Safety Always

Week 1

Concepts of Hazard, Exposure, Risk, Accident and Safety

 Safety Always

Hazard any thing with

the Potential to Cause harm

Exposure any object that

hazard is occurred on like
Human Animal Plant Building
and Environment any object that
is exposed to hazard

Risk The degree of Chan

likelihood that the hazard
will Cause harm to someone

Accident An unplanned
unexpected events that results
in Personal injury or Property

damage
 Safety Always

Safety: is any way of Protection against

harm to avoid accident by limiting the sources
of hazard or insulating from being exposed

to that hazard

also is state in which or a place where

you are sale and not in danger or at risk

It's important to realize that safety

is relative

Eliminating all rick if even Possible

would be difficult and very expensive

A sale situation is one where risk

of injury or Property damage are low
and manageable
 Safety Always

Use safety to minimize

minimize hazard by ace

1. Dams

2. Extinguishers

3. Fire resistant doors

4. Enclosures
 Safety Always

minimize Exposure by using

1. Caution Signs.

2. PPE.

3. Assembly point.
 Safety Always

Week 2

Hazard area classifications, zones, identification and

control
 Safety Always

Hazard Classification

• Chemical hazards

• Fire and Explosion

• Oxygen de ciency

• Biological Hazards

• Health Hazards

• Site and Equipment Hazards

• Electrical Hazards

• Environmental Hazards

• Radiological Hazards

Sources of hazard include

gases
vapors and flying which are coibittible
dust or flammable
jet
fibers
 Safety Always

In an plan such as a refinery

industrial
or chemical Plan handling with Lang
quantities of flammable Liquid and gases
creates a risk of exposure

So many regions have present the risk

of a clouds of dust

Consequently many regulations use terms

such as Cuation signs to reduce the
hazard
 Safety Always

É
Hazardous areas are classi ed into zones based on an assessment of
the frequency of the occurrence and duration of an explosive gas
atmosphere, as follows: in

Zone 0 : An area in which an explosive gas

atmosphere is present continuously or
long periods
Zone 1 :
An area in which an explosive gas
atmosphere is likly to occur in normal
operation

Zone 2 :An area in which an explosive gas

atmosphere isn't likly to occur in normal
operation and if it occur will only
exist for a short time
 Safety Always

Various sources have tried to place time limits on to these zones, but none
have been officially adopted. The most common values used are:

• Zone 0: Explosive atmosphere for more than 1000h/yr.

• Zone 1: Explosive atmosphere for more than 10, but less than
1000 h/yr.

• Zone 2: Explosive atmosphere for less than 10h/yr, but still

suf ciently likely as to require controls over ignition sources.
 Safety Always

Duste relating to auto ignition

Classi cation of dusts relating to auto-ignition and minimum ignition
current is undertaken similarly to gases/ vapors, but involves additional
complications. in x

.[Link]
The explicability of dusts is dependent upon a number of factors:

chemical composition
Partical size
oxgen concentration
 Safety Always

Equipment group classi cation:

equipment applies to used in

• Group I :

underground operations such as mines

equipment applies to surface

• Group II :

Processing industries such petrochemical

and chemical Processing industries
 Safety Always

Temperature classification
 Safety Always

Explosion group Type of group Characteristics of group

Gas explosion
group
IIC
Easily ignitable
IIB
Ignitable
IIA Less ignitable

Dust explosion IIIC Conductive dust

group
IIIB Non Conductive
IIIA flammable fibers
Safety Always

Week 3

Hazardous Area Classification Drawing

 Safety Always

Hazardous area classification drawing outlines the classifications

as a
of areas where flammable liquids, gasses or vapors are handed,
t
w processed or stored.
w

us Biv can a [Link] Ii em

It is created based on input from the Process Flow Diagrams, Piping
& Instrumentation Diagrams and the Equipment Location Plan.
[Link] [Link] I i i get

in if
After performing hazardous area classification assessments… the
I
results must be presented
i wa
and communicated [Link]
to staff, personnel,
wow wow stonemason
co-workers, contractors and other third parties in a Hazardous
win
a of the zones and the extent
Area Classification Drawing. The nature
a
of the zones must be presented in a clear way. This is an essential
part of the Hazardous Classification (HAC) process.
 Safety Always

I w
The easiest way to create Hazardous Area Classification Drawings
(HAC Drawings) is to use some kind of AutoCAD program, but it is
su Ta e
certainly not essential. But, in CAD programs, the base drawings
of a plant of factory can mostly be imported, so it is an easy way of
working.

Even pdf files or jpg and png files can be loaded into CAD. By
it mi mi
creating an additional layer, the HAC zones can be drawn. It is a
good practice to scale the zones correctly with the base-drawings.
4.6 a m t ti u ni e
S I say
 Safety Always

(AutoCAD Hazardous Area)

Safety Always
 Safety Always

Week 4

Ingress Protection (IP) and impact resistance rating (IK)

Ingress Protection
 Safety Always

Another consideration in the protection of equipment in

Ew s s
hazardous areas is the safeguarding against the ingress
sm E
of solid foreign objects and water. This is known as the
din
es a
degree of ingress protection and is commonly referred to
as the IP Code.
 Safety Always

IP69K

• Protected from total dust ingress.

• Protected from steam-jet cleaning.

He is

Wo t
The IP69K rating means a piece of equipment can withstand intensive
cleaning with high-pressure, high- temperature jets.

a U E
• IP69K is currently the highest rating on the ingress protection (IP)
scale.

we p im
• The IP scale is an international system that gives products a rating
based on their ability to withstand the intrusion of solids and liquids.
w ik wit wi I am
at w
A
• The first number of the rating indicates how dustproof a product is,
awes
ranging from 0 to 6. The second number indicates how watertight a
product is, ranging from 0 to 9. The addition of a ‘K’ after the second
number signifies specific protection from high-pressure jets.
se e so is
on aim
• These ratings allow a company to choose equipment with the right
level of protection for a given environment.
in
 Safety Always

IP69K means a product is completely dustproof and can withstand

washdown at pressures of 80 to 100 bar/1,160 to 1,450 PSI, in
phases of 14 to 16 l/min, and at temperatures up to 176°F/80°C.

i
Advantages of IP69k : • Food and beverage processing.
• Pharmaceutical applications.
• Chemical manufacturing.
• Petrochemical plants.
• Waste treatment. sew my
 Safety Always

WHAT IS THE IK IMPACT RESISTANCE RATING?

IK Ratings are an international numeric classification to indicate the

degrees of protection provided by enclosures for electrical equipment
against external mechanical impacts. LD i t Mi teh

ie t sa is
It provides a means of specifying the capacity of an enclosure to
protect its contents from external impacts.
wa
 Safety Always

IK00 - No Protection

I In
IK01 - Protected against 0.14 joules of impact (the equivalent to the impact of
a 0.25kg mass dropped from 56mm above the impacted surface).
I Ii so a

IK02 - Protected against 0.2 joules of impact (the equivalent to the impact of a
0.25kg mass dropped from 80mm above the impacted surface).

IK03 - Protected against 0.35 joules of impact (the equivalent to the impact of
a 0.2kg mass dropped from 140mm above the impacted surface).

IK04 - Protected against 0.5 joules of impact (the equivalent to the impact of a
0.25kg mass dropped from 200mm above the impacted surface).

IK05 - Protected against 0.7 joules of impact (the equivalent to the impact of a
0.25kg mass dropped from 280mm above the impacted surface).

IK06 - Protected against 1 joules of impact (the equivalent to the impact of a

0.25kg mass dropped from 400mm above the impacted surface).

IK07 - Protected against 2 joules of impact (the equivalent to the impact of a

0.5kg mass dropped from 400mm above the impacted surface).

IK08 - Protected against 5 joules of impact (the equivalent to the impact of a

1.7kg mass dropped from 300mm above the impacted surface).
 Safety Always

IK09 - Protected against 10 joules of impact (the equivalent to the impact

of a 5kg mass dropped from 200mm above the impacted surface).

IK10 - Protected against 20 joules of impact (the equivalent to the impact

of a 5kg mass dropped from 400mm above the impacted surface).

SECURITY NOTICES
Mobile phones are not intrinsically safe,
meaning that they have the potential to
produce a spark that it could ignite a vapor
air mix. i

said 1 si n
In oil refineries, although every effort is made to avoid having flammable
vapor air mixtures present, accidents do happen, so it makes sense to
keep potential sources of ignition away from these areas.

Mobile phones are radio transmitters - the sum

w 6
radio frequency energy from a
y't wa es
phone, although tiny, still has the potential to induce a spark in nearby
metallic objects if the conditions are right, and ignite petroleum or other
explosive vapors. That's why it's forbidden to use them at filling stations.
Imi [Link] h s sadism
 Safety Always

alternative is
 Safety Always

The explosion-proof antenna

i
explosion-proof antenna to enable full Wi-Fi coverage in hazardous
areas.
Safety Always

Week 5

Explosion protection concepts

Or

Explosion

ignition flammable
source material
 Safety Always

For explosions to happen in atmospheric air, three factors have to be present

at the same time.

• Flammable material.
• Oxygen (air).
• Source of ignition.

Flash point, Fire point, Auto Ignition, Surface Temp.

flash point of a material is the "lowest liquid temperature, the liquid can
gives off vapours in a quantity to be capable of forming an ignitable
vapour/air mixture. JEN do

5101ps
fire point is the lowest temperature at which the vapors keep burning
after the ignition source is removed. It is higher than the flash point,
because at the flash point vapor may not be produced fast enough to
sustain combustion.

autoignition temperature or kindling point of a substance is the lowest

w i s s i
temperature in which it automatically ignites in a normal atmosphere
without an external source of ignition.

iii m pi moi 6
Surface temperature or radiant heat is the infrared energy emitted by
surfaces warmer than the surroundings.
or T's m 1mn a'a
 Safety Always

Flammable material

Flammable gases

A flammable gas may be an element such as hydrogen

which can be made to react with oxygen with very little
a s sa
additional energy. Flammable gases are often compounds
of carbon and hydrogen. These flammable gases and
vapours require only small amounts of energy to react
with atmospheric oxygen.
 Safety Always

Flammable liquids (actually the vapor only]

Flammable liquids are often hydrocarbon compounds such

as ether, acetone or petroleum spirit.

I k
Even at room temperature, sufficient quantities of these
can change into the vapour phase so that an explosive
Ex e 6am
atmosphere forms near their surface.

Other liquids form such an atmosphere near their surface

only at increased temperatures.

it is
Under atmospheric conditions this process is strongly
J
influenced by the temperature of the liquid.

For this reason the flash point, or rather the flash point
temperature, is an important factor when dealing with
Sw s
flammable liquids.
 Safety Always

Flammable solids (actually dust only)

At Iii
Flammable solids in the form of dust or flyings can
react with atmospheric oxygen and produce
disastrous explosions.

Normally more energy is required for activating the

explosion in air than with gases and vapours.
e it

ws 5 on in
However, once combustion starts, the energy
v it
released by the reaction produces high
temperatures and pressures.

In addition to the chemical properties of the solid

itself, the fineness of the particles and the overall
surface area, which increases with increasing
fineness, play an important role.
 Safety Always

Oxygen

O2
The quantity of oxygen available in the air can only oxidise/burn
a certain quantity of the flammable material. a

The ratio can be determined theoretically, it is called the

stoichiometric mixture.
gun at
When the quantity of the flammable material and the available
atmospheric oxygen are near to the optimum (most ideal) ratio,
the effect of the explosion - temperature and pressure increase
is most violent.
s

If the quantity of flammable material is too small, combustion

will only spread with difficulty or will cease altogether.

The situation is similar when the quantity of flammable material

is too great for the amount of oxygen available in the air.

Cow oxgen no explosion

 Safety Always

Sources of ignition

• Hot surfaces.
• Flames and hot gases (including hot particles).
• Electrical equipment and components.
• Mechanically generated sparks. so 4 1 we
• Stray electric currents, cathodic corrosion protection.
• Radio frequency.
• Electro-magnetic radiation - radio RF waves.
• Electro-magnetic radiation - IR, visible and UV light.
• Ionising radiation - röntgen (X-rays) and gamma.
• Ultrasonic. si 6a
• Adiabatic compression and shock waves.
• Exothermic reactions.
 Safety Always

Explosion Range (limits)

Combustible materials mixed with air have a lower and an upper

flammable limit and the explosive range lies between these limits.

When considering the safety of the workplace, the lower flammable

limit is the more important value. In many cases, a possible
concentration ≤ 10 % of this value is considered to be safe.

Lower explosive limit (LEL)

Upper explosive limit (UEL)
 Safety Always

Explosion Protection

Explosion protection is used to protect all sorts

wii
of buildings and civil engineering infrastructure
I
against internal and external explosions or
deflagrations.
i i

The term explosion proof describes electrical

I
and non-electrical fixtures that can prevent
explosions from occurring, and withstand
explosions when they occur.

Primary explosion protection Secondary explosion protection

Primary explosion protection aims at If, despite primary explosion protection

either substituting or reducing the measures, it is possible for a hazardous,
quantity of the flammable substances potentially explosive atmosphere to form
or the atmospheric oxygen to a level (to a degree that requires measures to
where there is no danger of an protect employees against explosion
explosive mixture forming. hazards), the ignition of this hazardous,
potentially explosive atmosphere must
Increased air supply air flushing be effectively prevented.
through ventilation can be achieved by
structural measures; for example the All possible sources of ignition are
open layout of filling stations where the evaluated, and the appropriate
potentially explosive atmosphere is protective measures applied.
very small.
 Safety Always

Tertiary explosion protection

If the primary and secondary explosion protection measures are not enough,
additional protective measures shall be taken.

The purpose of these is to limit the impact of an explosion and/or to reduce it to

an occupational health and environmental safe level.
 Safety Always

Week 6

Explosion protection codes and examples

 Safety Always
ji na em m
Ex i Intrinsic Safety: is an explosion protection concept in which the electrical energy within
in
the equipment is restricted a level which is a
to saw below that what may cause an ignition or to
limit the heating of the surface of the hazardous area equipment. There are two main sub
types to Ex i protection, these being “ia” and “ib”. Type “ia” protection allows for the
occurrence of two faults during operation Type “ib” explosion protection allows for the
occurrence of one fault during operation.
til No spark s s

Ex d Flameproof: The equipment that may cause an explosion is contained within an

no
enclosure which can withstand the force of an explosion and prevent transmission to the
outside hazardous atmosphere. The Ex d flameproof method of explosion protection also
prevents the hazardous atmosphere from entering the enclosure and coming into contact
with equipment. Adi w
ziti w

Ex m Encapsulation: is an explosion protection concept

where by equipment that could potentially cause an
ignition is encapsulated within a compound or resin so
as to prevent contact with the explosive atmosphere.
The concept also limits the surface temperature of the
equipment under normal operating conditions.
 Safety Always

Ex e Increased Safety: is an explosion protection concept applied to the installation to

ensure increased security against the possibility of excessive temperatures and sparks
from hazardous area electrical equipment. Equipment that normally causes sparks is
excluded from use within this method of protection.

mi f just to E

Ex p Pressurized: One process ensures that the pressure inside an Ex p enclosure is

sufficient to prevent the entrance of a flammable gas, vapor, dust, or fiber and prevent a
possible ignition. Another process maintains a constant flow of air (or an inert gas) to
dilute to take away any potentially explosive atmosphere.

on w c i f
A
On a IIe im e E to 6s

Ex o Oil Immersion: All equipment that has the potential to arc and potentially cause an
ignition is immersed in a protective liquid or oil. The oil provides an insulating method to
prevent ignition.

til i II 0 i p
g dis ie pi f s i
Gio

Ex q Powder Filling: All equipment that has the potential to arc is contained within an
enclosure filled with quartz or glass powder particles. The powder filling prevents the
possibility of an ignition.

i i s p Gem him i i
Goi e's w's a bio s
 Safety Always

Ex n Non-Sparking: A type of explosion protection where precautions are taken so that

hazardous area electrical equipment that has the potential to arc is not capable of
igniting a surrounding explosive atmosphere. This can be further categorized as follows:

j s4
Ex nA -Where components used in construction are non-sparking.
Ex nC -Where components used in construction are non- incentive (Sparkling electrical equipment).
at enclosed
Ex nR – Where components used are tightly a ti theabreathing and prevent ignition.
to restrict
Ex nL -Where components used in construction do not contain enough energy to cause an ignition.
EX np - Where components used in construction are simplified pressurization equipment.

Ex s Special: This method of explosion protection, as its name indicates, has no specific
parameters or construction rules. In essence it is any method of explosion protection
which can provide a pre-determined level of safety to ensure that there is no potential for
an ignition. As such it does not fall under any specific protection method and may in fact
be a combination of more than one.
 Safety Always

Type of Explosion Protection Method Equipment Code Suitable for Zones

a a
Intended to prevent a potential Ex e 2 1
ignition arising. Ex nA
2
six
Intended to limit the ignition Ex ia
2 1 O
energy of the equipment. Ex ib
2 1
Ex ic
2
Ex nL 2

Intended to prevent an ignition from Ex d

2 1
escaping outside the equipment. Ex q
Ex nC
2 1
2

Special Ex s
2 1 O

Intended to prevent the explosive Ex px

2 1
atmosphere contacting the ignition Ex py
2 1
source. Ex pz 2
Ex m
2 1
Is smokin
Ex ma
2 1 O
Ex mb
storm o
Ex o
2 I
Ex nR
2 1
2
Safety Always
Safety Always