9 PB - G Micronizer Zone 22 IIA/IIB T* Ex d IIA/IIB T*
Wash Area Zone 1 IIA/IIB T3 Ex d IIA/IIB T3
10 PB -E FBD, Zone 1 IIA/IIB T3 Ex d IIA/IIB T3
Multimiller Zone 22 IIA/IIB T* Ex d IIA/IIB T*
11 Recovered Oudoor Zone 1 IIA/IIB T3 Ex d IIA/IIB T3

Solvent Storage
Tank

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REQUIRED
SPECIFICATION
12 SRP Oudoor Zone 1 IIA/IIB T3 Ex d IIA/IIB T3
13 Hydrogenation Oudoor Zone 1 IIC T3 Ex d IIC T3

Block
14 ETP Oudoor Unclassified
15 MEE Oudoor Zone 1 + IIA/IIB T3 Ex d IIA/IIB T3 in

Zone 2 Zone 1 area
Ex d IIA/IIB T3
(or)
In Zone 2 areas.
16 QC Chemical Zone 2 IIA/IIB T3 Ex d IIA/IIB T3
Storage (or)
Room Ex “e” IIA/IIB T3
17 Pilot Plant Indoor Zone 1 IIA/IIB T3 Ex d IIA/IIB T3
18 PB - H 1st Floor Zone 1 IIA/IIB T3 Ex d IIA/IIB T3
2nd Floor Zone 1 IIA/IIB T3 Ex d IIA/IIB T3
API (Tray Zone 1 IIA/IIB T3 Ex d IIA/IIB T3

drier, RCVD,
sifter,
multimiller)
19 Warehouse Unclassified

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REQUIRED
SPECIFICATION
20 AG Storage Outdoor Zone 1 IIA/IIB T3 Ex d IIA/IIB T3
Tank
Outdoor Zone 2 IIA/IIB T3 Ex d IIA/IIB T3

UG Storage (or)
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Tank
Note: During the Audit, Plant was in shutdown condition
Salient findings:-
PB – A
PB – A – 1st Floor:
• Earthing connection was found to be missing for the methanol tank. Static earthing connection shall be
provided for the methanol tank to dissipate the static charges.
• It is suggested to maintain minimum ventilation rate of about 12 air changes in the reactor 1st floor
area.
• Cable gland was observed to be loose and not fully engaged to the Temperature detector in SSR-08.
Cable gland size shall be matching the cable diameter and cable gland shall be engaged with five full
threads or 8 mm with the Ex d enclosure. Only certified cable cables shall be used.
• It shall be ensured that nitrogen blanketing be provided while performing cleaning operation of the
reactor.
PB – A – 2nd Floor:
• Allen bolt was observed to be in loose condition for the sparkler filter A/SF 005. Openings or
inadequate fastener tightening in the flameproof enclosure will result in loss of integrity and efficiency
to perform as flame proof.
• Oxygen level sensor shall be provided in the enclosed centrifuge room. It shall also be ensured that LEL
dedectors be provided in the enclosed centrifuge room.
• It is suggested to let the vent to open atmosphere, instead of letting so in corridor. Else, all the
electrical equipment installed in the corridor shall be of Flame proof type with the specification Ex d
IIA/IIB T3.

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• Spiral hose metallic part of LEV is not bonded properly and it was observed in other areas too. Metallic
part of the hose shall be in tact in order to provide continuity for the static charges generated.
• LEV vent line was found to be detached in the water washing area. It shall be connected to prevent the
escape of vapours from the vent line.
• Name plate of the reactor agitator flame proof motor have been completely painted. It is absolute
necessary to install and maintain the Ex equipments to ensure the integrity so as to avoid it becoming
an ignition source. In many locations the flame path of Ex installations are obstructed/painted (even
enclosed inside the wall). This will prevent escape of hot gas from the installations resulting in
explosion due to pressure pilling. Ex survey of all installations shall be carried out in all the blocks to
ascertain their integrity and Ex register shall be maintained for the Ex equipments.
• LEV was not covering the charging area of the sifter. LEV shall be place at the vicinity of the sifter for
efficiency.
• ATD – 001 back side, 15 A domestic socket was in place. It shall be replaced with flameproof type
socket of specification Ex d IIA/IIB T3.
• Stand alone split AC was being used in packing room and FG store room. Domestic split Ac are not
rated to run for 24/7. Therefore, 2 nos. of split AC shall be installed with timer for the operation
interchange.
PB – B
PB – B – 4th Floor:
• Vent of the methanol storage tank shall be let out to the open free area.
• It is recommended to bond the connections across the flanges in the methanol pipe lines, in order to
avoid accumulation of static charges during transfer process. The electrical continuity across is essential
to dissipate static charges safely.
• Non Ex light fitting was observed above the hydrogen cylinder. It shall be replaced with flameproof
light fitting with the specification Ex “ d” IIC T1.
• External earthing connection was found to be missing for the flame proof light fitting. External earthing
connection shall be provided for the light fitting.

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PB – B – 3rd Floor:
• Flange bonding was found to be missing in the glass vapour line of GLR -002. It is recommended to
bond the connections across the flanges in the vapour lines, in order to avoid accumulation of static
charges during transfer process. The electrical continuity across is essential to dissipate static charges
safely.
• Cable gland was found to be missing for temperature transducer GLR – 002. Cable gland size shall be
provided in matching the cable diameter and cable gland shall be engaged with five full threads or 8
mm with the Ex d enclosure. Only certified cable cables shall be used.
• Non Ex light fittings have been provided in the washing area. It shall be replaced with flameproof light
fitting with the specification Ex “d” IIA/IIB T3.
• Supply and exhaust ducts are located at the top. Exhaust louver shall be provided at floor level as
flammable materials handle are denser than air.
• Space in the wall was observed through which the AHU duct was found communicating with nearby
office area. Space around the AHU duct shall be sealed to prevent the escape of vapours to non-
hazardous areas.
• Doors which segregate reactor area and office area are not air tight. Doors segregating reactor area
and office area shall be air tight with auto closure provision. Dorr gaskets in the door shall be intact. It
is also recommended to maintain office area at positive pressurization of 2.5 mm of water column.
PB – F – Ground Floor:
• Nitrogen blanketing has been provided for the centrifuges but interlock is not provided. Interlock with
N2 shall be provided.
• Oxygen level sensor shall be provided in the centrifuge room.
• 1 no. of fastener was found to be missing in the flame proof weighing display unit. Openings or
• Non Ex telephone has been provided in the ground floor centrifuge room. Ex telephone with the
specification Ex d IIA/IIB T3 shall be provided.
PB – D – 2nd Floor:
• Flange bonding was found to be missing for the vapour column line of the reactor. Bonding across the
flanges shall be provided. This shall be followed across all the production blocks.

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PB – C – Ground Floor:
• Spot extractor LEV shall be provided in the washing room and to be in vicinity during equipment
cleaning process.
• Ventilation failure alarm shall be provided in RCVD, VTD, sifter and multimiller room. Ventilation unit
failure alarm needs to be provided in the centrifuge area. Alarm shall be triggered if ventilation unit
stops. All flammable material handling operations like cleaning process need to stopped. Solvent
container need to be closed. Manual open solvent handling operations need to be done only with the
presence of adequate ventilation. This shall be commonly followed across all the enclosed areas of the
plant.
• Magnehelic differential pressure gauge was showing zero. It is recommended to rectify or replace the
faulty gauge. It shall be ensured that minimum of 2.5 mm of water column differential pressure shall be
maintained.
SRP
• High flame path gap was observed on the for T2 Temperature J2. All allen bolts shall be provided and
tightened fully to meet the required flame path gap in the Ex enclosure.
• Temperature indicator (conde no: SRP1 TCH -001/T1) was found to be cracked and bolts are found to
be missing. All allen bolts shall be provided and tightened fully to meet the required flame path gap in
the Ex enclosure.
• Unused gland hole was observed to the light fitting near new GLR. It shall be sealed using flame proof
blanking element.
• Non Ex automatic level controller shall be replaced using flame proof and intrinsically safe level
controller.
• Non Ex gland has been used to terminate the cable for EX “d” IIC Telephone. It shall be replaced with
flame proof type double compression gland.
Hydrogenation
• It shall be ensured that explosion proof clock near the hydrogen cylinder shall be suitable for the
hydrogen gas area and it shall be of specification Ex “d” IIC T3.
• Unused gland hole was observed for the push button station of sparkler filter. It shall be replaced with
flame proof type blanking element.
• Effluent treatment pump was of flameproof type with specification Ex “d” IIA/ IIB. It shall be replaced
with EX “d” IIC T3.

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STANDARDS REFERRED
Guide for selection and installation of electrical equipments in Hazardous

IS 5571
locations (other than mines)
IS 5572 Classification of Hazardous area other than mines
IEC 60079-10-1 Classification of areas – Explosive gas atmospheres
IEC 60079-10-2 Classification of areas – Combustible dust atmospheres
Recommended Practice for the Classification of Flammable Liquids,

NFPA 497
Gases, or Vapors and of Hazardous (Classified) Locations for Electrical Installations
in Chemical Process Areas
IP 15 Area Classification Code for installations handling flammable liquids
Classification of Areas for Electrical installations at hydrocarbon processing and

OISD 113
handling facilities
Recommended Practice for Classification of Locations for Electrical Installations at

API 500
Petroleum Facilities Classified as Class I, Zone 0, Zone 1, and Zone 2

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CONTENTS
SECTION DESCRIPTION PAGE NO
I EXECUTIVE SUMMARY 3
II INTRODUCTION 13
III OBJECTIVE & SCOPE OF THE STUDY 13
IV HAZARDOUS AREA CLASSIFFICATION METHODOLOGY 17
V CRITERIA FOR HAZARDOUS AREA CLASSIFICAITON STUDY 18
VI HAZARDOUS AREA CLASSIFFICATION CONVENTION 23
VII HAZARDOUS AREA CLASSIFFICATION STUDY MANAGEMENT 27
VIII HAZARDOUS AREA CLASSIFICATION SUMMARY WITH SOURCE SHEETS 29

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INTRODUCTION
The management of Megafine Pharma (P) Ltd had approached Cholamandalam MS Risk Services Ltd.
(hereinafter referred as Chola MS Risk) to conduct Hazardous area classification study for their facilities at
Nashik. Accordingly, Consultants from Chola MS Risk visited the plant and carried out site study from 28th
to 30th January, 2020.
ABOUT MEGAFINE PHARMA (P) LTD :
Mega Fine Pharma Private Limited is a Private incorporated on 22 August 1995. It is classified as Non-
govt company and is registered at Registrar of Companies, Mumbai. Its authorized share capital is Rs.
20,000,000 and its paid up capital is Rs. 15,534,450. It is inolved in Manufacture of other chemical
products
ABOUT THE CONSULTANTS
Cholamandalam MS Risk Services Limited (Chola MS Risk) is a joint venture between the Murugappa Group
and Mitsui Sumitomo Insurance Group of Japan. Chola MS Risk offers specialized and innovative risk
management solutions to clients in Asia and Africa. Chola MS Risk has carried out consultancy, investigation
and training services to more than 2500 units / locations of various organizations belonging to various
industrial sectors including some of the major oil & gas, petrochemical and Pharma industries. In addition,
industrial sector and service sector located in Asia and Africa have been engaging the services of Chola MS
Risk to carry out a number of specialized safety studies. The team members have wide experience in risk
management studies and have carried out studies for a number of commercial and industrial sectors. For
further details, the reader may visit the website www.cholarisk.com
OBJECTIVES OF THE STUDY
Area classification is a method of analyzing and classifying the environment where explosive gas
atmospheres may occur so as to facilitate the proper selection and installation of equipment to be
used safely in that environment. The classification also takes into account the ignition characteristics
of the gas or vapour such as ignition energy (gas group) and ignition temperature (temperature
class).
Objective is to analyze and classify the environment where explosive gas atmospheres may occur to allow
the proper selection of electrical apparatus to be installed in that Hazardous environment.

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The object of the hazardous area classification approach is to reduce, to an acceptable level, the
probability of coincidence of a flammable atmosphere and an ignition source
In most practical situations where flammable materials are used, it is difficult to ensure that an explosive
gas atmosphere will never occur. It may also be difficult to ensure that equipment will never give
rise to a source of ignition. Therefore, in situations where an explosive gas atmosphere has a high
likelihood of occurring, reliance is placed on using equipment which has a low likelihood of creating
a source of ignition. Conversely, where the likelihood of an explosive gas atmosphere occurring is
reduced, equipment constructed with less rigorous requirements may be used.
SCOPE OF WORK
• To identify and classify the hazardous atmosphere present in the plant in to different zones and to
specify the equipment specification suitable for the particular zone based on the HAC Standards
mentioned in the reference.
• To review the electrical equipment installed in the plant on a sampling basis, based on IS 5572 (type of
protection, Temperature classifications, and Gas groups)

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TEAM
Megafine Pharma (P) Ltd Cholamandalam MS Risk Services
Mr. Rahul Shitole Mr. Suseendran A
Mr. Hari Kiran M
STUDY COVERAGE
Installations
The following installations were covered during the study,
Day 1:
• Production Block – PB - A
• Production Block – PB – B
• PB -F
• PB – I
• PB - D
Day 2:
• PB - C
• PB – D
• PB – I
• PB – K
• PB – J
• Warehouse WH -3

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• WH -4
• WH -5
• WH -1
• AG Storage Tank
• UG Solvent Storage Tanks
• Chiller Plant & Utility
Day 3:
• PB – G
• PB – E
• Spent Solvent Storage Area
• SRP
• Hydrogenation
• ETP
• MEE
• XRD Lab
• Potentiometer Lab
• Pilot Plant
• PB – H
Records / Reports / Drawings are to be provided

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HAC METHODOLOGY
Data collection and
review
Opening meeting with

M/s Megafine
Interaction with
employees
Site Visit
Identification of source of
release
Examination of
Determination of grade how flammable
of release materials are
handled
Classification of areas in
to different Zones and Ventilation factors
determining Zone assessment
extent
Hazardous area mapping

in plant layout
Submission of
Report

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CRITERIA FOR HAZARDOUS AREA CLASSIFICAITON STUDY
HAC Exercise - Basis:
✓ HAC is to be carried out for plants where the chemical Flash Point (FP) is less than 65° C as per
IS 5572. Hence all plants / areas where any chemical stored/handled has a FP less than 65° C will be
considered for this Hazardous Area Classification Study
✓ Depending on the lowest Auto Ignition Point (AIT) of the chemicals used in process plants, the
equipment Temperature class (T-Class) will be compared and decided
✓ Wherever there is a doubt in classifying hazardous areas- from the safety point of view- higher zone
(most hazardous) is given precedence (is considered).
✓ Chemical properties of chemicals used in the report are from the details provided by M/s Megafine
Pharma (p) Ltd
Major criteria for Hazardous Area Classification;
✓ Leak Potential & Presence of Ignition Sources
✓ Hazardous properties of flammable materials
✓ Safe selection (& optimization) of Electrical Equipment
The factors considered HAC zoning are follows:
Sources of release:
A point or location from which a gas, vapour, mist or liquid may be released into the atmosphere
so that an explosive gas atmosphere could be formed
Various Grades of releases:
There are three basic grades of release, as listed below in order of decreasing frequency and Likelihood of
the explosive gas atmosphere being present:

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1. Continuous grade of release :
A Release which is continuous or is expected to occur frequently or for long periods
2. Primary grade of release:
A release which can be expected to occur periodically or occasionally during normal operation
3. Secondary grade of release:
A release which is not expected to occur in normal operation and, if it does occur, is likely to do
so only infrequently and for short periods
Various Hazardous Zones:

Hazardous areas are classified into zones based upon the frequency of the occurrence and duration
of an explosive gas atmosphere, as follows:
• 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
• Zone 2
An area in which an explosive gas atmosphere is not likely to occur in normal operation but, if it
does occur, will persist for a short period only
Topography
The terms referred by Indian Standard “normal” and “abnormal” require some interpretation.
Normal conditions should be taken to be not ideal but real conditions as they actually exists, taking in to
account the precautions that are taken on a well run plant.
Abnormal conditions should be read to refer NOT to catastrophic accidents such as a major equipment
rupture but to the events that are generally non - catastrophic such as a pump gland or pipe gasket failure.
The ICI (Imperial chemical industries) Electrical Installations in Flammable Atmospheres Code describes the
two basic methods of HAC: (1) The generalized method and (2) the source of hazard method.
While this blanket application of a Zone 1 classification is in itself conservative, it is also expensive,

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And there may be a tendency which should be guarded against, to ignore a few high hazard points
and classify as Zone 2 an area that should be Zone 1. The source of hazard method is the newer approach
and involves identifying, assessing and delineating affected areas for individual sources of hazard. The
latter are classified according to the expected frequency and period of release of flammable materials. The
classification together with the suggested quantitative guidelines is as tabulated below:
Normal and abnormal operation
A situation when the equipment is operating within its designed parameters

• Minor releases of flammable material may be part of normal operation. For example, releases
from seals which rely on wetting by the fluid which is being pumped are considered to be
minor releases.
• Failures (such as the breakdown of pump seals, flange gaskets or spillages caused by accidents)
which involve urgent repair or shut-down are not considered to be part of normal operation
nor are they considered to be catastrophic.
• Normal operation includes start-up and shut-down conditions.
Relative density of gas:
Vapor-when it is released. i.e. denser gas would settle down and the lighter gas would move upwards. In
case of HAC, if the relative density of the gas is less than 0.75 times of relative density of air, then the gas is
considered to be lighter gas and any gas having relative density above 0.75 times of air is considered to be
a heavy gas. Chemicals with vapor density less than 0.75 are classified as lighter than air
• Quantity of flammable chemical released- Proximity towards the highest risk area.
• Climatic conditions

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Flashpoint
Lowest liquid temperature at which, under certain standardized conditions, a liquid gives off
Vapours in a quantity such as to be capable of forming an ignitable vapour/air mixture
Gas Group:
Flammable materials are sub-divided into groups based on minimum ignition energy required for igniting
them
Ventilation: -
With increased ventilation, the extent of hazardous zone would be reduced.
In case if 12 air changes or more is maintained then it is considered to be safe ventilation.
If the gas – air mixture in the area is below 25 % of the LEL concentration then the area is
Considered to be adequately ventilated.
Table below provides the guidelines for classification of zone with respect to effect of Ventilation.
Temperature Classification: -
The surface temperature of the electrical equipment is selected based on the Auto Ignition Temperature of
the chemicals being handled. The details are given in Table 2.

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Various Equipments protection technique and its suitability:-

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HAZARDOUS AREA CLASSIFICATION SHADING CONVENTION:-
EXTENT OF VARIOUS HAZARDOUS ATMOSPHERES:
Chemicals Heavier than Air as per IS 5572: - (open atmosphere)

• Vertically 8m above source of hazard, horizontally 16m in all direction, beyond 8m from source in
horizontal plane vertical extent 8m above ground level.
• if there are chances of large release from the plant areas, the zone 2 area horizontally extends up
to 32m with height 0.63 m from the floor level.
• Any trench or pit or similar depressions below ground level in zone 2 area should be classified as
Zone 1 area.

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Vent lines as per IS 5572: -

If Vent lines in the plants are not connected to the flare / Sample points are not plugged and are left open
in the plant area itself;
A sphere of radius 1.5 m surrounding any tank vent / breather valves is classified as Zone 1 and Zone 2 to
be extended up to 3 m from the sample point opening
Fixed storage tanks as per IS 5572: -

As per IS – 5572 the hazardous area for the fixed roof storage tanks is as follows;
• Zone 1 – 3 m vertically above the tank level and extended 3 m horizontally from the sides of
the tank.
• Zone 1 area – to be extended up to the dyke wall or up to a distance of 3m at ground level
whichever is greater. The height of Zone 1 area will be equal to the height of the dyke wall.

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Fixed storage tanks as per IS 5572: - (with nitrogen blanketing)
Tanker unloading operation (Bottom transfer only):-

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Normal Industrial pump located at outdoor conditon:-

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HAZARDOUS AREA CLASSIFICATION STUDY MANAGEMENT:-
This study is based on the present operating conditions, solvent handled and the inputs provided by the
operators and data collected from the site. Any change in process operating conditons, method of handling
solvents will result in different results and warrants equipments with different protection levels. Hazardous
area classification study shall be reviewed accordingly and HAC drawings shall be updated to take account
of
• New or modified equipment.
• Changes in installation protection.
• Experience in operation of the installation.
• Changes in method or frequency of operations.
• Reclassification as a result of measurements in and around hazardous areas
Hazardous area classification should be incorporated into a company’s Health, Safety and
Environmental Management System.
The person responsible for the co-ordination of the hazardous area classification should be identified and
be competent in this field. The work, which requires an interdisciplinary approach, should be carried out by
persons who have full knowledge of the process systems and equipment, in consultation with safety, loss
prevention and electrical engineering personnel, as appropriate. Agreements reached on the hazardous
area classification should be formally recorded, continually reviewed and kept updated. Records, such
as drawings and/or tabulated data sheets, should include details as to the type of protection selected to
meet the zone requirements and the apparatus sub-group and temperature class
In classifying a new facility or a modification, the hazardous area classification should be carried out before
the design and layout of equipment are finalised. At this stage, it may be possible to make considerable
improvements at little cost. The hazardous area classification should always be reviewed and
drawings modified, if necessary, on completion of design and before any change is made to existing
plants handling flammable fluids. The company operating a facility has the prime responsibility to
ensure that hazardous area classification has been carried out on installations handling
flammable fluids

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ACKNOWLEDGEMENTS
Chola MS Risk Services gratefully acknowledges the co-operation received from the management of
M/s Megafine Pharma (P) Ltd during the site visit. Chola MS Risk in particular would like to thank Mr. Rahul
Shitole and their team for their full support and coordination throughout the study and courtesy extended
to the Chola MS team members during the site visit.
DISCLAIMER
This report is for the sole use by the Client for the purpose for which they have claimed it is required to us.
We are not responsible to any other person/party for any decision of such person/party based on this
report. It is hereby notified that reproduction, copying or otherwise quoting of our report or any part
thereof other than the aforementioned purpose, can be done only with our prior permission.
The report cannot be used or relied by the Client for any other purpose or any other third party for any
purpose whatsoever and we will not be liable which the client may incur on this account including in tort
(including but not limited to negligence) arising out of or in connection with this Report. This Report is not
intended to identify all hazards which may exist nor is it intended to be an exhaustive review of all possible
eventualities. The recommendations for risk improvement contained in the report are purely advisory and
the decision and responsibility for implementation rests with the Client.

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HAZARDOUS AREA CLASSIFICATION
SUMMARY
WITH SOURCE SHEETS

29
I. Production Block – A (PB – A):
PB – A 1st Floor
Observations
• 11 nos. of Process reactors SSR -001 to 008 have been provided.

• Solvent is charged through the reactor vessel through vacuum process from the barrel.
• Nitrogen purging has been carried out before solvent dispensing process.
• Cleaning of the reactor is through methanol solvent. It was informed that methanol is flushed through
manhole.
• Methanol overhead tank of capacity 500 litres is also provided.
• It was informed that Nitrogen blanketing is provided during powder addition to the reactor.
• Nitrogen blanketing is not provided while performing cleaning operations manhole will be in open
condition.
• Few reactors have been provided with Local exhaust ventilation, which will be used during solid
powder charging and not while manual cleaning of reactor through solvent.
• Vacuum distillation and atmospheric distillation are carried out according to the process.
• During the time of audit, it was observed that plant process was in shutdown condition.
Hazardous area classification PB- A – Flammable material list and characteristics

These are the list of solvents used utilized in the various Reactors / process vessel
S.NO Flammable Flash Vapour Boiling LEL UEL Auto Ignition T Gas Group
Materials point Density Point (%) (%) Temperature Class
(°C) (o C) (o C)
1. N - Butanol 35 2.55 118 1.4 12.0 343 T2 IIA
2. Toluene 4 3.20 111 1.1 7.1 480 T1 IIA
3. Methanol 9 1.11 65 6.0 36 440 T1 IIA
4. n-Heptane -7 3.46 105 0.85 6.7 204 T3 IIA
5. Methanol 9 1.11 65 6 36 440 T2 IIA
6. IPA 12 2.1 83 2 12.7 399 T2 IIA
7. Tetra Hydro -14 2.49 64 1.5 12.4 230 T3 IIB
Furan (THF)
8. MDC Non – Flammable Material
9. Aqueous Non – flammable Material
Ammonia
10. DMF 58 2.51 153 1.8 16 440 T2 IIA
(Dimethyl
Formamide)
11. Tri Ethyl -8 3.5 89 1.2 8 215 T3 IIA
Amine
12. Ethyl Acetate -4 3.04 77 2 12.8 470 T1 IIA
13. Methyl Tert. -27 3.03 55 1.5 8.4 385 T2 IIA
Butyl Ether
14. 1-3 Dimethyl 58 201.5
admantane
15. Methyl -20 2.07 32 5.0 23.0 525 T1 II A
Formate
30
16. Di-isopropyl -28 3.52 69 1.0 21.0 405 T2 IIA
ether(DIPE)
17. Acetone -20 2.0 56 2.5 14.3 399 T2 IIA
18. Isopropyl 2 3.52 89 1.8 7.8 460 T1 IIA
Acetate
Hazardous area classification – PB – A - 1st Floor - Source data sheet
Ventilation Extent of Zone in (m)

Grade of
S.NO Source of release Type Area Availa Degree Zone H V
release
bility
1 Vents of Primary & Natural Open Fair Medium Zone 1 1.5 m around vent
condenser secondary + in all directions is
located outside Zone 2 zone 1 and from
1.5 m upto 3 m
around vent in all
directions is Zone 2
2 Flanges, valves Secondary Natural Obstruc Fair Medium Zone 2 A distance of 3 m
and fittings of ted around valve,
all the pipelines fitting and flanges
3 Opening of Primary Natural Obstruc Fair Medium Zone 1 A distance of 2m

reactor manhole ted + from the reactor in
while charging Zone 2 all directions is
solid materials Zone 1 and further
& while cleaning 2m in all directions
by methanol is zone 2 hazardous
flushing area.
Open charging Since, series of

of methanol reactors are
solvent drum located nearby,
entire area is
classified as Zone 1
4 Sampling from Primary Natural Obstruc Fair Medium Zone 1 A distance of 1m
the reactors ted Area from the reactor
through or from the sample
manhole port in all
directions is Zone
1.
5 Condenser & Secondary Natural Obstruc Fair Medium Zone 2 A distance of 3 m
reflux / vapour ted Area around valve,
column line fitting and flanges
flange leaks ( for
reactors which
has condenser)
6 Receiver vessel Secondary Natural Obstruc Fair Medium Zone 2 A distance of 3 m
ted Area around the
31
receiver vessel
7 Methanol Secondary Natural Obstruc Fair Medium Zone 2 A distance of 3 m

overhead tank ted Area around the
methanol over
head tank
6 Solvent Secondary Natural Obstruc Fair Medium Zone 2 A distance of 3 m
Pipelines ted Area (First around valve,
around the Floor fitting and flanges
building in first Ventilati
floor area on )
Summary – PB -A – 1st Floor
• When zones created by adjacent sources of release overlap and are of different zonal classification,
the higher classification criteria will apply in the area of overlap. Where overlapping zones are of the
same classification, the common classification will normally apply.
• Entire first floor building area is classified as Zone 1 hazardous location and a distance of 3m
surrounding the building is classified as Zone 2 hazardous location
• A distance of 3m surrounding the building at first floor level is classified as zone 2 hazardous location,
if the solvent pipe lines are running around.
• Electrical equipments shall be with the specification Ex d IIA/IIB T3 and instruments mounted on the
process equipments shall be Ex ia IIA/IIB T3.
• Solvent storage barrel was stored in the service area. A distance of 3m in all the directions from the
barrel storage area is classified as zone 2. Therefore, electrical equipment installation in that region
shall be flameproof with the specification Ex d IIA/IIB T3. If lift communicates, then it should also be of
the flameproof type.
Recommendations – PB – A – 1st Floor:
• Earthing connection was found to be missing for the methanol tank. Static earthing connection shall
be provided for the methanol tank to dissipate the static charges.
• It is suggested to maintain minimum ventilation rate of about 12 air changes in the reactor 1 st floor
area.
• Cable gland was observed to be loose and not fully engaged to the Temperature detector in SSR-08.
Cable gland size shall be matching the cable diameter and cable gland shall be engaged with five full
threads or 8 mm with the Ex d enclosure. Only certified cable cables shall be used.
• It shall be ensured that nitrogen blanketing be provided while performing cleaning operation of the
reactor.
• It shall be ensured that minimum of 6 air changes shall be maintained in the reactor first floor area in
the PB – A.
32
PB – A Ground Floor
Observations
• SSR & GLRs bottom reactor transfer line, centrifuge area, sparkler filter, Tray dryer area
• Nitrogen blanketing has been provided with interlock provision to oxygen sensor for the centrifuge.
• Sifter is located in the room. 3 in ground floor area.
• Washing and cleaning of the equipments using mater and methanol is carried out with LEV at vicinity
Hazardous area classification – PB- A- Ground Floor Area - Source data sheet

Grade of
release
bility
1 Transfer of Secondary Natural Obstructe Fair Medium Zone 2 3 m in all directions
slurry mass from d from filling point.
reactors to the (For multiple tanks
sparkler filter Zone 2 Area gets
and to the extended)
centrifuge
through bottom
transfer line
2 Collection of Primary Natural Obstructe Fair Medium Zone 1 A distance of 2m
solvents or d from the reactor in
solvent content all directions is
slurry mass Zone 1 and further
remains in the 2m in all directions
open container is zone 2 hazardous
while manual area.
cleaning of
reactors from Since, series of
bottom reactor reactors are
valve or adapter located nearby,
entire area is
3 Sparkler filter Primary Natural Obstructe Fair Medium Zone 1 A distance of 3 m

transfer pump d around the pump
4 Vapours while Primary Artifici Obstructe Fair Medium Zone 1 2 m from the
unloading al d/ centrifuge in all the
material from Enclosed directions is
centrifuge Area classified as Zone 1
and further 2m in
all directions is
zone 2 hazardous
area.
33
Grade of
release
bility
In enclosed
centrifuge room,
entire room is
classified as zone 1
5 Centrifuge Secondary Natural Obstructe Fair Medium Zone 2 A distance of 3 m
solvent line and d& around valve,
ML (mother Enclosed fitting and flanges
liquor) line
6 Centrifuge Primary Natural Obstructe Fair Medium Zone 1 Zone 1 Entire area
Cleaning d&
Enclosed
7 Leak from Secondary Natural Obstructe Fair Medium Zone 2 A distance of 3 m
Centrifuge d around valve,
solvent line, ML fitting and flanges
Tank
8 Sparkler Filter Secondary Natural Obstructe Fair Medium Zone 2 A distance of 3 m
Transfer pump d around the transfer
& ML Transfer pump
pump
9 Tray dryer Primary Artifici Enclosed Fair Medium Zone 1 Zone 1
cleaning al Entire area is zone
1
10 Tray dryer Primary Artifici Enclosed Fair Medium Zone 2 Zone 2 / Zone 22
material al / Zone (During unloading
unloading 22 of powder after
drying, vapour
content may be
small
11 Washing room Primary Artifici Enclosed Fair Medium Zone 2 Zone 1
(washing carried al Entire area is zone
under the 1
process of LEV,
but the vent Zone 1 in room 5
pipe was found washing area, since
to be LEV is not used
disconnected) there.
12 Sifter Secondary Artifici Enclosed Fair Medium Zone 1m from the
al Area 22 equipment is Zone
22 hazardous
location
(Considering the
operation of dust
collector)
13 Blending, Sifting Secondary Artifici Enclosed Fair Medium Zone 1m from the
and packing in al Area 22 equipment is Zone
room-6 22 hazardous
location
34
Grade of
release
bility
(Considering the
operation of dust
collector)
14 Drain pit Primary Natural Obstructe Fair Poor Zone 1 Entire pit zone 1
d
Summary of Plant PB –A Ground Floor area

• Entire Ground floor building area is classified as Zone 1 hazardous location and a distance of 1.5m
surrounding the building (ground floor)is classified as Zone 1 hazardous location.
• Enclosed centrifuge room is classified as zone 1.
• Sifter is classified as Zone 22
• Corridor area will be classified as Zone 1.

• Vent of the safety relief valve and the condenser valve have been let out in the corridor.
• In an enclosed sifter room, flameproof equipment shall be with the with the specification Ex d IIA/IIB
T* or Ex “td” *
Note: Dust classification group and Temperature classification shall be decided after laboratory test
results
Recommendations of Plant PB – A reactor Ground floor area
• Allen bolt was observed to be in loose condition for the sparkler filter A/SF 005. Openings or
• Oxygen level sensor shall be provided in the enclosed centrifuge room. It shall also be ensured that
LEL dedectors be provided in the enclosed centrifuge room.
• It is suggested to let the vent to open atmosphere, instead of letting so in corridor. Else, all the
electrical equipment installed in the corridor shall be of Flame proof type with the specification Ex d
IIA/IIB T3.
• Spiral hose metallic part of LEV is not bonded properly and it was observed in other areas too. Metallic
part of the hose shall be in tact in order to provide continuity for the static charges generated.
35
• LEV vent line was found to be detached in the water washing area. It shall be connected to prevent
the escape of vapours from the vent line.
• Name plate of the reactor agitator flame proof motor have been completely painted. It is absolute
necessary to install and maintain the Ex equipments to ensure the integrity so as to avoid it becoming
an ignition source. In many locations the flame path of Ex installations are obstructed/painted (even
enclosed inside the wall). This will prevent escape of hot gas from the installations resulting in
explosion due to pressure pilling. Ex survey of all installations shall be carried out in all the blocks to
ascertain their integrity and Ex register shall be maintained for the Ex equipments.
• LEV was not covering the charging area of the sifter. LEV shall be place at the vicinity of the sifter for
efficiency.
• ATD – 001 back side, 15 A domestic socket was in place. It shall be replaced with flameproof type
socket of specification Ex d IIA/IIB T3.
• Stand alone split AC was being used in packing room and FG store room. Domestic split Ac are not
rated to run for 24/7. Therefore, 2 nos. of split AC shall be installed with timer for the operation
interchange.
• It shall be ensured that minimum of 6 air changes shall be maintained in the ground floor area in the
PB – A.
PB – A Terrace:
Observations:
• All the steam ejector circulation tanks and vacuum trap tanks are located in the terrace.
• 4 nos. of scrubber column are also located in the terrace
• Ventilation is natural.
Hazardous area classification –Distillate receiver / Ejector tank Source data sheet

Grade of
release
bility
1 Scrubber Blower Secondary Natural Open Fair Medium Zone 2 3 m around
2 Steam Ejector Secondary Natural Open Fair Medium Zone 2 3 m around valve,
Tank & Vacuum fitting and flanges
Trap receiver
vessel and
pipeline
36
Summary:
• Terrace area is classified as Zone 2.

• Electrical equipments shall be with the specification Ex d IIA/IIB T3 or Ex “e” IIA/IIB T3 and instruments
mounted on the process equipments shall be Ex ia IIA/IIB T3.
PB – A Service Area – Utility:
AHU unit for the block C, D, H are provided in the utility section. It was informed that Flame proof blower
and exhaust motors are provided. It is suggested to ensure flame proof motors provided are with the
specification Ex d IIA/IIB T3. Megafine shall consider providing fire detectors in the duct.
II. Production Block – B (PB – B):

PB – B - 4th Floor:
Observation:
• Methanol storage tank of 1.3 kL has been located in the 4th floor inside a room.
• Process cooling towers 07, 08 are located in the terrace. FD cooling fans have non FLP motors.
• Area is well ventilated.
• Hydrogen cylinder storage was also observed.
Hazardous area classification – PB- B 4th Floor - Source data sheet

Grade of
release
bility
1 Vent of the Primary & Natural Obstruc Fair Medium Zone 1 1.5 m around vent
Methanol secondary ted + in all directions is
storage tank Zone 2 zone 1 and from
inside 1.5 m upto 3 m
around vent in all
2 Valve, flanges in Secondary Natural Obstruc Fair Medium Zone 2 3 m around valve,
the Methanol ted fitting and flanges
tank
3 Valve, flanges in Secondary Natural Open Fair Medium Zone 2 3 m around valve,
the Vacuum fitting and flanges
Trap receiver
and ejector tank
pipeline
4 Hydrogen Secondary Natural Open Fair Medium Zone 2 A distance of 4.5 m
37
cylinder pipeline is considered as
flanges and zone 2 in all the
valves in open directions.
areas
Summary of Plant PB – B 4th Floor:

• Entire Terrace area is classified as Zone 2.
• A distance of 4.5 m around the Hydrogen cylinder pipeline, pipe line valve and flange is considered as
zone 2.
Recommendations:
• Vent of the methanol storage tank shall be let out to the open free area.
• It is recommended to bond the connections across the flanges in the methanol pipe lines, in order to
avoid accumulation of static charges during transfer process. The electrical continuity across is
essential to dissipate static charges safely.
• Non Ex light fitting was observed above the hydrogen cylinder. It shall be replaced with flameproof
light fitting with the specification Ex “ d” IIC T1.
• External earthing connection was found to be missing for the flame proof light fitting. External
earthing connection shall be provided for the light fitting.
PB – B 3rd Floor:
Observations:
• Reactors SSR – 001, 001, 003, 004, 005 & GLR 001, 002, 003 are located in the 3rd floor
• Hydrogen is used in the reactor SSR – 003 & SSR - 005.
• Hydrogen from the pressurized cylinder is reduced to atmospheric pressure using pressure reducing
valve.
• Solvent is charged through the reactor vessel through vacuum process from the barrel.
• Nitrogen purging has been carried out before solvent dispensing process.
manhole for Type B cleaning.
• Local exhaust ventilation is available for the reactors and it is connected to the scrubber.
Hazardous area classification PB- B – Flammable material list and characteristics
38
(°C) (o C) (o C)
1. Toluene 4 3.20 111 1.1 7.1 480 T1 IIA
2. Acetone - 20 2.0 56 2.5 14.3 539 T1 IIA
3. Methanol 9 1.11 65 6 36 440 T2 IIA
6. IPA 12 2.1 83 2 12.7 399 T2 IIA
7. Tetra Hydro -14 2.49 64 1.5 12.4 230 T3 IIB
Furan (THF)
8. Acetonitrile 2 1.42 82 3.0 16.0 523 T1 IIA
9. Tri Ethyl -8 3.5 89 1.2 8 215 T3 IIA
Amine
10. Dimethyl 89 2.71 189 2.6 28.5 215 T3 IIA
Sulfoxide
11. DMF 58 2.51 153 1.8 16 440 T2 IIA
(Dimethyl
Formamide)
12. n-Heptane -7 3.46 105 0.85 6.7 204 T3 IIA
Ammonia
Hazardous area classification – PB – B – 3rd Floor - Source data sheet

Grade of
release
bility
1.5 m upto 3 m
around vent in all
2 Flanges, valves Secondary Artificial Obstruc Fair Medium Zone 2 A distance of 3 m
or reactor not
using H2
3 Opening of Primary Artificial Obstruc Fair Medium Zone 1 A distance of 2m

flushing area.
39
entire area is
4 Sampling from Primary Artificial Obstruc Fair Medium Zone 1 A distance of 1m
manhole port in all
directions is Zone
1.
5 Condenser & Secondary Artificial Obstruc Fair Medium Zone 2 A distance of 3 m
flange leaks ( for
reactors which
has condenser)
6 Flanges, valves Secondary Artificial Obstruc Fair Medium Zone 2 A distance of 4.5 m
and fittings of ted Area around valve,
hydrogen fitting and flanges,
pipeline of manhole is zone 2
reactor SSR -003 and vertically 8m
& SSR - 005 distance is zone 2.
7 Condenser of Secondary Artificial Obstruc Fair Medium Zone 2 A distance of 4.5 m

SSR -003 & SSR - ted Area around condenser
005 & Solvent & solvent pipeline
pipeline is Zone 2 and
vertically 8m
distance is zone 2.
8 Solvent Secondary Artificial Obstruc Fair Medium Zone 2 A distance of 3 m
Pipelines ted Area around valve,
around the fitting and flanges
building in first
floor area
Summary of Plant PB – B 3rd Floor:

• Entire 3rd floor is classified as Zone 1.
• A distance of 4.5m around the pipelines, flanges, solvent line, hydrogen pipeline, condenser line is
classified as zone 2 and it further extends 8m vertically.
• Electrical equipments with flame proof type of specification Ex d IIC T3 shall be provided at SSR -003 &
005 and at distance of 4.5 m shall also be provided with FLP equipment of IIC gas group.
40
Recommendations:
• Flange bonding was found to be missing in the glass vapour line of GLR -002. It is recommended to
bond the connections across the flanges in the vapour lines, in order to avoid accumulation of static
charges during transfer process. The electrical continuity across is essential to dissipate static charges
safely.
• Cable gland was found to be missing for temperature transducer GLR – 002. Cable gland size shall be
provided in matching the cable diameter and cable gland shall be engaged with five full threads or 8
mm with the Ex d enclosure. Only certified cable cables shall be used.
• Non Ex light fittings have been provided in the washing area. It shall be replaced with flameproof light
fitting with the specification Ex “d” IIA/IIB T3.
• Supply and exhaust ducts are located at the top. Exhaust louver shall be provided at floor level as
flammable materials handle are denser than air.
• Space in the wall was observed through which the AHU duct was found communicating with nearby
office area. Space around the AHU duct shall be sealed to prevent the escape of vapours to non-
hazardous areas.
• Doors which segregate reactor area and office area are not air tight. Doors segregating reactor area
and office area shall be air tight with auto closure provision. Dorr gaskets in the door shall be intact. It
is also recommended to maintain office area at positive pressurization of 2.5 mm of water column.
• It shall be ensured that minimum of 6 air changes shall be maintained in the 3 rd floor area in the PB –
B.
PB – B 2nd Floor:
Observations:
• 2 nos. of reactors GLR -005 and SSR – 001 are located in the 2nd floor.
• Sparkler filter has been provided and the reaction mass is transferred through sparkler filter to the
next reactor.
manhole for Type B cleaning.
• Process was under shutdown during the time of audit.
Hazardous area classification – PB-B 2nd Floor - Source data sheet

Grade of
release
bility
41
1.5 m upto 3 m
around vent in all
2 Transfer of Secondary Natural Obstruc Fair Medium Zone 2 3 m in all directions

slurry mass from ted from filling point.
centrifuge
through bottom
transfer line
3 Collection of Primary Natural Obstruc Fair Medium Zone 1 A distance of 2m
solvents or ted from the reactor in
while manual area.
cleaning of
entire area is
(Bottom of the classified as Zone 1
reactors located
in the 3rd floor
extended to 2nd
floor)

process is zone 2 hazardous
area.
Since, series of
reactors are
located nearby,
entire area is
5. Sampling from Primary Natural Obstruc Fair Medium Zone 1 A distance of 1m
manhole port in all
directions is Zone
1.
42
flange leaks ( for
reactors which
has condenser)
7 Sparkler filter Primary Natural Obstruc Fair Medium Zone 1 A distance of 3 m
transfer pump ted around the pump
Summary of PB – B – 2nd Floor:
• Entire first floor building area is classified as Zone 1 hazardous location and a distance of 3m
surrounding the building is classified as Zone 1 hazardous location.
• It shall be ensured that minimum of 6 air changes shall be maintained in the 2 nd floor area in the PB –
B.
III. F - Block (PB – B – 1st Floor):

Observation – PB – “F” – 1st Floor:
• Reactors B/GLR 005 and SSR – 001 are located.

• Sparkler filter has been provided between B/GLR 005 and SSR – 001.
• Centrifuge and F/GLR -002 were also located.
• Ventilation is artificial
Hazardous area classification PB- F (1st Floor) – Flammable material list and characteristics
(°C) (o C) (o C)
1. Toluene 4 3.20 111 1.1 7.1 480 T1 IIA
2. Acetone - 20 2.0 56 2.5 14.3 539 T1 IIA
3. Methanol 9 1.11 65 6 36 440 T2 IIA
Ammonia
ether (DIPE)
43
Hazardous area classification – “F” Block 1st floor – (PB -B – 1st floor)

Source of Grade of
S.NO Type Area Availa Degree Zone H V
release release
bility
1.5 m upto 3 m
around vent in all
2 Collection of Primary Natural Obstruct Fair Medium Zone 1 A distance of 2m
solvents or ed from the reactor in
solvent all directions is
content slurry Zone 1 and further
mass remains 2m in all directions
in the open is zone 2 hazardous
container while area.
manual
cleaning of Since, series of
reactors from reactors are
bottom reactor located nearby,
valve or entire area is
adapter classified as Zone 1
(Bottom of the
reactors
located in the
3rd floor
extended to 2nd
floor)
3 Opening of Primary Natural Obstruct Fair Medium Zone 1 A distance of 2m

reactor ed + from the reactor in
manhole Zone 2 all directions is
while charging Zone 1 and further
solid materials 2m in all directions
& during is zone 2 hazardous
cleaning area.
process
Since, series of
reactors are
located nearby,
entire area is
4 Sampling from Primary Natural Obstruct Fair Medium Zone 1 A distance of 1m
44
the reactors ed Area from the reactor
manhole port in all
directions is Zone
1.
5 Condenser & Secondary Natural Obstruct Fair Medium Zone 2 A distance of 3 m
reflux / vapour ed Area around valve,
flange leaks (
for reactors
which has
condenser)
6 Transfer of Secondary Natural Obstruct Fair Medium Zone 2 3 m in all directions
slurry mass ed from filling point.
from reactors (For multiple tanks
to the sparkler Zone 2 Area gets
filter and to extended)
the centrifuge
through
bottom
transfer line
manual
(Bottom of the
reactors
located in the
2nd floor
extended to 1st
floor)

is zone 2 hazardous
area.
45
or from the sample
port in all
directions is Zone
1.
flange leaks (
for reactors
which has
condenser)
11. Sparkler filter Primary Natural Obstruct Fair Medium Zone 1 A distance of 3 m
transfer pump ed around the pump
Summary of PB – F – 1st Floor:
• Entire floor area is classified as Zone 1 hazardous location and a distance of 3m surrounding the
building is classified as Zone 2 hazardous location.
“F” Block Ground Floor Area
Observation:
• Centrifuge F/SSCH – 001 has been located in the F- block.
• Nitrogen blanketing has been provided for the centrifuges but interlock is not provided.
• Oxygen level sensor shall be provided.
Hazardous area classification – PB -F Block (PB-B Ground Floor) - Source data sheet
Ventilation Extent of Zone in

(m)
Grade of
S.NO Source of release Type Area Avail Degree Zone H V
release
abilit
y
1 Transfer line Secondary Natural Obstructed Fair Medium Zone 2 A distance of 3 m
valve point from around the
reactors to the discharge point of
centrifuge room reactor
through fixed
line
2 Leak from the Secondary Natural Obstructed Fair Medium Zone 2 A distance of 3 m
valve, flanges of around valve,
46
Ventilation Extent of Zone in
(m)
Grade of
S.NO Source of release Type Area Avail Degree Zone H V
release
abilit
y
Solvent line, fitting and flanges
vent of the
centrifuge
connected to
scrubber line
3 Leakage from Secondary Artificial Enclosed Fair Medium Zone 1 A distance of 3 m
centrifuge around valve,
charging lines fitting and flanges
4 Centrifuge Secondary Natural Obstructed Fair Medium Zone 2 A distance of 3 m

solvent line and around valve,
ML (mother fitting and flanges
liquor) line, ML
Tank
5 Centrifuge Primary Artificial Enclosed Fair Medium Zone 1 Zone 1 Entire area
Cleaning with Area
solvent
6 Leak from Secondary Natural Obstructed Fair Medium Zone 2 A distance of 3 m
Centrifuge around valve,
solvent line fitting and flanges
7 Collection of Primary Natural Obstructed Fair Medium Zone 1 A distance of 2m
solvents or from the reactor
solvent content in all directions is
slurry mass Zone 1 and
remains in the further 2m in all
open container directions is zone
while manual 2 hazardous area.
cleaning of
reactors from
bottom reactor
valve or adapter
(Bottom of the
reactors located
in the 1st floor
extended to
Ground floor)
Summary - F Block (PB-B Ground Floor):
47
• Entire PB – B classified as Zone 1 hazardous location and a distance of 1.5m surrounding the building is
classified as Zone 1 hazardous location.
• Solvent to the first floor reactor has been discharged from ground floor service area. Therefore,
service area in the ground floor is classifies as zone 1.
Recommendations – F Block (PB-B Ground Floor):
• Nitrogen blanketing has been provided for the centrifuges but interlock is not provided. Interlock with
N2 shall be provided.
• Oxygen level sensor shall be provided in the centrifuge room.
• 1 no. of fastener was found to be missing in the flame proof weighing display unit. Openings or
• Non Ex telephone has been provided in the ground floor centrifuge room. Ex telephone with the
specification Ex d IIA/IIB T3 shall be provided.
IV. PB -D – Block:
“D” Block – 1st Floor Area:
• Reactors DGLR – 001 and DSSR – 001 are located in the first floor.
• Ventilation is artificial.
Hazardous area classification PB- D – Flammable material list and characteristics
(°C) (o C) (o C)
1. Toluene 4 3.20 111 1.1 7.1 480 T1 IIA
2. Acetone - 20 2.0 56 2.5 14.3 539 T1 IIA
3. Methanol 9 1.11 65 6 36 440 T2 IIA
Ammonia
ether (DIPE)
8. DMF 58 2.51 153 1.8 16 440 T2 IIA
48
(Dimethyl
Formamide)
9. Di-ethylene 138 3.66 245.8 2.0 12.3 143 T3 IIA
Glycol
Hazardous area classification – “D” Block

Source of Grade of
release release
bility
1.5 m upto 3 m
around vent in all
& while is zone 2 hazardous
cleaning by area.
methanol
flushing
is zone 2 hazardous
area.
Since, series of
reactors are
located nearby,
entire area is
or from the sample
port in all
directions is Zone
1.
flange leaks (
for reactors
49
which has
condenser)
Summary of PB – D – 1st Floor:
Recommendation – PB -D – 1st Floor:

• Flange bonding was found to be missing for the vapour column line of the reactor. Bonding across the
flanges shall be provided. This shall be followed across all the production blocks.
“D” Block – Ground Floor Area:
• Bottom transfer port of the Reactors DGLR – 001 and DSSR – 001 are located in the first floor.
• Centrifuge D – SSCF is located at the ground floor.
• Multimill DMM 001, sifter DSFT 001 are located.
• D-GLR – 001 (crystallizer) reactor and D-RCVD 001 are also located in the PB – D block
• Ventilation is artificial and in once through mode.
Hazardous area classification – PB-D- Ground Floor Area - Source data sheet

Grade of
release
bility
reactors the (For multiple tanks
centrifuge Zone 2 Area gets
through bottom extended)
transfer line
while manual area.
cleaning of
entire area is
50
Grade of
release
bility
reactors located
in the 1st floor
extended to
Ground floor)
centrifuge Area classified as Zone
1.
In enclosed
centrifuge room,
entire room is

liquor) line
Cleaning d&
Enclosed
Tank
8 ML Transfer Secondary Natural Obstructe Fair Medium Zone 2 A distance of 3 m
pump d around the transfer
pump
9 RCVD mopping Primary Artifici Enclosed Fair Medium Zone 1 Zone 1

with solvent al
10 Milling Room - Secondary Artifici Enclosed Fair Medium Zone Area is classified as
Multimiller al 22 Zone 22 location
on consideration of
presence of dust
collection system
and if dust handled
is combustible.
11 Cleaning of Primary Artifici Enclosed Fair Medium Zone 1 Zone 1
multimiller al
22 hazardous
location
51
Grade of
release
bility
(Considering the
operation of dust
collector)
Summary of PB – D – Ground Floor:
• Sifter – C/SFT -001 and multimiller room is classified as zone 22
• In an enclosed sifter & multimiller room, flameproof equipment shall be with the specification Ex d
IIA/IIB T* or Ex “td” *
“C & D” Block – Service Area:
Interlock between dehumidifier and AHU unit was not provided. Interlock shall be provided in the AHU
unit so that dehumidifier shall not be in ON condition when the blower is in off condition.
V. PB – C:
PB -C – Ground Floor:
Observation:
• Wet material from crystallizer is received from the pass box

• VTD, RCVD, Milling room are located.
• Portable dust collector has been provided for the multimiller.
• Nitrogen purging has been interlocked with AHU system in the multimiller room.
• Ventilation is artificial and is once through mode.
Hazardous area classification – PB – C Source data sheet

Grade of
release
bility
1 Vacuum tray Primary Artificial Enclosed Fair Medium Zone 1 Zone 1
dryer cleaning
2 Vacuum tray Primary Artificial Enclosed Fair Medium Zone 2 Zone 2 / Zone 22
52
Grade of
release
bility
dryer material
unloading (Vapour will be
small after drying)
3 RCVD mopping Primary Artificial Enclosed Fair Medium Zone 1 Zone 1

with solvent
4 Milling Room - Secondary Artificial Enclosed Fair Medium Zone Area is classified as
Multimiller 22 Zone 22 location
on consideration of
presence of dust
collection system
and if dust handled
is combustible.
5 Cleaning of Primary Artificial Enclosed Fair Medium Zone 1 Zone 1
multimiller
6 Sifter Secondary Artificial Enclosed Fair Medium Zone 1m from the
Area 22 equipment is Zone
22 hazardous
location
(Considering the
operation of dust
collector)
7 Wash and Primary Artificial Enclosed Fair Medium Zone 1 Zone 1

Ancillary room
Summary:
• RCVD, VTD and washroom areas are classified as zone 1

• Sifter – C/SFT -001 and multimiller room is classified as zone 22
• In an enclosed sifter & multimiller room, flameproof equipment shall be with the specification Ex d
IIA/IIB T* or Ex “td” *
Recommendations:
• Spot extractor LEV shall be provided in the washing room and to be in vicinity during equipment
cleaning process.
• Ventilation failure alarm shall be provided in RCVD, VTD, sifter and multimiller room. Ventilation unit
failure alarm needs to be provided in the centrifuge area. Alarm shall be triggered if ventilation unit
stops. All flammable material handling operations like cleaning process need to stopped. Solvent
container need to be closed. Manual open solvent handling operations need to be done only with the
53
presence of adequate ventilation. This shall be commonly followed across all the enclosed areas of the
plant.
• Magnehelic differential pressure gauge was showing zero. It is recommended to rectify or replace the
faulty gauge. It shall be ensured that minimum of 2.5 mm of water column differential pressure shall
be maintained.
54
VI. PB – I:
PB - I – 2nd Floor:
Observation:
• Reactors I/GLR – 008, I/GLR -002, I/SSR -001, I/SSR -002, are located.
• Ventilation is natural
Hazardous area classification PB- I – Flammable material list and characteristics
(°C) (o C) (o C)
1. Methyl Tert. -27 3.03 55 1.5 8.4 385 T2 IIA
Butyl Ether
2. Toluene 4 3.20 111 1.1 7.1 480 T1 IIA
3. Methanol 9 1.11 65 6.0 36 440 T1 IIA
Ammonia
ether(DIPE)
11. DMF 58 2.51 153 1.8 16 440 T2 IIA
(Dimethyl
Formamide)
12. Acetone -20 2.0 56 2.5 14.3 399 T2 IIA
13. n-Heptane -7 3.46 105 0.85 6.7 204 T3 IIA
14. Tri Ethyl -8 3.5 89 1.2 8 215 T3 IIA
Amine
15. IPA 12 2.1 83 2 12.7 399 T2 IIA
16. Ethanol 12 1.59 78 3.1 19.0 400 T2 IIB
Hazardous area classification – PB -I - 2nd Floor

Grade of
release
bility
1.5 m upto 3 m
around vent in all
2 Flanges, valves Secondary Natural Obstruc Fair Medium Zone 2 A distance of 3 m
55

& while cleaning 2 m in all directions
flushing area.

entire area is
4 Sampling from Primary Natural Obstruc Fair Medium Zone 1 A distance of 1m
or from the sample
port in all
directions is Zone
1.
flange leaks ( for
reactors which
has condenser)
6 Receiver vessel Secondary Natural Obstruc Fair Medium Zone 2 A distance of 3 m
ted Area around the
receiver vessel
7 Solvent Secondary Natural Obstruc Fair Medium Zone 2 A distance of 3 m

Pipelines ted Area (First around valve,
around the Floor fitting and flanges
building in first Ventilati
floor area on )
Summary - PB -I - 2nd Floor:
• Entire 2nd floor building area is classified as Zone 1 hazardous location and a distance of 3m
• A distance of 3m surrounding the building is classified as zone 2 hazardous location, if the solvent pipe
lines containing source of release are running around.
process equipments shall be Ex ia IIA/IIB T3. Light fittings shall also be ensured to be flameproof type
with specification Ex d IIA/IIB T3
56
PB - I – 1st Floor:
Observation:
• I/GLR -007, I/SSR-004 , I/ SSR -004, I/GLR -004are located in the first floor.
• Bottom of the reactor GLR 008, GLR 002, SSR 001 and SSR -002 are located.
• I/SF-003 sparkler filter has been provided.
• Ventilation is natural.
Hazardous area classification – PB -I - 1st Floor - Source data sheet

Source of Grade of
release release
bility
located out Zone 2 zone 1 and from
1.5 m upto 3 m
around vent in all
manual
(Bottom of the
reactors
located in the
3rd floor
extended to 2nd
floor)

& during is zone 2 hazardous
cleaning area.
process
57
or from the sample
port in all
directions is Zone
1.
flange leaks (
for reactors
which has
condenser)
6 Transfer of Secondary Natural Obstruct Fair Medium Zone 2 3 m in all directions
slurry mass ed from filling point.
from reactors (For multiple tanks
to the sparkler Zone 2 Area gets
filter and to extended)
the centrifuge
through
bottom
transfer line
manual
(Bottom of the
reactors
located in the
2nd floor
extended to 1st
floor)

58
is zone 2 hazardous
area.
manhole port in all
directions is Zone
1.
flange leaks (
for reactors
which has
condenser)
11. Sparkler filter Primary Natural Obstruct Fair Medium Zone 1 A distance of 3 m
transfer pump ed around the pump
Summary - PB -I - 1st Floor :
• Entire 1st floor building area is classified as Zone 1 hazardous location and a distance of 3m
• A distance of 3m surrounding the building is classified as zone 2 hazardous location, if the solvent pipe
lines containing source of release are running around.
process equipments shall be Ex ia IIA/IIB T3. Light fittings shall also be ensured to be flameproof type
with specification Ex d IIA/IIB T3
PB - I – Ground Floor:
Observation:
• Centrifuge SSCF – 003, SSCF -002 are located in the ground floor.
• All 1st floor reactor bottom and receiver vessel
• Milling and sifting room is also located and equipments multimiller A/MM-002 and sifter I/SFT 001
have been deployed. Vacuum Tray drier I/VTD-001, I/VTD -002 and I/VTD -003 are located.
• It was informed that VTD tray cleaning is carried out in the same location.
• Solvent storage in barrels have been observed in the intermediate area near the entrance of “ I” & “J”
block.
59
Hazardous area classification – PB- I- Ground Floor Area - Source data sheet

Grade of
release
bility
centrifuge
through bottom
transfer line
while manual area.
cleaning of
entire area is
reactors located
in the 1st floor
extended to
ground floor)
3 Sparkler filter Primary Natural Obstructe Fair Medium Zone 1 A distance of 3 m

transfer pump d around the pump
1.
In enclosed
centrifuge room,
entire room is
liquor) line
Cleaning d&
60
Grade of
release
bility
Enclosed
Tank
pump d around the transfer
pump
9 Vacuum Tray Primary Artifici Enclosed Fair Medium Zone 1 Zone 1

dryer cleaning al
(Vacuum Tray
cleaning carried
out in the same
place)
10 VTD material Primary Artifici Enclosed Fair Medium Zone 2 Zone 2 / Zone 22
unloading al / Zone
22

22 hazardous
location
(Considering the
operation of dust
collector)
13 Multimiller Secondary Artifici Enclosed Fair Medium Zone 1m from the
22 hazardous
location
(Considering the
operation of dust
collector)
14 Solvent barrel Secondary Natural Obstructe Fair Medium Zone 2 A distance of 2 m
storage at the d around in all the
intermediate directions around
area near the the barrel storage
entrance of “ I” area is classified as
block zone 2.
15 Solvent Storage Secondary Natural Obstructe Fair Medium Zone 2 A distance of 3 m

Day Tank in d around valve,
Mezzanine floor fitting and flanges
61
Summary - PB -I - Ground Floor :
• Entire Ground floor building area is classified as Zone 1 hazardous location and a distance of 3m
• Sifter and multimiller location is classified as Zone 22
• A distance of 3m surrounding the building at ground floor level is classified as zone 2 hazardous
location, if solvent pipelines are running by.
• Vent of the safety relief valve and the condenser valve have been let out in the corridor.
T* or Ex “td” *
results
62
VII. PB – K:
PB – K – 1st & Ground Floor:
Observation:
• Process reactors such as KGLR 001, 002 and KHLC F001are located.
• It was informed that acids such as chlorosulphonic acid and bases such as thynyl chloride are used.
They are non flammable.
• Ventilation is natural with all the sides open.
Hazardous area classification – PB -K - 1st Floor - Source data sheet

Grade of
release
bility
1 Reactor Primary Natural Open Fair Medium Zone A distance of 1m
manhole 21 from the reactor
opening for raw manhole
material is Zone 21.
charging and
opening the
manhole for
reactor cleaning
2 Cleaning of Primary Artifici Open Fair Medium Zone 1 A distance of 2m

process reactor al from the reactor
using solvent or from the sample
charged from port in all
manhole directions is Zone
1.
Summary – PB “K” – 1st Floor & Ground floor:
• A distance of 2m from the reactor is considered as Zone 1, during cleaning process.

• If raw material powder is combustible, then powder charging through manhole activity will be
classified under zone 21, upto a distance of 1 m.
• It is suggested to charge the powder in the reactor with LEV provision.
63
VIII. PB – J:
PB – “ J “ 2nd Floor:
Observation:
• Reactors J/GLR 001, J/SSR -002, J/SSR-001, J/GLR -008, J/SSR-009 and J/GLR -006 are located in the 2nd
floor.
• Solvent to the process reactor is transferred through AOD pump.
• Ventilation is natural and obstructed.
Hazardous area classification – PB – “J” Flammable material list and characteristics
These are the list of solvents used utilized in the second floor
(°C) (o C) (o C)
1. N - Butanol 35 2.55 118 1.4 12.0 343 T2 IIA
2. Toluene 4 3.20 111 1.1 7.1 480 T1 IIA
3. Acetone -20 2.0 56 2.5 14.3 399 T2 IIA
Ammonia
6. Tri Ethyl -8 3.5 89 1.2 8 215 T3 IIA
Amine
7. IPA 12 2.1 83 2 12.7 399 T2 IIA
8. Methanol 9 1.11 65 6 36 440 T2 IIA
9. Ethanol 12 1.59 78 3.1 19.0 400 T2 IIB
ether(DIPE)
12. Dimethyl 89 2.71 189 2.6 28.5 215 T3 IIA
Sulfoxide
13. Methyl -20 2.07 32 5.0 23.0 525 T1 II A
Formate
64
Hazardous area classification – PB “J”- 2nd Floor - Source data sheet

Grade of
release
bility
condenser out secondary + in all directions is
Zone 2 zone 1 and from
1.5 m upto 3 m
around vent in all
2 Bottom Transfer Secondary Natural Obstruc Fair Medium Zone 2 A distance of 3 m

adapter of ted Area around valve,
reactor vessel fitting and flanges
while cleaning Zone 2 all directions is
process Zone 1 and further
2m in all directions
is zone 2 hazardous
area.
4 Powder Primary Natural Obstruc Fair Medium Zone 1 A distance of 2m

charging ted + from the reactor in
through port Zone 2 all directions is
and sampling Zone 1 and further
through the 1m in all directions
port is zone 2 hazardous
area.
Since, series of
reactors are
located nearby,
entire area is
5. Addition of Primary Natural Obstruc Fair Medium Zone 1 1m from the
solvent to the ted solvent charging
reactor through area
AOD pump
flange leaks ( for
reactors which
has condenser)
65
Summary:
• Entire PB “J” second floor building reactor area is classified as Zone 1 hazardous location and a
distance of 3m surrounding the building is classified as Zone 2 hazardous location.
• A distance of 3m surrounding the building at second floor level is classified as zone 2 hazardous
location
PB – “ J “ 1st Floor:
Observation:
• Reactors J/SSR -006, J/SSR -005, J/SSR -004, J/GLR -002, J/SSR 008, J/GLR-007, J/GLR-003 are located in
the 1st floor.
• Ventilation is natural
Hazardous area classification – PB “J” – 1st Floor Area - Source data sheet

Grade of
release
bility
condenser out secondary + in all directions is
1.5 m upto 3 m
around vent in all

while manual area.
cleaning of
entire area is
reactors located
in the 2nd floor
66
extended to 1st
floor)

is zone 2 hazardous
area.

area.
Since, series of
reactors are
located nearby,
entire area is
6 Addition of Primary Natural Obstruc Fair Medium Zone 1 1m from the
solvent to the ted solvent charging
AOD pump
flange leaks ( for
reactors which
has condenser)
Summary - PB “J” – 1st Floor Area:
• Entire first floor building reactor area is classified as Zone 1 hazardous location and a distance of 3m
• A distance of 3m surrounding the building at first floor level is classified as zone 2 hazardous location
67
PB “J” – Ground Area :
Observation:
• Crystallizer - J / GLR 004 has been installed in the clean rooms.
• Reactor bottom of the 1st floor are also located.
• Centrifuges J/SSCF 005, J/SSCF 001, J/SSCF 004.
• Ventilation is artificial in crystallizer clean room
Hazardous area classification – PB “J” - Ground Floor

Grade of
release
bility
to the (For multiple tanks
centrifuge Zone 2 Area gets
through bottom extended)
transfer line
while manual area.
cleaning of
reactors from
bottom reactor
valve or adapter
1.
In enclosed
centrifuge room,
entire room is
liquor) line
Cleaning d&
Enclosed
Centrifuge d& around valve,
solvent line, ML Enclosed fitting and flanges
68
Grade of
release
bility
Tank
pump d& around the transfer
Enclosed pump
9 Opening of Primary Natural Obstructe Fair Medium Zone 1 A distance of 2m

Reactor d + from the reactor in
crystallizer Zone 2 all directions is
manhole Zone 1 and further
while cleaning 2m in all directions
process is zone 2 hazardous
area.
10 Condenser & Secondary Natural Obstructe Fair Medium Zone 2 A distance of 3 m

reflux / vapour d Area around valve,
flange leaks ( for
reactors which
has condenser)
11 Powder Primary Natural Obstructe Fair Medium Zone 1 A distance of 2m
charging d + from the reactor in
area.
12. Collection of Primary Natural Obstructe Fair Medium Zone 1 A distance of 2m

while manual area.
cleaning of
reactors from
bottom reactor
valve or adapter
(Bottom of the
reactors located
in the 1st floor
extended to
Ground floor
floor)
69
Grade of
release
bility
13. Valves, Fittings Secondary Artifici Enclosed Fair Medium Zone 2 A distance of 3 m
of ANFD al Area around valve,
fitting and flanges
14 ANFD cleaning Primary Artifici Enclosed Fair Medium Zone 1 Entire ANFD room
activity al Area
15 ML and receiver Secondary Artifici Enclosed Fair Medium Zone 2 A distance of 3 m
tank in ANFD al Area around valve,
room fitting and flanges
Summary – PB – “J” Ground Floor Area:
• Ground floor centrifuge area and crystallizer room are classified as Zone 1.
• ANFD area is considered Zone 1
• PRV vent of the crystallizer is vent out in the same location. PRV shall be extended and connected to
scrubber line or to be let out
PB – J – Vacuum pump Trap receiver area:
Observation & Recommendation:
• Vacuum Trap pumps have been installed in the PB – “J” service area.
• It is an open are with restricted ventilation.
• Distance of 3 m around Vacuum Trap pump is classified as zone 2.
• Non Ex starter switch and temperature display have been installed. All the equipments shall be of
type Ex “ d” IIA / IIB T3.
PB – J – Service Area:
Observation:
• Dust collector has been located in the service area.

• Scrubber has been located on the other side of the service area.
Hazardous area classification – PB – J Service area:

Grade of
release
bility
1 Dust Collector Primary Natural Open Fair Medium Zone A distance of 1m
Manhole 22 from the reactor
opened to manhole
remove the is Zone 21.
filter bag
70
Grade of
release
bility
2 Inside the dust Primary Natural Enclosed Fair Medium Zone Zone 21
collector 21
chamber – dirty
side of the filter
collector 22
chamber –
Clean side of the
filter
4 Scrubber Blower Secondary Natural Open Fair Medium Zone 2 3 m around
Summary – PB – “J” Service Area:
• A distance of 1m from the dust collector manhole is considered as zone 22. This is applicable across all
dust collectors in the plant.
• All electrical fittings shall be suitable to dust type and with specification Ex d IIA/IIB T* or Ex “td” *
results
• A distance of 3m around the scrubber is Zone 2. This is applicable across all the scrubber units in the
plant.
• Solvent line consisting of flanges was observed to be passing close to the AC outdoor unit. A distance
of 3m from the solvent line is classified as zone 2. Therefore, if the AC outdoor unit falls within the
range, it shall be relocated.
• Solvent pipelines with flanges was found to be running above AHU unit in utility. If the flanges in the
solvent line passing by are sealed, then the area will be unclassified or distance of 3m from flange
joints will be classified as zone 2.
• Steam ejector tanks are located above the brine tank area (Outside first floor area of Block J). A
distance of 3m around the ejector tank and pipeline shall also be classified as zone 2.
Chiller Plant:
MEG has been used as brine solution at present for the process chiller and it is non -flammable.
But it was informed that MEG will be replaced by Methanol (35 %) + water in future. From the laboratory
report shared from the Megafine, it was observed that the flash point for 35 % of methanol brine solution
is 35 °C.
71
If that is the case, then a distance of 3m around the tank and pipelines containing source of release shall
be considered as Zone 2. Therefore, transfer pump motors, all other electrical installation shall be of
flameproof type with the specification Ex “d” IIA/IIB T2 or Ex “e” IIA/IIB T2.
IX. PB – G:
Observation:
• Micronizer (G/MCR 001)is located in the G block

• Compressed air is used for milling process.
Hazardous area classification – PB – G:

Grade of
release
bility
1 Micronizer Secondary Artifici Enclosed Fair Medium Zone 1m from the
22 hazardous
location
(Considering the
operation of dust
collector)
2 Wash area Primary Artifici Enclosed Fair Medium Zone 1 Zone 1
al Entire area is zone
1
Summary – PB – “G”:
T* or Ex “td” *
results
• In wash area, all the electrical equipments shall be of type Ex “d” IIA/IIB T3.
• Megafine can consider replacing compressed air with N2 for the micronizing process.
72
X. PB – E:
Observation:
• E/FBD equipment and Multimiller CMM -001 are located in the E – block
• Ventilation is artificial through AHU.
Hazardous area classification – PB – E:

Grade of
release
bility
1 FBD Cleaning Primary Artifici Enclosed Fair Medium Zone 1 Zone 1
al Area
2 FBD Unloading Primary Artifici Enclosed Fair Medium Zone Zone 22
al 22
3 Multimiller Secondary Artifici Enclosed Fair Medium Zone Area is classified as

al 22 Zone 22 location
on consideration of
presence of dust
collection system
and if dust handled
is combustible.
multimiller al
Summary – PB – “E”:
• Entire FBD room is classifies as zone 1. All the electrical equipments shall be of type Ex “d” IIA/IIB T3.
73
XI. Recovered Solvent Storage Tanks:
Observation:
• 12 nos. of recovered solvent storage tanks are deployed.
• Tank no. 10, 11, and 12 are of 3 kL capacity and are dedicated for Toluene storage.
• Spent solvent is stored in the 6 tanks.
• Tanks are located in the open area with free ventilation
• It was informed that all storage tanks will be blanketed with nitrogen
Hazardous area classification – Source data sheet

Grade of
release
bility
1 Storage Tank Primary & Natural Open Fair Medium Zone 1 1.5 m around vent
vent fitted with secondary + in all directions is
flame arrester Zone 2 zone 1 and from
1.5 m upto 3 m
around vent in all
2 Storage tank Secondary Natural Open Fair Medium Zone 2 A distance of 3m in
pipe line valves, all directions from
fittings and valves, fittings and
flanges flanges.
3 Storage Tank Secondary Natural Open Fair Medium Zone 1 Space around the
Dyke wall storage tank in all
the directions upto
dyke or 3m.
4 Solvent Transfer Secondary Natural Open Fair Medium Zone 2 3m horizontally &
pump 1 m above ground
Summary – PB – Recovered solvent storage Tank:
• A distance of 3 m from the storage tank is considered as Zone 1.
74
XII. SRP:
Observation:
• Reactors SSR -001, SRP/SSR -004, GLR 001, are located.

• Process of solvent recovery is through fractional distillation.
• Area is well ventilated and open.
• It was informed that administrative control has been taken in such a manner that adjacent
Hydrogenation reactor process will not be carried out when SRP plant is running as a safety factor.
Hazardous area classification – SRP Flammable material list and characteristics
o
(°C) ( C) (o C)
1. Ethanol 12 1.59 78 3.1 19.0 400 T2 IIB
3. Acetone -20 2.0 56 2.5 14.3 399 T2 IIA
6. Toluene 4 3.20 111 1.1 7.1 480 T1 IIA
7. Hydrogen 0.1 4 75 500 T1 IIC
Hazardous area classification – SRP

Grade of
release
bility
1.5 m upto 3 m
around vent in all
2 Bottom Transfer Secondary Natural Open Fair Medium Zone 2 A distance of 3 m

adapter of SRP around valve,
3 Collection of Primary Natural Open Fair Medium Zone 1 A distance of 2m
solvents or from the reactor in
while manual area.
cleaning of
reactors from
bottom reactor
valve or adapter
75
4 Opening of Primary Natural Open Fair Medium Zone 1 A distance of 2m
reactor manhole + from the reactor in
is zone 2 hazardous
area.
5 Sampling Primary Natural Open Fair Medium Zone 1 A distance of 2m

collected in the from the reactor
bucket or from the sample
port in all
directions is Zone
1.
6 Addition of Primary Natural Open Fair Medium Zone 1 1m from the
solvent to the solvent charging
AOD pump
7 Condenser & Secondary Natural Open Fair Medium Zone 2 A distance of 3 m
reflux / vapour around valve,
flange leaks in
4th floor
8 Cooling Tower Secondary Natural Open Fair Medium Zone 2 A distance of 3 m
(3rd Floor)
9 Receiver tank Secondary Natural Open Fair Medium Zone 2 A distance of 3 m
(5th Floor)
10 Distillation Secondary Natural Open Fair Medium Zone 2 A distance of 3 m
column (2nd
Floor)
Summary - SRP:
• SRP area will be classified as Zone 1.

Recommendations - SRP:
• High flame path gap was observed on the for T2 Temperature J2. All allen bolts shall be provided and
tightened fully to meet the required flame path gap in the Ex enclosure.
• Temperature indicator (conde no: SRP1 TCH -001/T1) was found to be cracked and bolts are found to
be missing. All allen bolts shall be provided and tightened fully to meet the required flame path gap in
the Ex enclosure.
76
• Unused gland hole was observed to the light fitting near new GLR. It shall be sealed using flame proof
blanking element.
• Non Ex automatic level controller shall be replaced using flame proof and intrinsically safe level
controller.
• Non Ex gland has been used to terminate the cable for EX “d” IIC Telephone. It shall be replaced with
flame proof type double compression gland.
XIII. Hydrogenation Block:

Observation:
• Hydrogen reactor GLR -001 is located in the open area. It is close to the SRP area.
• 4 cylinders of pressurized at 150 kg/cm2 are provided for charging the reaction
• When the hydrogen is charged to the process reactor, pressure is reduced to 8 kG/cm2.
• From reactor vessel, reaction mass is transferred through sparkler filter.
• Reaction mass is added through scoop to the charging port.
Hazardous area classification – Hydrogenation – 1st & Ground floor

Grade of
release
bility
1 Vents of 1000 L Secondary Natural Open Fair Medium Zone 2 A distance of 1 m
tank passing to around the dump
dump tank tank vent is Zone 2.
2 1000 L & 500 L Secondary Natural Open Fair Medium Zone 2 A distance of 4.5 m
reactor and around valve,
Flanges, valves fitting and flanges
fittings of and further 8m
hydrogen line vertically is zone 2.
and solvent line
solvents or from the reactor in
while manual area.
cleaning of
reactors from
bottom reactor
valve or adapter
77
4 Powder Primary Natural Open Fair Medium Zone 1 Zone 1
charging
through port
5 Sampling port Primary Natural Open Fair Medium Zone 1 A distance of 1m

from the reactor
or from the sample
port in all
directions is Zone
1.
6 Dump Tank Secondary Natural Open Fair Medium Zone 2 A distance of 1 m
around valve,
fitting and flanges
and tank is zone 2.
7 Sparkler filter, Secondary Natural Open Fair Medium Zone 2 A distance of 3 m
Effluent transfer from the pump.
pump
8 Oil Vacuum Secondary Natural Open Fair Medium Zone 2 A distance of 4.5 m
pump for from the pump.
Hydrogen
reactor
9 Distilled Secondary Natural Open Fair Medium Zone 2 A distance of 3 m
Toluene Tank, from the pump.
pipeline and
flanges
10 Distilled Primary & Natural Open Fair Medium Zone 1 1.5 m around vent
Toluene Tank secondary + in all directions is
Vent Zone 2 zone 1 and from
1.5 m upto 3 m
around vent in all
Summary - Hydrogenation:
• Hydrogenation reactor area will be classified as Zone 1.

• Electrical equipments shall be with the specification Ex d IIC T3 and instruments mounted on the
process equipments shall be Ex ia IIC T3.
Recommendation - Hydrogenation:
• It shall be ensured that explosion proof clock near the hydrogen cylinder shall be suitable for the
hydrogen gas area and it shall be of specification Ex “d” IIC T3.
• Unused gland hole was observed for the push button station of sparkler filter. It shall be replaced with
flame proof type blanking element.
78
• Effluent treatment pump was of flameproof type with specification Ex “d” IIA/ IIB. It shall be replaced
with EX “d” IIC T3.
XIV. ETP:
Observation:
• It was informed that only low TDS liquid are sent to ETP and neutralizer tank. Therefore, concentration
of the flammable solvent may be less and the ETP shall be considered as hazardously non classified.
XIV. MEE:
Observation:
• High TDS solvent are heated in the MEE to evaporate the waste and solvent is collected.
• Ventilation is open air.
• High TDS solvent is stored in the tank.
Hazardous area classification – MEE

Grade of
release
bility
1 High TDS Pit Secondary Natural Open Fair Medium Zone 2 Interior of tank up
to ground level is
Zone 1 hazardous
location. 0.5 m
above the tank and
extending 3m
laterally from the
tank is Zone 2
hazardous location.
2 Transfer pump, Secondary Natural Open Fair Medium Zone 2 A distance of 3m

pipe line flanges from the storage
and valves tank is zone 2.
solvents and from the barrel
charging in the filling is zone 1 and
barrel further distance of
0.5 m is zone 2.
Summary - MEE:
• Electrical equipments shall be with the specification Ex d IIA/IIB T3 in Zone 1 and it shall of Ex d or Ex
“e” IIA/IIB T3 in Zone 2 region.
79
DG Diesel Day Tank , Diesel Fire pump day tank and Canteen LG:
Summary:
• A distance of 3m from the diesel day tank, fire pump day tank, LPG cylinder and pipelines shall be
classified as zone 2.
• It shall be ensured that vent of diesel day tank shall be let out to free open space.
Summary & Recommendations– Diesel & LPG
• Any electrical installation within the 3m from the diesel tank or pipeline shall be of flame proof with
the specification Ex “d” IIA/IIB T3 or Ex “e” IIA/IIB T3 .
• Any electrical installation within the 3m from the LPG cylinder or pipeline shall be flameproof with
specification Ex “d” IIA/IIB T2. Power supply socket was observed adjacent to the LPG cylinder. It
shall be discarded or replaced with flameproof socket of type Ex “d” IIA/IIB T2 or Ex “e” IIA/IIB T2.
TFH Oil:
• From MSDS information, Flash point of heater oil was found to be 220 °C. Therefore, if oil is heated
above its flash point then the TFH area will be classified as zone 2 and flame proof equipment shall
be installed with the specification Ex “ d” IIA/IIB T2 or Ex “ e” IIA/IIB T2.
XV. QC, VC, R & D, XRD Lab & Potentiometer Lab:

Observation & Recommendations:
According to International and Indian standards, Laboratories are not considered for Hazardous
classification, provided good and standard storage practice and engineering controls are followed.
• Solvent container of 30 Liters capacity has been provided at the wash area of QC lab. Quantity of
single barrel shall be restricted below 20 Litres.
• VC Wash area is not provided with the spot extractors and spot extractor was found to be in off
condition in QC lab. Spot extractors shall be provided in all the washing areas in vicinity and ensured
that it will be in the working condition. Megafine can even consider installing spot extractors at HPLC
areas
• Spot extractor LEV was also not provided in the potentiometer lab washroom area.
• 10 litres of solvent HDPE (4 nos) container are stored in the area below fume hood. Area below fime
hood shall not be used to store solvent containers.
• 35 L waste solvent storage barrel was observed in the R & D unit. Quantity of single barrel shall be
restricted below 20 Litres.
• GCs are installed and the hydrogen cylinder for the same has been installed in the corridor, which was
found to be closed to the Ac compressor unit. A distance of 4.5 m clearance shall be maintained.
80
• Chemical storage room will be classified as zone 2 and all electrical equipment shall be of flame proof
type with the specification Ex “d” IIA/IIB T3 or Ex “e” IIA/IIB T3.
XVI. Pilot Plant:

Observation:
• Pilot plant consists of equipments made of glass

• Ventilation is natural but obstructed.
Hazardous area classification – Pilot Plant

Grade of
release
bility
1.5 m upto 3 m
around vent in all

while manual area.
cleaning of
reactors from
bottom reactor
valve or adapter

is zone 2 hazardous
area.

81
area.
flange leaks ( for
reactors which
has condenser)
8 Leakage from Secondary Artificial Enclose Fair Medium Zone 1 A distance of 3 m
centrifuge d around valve,
charging lines fitting and flanges
9 Centrifuge Secondary Natural Obstruc Fair Medium Zone 2 A distance of 3 m

solvent line and ted around valve,
ML (mother fitting and flanges
liquor) line, ML
Tank
10 Centrifuge Primary Artificial Enclose Fair Medium Zone 1 Zone 1
Cleaning with d Area
solvent
11 Leak from Secondary Natural Obstruc Fair Medium Zone 2 A distance of 3 m
Centrifuge ted around valve,
solvent line fitting and flanges
Summary & Recommendation– Pilot Plant:
• Piot Pant area is classified as Zone 1.

• Allen bolt was found to be missing for door sensor switch. Openings or inadequate fastener tightening
in the flameproof enclosure will result in loss of integrity and efficiency to perform as flame proof.
82
XVII. PB – H:
PB – H – 1st Floor:
Observation:
• Reactors such as H/SSR -003, H/SSR -002, H/GLR -002, H/SSR -001 and F/GLR – 001 are located in the
first floor.
• Ventilation is artificial with AHU.
Hazardous area classification – PB “H” – 1st Floor Area - Source data sheet

Grade of
release
bility
1.5 m upto 3 m
around vent in all

while manual area.
cleaning of
reactors from
bottom reactor
valve or adapter

is zone 2 hazardous
area.

83
area.

flange leaks ( for
reactors which
has condenser)
7 Vapours while Primary Artificial Obstruc Fair Medium Zone 1 2 m from the
unloading ted / centrifuge in all the
material from Enclose directions is
centrifuge d Area classified as Zone
1.
In enclosed
centrifuge room,
entire room is
8 Centrifuge Secondary Natural Obstruc Fair Medium Zone 2 A distance of 3 m
solvent line and ted & around valve,
ML (mother Enclose fitting and flanges
liquor) line d
9 Centrifuge Primary Natural Obstruc Fair Medium Zone 1 Zone 1 Entire area
Cleaning and ted &
equipment Enclose
cleaning in same d
place
10 Valves, Fittings Secondary Artificial Enclose Fair Medium Zone 2 A distance of 3 m
of Nutsche filter d Area around valve,
fitting and flanges
11 Nutsche filter Primary Artificial Enclose Fair Medium Zone 1 Entire ANFD room
cleaning activity d Area
12 ML and receiver Secondary Artificial Enclose Fair Medium Zone 2 A distance of 3 m
tank of Nutsche d Area around valve,
filter fitting and flanges
Summary - PB “H” – 1st Floor Area:
• Entire area of PB – H – 1st floor is classified as zone 1.
84
PB – H – 2nd Floor:
Summary – PB -H – 2nd Floor:

• H/GLR -004, H/SSR -004 and centrifuge -002 are located.
• Entire area is classified as Zone 1.
• Washing area in the 2nd floor Mezzanine is classified as Zone 1.
PB – H (API):
Observation – PB – H (API):
• RCVD, Multimill, sifter, VTD are located.
Hazardous area classification – PB “H” – API Floor Area - Source data sheet

Grade of
release
bility
1 Tray dryer Primary Artifici Enclosed Fair Medium Zone 1 Zone 1
cleaning al Entire area is zone
1
2 Tray dryer Primary Artifici Enclosed Fair Medium Zone 2 Zone 2 / Zone 22
material al / Zone (During unloading
unloading 22 of powder after
drying, vapour
content may be
small
22 hazardous
location
(Considering the
operation of dust
collector)
4 RCVD mopping Primary Artifici Enclosed Fair Medium Zone 1 Zone 1
with solvent al
5 Multimiller Secondary Artifici Enclosed Fair Medium Zone Area is classified as
al 22 Zone 22 location
on consideration of
presence of dust
collection system
and if dust handled
is combustible.
multimiller al
85
Summary – PB -H – API:
• Entire area of PB – H – API is classified as zone 1.
Summary – PB -H – 3rd Floor:

• AHU unit and dust collector are located.
Hazardous area classification – PB – H Service area:

Grade of
release
bility
1 Dust Collector Primary Natural Open Fair Medium Zone A distance of 1m
Manhole 22 from the reactor
opened to manhole
remove the is Zone 21.
filter bag
collector 21
chamber – dirty
side of the filter
collector 22
chamber –
Clean side of the
filter
Summary – PB – “ H ” Service Area:
• A distance of 1m from the dust collector manhole is considered as zone 22. This is applicable across all
dust collectors in the plant.
• All electrical fittings shall be suitable to dust type and with specification Ex d IIA/IIB T* or Ex “td” *
results
86
XVIII. Warehouse:
Observation and Summary – Warehouse:
• Warehouse I, II, III, IV, V are used for the storage of raw material powder in the paper fiber drum.
• Sample dispensing of powder is carried out under RALF.
• Therefore, warehouse area is considered to be hazardously unclassified area.
XIX. AG Storage Tank:

Observation – AG Storage Tank:
• Storage tanks such as SSST /14 (15 kL – Ethyl acetate), MSST /05 (13 kL - Aqueous Ammonia),
SSST/01(13 kL – Ethyl acetate), SSST/02 (13 kL – MDC), MSST/08 (6 kL – MDC), MSST/07 (6 kL – MDC)
• IPA Tanks SSST 03 (7 kL), SSST – 04 (7 kL) and MSST 06 (12 kL) are also located.
• All the tanks are located in the open area.
• SSST/14 tank provided with safety vent and SSST/01 tank provided with open vent.
• Nitrogen blanketing is carried out only during storage tank filling.
• Vent of the storage tank is open to the transformer
Hazardous area classification – Flammable material list and characteristics
(°C) (o C) (o C)
2. IPA 12 2.1 83 2 12.7 399 T2 IIA
Ammonia
Hazardous area classification – AG Storage Tank

Grade of
release
bility
1. Storage Tank Primary & Natural Open Fair Medium Zone 1 1.5 m around vent
vent secondary + in all directions is
1.5 m upto 3 m
around vent in all
2. Storage Tank Secondary Natural Open Fair Medium Zone 2 3m around the
Pipeline, valves, valve, fittings and
fittings and flanges or up to
87
flanges bund wall
whichever is
greater
3. Pits or Primary Natural Open Fair Medium Zone 2 Any pits or
depression in depressions Zone
tank farm area 1, because of
greater tendency
of heavier than air
Vapour to persist
4. Solvent Transfer Secondary Natural Open Fair Medium Zone 2 3 m from the pump
pumps
Hazardous area classification – Tanker Unloading

Grade of
release
bility
1. Tank Filing fixed Primary Natural Open Fair Medium Zone 1 A distance of 1.5m
pipe point in all the direction
2. Flanges of Secondary Natural Open Fair Medium Zone 2 3m around the
pipeline valve, fittings and
flanges
3. Tanker bottom Primary Natural Open Fair Medium Zone 1 A distance of 1.5m
loading in all directions
adaptors extending up to
ground level.
4. Tanker vent Primary & Natural Open Fair Medium Zone 1 1.5m around the
Secondary vent in all
directions
5. Opening of tank Primary Natural Open Fair Medium Zone 1 A distance of 1.5m
hatches at the in all the direction
top of tanker
6. Manual Primary Natural Open Fair Medium Zone 1 A distance of 1.5m
sampling at the in all the direction
top of tank and extends 2m
hatch vertically
7. Tanker Secondary Natural Open Fair Medium Zone 2 Zone 2. 3m radius
Unloading from the tanker
connections unloading
connections.
88
Summary:
• A distance of 3m from the storage tanks containing flammable liquid SSST/14, SSST/01, SSST 03, SSST
04, MSST 06 in all directions is classified as Zone 1 hazardous location Pit/depressions in the tank farm
area is Zone 1 hazardous location and a distance of 1.5m from the storage tank vent is Zone 1
hazardous location.
• A distance of 1.5 m in all directions up to the ground level from the tanker bottom loading adaptors is
classified as Zone 1 hazardous location and further a distance of 3m from the unloading pipe
connections is classified a Zone 2 hazardous location and its extends 0.63 m vertically above the
ground level.
• Electrical equipments shall be with the specification Ex d IIA/IIB T2 and instruments mounted directly
on the storage tanks shall be Ex ia IIA/IIB T2
XX. UG Storage Tank:

Observation – AG Storage Tank:
• UG storage tanks SSST 05 (Methanol), SSST 06 (Acetone), SSST 07 (Toluene), SSST 08 (Ethanol), SSST
09(Methanol) of each capacity 30 kL are located.
• UG storage tanks are blanketed with Nitrogen.
Hazardous area classification – Flammable material list and characteristics
o
(°C) ( C) (o C)
1. Methanol 9 1.11 65 6 36 440 T2 IIA
2. Acetone - 20 2.0 56 2.5 14.3 539 T1 IIA
3. Toluene 4 3.20 111 1.1 7.1 480 T1 IIA
89
4. Ethanol 12 1.59 78 3.1 19.0 400 T2 IIB
Hazardous area classification – UG Storage Tank

Grade of
release
bility
1. Storage Tank Primary & Natural Open Fair Medium Zone 1 1.5 m around vent
vent (Blanketed secondary + in all directions is
with Nitrogen) Zone 2 zone 2 and from
1.5 m upto 3 m
around vent in all
2. Storage Tank Secondary Natural Open Fair Medium Zone 2 3m around the
Pipeline, valves, valve, fittings and
fittings and flanges or up to
flanges bund wall
whichever is
greater Zone 2.
3. Pits or Primary Natural Open Fair Medium Zone 2 Any pits or
depression in depressions Zone
tank farm area 1, because of
greater tendency
of heavier than air
Vapour to persist
4. Solvent Transfer Secondary Natural Open Fair Medium Zone 2 3 m from the pump
pumps
Summary:
• A distance of 3m from the storage tank in all directions is classified as Zone 2 hazardous location
Pit/depressions in the tank farm area is Zone 1 hazardous location and a distance of 1.5m from the
storage tank vent is Zone 2 hazardous location.
• A distance of 1.5 m in all directions up to the ground level from the tanker bottom loading adaptors is
classified as Zone 1 hazardous location and further a distance of 3m from the unloading pipe
connections is classified a Zone 2 hazardous location and its extends 0.63 m vertically above the
ground level.
• Electrical equipments shall be with the specification Ex d IIA/IIB T2 and instruments mounted directly
on the storage tanks shall be Ex ia IIA/IIB T2
90
XXI. Dispensing Room & Barrel Storage Room:
Dispensing Room – Observations & Recommendations:
• Dispensing solvent activity takes place.

• Solvents such as acetonitrile, DMF, DIP and N-Heptane are dispensed.
• Entire area is classified as Zone 2.
• Non Ex motor has been provided for the blower. It shall be replaced with flame proof blower motor
with the specification Ex “d” IIA/IIB T3 or Ex “e” IIA/IIB T3.
Dispensing Room – Observations & Recommendations:
• Solvent barrel is stored in the barrel room.

• Entire barrel storage area is classified as Zone 2.
• All the electrical equipments shall be of flameproof type with the specification Ex “d” IIA/IIB T3 or Ex
“e” IIA/IIB T3.
91
Annexure – A - Ventilation ACPH details Shared by Megafine:
Block wise List of ACPH for Classified area

Sr
Capacit ACP
no Location AHU/VU Remark
y H
.
Micro Lab
1 Buffer Room 66.11
2 Change Room-I 38.07
3 Passage 86.07
4 Documentation room 51.3
5 Entry air lock 57.02
6 Change Room-II 57.37
MB/AHU-001 8500 CFM
7 Air lock-II 70.55
8 Return air lock 80.83
9 Material room 45.02
10 Media preparation room 50.69
11 Incubator room 55.02
12 Wash room 33.31
Warehouse-I (Repacking area)
1 Repacking area 34.55
2 Material In/Out WH/AHU-003 1091 37
3 Change room 30.21
Warehouse-III
1 Change room-I 52.99
2 Dispensing booth area 55.36
WH/AHU-002 3756 CFM
3 Change room-II 54.29
4 Sampling & dispensing booth area 42.47
Warehouse-IV
1 Change room 42.96
2
Primary packing material storage area 55.67
3 Sampling & testing area WH/AHU-001 3863 CFM 29.62
4 Quarantine room 47.85
5 Buffer Room 51.87
6 Receiving & dispensing area 69.42
Production Block-D
1 Change room 41.39
2 Centrifuge Room VU-301 9498 CFM 31.73
3 Material air lock 60.71
92
4 wash & ancillary room 72.15
5 Reactor area 56.15
6 staircase 25.27
Production Block-C & D
1 Change room 43.44
2 Repacking area 12317 30.23
VU-302
3 wash & ancillary room-C CFM 22.42
4 wash & ancillary room-D 22.8
Production block-E
1 Air lock-I 37.93
2 Change room 27.4
3 FBD Area 38.13
4 Air lock-II 56.14
5 Wash room E/AHU-001 5850 CFM 30.23
6 Ancillary area 28.3
7 Sifter, milling & packing room 33.84
8 Intermediate F.G area 41.39
9 Material In/Out 38.78
Production block-J (API)
1 Air lock 84.4
2 Change room 28.63
3 Reactor area 11456 37.69
J/AHU-001
4 Filteration & drying area CFM 32.68
5 Wash room 52.02
6 Buffer Room 93.13
DMB-C
1 Air lock-I 81.31
2 Change room 62.65
3 clean corridor 40.16
4 Air Lock-II 10633 57.88
AHU-301
5 Packing room CFM 83.02
6 RCVD Room 54.2
7 Milling & sifting room 76.41
8 wet material storage area 43.05
DMB-F
1 WIP Room 40.73
2 Quarantine room 29.46
3 Finish goods storage room AHU-502 5243 CFM 41.51
4 Packing material in 32.86
5 packing area 37.13
Production Block-F
93
1 Air Lock 59.15
2 Centrifuge area 30.56
3 Material In/Out F/AHU-001 9746 CFM 41.32
4 Wash room 24.2
Production Block-G
1 Air Lock-I 44.06
2 Air Lock -II 40.85
AHU-503 2820 CFM
3 Microniser room 29.1
4 Wash room 59
Production Block-H(API)
1 Air lock 52.77
2 Change room 50.08
3 Centrifuge area H/AHU-001 4762 CFM 34.37
4 Dryer, Sifter & Milling Room 36.26
94
S
E W
N
Zone 1 Ex d IIA/IIB T3
A/GLR - 002 A/SSR - 010 A/SSR - 004 A/SSR - 003 A/SSR - 002 A/SSR - 001
Capacity 630 Ltr. Capacity 600 Ltr. Capacity 600 Ltr. Capacity 600 Ltr. Capacity 600 Ltr. Capacity 600 Ltr.
MOC MSGL MOC SS 316 MOC SS 316 MOC SS 316 MOC SS 316 MOC SS 316
A/GLR - 002 A/SSR - 010 A/SSR - 004 A/SSR - 003 A/SSR - 002 A/SSR - 001
DN
A/SSR - 007 A/GLR - 001 A/SSR - 006 A/SSR - 008 A/GLR - 003
Capacity 1200 Ltr. Capacity 1000 Ltr. Capacity 2000 Ltr. Capacity 2000 Ltr. Capacity 1000 Ltr.
MOC SS 316 MOC MSGL MOC SS 316 MOC SS 316 MOC MSGL
A/SSR - 007
A/SSR - 006 A/SSR - 008 OPEN UP TO
A/GLR - 001 A/WT - 001 A/GLR - 003 GROUND FLOOR
Capacity 400 Ltr.
MOC SS 316
A/WT-001
MEZZANINE FLOOR
EE
A/SSCF - 007 A/SSCF - 004 A/SSCF - 005

Capacity 36" Dia. Capacity 48" Dia. Capacity 36" Dia.
MOC SS 316 MOC SS 316 MOC SS 316 A/SSCF - 006
Capacity 48" Dia.
A/SSCF - 007 A/SSCF - 004 A/SSCF - 005
MOC SS 316
UP CENTRIFUGE
A/SSCF - 006
ROOM
PRODUCTION AREA
UP
GROUND FLOOR
S
Title :- EQUIPMENT LAYOUT - DMB AREA (PB-A)
E W
A/TD - 002 A/TD - 004

TI TI
A/TD - 002 A/TD - 004
SCRUBBER
Capacity 48 Trays Capacity 48 Trays
SOLVENT
MOC SS 316 MOC SS 316
PASSAGE
AREA
CENTRIFUGE ROOM TRAY DRYER TRAY DRYER
ROOM ROOM
Zone 22 Zone 22
PASSAGE
INTERMEDIATE /
UP
F.G. STORE - 1
HOIST
PASSAGE
AIR
LOCK
WASH & UNDER QUARANTINE &
ANCILLARY APPROVED MATERIAL Zone
WASH
1 Ex d IIA/IIB T3
ROOM STORAGE ROOM
ROOM
Zone 22 F.G. STORAGE

1.5 M CORRIDOR
ROOM
MULTIMILL
AREA
A/MM - 001 A/BL - 002
Capacity 1500 Ltr.
A/MM - 001 A/BL - 002
MOC SS 316
Capacity 100 Kg/Hr. SIFTER ROOM
MOC SS 316
BLENDER, SIFTER
A/SFT - 001
& PACKING ROOM
A/SFT - 001
Capacity 30" Dia.
MOC SS 316
A/SFT - 002 INTERMEDIATE /
A/SFT - 002
F.G. STORE - 2
Capacity 30" Dia.
Zone 22 TRAY DRYER

ROOM - I
TRAY DRYER
ROOM - II
MOC SS 316
CHANGE A/TD - 003

48 Trays
A/TD - 001
Capacity Capacity 48 Trays
ROOM MOC SS 316 MOC SS 316
Zone 22
A/TD - 003 A/TD - 001
COB TI
TI
CHANGE
ROOM F.G. OUT
AIR LOCK
COB
SERVICE AREA SERVICE AREA

RAMP
Zone 22
PERSONNEL GROUND FLOOR
ENTRY
S
E W
Title :- EQUIPMENT LAYOUT - PRODUCTION AREA (PB-B)
B/SSCF-001 B/VTD-001
EE
Zone 22
Capacity 36" Dia. Capacity 48 Trays
B/SSCF-001
B/VTD - 001
CENTRIFUGE ENTRY
ANCILLARY EE
SERVICE
VTD WASH ROOM
ROOM
SERVICE ROOM ROOM DRYER
ROOM ROOM
ROOM
B/SSCF-002
PRODUCTION AREA Capacity 24" Dia.
B/SSR-001 B/GLR-005 B/SSCF-003 B/GLR-003 B/WT-001 B/SSR-006 MOC SS 316
UP
HOIST Capacity 2000 Ltr. Capacity 2000 Ltr. Capacity 48" Dia. Capacity 250 Ltr. Capacity 2400 Ltr. Capacity 190 Ltr.
B/SSCF-002
MOC SS 316 MOC MSGL MOC SS 316 MOC MSGL MOC SS 316 MOC SS 316
B/SSR-001 B/GLR-005 B/GLR-003 B/SSR-006

B/WT-001
1.20 M CORRIDOR
B/SSCF-003
UP
UP DN
2.00 M SERVICE AREA
EE
SECOND FLOOR
S
E W
Title :- EQUIPMENT LAYOUT - PRODUCTION AREA (PB-B)
UP
ANCILLARY
CHEMIST OFFICE STORE ROOM WASH ROOM SERVICE ROOM
EE ROOM
EE
B/SSR-002 B/SSR-003 B/SSR-007 B/GLR-002 B/GLR-006 B/SSR-004 B/SSR-005 B/GLR-007
Capacity 3000 Ltr. Capacity 3000 Ltr. Capacity 3000 Ltr. Capacity 2000 Ltr. Capacity 1600 Ltr. Capacity 1000 Ltr. Capacity 1000 Ltr. Capacity 2000 Ltr.
HOIST
MOC SS 316 MOC SS 316 MOC SS 316 MOC MSGL MOC MSGL MOC SS 316 MOC SS 316 MOC MSGL
B/SSR-002 B/SSR-003 B/SSR-007 B/GLR-002 B/GLR-006 B/SSR-004 B/SSR-005 B/GLR-007
PRODUCTION
AREA
1.20 M CORRIDOR
DN
UP DN
2.00 M SERVICE AREA
EE
THIRD FLOOR
S
EQUIPMENT LAYOUT - CLEAN ROOM AREA (PB-C) E W
N
EE
ML TANK ROOM
EE
C/HLCF - 001
Capacity 36" Dia.
C/HLCF - 001
MOC SS 316 C/GLR - 001
Capacity 1000 Ltr.
MOC MSGL
Zone 1 Ex d IIA/IIB T3 CENTRIFUGE ROOM REACTOR AREA
UP UP DN
C/GLR - 001
PB
C
O CHANGE
B ROOM
PB
AIR
LOCK-III WASH ROOM ANCILLARY
WET MATERIAL
STORAGE ROOM
PB FIRST FLOOR
C/VTD - 001 C/VTD - 001
SERVICE
Capacity 12 Trays
AREA
MOC SS 316
C/RCVD - 001
VTD Capacity 300 Lit.
ROOM MOC SS 316
C/MM - 001 C/MM - 001
Zone 22 C/RCVD - 001
Capacity 100 Kg/Hr.
SIFTER &
MOC SS 316
MULTIMILL RCVD ROOM
ROOM
2.50 M CORRIDOR
C/SFT - 001
Capacity 30" Dia.
MOC SS 316 C/SFT - 001
C/BL - 001
CORRIDOR
C/BL - 001 Capacity 250 Lit.
MOC SS 316
PB
BLENDING ROOM
ANCILLARY
ROOM
Zone 22
WASH ROOM
PACKING ROOM
AIR LOCK - II PB
C
CHANGE
AIR LOCK - I ROOM
O
MATERIAL
B
IN / OUT
ENTRY ROOM
RAMP
GROUND FLOOR
S
EQUIPMENT LAYOUT - CLEAN ROOM AREA (PB-D) E W
EE
DN
D/SSCF - 001
Capacity 48" Dia.
MOC SS 316 UP
Zone 1 Ex d IIA/IIB T3 D/SSCF - 001
D/SSR - 001
Capacity 3000 Ltr.
EE D/GLR - 001
Capacity 3000 Ltr.
MOC SS 316
MOC MSGL D/SSR - 001
D/GLR - 001
REACTOR AREA
CENTRIFUGE ROOM Zone 1 Ex d IIA/IIB T3
CHANGE
WASH ROOM
ANCILLARY MAL
ROOM COB
ROOM
PB
AIR LOCK
1.78 M CORRIDOR PB
FIRST FLOOR
PB D/RCVD - 001
D/RCVD - 001
WET MATERIAL Capacity 2000 Lit.
STORAGE MOC SS 316
RCVD ROOM
2.75 M CORRIDOR
WASH ROOM
ANCILLARY
2.50 M CORRIDOR
ROOM
AIR LOCK
PASSAGE
PACKING ROOM
Zone 22
D/SFT - 001
MULTIMILL & SIFTER Capacity 30" Dia.
ROOM MOC SS 316
D/MM - 001
D/SFT - 001
D/MM - 001
Capacity 100 Kg/Hr.
PB MOC SS 316
QUARANTINE
C CHANGE
O ROOM AIR LOCK
F.G. STORE B
ENTRY ROOM
MATERIAL F.G. LOADING BAY

IN / OUT
RAMP
GROUND FLOOR
S
E W
Title : EQUIPMENT LAYOUT - CLEAN ROOM AREA (PB-E) N
PB E/MM - 001
ANCILLARY E/MM - 001

ROOM Capacity 100-250 Kg/Hr.
MOC SS 316
MULTIMILL, SIFTER
& PACKING ROOM
E/SFT - 001
WASH ROOM Capacity
MOC
30" Dia.
SS 316 E/SFT - 001
Zone 22
EE
FBD ROOM
M
O
T
O
R
INTERMEDIATE / F.G.
E/FBD - 001 STORAGE ROOM
S.P.
Capacity 120 Kg.
MOC SS 316
H
E
P
A
E/FBD - 001 F
I
L
T
E
R
H
E
A
T
I
N
G
C
O
I
L
Material In / Out
PASSAGE
PB
CHANGE
ROOM
COB
RAMP
AIR
LOCK
GROUND FLOOR
S
E W
N
F/SSR - 001
DN
Capacity 2500 Ltr.
MOC SS 316 F/GLR - 002
EE
HOIST Capacity 3000 Ltr.
MOC MSGL
REACTOR AREA
F/SSR - 001
F/GLR - 002
DPB
UP DN
2.00 M SERVICE AREA
EE
F/TD - 001
PB TI
F/MM - 001
F/MM - 001
F/TD - 001
Capacity 100 Kg / Hr.
Capacity 96 Trays
SERVICE AREA
MOC SS 316
MOC SS 316
F/RCVD - 001
PACKING
ANCILLARY
Capacity 1000 Lit.

WASH MULTIMILL &
MOC SS 316
TRAY DRYER ROOM ROOM
ROOM
ROOM SIFTER ROOM

Zone 22
F/RCVD - 001
RCVD ROOM
Zone 22
F/SFT - 001
F/SFT - 001 Capacity 30" Dia.
MOC SS 316
EE
1.20M CORRIDOR
AIR PB
LOCK-2
COB
WORK IN PB
QUARANTINE ROOM FINISHED
PROCESS
ROOM GOODS PM IN
AIR STORAGE
LOCK- 1
EE
MOC
F/SSCF - 001
Capacity 48" Dia.
SS 316
FIRST FLOOR
F/SSCF - 001
UP
CENTRIFUGE ROOM
PAL MAL WASH ROOM

DPB
GROUND FLOOR
S
E W
EQUIPMENT LAYOUT - CLEAN ROOM AREA (PB-G)
G/MCR - 001 G/SFT - 001

Capacity 15-50 Kg/Hr. Capacity 30" Dia.
MOC SS 316 MOC SS 316 AIR
WASH ROOM LOCK - I
PM IN
G/MCR - 001 G/SFT - 001

C AIR
PB MICRONISER ROOM O LOCK - II
B
Zone 22
FIRST FLOOR
S
E W
EQUIPMENT LAYOUT - DMB AREA (PB-I)
H.W. V.G. V.T. H.W. V.G. V.T.
I/VTD - 002 I/VTD - 003
I/VTD - 002 I/VTD - 003

Capacity 48 Trays Capacity 48 Trays
DRYER ROOM - 1
UP
C
O CHANGE
B ROOM
A/MM - 002
PASSAGE
A/MM - 002
Capacity 100 Kg / Hr.
PB
MOC SS 316
MILLING &
SIFTING ROOM
I/SFT - 001
Capacity 30" Dia. I/SFT - 001 PRODUCTION AREA
MOC SS 316
I/TD - 001
TI
I/TD - 001
Capacity 96 Trays
MOC SS 316
DRYER ROOM - 2
UP
H.W. V.G. V.T.
I/VTD - 001
Capacity 48 Trays
MOC SS 316
I/VTD - 001
CHANGE ROOM
INPROCESS MATERIAL
STAGING AREA
UP
PORCH
GROUND FLOOR
S
I/GLR - 002 I/GLR - 008 I/SSR - 001 I/SSR - 002

E W Capacity 3000 Lit. Capacity 2000 Lit. Capacity 1600 Lit. Capacity 1600 Lit.
MOC MSGL MOC MSGL MOC SS 316 MOC SS 316 DN
I/GLR - 008 I/SSR - 001 I/SSR - 002

I/GLR - 002
OPEN UP TO
ANC. AREA
1st FLOOR
DN
SECOND FLOOR
I/SSR - 003
Capacity
MOC
1000 Lit.
SS 316
PRODUCTION AREA
(MEZZANINE FLOOR)
I/SSR - 004 I/GLR - 004 I/GLR - 007
Capacity 1000 Lit. Capacity 500 Lit. Capacity 3000 Lit.
UP
MOC SS 316 MOC SS 316 MOC MSGL
I/SSR - 003
DN
I/GLR - 004 I/GLR - 007 OPEN UP TO

GR. FLOOR
I/SSR - 004
DN UP
FIRST FLOOR
I/SSCF - 002 I/SSCF - 003

Capacity 48" Dia. Capacity 48" Dia.
I/SSCF - 002 I/SSCF - 003

UP
PRODUCTION AREA
UP
CHANGE
ROOM
COB
PB
GROUND FLOOR
S
E W
Title :- EQUIPMENT LAYOUT - PRODUCTION AREA (PB-J) Zone 1 Ex d IIA/IIB T3
J/ANFD - 001 J/SSCF - 005

Capacity 3000 Lit. Capacity 48" Dia.
J/ANFD- 001
HOIST J/SSCF - 005
UTILITY AREA
FILTRATION &
slovent line passing DRYING AREA
above AHU ( Ref Pg:71) UP
WASH EE J/SSCF - 001

Capacity 48" Dia.
WASH
ROOM BUFFER PB MOC SS 316
ROOM
ROOM J/SSCF - 001
UP
CENTRIFUGE AREA
J/SSCF - 002 J/SSCF - 003
Capacity 48" Dia. Capacity 48" Dia. CENTRIFUGE AREA
UTILITY AREA J/SSCF - 002 J/SSCF - 003
J/SSCF - 004
Capacity 48" Dia.
MOC SS 316
J/SSCF - 004
J/SSR - 010
UP Capacity 500 Lit.
MOC SS 316
J/SSR - 010
GROUND FLOOR
S
E W
EQUIPMENT LAYOUT - PRODUCTION AREA (PB-J)
J/SSR - 004
Capacity 10000 Lit.
J/GLR - 004
MOC SS 316
Capacity 6300 Lit.
HOIST
MOC MSGL
UTILITY AREA
J/GLR - 004
J/SSR - 004
BAG STORAGE ROOM J/SSR - 005

Capacity 8000 Lit.
DN MOC SS 316
REACTOR AREA
C AIR
EE CHANGE O
ROOM B LOCK J/SSR - 005
PRODUCTION AREA
UP DN J/GLR - 007 J/SSR - 008 J/GLR - 003
J/SSR - 006
Capacity 5000 Lit.
Capacity 8000 Lit. Capacity 5000 Lit. Capacity 6300 Lit.
MOC SS 316
MOC MSGL MOC SS 316 MOC MSGL
PRODUCTION
COMMUNICATION
J/GLR - 007 J/SSR - 008

J/GLR - 003
AREA J/GLR - 002
Capacity 8000 Lit.
J/SSR - 006
BAY
MOC MSGL
Zone 1 Ex d IIA/IIB T3 DN
J/SSR - 007
J/GLR - 002
Capacity 150 Lit.

MOC SS 316
UP
J/SSR - 007
FIRST FLOOR
S
E W
EQUIPMENT LAYOUT - PRODUCTION AREA (PB-J)
J/SSR - 001
WASH Capacity
MOC
5000 Lit.
SS 316
ROOM
UTILITY AREA HOIST
J/SSR - 001
UTILITY AREA
J/SSR - 002
Capacity 5000 Lit.
MOC SS 316
DN
J/SSR - 002 PRODUCTION
J/GLR - 006
Capacity 6300 Lit.
J/SSR - 009
Capacity 5000 Lit.
J/GLR - 005
Capacity 6300 Lit. AREA
COMMUNICATION
MOC MSGL MOC SS 316 MOC MSGL
J/GLR - 001
Capacity 2500 Lit.
PRODUCTION
BAY
J/GLR - 006 J/GLR - 005 MOC MSGL
J/SSR - 009
AREA
UP
J/GLR - 001
DN
SECOND FLOOR
S
E W
UTILITY AREA
CUTOUT
11.75 X 3.50
CUTOUT
K/GLR - 002
Capacity 6300 Lit.
MOC MSGL
K/GLR - 002
REACTOR AREA
11.75 X 11.00
(Only 2m from reactor

manhole will be
UP
classified as zone)
LIFT AREA
2.10 X 2.40
FIRST FLOOR
S
E W
CUTOUT
UTILITY AREA
11.75 X 3.50
CUTOUT
K/GLR - 003 K/GLR - 001

Capacity 2000 Lit. Capacity 3000 Lit.
MOC MSGL MOC MSGL
K/GLR - 003 K/GLR - 001
REACTOR AREA
11.75 X 11.00
DN
(Only 2m from reactor

manhole will be
classified as zone)
LIFT AREA
2.10 X 2.40
SECOND FLOOR

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HAC Report of Megafine Pharma (P) LTD, Nashik

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HAZARDOUS AREA CLASSIFICATION STUDY

MEGAFINE PHARMA (P) LTD

(A JV between Murugappa Group and Mitsui Sumitomo Insurance Group)

00 23.02.2020 Draft report

Final Report With Comments

Prepared By Reviewed By Approved By

Mr. Hari Kiran M Mr. Gopala Krishnan AM Mr. Gopala Krishnan AM

Cholamandalam MS Risk Services Limited, Chennai (India)

Megafine Pharma (P) Ltd, Nashik

Ground Floor Zone 1 IIA/IIB T3 Ex d IIA/IIB T3

Megafine Pharma (P) Ltd, Nashik

Ground Floor Zone 1 IIA/IIB T2 Ex d IIA/IIB T2

4 PB - D First Floor Zone 1 IIA/IIB T3 Ex d IIA/IIB T3

Ground Floor Zone 1 IIA/IIB T3 Ex d IIA/IIB T3

Sifter & Zone 22 IIA/IIB T* Ex d IIA/IIB T*

Multimiller, Zone 22 IIA/IIB T* Ex d IIA/IIB T*

Wash and Zone 1 IIA/IIB T3 Ex d IIA/IIB T3

1st Floor Zone 1 IIA/IIB T3 Ex d IIA/IIB T3

Ground Floor Zone 1 IIA/IIB T3 Ex d IIA/IIB T3

Sifter, Zone 22 IIA/IIB T* Ex d IIA/IIB T*

Megafine Pharma (P) Ltd, Nashik

1st Floor Zone 1 IIA/IIB T3 Ex d IIA/IIB T3

Ground Floor Zone 1 IIA/IIB T3 Ex d IIA/IIB T3

9 PB - G Micronizer Zone 22 IIA/IIB T* Ex d IIA/IIB T*

Wash Area Zone 1 IIA/IIB T3 Ex d IIA/IIB T3

10 PB -E FBD, Zone 1 IIA/IIB T3 Ex d IIA/IIB T3

Multimiller Zone 22 IIA/IIB T* Ex d IIA/IIB T*

11 Recovered Oudoor Zone 1 IIA/IIB T3 Ex d IIA/IIB T3

Megafine Pharma (P) Ltd, Nashik

13 Hydrogenation Oudoor Zone 1 IIC T3 Ex d IIC T3

14 ETP Oudoor Unclassified

15 MEE Oudoor Zone 1 + IIA/IIB T3 Ex d IIA/IIB T3 in

18 PB - H 1st Floor Zone 1 IIA/IIB T3 Ex d IIA/IIB T3

2nd Floor Zone 1 IIA/IIB T3 Ex d IIA/IIB T3

API (Tray Zone 1 IIA/IIB T3 Ex d IIA/IIB T3

Megafine Pharma (P) Ltd, Nashik

Outdoor Zone 2 IIA/IIB T3 Ex d IIA/IIB T3

Megafine Pharma (P) Ltd, Nashik

Megafine Pharma (P) Ltd, Nashik

Megafine Pharma (P) Ltd, Nashik

Megafine Pharma (P) Ltd, Nashik

Guide for selection and installation of electrical equipments in Hazardous

IS 5572 Classification of Hazardous area other than mines

IEC 60079-10-1 Classification of areas – Explosive gas atmospheres

IEC 60079-10-2 Classification of areas – Combustible dust atmospheres

Recommended Practice for the Classification of Flammable Liquids,

IP 15 Area Classification Code for installations handling flammable liquids

Classification of Areas for Electrical installations at hydrocarbon processing and

Recommended Practice for Classification of Locations for Electrical Installations at

Megafine Pharma (P) Ltd, Nashik

SECTION DESCRIPTION PAGE NO

III OBJECTIVE & SCOPE OF THE STUDY 13

IV HAZARDOUS AREA CLASSIFFICATION METHODOLOGY 17

V CRITERIA FOR HAZARDOUS AREA CLASSIFICAITON STUDY 18

VI HAZARDOUS AREA CLASSIFFICATION CONVENTION 23

VII HAZARDOUS AREA CLASSIFFICATION STUDY MANAGEMENT 27

VIII HAZARDOUS AREA CLASSIFICATION SUMMARY WITH SOURCE SHEETS 29

Megafine Pharma (P) Ltd, Nashik