Hazardous Area Classifications

- Participate in Classification with Confidence -

Presented by:

David Maree
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Index Page
About the course

Module 1: Why is classification of hazardous areas needed? 3

Module 2: Terminology 8

Module 3: Legal Requirements 14

Module 4: Classification concepts 18

Module 5: Classification Standards 21

Module 6: Classification of Gases by point of source of release 24

Module 7: More on ventilation 46

Module 8: Practical example of the classification of a meter station 49

Module 9: Working Group Approach and records 51

Module 10: Demarcation of Hazardous Locations 55

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About the course

0.1 Scope

This course deals with the classification of hazardous locations, i.e. locations where flammable gases,
vapours, mists or dusts may get in contact with air and form an explosive mixture with air.

The purpose of classification is to determine the probability that explosive atmospheres will form.

It is part of the overall explosion prevention strategy and is complemented by methods to prevent the
ignition of such explosive atmospheres.

Explosion prevention being an essential risk management activity and a legal requirement, people involved
in explosion prevention must be armed with the necessary competence. This includes staff operating and
maintaining industrial plants, factories and mines, staff from engineering houses that design and build new
plants or extend/upgrade existing ones, and staff from equipment suppliers.

Often, people hesitate to get involved in area classifications simply because they do not feel confident
enough to provide the inputs expected of them. The purpose of this course is firstly to boost such people’s
confidence by establishing a firm foundation of the principles involved. Secondly, to those that want to
become experts in area classification, a toolbox filled with the right methodology is provided, together with
practical applications.

0.2 Structure

The course is divided into 10 modules. The first module explains the philosophy of explosion protection and
the important part of the classification of potentially hazardous locations as an explosion risk management
tool. Module 2 gives the terms and definitions relevant to the classification process. Module 3 deals with
relevant legislation. Module 4 describes specific methods of classifying hazardous areas where flammable
gases or vapours occur. Modules 5 discusses classification standards, their strengths and weaknesses,
and their differences. Module 6 expands on the most flexible of the classification methods and one that can
be applied to all plant situations where explosive gas and vapour atmospheres are present, i.e. the Point
Source method. Further aspects of ventilation are highlighted in Module 7. Module 8 explains the
classification of locations where flammable dusts are found.

As this course suggests a team approach towards classification, Module 9 elaborates on the functioning of
such a team. Module 10 gives ideas on how to identify hazardous locations by suitable marks and signage.

0.3 Outcomes

At the conclusion of the course students should:

• have a clear understanding of the reasons for and goals of area classification.
• have a clear understanding of the classification concept.
• have the basic skills required to participate in a classification study.
• have a clear understanding of their role and responsibility (in technical and legal terms).
• be able to make an accurate estimation of whether zoning is required and of the zoning details in a
given plant.

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Module 1: Why is classification of hazardous areas needed ?

1.1 Flammable materials and explosive atmospheres in industry

There are various industries in which the presence of flammable gases, vapours and dusts in certain places
at certain times is inevitable:
- coal mining, especially underground
- mineral processing
- chemical and petrochemical
- food and beverage
- pharmaceutical
- paints and inks

In these industries, precautions have to be taken to prevent fires and explosions, as the results of such fires
and explosions can be disastrous (statistics and photos on the next two pages).

Electrical apparatus constitutes a potential danger in explosive atmospheres, since it may produce
electrical, mechanical (friction) or static sparks or hot surfaces as a result of normal operation or abnormal
conditions such as high or fault currents, friction or impact. Both sparks and hot surfaces could ignite a
flammable atmosphere, ie can serve as a source of ignition. If the electrical apparatus and the explosive
atmospheres cannot be kept apart by separation (segregation) by containing the flammable material better,
relocation of apparatus, separation walls, improved ventilation and such like, the electrical apparatus has to
be designed not to cause a fire or explosion - this is explosion protection.

1.2 Prevention of a fire or explosion

A fire is the oxidation of a fuel with an explosion being the oxidation of the fuel at an extremely fast
rate. While not all fires will result in explosions, the effects of either can be devastating in terms of
injury or death to personnel and destruction of equipment and other property.
In order for a fire to start, three elements must be present.
First, some type of fuel must be available, secondly the presence of oxygen to oxidise the fuel, and finally,
an ignition source that will kick start the oxidation process in the form of a spark, a heated surface or
anything else that can supply the energy to initiate the chemical reaction. These three elements are
commonly referred to as the fire triangle (see Figure).
Since all three are needed for a fire, it is only necessary to remove just one of them, or the risk of one, since
the others will not be able to complete the reaction. Once the fire has started, as long as there is sufficient
fuel and oxygen available, the reaction will be self-sufficient and there will be no need for an external heat
source (the flames themselves are the heat source). So, the idea is to stop a fire before it happens.
The selection of equipment for use in areas deemed as hazardous, are thereofore a vital step in preventing
a fire or explosion.

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Gas explosions in underground hard rock mines – statistics for 1999/August 2001

Year Mine Persons killed Persons injured

1999 RPM Rustenburg Section 1 0
St Helena 1 1
Beatrix Mining Co Ltd 1 0
Northam Platinum Mine, Thabazimbi 0 1
Karee Platinum Mine, Rustenburg 2 0
Oryx Mine 0 2
Impala Platinum – Mining operations 1 0
Mponeng Mine 19 2
Kopanang Mine 1 3
2000 St Helena 1 0
Beatrix Mining Co Ltd 7 0
Impala Platinum – Mining operations 0 1
2001 Beatrix Mining Co Ltd 13 0

Table 1.2: Industrial explosions – some South African examples from the last 10 years

Sasol Sasolburg Fire in Wax Factory Totally destroyed

PetroSA Gas explosion in Methane Reformers Badly damaged
Viljoenskroon Gas/dust explosion in Grain Silos Badly damaged
Several Fuel Filling Stations Petrol fires Damaged / destroyed
Colour-X paprika factory in Brits Hexane explosion Large damage
Polifin Polypropylene Plant Polypropylene dust explosion Destroyed
Natref Refinery Oil fire/explosion Large damage
Zimalco aluminium plant Aluminium dust explosion Large damage

Dust explosion in a grain mill in October 2000.

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Explosion of hydrogen coolant gas in an electric generator in 2003.

Destruction caused by solvent vapour explosions in 2006 and 2007

1.3 Risk of Fire or Explosion versus Protection required

The risk of a fire or explosion depends on its probability, composed of:

- the probability pg that an explosive atmosphere will be present in a particular place at a

particular time; and
- the probability pi that the above explosive atmosphere can be ignited.

As the risk of fire or explosion must be acceptably low, this means that the product pg x pi must be
acceptably low (a probability of 10-5 is considered acceptable, refer to Hickes and Brown). In other words,
if the probability of an explosive atmosphere being present increases, the probability that it can be
ignited must decrease and vice versa.

The process to determine the probability that an explosive atmosphere will be present is known as area
classification (classification of hazardous locations) and is the subject of this course.

1.4 Aims of Area Classification

The primary and secondary aims of area classification (classification of hazardous locations) are:

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● to determine zones, i.e. the probability of explosive atmospheres being present.

● to determine ignition properties of explosive atmospheres.

1.5 Application of Classification to Select Ex Equipment

In 1.3 the principle of increased apparatus protection to offset more frequent exposure of such apparatus to
explosive gas has been defined.

There are two methods to select appropriate Ex equipment using the area classification, i.e. the statistical
method and the risk-based method.

To facilitate the risk-based method, the concept of Equipment Protection Level (EPL) has been introduced.

It is recommended that the required equipment protection levels (EPLs) are recorded on the area
classification drawing.

Statistical approach

In this approach, only the probability of an explosion is considered a direct relationship exists between the
zone and the Equipment Protection Level (EPL) required:

Zone Minimum Equipment Protection Level Examples of Suitable Ex Equipment

(EPL)
0 Ga Ex ia, Ex ma, Ex d+e
1 Gb Above plus Ex ib, Ex mb, Ex d, Ex e,
Ex py, Ex q
2 Gc Above plus Ex ic, Ex pz, Ex nA, Ex nR,
Ex nC
20 Da Ex tD, Ex iD, Ex mD
21 Db Above
22 Dc Above plus Ex pD

Risk-based approach

According to this approach, equipment is selected taking into account probability (related to the zoning) as
well as the consequence of an explosion.

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Module 2: Terminology
The following terms are widely in use in the explosion protection industry. The definitions are taken or
derived from the standards listed in the Bibliography.

Related terms have been ordered together, rather than following an alphabetical ordering system.

Other terms have been defined in the text where this was more appropriate.

Hazardous locations

explosive atmosphere: Mixture with air, under atmospheric conditions, of flammable substances in the
form of gas, vapour or dust, which, after ignition, permits self-sustaining flame propagation.

hazardous location/area: Any three-dimensional area or space where an explosive atmosphere or

flammable dust layer can occur, in quantities such as to require special precautions for the construction,
installation and use of equipment, and divided into hazard zones.

NOTE - Internationally, the term “hazardous area” is preferred.

Underground coal mines Any location where, under normal operating conditions, there is a continuous
presence of flammable gas, measured at a concentration of 0,5% or more by volume in the general body
of the air, including:
(i) A return airway, and
(ii) Any location determined by risk assessment but not less than 180m from any working face.

Underground mines other than coal mines Any location where, under normal operating conditions, there
is a continuous presence of flammable gas measured at a concentration of 0,5% or more by volume in
the air

Surface mines and surface locations at all mines including offshore installations Any location as
identified in accordance with South African Standard SANS 10108: 2004 (Edition 5), “The classification of
hazardous locations and the selection of apparatus for use in such locations”.

source of release: A feature of finite size (“point”) in a works from where sufficient flammable gases or
vapours can be released to form an explosive atmosphere under normal operation or due to recognized
failures of equipment, i.e. a feature giving rise to a hazardous location.

NOTE – Provision is not made for catastrophic events such as earthquakes or earth tremors, flood
damage, meteoritic impacts, hurricanes or terrorist acts.

grade of release: continuous - Release that occurs all the time or for long periods, or frequently for
short periods
primary - Release that is likely to occur periodically or occasionally in normal
operation (ie a release covered by operating procedures)
secondary - Release that is unlikely to occur in normal operation (ie a release not
covered by operating procedures).

hazard zone: Zones 0, 1 and 2 for locations in which explosive gas, vapour or mist atmospheres may be
present, and zones 20, 21 and 22 for locations in which explosive dust atmospheres may be present.
The zone number is indicative of the probability of the explosive atmosphere being present at any given
time.

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hole size / release hole diameter / equivalent leak hole diameter: Together with pressure, the size
(diameter) or equivalent diameter of a circular or non-circular hole that will deliver the dispersion distance
determined by dispersion modeling. Related to the hazard radius.

hazard radius: The horizontal distance from a source required for the concentration of the explosive
atmosphere to decrease to a safe level (normally 20% of the lower explosive limit) by means of dilution.
It is the primary dimension to be determined in specifying the geometry of a hazard zone.

ignition source: A source of energy in the form of a flame, arc, spark or heat that is capable of igniting
an explosive atmosphere.

ventilation, pressurization, segregation: Introduction of structures and/or processes that influence the
concentration of flammable gases and vapours in a particular area.

classification of a hazardous location: Determining the appropriate zones and zone geometries
associated with sources of release, as well as the properties of the explosive atmosphere including gas
group and temperature class, that can occur in these zones.

NOTE - Internationally called ”area classification” which is a bit of a misnomer since a three-dimensional space is involved.

explosion protection: The application of certain specialized design techniques to apparatus to prevent
such apparatus from being an ignition source.

explosion prevention: The collection of strategies to prevent explosions in locations where explosive
atmospheres can be formed and including explosion protection, ventilation, segregation and
pressurization.

Ventilation

natural ventilation: Ventilation due to air movement caused by the natural environment, e.g. wind or
convection effects. It applies to open and sheltered/obstructed areas.

forced or artificial ventilation: Ventilation where air movement is artificially induced (e.g. fans or
extractors). It applies to enclosed areas only.

open area: An outdoors area without stagnant regions. Any space that is substantially open and offers
no obstruction to the free and natural passage of air through it. Such premises may be roofed for
weather protection or enclosed (for example in wire mesh or expanded metal (or both)), provided that
adequate ventilation exists and the supports for the roof and side enclosures do not at any point
materially obstruct the free passage of air to and through any part of the space within.

sheltered area: Any space where some obstruction to the free and natural passage of air through it
exists.

enclosed area: A building, a room or an enclosed space that is not substantially open to the outside air
and through which there is no free and natural passage for that air.

NOTE – Any space that has more than a roof and one solid wall or is surrounded by other buildings or
structures in such a way as to obstruct quick dissipation of any released gases or vapours, should be
considered to be enclosed.

vents: Openings in an enclosure that have been deliberately introduced to allow breathing, venting, or
the drainage of water formed by condensation.

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Flammable materials and atmospheres

flash point: 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

volatile flammable liquid: A flammable liquid that is stored, processed or handled at a temperature at
or above its closed-cup flash point.

NOTES

In the petroleum industry, flammable liquids are classified according to their closed-cup flash points, as
follows:

– Class 0 : liquefied petroleum gases (LPG’s);

– Class I : liquids that have flash points not exceeding 21 °C;

– Class II(1) : liquids that have flash points exceeding 21 °C but not exceeding 55 °C, and that are
handled below their flash point;

– Class II(2) : liquids that have flash points exceeding 21 °C but not exceeding 55 °C, and that are
handled above their flash point;

– Class III(1) : liquids that have flash points exceeding 55 °C but not exceeding 100 °C, and that are
handled below their flash point;

– Class III(2) : liquids that have flash points exceeding 55 °C but not exceeding 100 °C, and that are
handled above their flash point; and

– Unclassified : liquids that have flash points exceeding 100 °C.

If the flash point of a flammable liquid is not known, it should be obtained from the supplier.

fluid category: An indication of the rate at which an explosive atmosphere will be formed if a release of
the fluid occurs. Influenced by fluid properties such as flash point and boiling point compared to
operating conditions such as pressure and temperature.

boiling point: Temperature of a liquid boiling at an ambient pressure of 101,3 kPa (1 013 mbar)
NOTE - The initial boiling point that should be used for liquid mixtures is to indicate the lowest value of the
boiling point for the range of liquids present, as determined in a standard laboratory distillation without
fractionation.

vapour pressure: Pressure exerted when a solid or liquid is in equilibrium with its own vapour. It is a
function of the substance and of the temperature.

relative density: Density of a gas or a vapour relative to the density of air at the same pressure and at the
same temperature (air is equal to 1,0).

gas group: Explosive gas and vapour atmospheres are divided into the following:
Group I: mines susceptible to firedamp;
Group II: explosive gas atmosphere other than in mines susceptible to firedamp (e.g. surface plants).
Group III: explosive dust atmospheres occurring in areas mines susceptible to firedamp (surface
applications).

Group II explosive gas atmospheres are divided based on spark ignition energies into IIA, IIB and IIC, IIC
gases having the lowest ignition energies.

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Group II explosive atmospheres may be subdivided into IIA, IIB and IIC, according to the nature of the
explosive atmosphere as follows. This subdivision is based on the maximum experimental safe gap
(MESG) for flameproof enclosures or the minimum ignition current ratio (MIC ratio) for intrinsically safe
electrical apparatus; these are again dependent on the minimum ignition energy (MIE) of the explosive
atmosphere.
Likewise, Group II explosive atmospheres are divided into subgroups IIIA, IIIB and IIIC.

ignition temperature and temperature class: For Group I explosive atmospheres, the ignition
temperature is considered to be
>150 °C on any surface where coal dust can form a layer,
>450 °C where coal dust is not expected to form a layer.

For Group II explosive atmospheres, the maximum surface temperature can be classified in a temperature
class in accordance with the auto-ignition temperature as follows:

Temperature class Ignition temp of gas/vapour

T1 > 450 °C
T2 > 300 °C < 450 °C
T3 >200 °C < 300 °C
T4 > 135 °C < 200 °C
T5 > 100 °C < 135 °C
T6 > 85 °C < 100 °C

Explosion protection techniques

explosion protected: Descriptive of electrical apparatus designed and approved for use in hazardous
locations in accordance with a suitable protection method, including Ex d, Ex i, Ex e, Ex p, Ex n, Ex s,
Ex m or Ex q.

NOTE – Some of those methods also apply to mechanical equipment, for example flameproof diesel
engines.

encapsulated electrical equipment (Ex m apparatus): Electrical equipment in which parts that could
ignite an explosive atmosphere by either sparking or heating are enclosed in a compound in such a way
that this explosive atmosphere cannot be ignited.

flameproof equipment (Ex d equipment): Equipment in which the parts of the equipment that can ignite
an explosive atmosphere are placed in an enclosure that can withstand the pressure developed during
an internal explosion of a defined explosive mixture and that prevents the transmission of the explosion
to the explosive atmosphere surrounding the enclosure.

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increased safety electrical equipment (Ex e equipment): Electrical equipment in which measures are
applied to prevent, with a minor degree of security, the possibility of excessive temperatures and of the
occurrence of arcs or sparks in the interior and on the external parts of an electrical equipment that does
not produce them in normal service.

intrinsically safe electrical equipment (Ex i equipment): Electrical equipment that is suitable for use in
a hazardous location and in which all the circuits are intrinsically safe, or electrical equipment that is
designed to form part of an intrinsically safe system.

R L

intrinsically safe electrical equipment of categories "ia" and "ib": Electrical equipment that, when
tested in accordance with SABS 549, is incapable of causing ignitions under the following conditions and
when the following safety factors are applied to the current or voltage:

Condition Safety factor

Only non-countable faults applied 1,5
One countable fault applied 1,5
Two countable faults applied 1,0 (category "ia" only)

NOTE – Countable and non-countable faults are those which occur in parts of the electrical equipment or
system that respectively are or are not of intrinsically safe design.

intrinsically safe system (Ex i system): A system that comprises electrical equipment and
interconnecting wiring in which any spark or thermal effect in any part of the system intended for use in a
hazardous location is incapable, under prescribed test conditions, of causing ignition of a prescribed gas
or vapour.

intrinsically safe circuit (Ex i circuit): A circuit in which any spark, arc or thermal effect, whether
produced normally (i.e. by breaking or closing of the circuit) or accidentally (for example, by a
short-circuit or an earth fault), is incapable, under prescribed test conditions, of causing ignition of a
prescribed gas or vapour.

non-sparking electrical equipment (Ex nA equipment): Electrical equipment that, in normal operation
and in the absence of electrical or mechanical failure, cannot, because of its construction, because of its
method of operation or because of its enclosure, ignite mixtures of air and prescribed flammable gases or
vapours.

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NOTE – The terms “Ex N” and “Ex n” have been used in some older standards.

powder-filled or sand-filled electrical equipment (Ex q equipment): Electrical equipment of which the
enclosure is so filled with a material in a finely granulated state that, in the intended conditions of service,
any arc occurring within the enclosure will not ignite the surrounding atmosphere, and ignition will not be
caused either by flame or by excessive temperature of the surfaces of the enclosure.

pressurized electrical equipment (Ex p equipment): Electrical equipment in which the entry of a
surrounding atmosphere into the enclosure of the electrical apparatus is prevented by maintaining, inside
the said enclosure, a protective gas at a higher pressure than that of the surrounding atmosphere. The
over pressure is maintained either with or without a continuous flow of the protective gas (ie instrument
air).

NOTE – This definition does not cover electrical apparatus installed in a pressurized room; the enclosure
houses the apparatus only.

specially protected electrical equipment (Ex s equipment): Electrical equipment that, by its nature,
cannot easily comply with, or be tested to other established standards, but that can be shown, by test or
otherwise, to be unlikely to cause ignition of an explosive atmosphere.

electrical equipment dust ignition protected by enclosure (Ex t previously DIP equipment):
Electrical equipment so enclosed as to prevent

a) the entry of enough dust to be ignited or to impair the performance of the electrical apparatus, and
b) arcs, sparks and heat, generated or liberated in the enclosure, from igniting either accumulations of
dust on the outside of the enclosure or atmospheric suspensions of dust in the vicinity of the
enclosure.

degree of protection of enclosure (IP): Numerical classification according to IEC 60529 preceded by the
symbol IP applied to the enclosure of electrical apparatus to provide
– protection of persons against contact with, or approach to, live parts and against contact
with moving parts (other than smooth rotating shafts and the like) inside the enclosure,
– protection of the electrical apparatus against ingress of solid foreign objects, and
– where indicated by the classification, protection of the electrical apparatus against harmful
ingress of water

NOTE – Some explosion protected techniques requires apparatus to have an ingress protected enclosure.
However, it should not be concluded that an enclosure with the required IP rating automatically complies
with all explosion protection requirements.

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Module 3: Legal Requirements

The legal requirements in terms of explosion prevention including area classification are stipulated below
for surface installations.

Industry: Surface
Law: Occupational Health and Safety Act (Act 85 of 1993)
Regulation Aspect Standard Who is responsible
EIR Definition of specialized Area SANS 10108 Delegated by Plant Management to
electrical installations. classification Technical team including specialist
EMR 9(1).
EIR Definition of specialized Selection of Ex SANS 10108 Delegated by Plant Management to
electrical installations. equipment technical staff
EMR 9(2).
EIR Definition of specialized Certification of Ex ARP 0108 Approved Test Laboratory (ATL)
electrical installations. equipment and
EMR 9(3). systems
EIR 9(1) and definition of Ex installations SANS 10086-1 Delegated by Plant Management to
registered person. SANS 10142-1 technical staff, Certificate of
EMR 9(4) and 9(7). Compliance must be issued by
Master Installation Electrician (MIE)
EIR Definition of specialized Use, inspection SANS 10086-1 Delegated by Plant Management to
electrical installations. and SANS 10142-1 technical staff
EMR 9(5), 9(6), 9(8) and maintenance of
9(9). Ex equipment
EIR Definition of specialized Repair of Ex SANS 10086-3 Accredited Repairer, or re-test by
electrical installations. equipment (SANS 10242-1, ATL
EMR 9(4). SANS 10227 etc.)
EIR = Electrical Installation Regulations EMR = Electrical Machinery Regulations

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Act No 85 of 1993 (Occupational Health and Safety)

Electrical Installation Regulations, March 2009

Definition

Definition

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11 (2) Any natural person who satisfies the chief inspector that he or she

Definitions

Comment – Including specialized electrical installations that may only be

certified by a MIE.

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Electrical Machinery Regulations, 2011

These Regulations shall be called the Electrical Machinery Regulations, 2011, and shall commence on 1
July 2011: Provided that regulation 12(4) shall commence on 1 October 2012.

9.(1) Every employer or user shall identify all hazardous locations and classify them in accordance
with the relevant health and safety standard incorporated into these Regulations under section 44 of
the Act.

AUTHOR NOTE - The zoning technique as described in, and the standards referred to by SANS
10108 are used.

(2) No person may use electrical machinery in locations where there is danger of fire or explosion owing to
the presence, occurrence or development of explosive or flammable articles, or where explosive articles are
manufactured, handled or stored, unless such electrical machinery, with regard to its construction relating to
the classification of the hazardous locations in which it is to be used, meets the requirements of the safety
standard incorporated for this purpose in these Regulations under section 44 of the Act.

(3) Every employer or user referred to in sub-regulation (1) shall be in possession of a certificate in a form
acceptable to the chief inspector, which has been issued by an approved inspection authority and in which it
is certified that the electrical machinery referred to in sub-regulation (2) has been manufactured and tested
for the groups of dangerous articles in accordance with the relevant health and safety standard incorporated
into these Regulations under section 44 of the Act: Provided that in lieu of such certificate an inspector may
approve permanent labelling on such machinery, which label shall contain all the relevant information.

(4) When diverse items of electrical machinery such as motors, cables and control apparatus are used
together to form a system, the employer or user shall ensure that the selection, arrangement, installation,
protection, maintenance and working of the system results in no less a degree of safety than when the
individual items of such machinery are used separately.

(5) The employer or user shall use electrical machinery to which this regulation applies only under such
conditions and in such surroundings as prescribed in the health and safety standard referred to in sub-
regulation (2).

(6) No employer or user shall affect repairs or adjustments to or otherwise work on electrical machinery
under conditions envisaged by sub-regulation (2) unless such machinery has been rendered dead and
effective measures have been taken to ensure that such machinery remains dead.

(7) Wherever there is a possibility of the formation of static electricity under working conditions, the
employer or user shall earth all metallic structures, machine parts, pneumatic conveyor ducts and pipelines
conveying flammable articles and the like, or take such other measures as may be necessary to prevent the
formation of electric sparks.

(8) The employer or user shall cause all electrical machinery in a hazardous location to be visually inspected
and tested at intervals not exceeding two years, or any other interval approved by the chief inspector after a
risk assessment has been conducted by a person who is competent to express an opinion on the safety
thereof: Provided that installed intrinsically safe equipment may in lieu of a test be verified in terms of the
approved design.

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Module 4: Classification Concepts

4.1 Background

Practical area classification is simplified if one of the following two methods is followed, where possible:

a) Classification of hazardous locations by direct example, which is a method that applies to standard
installations, a few examples of which are given in clause 4.2.

NOTE - Care should be taken to ensure that, same products and conditions apply.

OR

b) Classification based on dispersion theory.

c) If the release rate for secondary sources of release in (b) cannot be determined by dispersion theory, a
risk-based calculation can be done.

4.2 Classification of Gas/Vapour Locations by Direct Example approach

4.2.1 Definition

This method applies to standard installations, meaning installations where normally a single material under
well-known conditions is handled by standardized equipment. The classification is based on practical
experience.

Careful consideration must be given to deviations from the given set of conditions, which may affect the
zoning.

4.2.2 Examples

♦ Rail car and road tanker loading and unloading

♦ Container filling
♦ Filling station forecourts
♦ Bulk storage tanks

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4.2.3 Special Case: Gas and Liquid Fuel Burners

The hazards associated with burners are leakage of flammable fuel, ignition failure or incorrect ignition, and
flame-out, all which could lead to the formation of explosive atmospheres. As burners are powerful ignition
sources, such explosive atmospheres must be avoided. Therefore burner equipment is normally not
explosion protected but the burner management systems must comply with a suitable burner standard such
as SANS 329 Edition 1: 2007 “Industrial thermo-processing equipment, Part 2: Safety requirements
for combustion and fuel handling systems”, based on EN 746-2 Edition 1: 1997, that incorporates a
leak prevention strategy. This standard ensures safety of fuel burners by means of appropriate construction
and operation of the burner system, pre-commissioning inspections and post-commissioning inspections.
Typical safety features will include:

• Double-block-and-bleed safety valves on main burner.

• No flexible pipes used.
• Leak detection on two safety shut-off valves before each start-up.
• Total system leak detection at commissioning, recommended maintenance procedure.
• Welded supply line recommended inside buildings.
• Fail-safe flame detection system or pilot burner fitted.
• Burner monitoring unit for temperature control, leak detection control.

In summary, an appropriate leak prevention strategy removes the need for zoning of a burner management
system.

4.2.4 Special Case: Laboratories and Pilot Plants

Laboratories are normally not zoned ie explosion prevention is not achieved by the use of explosion
protected apparatus, because
a) activities involving flammable liquids normally involve small quantities;
b) trained staff is used;
c) numerous non-electrical ignition source may be present; and laboratory apparatus are not manufactured
in an explosion protected format.

Good natural and/or artificial ventilation is essential to prevent the formation of explosive atmospheres. The
maximum amount of flammable shall be limited; these materials shall be kept in well ventilated areas, either
in a dedicated store room or in a flame-retardant storage cupboard. A storage room shall comply with the
requirements for hazardous substance stores, refer SANS 10263. Release of vapour shall further
minimized by using closed containers wherever possible. Activities causing more vapour to be released (eg
distillation, evaporation of solvents) shall be carried out in a fume cupboard if; this is a health requirement
but also reduced explosion risk. The operation of the vapour extraction system during these operations
shall be ensured. Depending on vapour release rate and extraction rate, the interior and exhaust of the
vapour extraction system may involve an explosive atmosphere.

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Proper procedure shall be followed to dispose of waste chemicals. Gas supply systems for benchtop gas
burners (Bunsen burners) etc. shall be closed at sources when not in use and shall be submitted to a
suitable inspection and maintenance programme.

Staff shall be trained and equipment provided to deal with small fires or risk of fire due to accidental large
release of vapour (spillage), e.g. isolation of electrical supply outside laboratory.

Similar considerations apply to pilot plants where development work is conducted. This excludes pilot
plants turned into small permanent production plants where traditional explosion prevention methodologies
may be more appropriate.

4.3 Classification of Gas/Vapour Locations by Point Source approach

This approach to classification covers all situations outside of direct examples and includes the Risk-based
approach.

This method is employed when the standard conditions assumed for the Direct Example approach do not
apply, due to variances of operational temperature and pressure, ventilation and equipment, causing the
extent of vaporisation (hazard radius) to vary greatly. Therefore assessment of individual sources of release
is required.

This method is based on

(a) specific structural features of a plant, features of which the release/leak behaviour is well known from
theory and practice (called sources of release), and
(b) the other parameters (rate of release, rate of vaporization, and rate of dilution) that determine the
size of the resulting explosive atmosphere as follows:

Size factors Determined by Expressed as

Rate of release Pressure and Hole Size/Diameter
Temperature
Rate of vaporization (if liquid) Volatility i.e. liquid state Fluid Categories
Rate of dilution Ventilation Open, Sheltered or Enclosed areas
(Alternative as per SANS 60079-10:
Degree of ventilation; High, Medium or
Low)

This method is flexible enough to cover all plants. It is the method mostly used to classify plants where
standard conditions allowing classification by direct example do not exist. This method is further described
in Module 6.

4.4 Classification of Gas/Vapour Locations by Risk-based approach

When the rate of release (equivalent hole size and pressure) is not known when applying the Point Source
concept, for secondary sources of release the Risk-based approach can be used. This approach provides a
means of adjusting release frequency and thus hazard radii, to fit specific processes.

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Module 5: Classification Standards

5.1 Available Standards and Application

Approved standards must be used for the classification of hazardous locations, ie those listed in or meeting
the requirements of SANS 10108.

SANS 10108 requires that preference is given to IEC (international) standards where such a standard is
suited to the type of plant to be classified. This means that 60079-10-1 (flammable gases and vapours) and
SANS 60079-10-2 (combustible dusts and fibres) are therefore the primary standards to be used.

However, SANS 60079-10 does not provide detailed information on specific industries or applications
involving flammable gases and vapours. Classification based on the following complementary standards (ie
standards that do not provide conflicting results compared to IEC/SANS 60079-10) may be considered to
comply with SANS 10108:

United Kingdom
• Institute of Petroleum, Model Code of Safe Practice, Part 9 “Liquefied Petroleum Gas”
• Institute of Petroleum, Model Code of Safe Practice, Part 15 “Area Classification Code for Petroleum
Installations”, Editions 1 to 3
• LP Gas Association’s Code of Practice 1-1 “Code of Practice 1: Bulk LPG Storage at Fixed Installations,
Part 1: Design, Installation and Operation of Vessels Located above Ground”
• LP Gas Association/Institute of Petroleum Technical Memorandum No 70: 2000 “Storage and
Dispensing of LPG as an Automotive Fuel at Petrol Filling Stations”
• HSE Health and Safety Series Booklet HS(G)41: 1990 “Petrol Filling Stations: Construction and
Operation”
• Institute of Gas Engineers, IGE/SR/25 “Hazardous Area Classification of Natural Gas Installations”

United States of America

• American Petroleum Institute Recommended Practice 500 “Recommended Practice for Classification of
Locations for Electrical Installations at Petroleum Facilities Classified as Class I, Division 1 and Division
2”
• American Petroleum Institute Recommended Practice 505 “Recommended Practice for Classification of
Locations for Electrical Installations at Petroleum Facilities Classified as Class I, Zone 0, Zone 1 and
Zone 2”
• NFPA 497 “Recommended Practice for the Classification of Flammable Liquids, Gases, or Vapours and
of Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas”
• NFPA 52 “Compressed Natural Gas (CNG) Vehicular Fuel Systems”
• NFPA 30 “Flammable and Combustible Liquids Code”
• NFPA 58 “Standard for the Storage and Handling of Liquefied Petroleum gases”

Australia and New Zealand

• AS/NZS 2430 “Classification of hazardous areas”

South Africa
• SANS 10108 “The Classification of Hazardous Locations and the Selection of Apparatus for Use in
Such Locations”
• SANS 10087 series “The Handling, Storage and Distribution of Liquefied Petroleum Gas in Domestic,
Commercial, and Industrial Installations”
• SANS 10089 series “The Petroleum Industry”
• SANS 60079-10-1 Ed. 1.0 “Explosive atmospheres - Part 10-1: Classification of areas - Explosive gas
atmospheres”

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• SANS 60079-10-2 Ed. 1.0 “Explosive atmospheres - Part 10-2: Classification of areas - Explosive dust
atmospheres”

Europe
• EN 60079-10-1 Ed. 1.0 “Explosive atmospheres - Part 10-1: Classification of areas - Explosive gas
atmospheres”
• EN 60079-10-2 Ed. 1.0 “Explosive atmospheres - Part 10-2: Classification of areas - Explosive dust
atmospheres”

International/IEC
• IEC 60079-10-1 Ed. 1.0 “Explosive atmospheres - Part 10-1: Classification of areas - Explosive gas
atmospheres”
• IEC 60079-10-2 Ed. 1.0 “Explosive atmospheres - Part 10-2: Classification of areas - Explosive dust
atmospheres”

Some of the most widely used standards are reviewed in terms of their area of application and approach to
area classification in the table below.

Table 5.1: Comparison of various national/international classification standards

Country/ Reference Scope Comments

region
RSA SANS 10108 Flammable gases, vapours, Direct example, reference.
mists, dusts.
SANS 60079-10-1 Flammable gases, vapours, Some direct examples, first
mists. principles, reference.
Refers to SANS 10108.
SANS 10087 series LPG. Direct example.
SANS 10089 series Petroleum.
SANS 60079-10-2 Explosible dusts and fibres.
Internatn’l IEC 60079-10-1 Flammable gases, vapours, Some direct examples, first
(IEC) mists. principles, reference.

IEC 60079-10-2 Explosible dusts and fibres.

North API RP 500, 505 Petrochemical Direct example, source of
America release
NFPA 58 LPG Direct example
NFPA 497 Chemical Direct example, source of
release
UK IP Code Part 15 All plants. Direct example, source of
release, risk-based approach.
Direct example.
LPG COP 1-1 and LPG.
TM70

A comparison of various standards show a phenomenon that comes as no surprise but could be frustrating
and confusing if not understood: The classification results, and in particular the size of zones, will often
differ. The zone sizes specified in a standard depends on
- How conservative the approach was that was taken. This goes hand-in-hand with the age of the
standard (older standards tending to be more conservative).
- Another age-related factor is that modern technologies produce cleaner plants with fewer and
smaller releases, due to better sealing systems, restrictions on emissions and more reliable
equipment requiring less maintenance.
- How general the application of the standard is (the more general, the more conservative the
approach tends to be).

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An example is the classification in the old SABS 089-2:1965 (now obsolete) compared to UK IP Code Part
15 for a pump/tank containing petrol (15m versus 15/3 to 1,5m).

Newer standards tend to be more specific, compare the 2m/5m approach of SABS 0108:1974 to the
differentiation of petroleum products into four fluid categories eg LPG or any other flammable liquid handled
under conditions that will produce at least 40% vaporization instantly upon release, liquids that will boil off
when released, liquids released above their flash point or as a mist, and gases.

In summary, new standards tend to be more precise and therefore complex to work with, but also allow cost
savings by reducing the size of zones because of the nature of the product, the way it is handled or the
effect of ventilation.

5.2 Standards relevant for this course

SANS 10108 is the basic reference document. For technical guidance, the following standards have been
considered, as referenced in.

5.2.1 Gases, vapours, mists

SANS 60079-10-1 Edition 1

This is essentially a reference document, although methods for determining degree of ventilation and direct
examples are provided.

IP Part 15 Edition 3
This is the most recent classification standard. Its scope covers practically all plants. Differences compared
to Edition 2 include:
● Omissions such as hydrogen are included
● A justifiable technical basis for hazard radii (in terms of source of release hole size etc.) is provided
(as opposed to a semi-empirical basis).

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Module 6 Classification of Gases by Point Source of Release

6.1 Classification procedure

In practice, the following eight steps can be followed.

1. List of flammable materials

2. Select those present in significant quantities
3. Determine sources of release
4. Determine grades of release
5. Determine zones (0/1/2)
6. Size (hazard radius) and shape of zones
7. Rationalize
8. Properties of explosive atmospheres

Exercise 1
Name one purpose of area classification
Which standards are used for area classification in this course?
Name 2 area classification techniques
List at least 5 steps in the area classification process (in proper sequence)

6.2 Details for each step

Step 1: List of flammable materials

Draw up a list of all flammable gases and liquids (vapours). Establish where they are present in the plant.
Obtain their ignition properties and other relevant physical properties.

Step 2: Select those present in significant quantities

The following minimum quantities of different flammable fluids must be present to create a significant
explosion hazard and to warrant area classification.

- gas inside/outside 50/1000 litres

- liquefied gas inside/outside 5/100 litres
- liquid inside/outside 25/200 litres

Step 3: Determine sources of release

A source of release (see definition Module 2) is essentially a plant feature that during normal operation or
due to equipment failures or incorrect process conditions, results in exposure of flammable materials
contained in the plant to atmospheric oxygen (air) and where the gas and vapour mixtures so formed are
explosive.

In a well-designed, operated and maintained plant, one expects mostly secondary sources of release with a
limited number of primary and continuous sources of release. Whereas all primary and continuous sources
should be assessed for extent, only the large secondary sources and those close to the periphery of a plant
need to be considered, since in many cases a general Zone 2 area is determine, see rationalization - Step
7.

Some sources of release are true point sources such as vents, drains and sample points; others equipment
e.g. pumps, are composed of an assembly of individual sources of release. The “Point Source” concept
requires consideration of each individual source.

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A source of release implies that vapour/gas mixes with O2 (air) to form an explosive atmosphere. For a
liquid, this means that the liquid must be above its flash point.

liquid flash point The lowest temperature at which a flammable liquid releases enough vapours to sustain
combustion.

For example, vehicle oils and greases do not create significant vapours when handled under ambient
conditions. Petroleum liquids with flash point of >55°C is considered to fall in this category, diesel fuel being
a borderline case.

Note – Provision must of course still be made to handle the material safely, as typified by SANS 10263.

Potential sources of release in a plant typically include the following:

●Pumps, compressors
●Equipment drains and sample points
● Instrument vents
●Process vents
●Sumps, interceptors, separators
●Pits or depressions
●Pipe joints, valves
●Pig receivers/launchers
●Spillages

Exercise 2
Describe what a source of release is.
Give 4 examples of sources of release.

Step 4: Determine grade of release

Determine the grade of release associated with each source of release :

Grade of release Frequency and duration of release

Continuous Release that occurs all the time or for long periods, or
frequently for short periods.
Primary Release that is likely to occur periodically or occasionally in
normal operation (i.e. a release covered by operating
procedures).
Secondary Release that is unlikely to occur in normal operation (i.e. a
release not covered by operating procedures). Such
releases may be of known size e.g. fracture of a drain, or
unknown size e.g. a corrosion hole.

Completely independent of physical aspects (process conditions, volatility, ventilation). Solely depends on
frequency and duration of the release.

Total exposure can therefore consist of one continuous period or a combination of shorter periods; for
example, a scheduled annual maintenance operation versus the weekly filling of a storage tank.
All operations to be considered; i.e.
◘ Normal operation
◘ Scheduled maintenance

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◘ Dual grades of release, e.g. a vent with a continuous or primary grade of release during normal
operation and a larger, secondary grade of release during abnormal or emergency operations.
Example: Draining/blow-off of a gas system. Dual grade not a rule!

In the case of operationally controlled releases, e.g. sampling and drain points, no one grade of release
is applicable; the chosen operational frequency will determine the grade of release.

For uncontrolled releases such as leakage from a pump seal and pipe flanges, a secondary grade of
release is applicable.

A problem in determining grade of release is of course to quantify terms such as “continuously or for long
periods”, “likely to occur in normal operation” and “not likely to occur in normal operation”. The following
guideline is suggested.

Total exposure to explosive atmosphere Grade of release

> 1000 hours per year Continuous
> 10 ≤1000 hours per year Primary
> 1 ≤10 hours per year Secondary

Exercise 3
3.1 Complete: A grade of release is associated with a …………………….
3.2 How many grades of release are there?
3.3 Which two parameters determine the grade of release?
3.4 (a) Can a source of release be associated with more than one grade of release ?
(b) Mention an example.

Step 5: Determine zones (0/1/2)

Definition and explanation of zones

Three zones are defined, as follows:

Zone 0 - Zone 0 locations are those in which an explosive gas, vapour or mist atmosphere is present
continuously or for long periods.

Zone 1 - Zone 1 locations are those in which an explosive gas, vapour or mist atmosphere is likely to occur
in normal operation

Zone 2 - Zone 2 locations are those in which an explosive gas, vapour or mist atmosphere is not likely to
occur in normal operation and, if it does occur, is likely to do so only infrequently and will exist for
a short period only.

NOTE 1 – A Zone 2 is not a “temporary zone”; it is the explosive atmosphere that is temporary.
NOTE 2 – The relationship between zones and the North-American Divisions are as follows.

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Zone NOTES
Zone 0 Division 1(USA)
Zone 1
Zone 2 Division 2 (USA)

The reason why three zones exist and not two or five must be understood in terms of the overall philosophy
of explosion protection i.e. risk control. This means that each zone relates to a certain probability that an
explosive atmosphere will exist at any given time, and that measures can be taken to reduce the probability
of the coincidental existence of an ignition source to an acceptable level.

Factors influencing the zone

The zone is a function of:

- grade of release (Step 4)

- degree of ventilation

Ventilation

In general, good ventilation (a) could serve to reduce the extent of a hazardous location, or (b) could so
affect the frequency and duration of an explosive atmosphere that a less hazardous zone can be allocated.
The opposite can also happen.

For the purposes of area classification, three degrees of ventilation can be defined. Their effects on zoning
are discussed below.

Open areas

Good natural ventilation is typically associated with open-air areas where no structures restricting air flow
are present. Typically the air flow speed is rarely less than 0,5m/s and frequently more than 2m/s.
Turbulent diffusion occurs under these conditions. The net result is that an explosive atmosphere is quickly
dispersed. Therefore in open air, the type of zone is directly related to the grade of release as follows (see
Step):

Grade of release Zone

Continuous 0
Primary 1
Secondary 2

“Grade of release” and “zone” are however not synonymous, as the above relationship may not exist in
different ventilation conditions. For example, poor ventilation may result in a more stringent zone.

Sheltered or obstructed areas

The air speed will be less than in open areas but substantially more than in enclosed areas. Typical
examples are structures with a roof and partial walls, closely spaced pipe racks in an open area, open air
plant where air movement is restricted by walls or large tanks, and below-grade areas such as pits and pipe
trenches. This requires a judgment call as to whether adequate ventilation = a minimum air flow rate of
12 air changes/hour is achieved. (Tip: Open areas vent at about 100 air changes per hour.) If so then the
zone will be the same as for open areas; if not then the zone should be made one grade more severe than
for open areas. The hazard radius is expanded to fill the whole sheltered area. The extent of the zoned

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area beyond a sheltered area can be less than but need not exceed the radius applicable in open air,
depending on ventilation, and the zone will be the same as inside the sheltered area.

Enclosed areas

An enclosed area is any building, room or enclosed space where adequate ventilation is not achieved
WITHOUT ARTIFICIAL VENTILATION. This implies that natural air movement is limited and flammable
atmospheres will not disperse naturally. Normally, artificial ventilation will be provided and will be assisted
by openings in walls and temperature- and pressure-induced draughts. Extraction ventilation is generally
more effective, as flammable fluids can be removed from the area. Ventilation will be qualified as adequate
or inadequate.

a) Adequate ventilation

If a minimum air flow rate of 12 air changes/hour is achieved in an enclosed space (building), flammable
gas releases occurring occasionally for short periods will be dispersed reasonably quickly viz. within 10
minutes. This implies the goal is achieved that a secondary source of release will result in a Zone 2 area.
This zone may cover the enclosed space or may be smaller for a source of small hazard radius combined
with a high enough ventilation rate. In the latter case, the hazard radius will still be larger, e.g. typically
twice the size than in open air. Continuous or primary sources of release should not be discharged
internally but should be removed by piping or extraction ventilation

b) Inadequate ventilation

Inadequate natural ventilation does not meet the requirements for adequate ventilation. The net result is
that an explosive atmosphere will persist. The flammable gas or vapour release can be internal or external.
Another example is a deep pit, sump or ditch or other below-grade structure (guideline: depth more than 6x
width). The natural ventilation rate is probably 1 air change/hour, allowing gas layering and insufficient
mixing and dilution. Such inadequately ventilated spaces should be minimized. Access must be regulated
(confined spaces).

A continuous or a primary source of release should be avoided in inadequately ventilated spaces. A

secondary source of release will generate a Zone 1 hazardous area.

The table below shows a summary.

Enclosed area with an internal source of release – Effect of ventilation on zoning within enclosed
area.

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Exercise 4
Name the three zones for gases and vapours
Complete: The zone is an indication of ………………….
Under open-air ventilation conditions there will be a direct relationship between the zone and the
…………………..
For ventilation conditions less good than open air, 2 effects may arise. Describe them.
(a) ………………….. (change in hazard radius)
(b) ………………….. (change in hazard zone)

Step 6: Size (hazard radius) and shape of zones

In this step, the hazard radius (main dimension; extent of hazardous area) associated with each source of
release is determined. It is based on:

rate or volume of release;

rate of vaporization; and
rate of dilution (ventilation).

A hazard radius should generally not exceed 30m for normal area classification purposes; in such a case
consideration should be given to modifying the facility design to reduce the release.

A. Rate of release

The rate of release is affected by operating pressure and temperature and the release properties of the
source.

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● Operating pressure and temperature

High pressure compared to ambient pressure obviously increases the rate of release of the flammable
substance.

High temperature also results in a pressure and release rate increase, as the vapour pressure increases
with temperature.

Compressed gases and cryogenic liquids are examples of substances in this category. Natural gases
(normally rich in methane and carbon monoxide) are often highly pressurized/compressed (200 to 300 bar
or 20000 to 30000 kPa) to increase their density and reaction speed and to make them more manageable.
Petroleum classification standards consider pressures in excess of 3000 kPa as high and make provision for
large hazard zones in such cases (provided of course that the capacity of the source of release is
adequate).

● Release properties of source

Typical sources of release have been defined as:

◊ Pumps, compressors
◊ Equipment drains and sample points
◊ Instrument vents
◊ Process vents
◊ Sumps, interceptors, separators
◊ Pits or depressions
◊ Pig receivers/launchers
◊ Spillages

According to IP Part 15, each of the release types is due to its design and operating pressure, responsible
for a certain rate of release. A hole size / release hole diameter / equivalent leak hole diameter is
defined.

● Hole size / release hole diameter / equivalent leak hole diameter

The hole size is defined as the size (diameter) diameter of a round hole in equipment with equivalent
release properties. It quantifies the rate of release. The method for determining hazard radii varies
depending on the grade of release:

∆ For continuous and primary grades of release, release rates and therefore hazard radii are known
from dispersion modeling because these are intended releases.

∆ For secondary grades of release, releases are typically caused by equipment failures with unknown
rates of release. If this is the case, a risk-based approach may be used to determine hole sizes
and further hazard radii.

The risk-based approach requires a so-called release frequency Level (Level I, II or III) to be
determined based on the exposure of the most exposed plant worker to potential explosions, with
the aim to prevent his risk to exceed the target of 1.0 x 10-5/yr. The Level is then used to determine
hole sizes.
NOTE – Level I is the highest release frequency and hence the highest risk, and vice versa.

In general, the release that occurs at a frequency of Level I may be used to establish the Zone 2
boundary. Higher Levels may be required if the exposure (to sources of release) is high or there is
a concentration of strong ignition sources (e.g. a flare) at the plant boundary (both factors
increasing the risk of exposure to an explosion). In a typical process plant, Level I will be
acceptable.

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B. Rate of vaporization

For a liquid, rate of vaporization or volatility is a key property since it determines the extent of rapid vapour
formation from a release. For the common facilities classified by the Direct Example approach,
classification solely based on flash point is adequate (see definition of “volatile flammable liquid” and
petroleum classes). In situations where greater variations of fluid volatility as well as operational pressure
and temperature occurs, the Point Source concept has to be applied and makes provision for five categories
of fluids, see below.

● Fluid category

The term “fluid category” is used in IP Part 15 to indicate the volatility of the released product in terms of the
operational conditions.

The fluid category is based on the flash point and boiling point (alternatively vapour pressure) of a gas or
vapour as follows.

Fluid category Description

A Flammable liquid vapourizing rapidly and substantially when released
(LPG).
B Flammable liquid, not category A, but boiling off when released (petrol).
C Flammable liquid, not categories A or B, but above flash point when
released, or forming a flammable mist/spray (methanol).
G(1) A typical methane-rich natural gas.
G(2) Hydrogen-rich gas.

The lower the flash point and boiling point of a liquid, or the higher the operational temperature, the more
rapidly it will vaporize when released and the larger the explosive volume will be. Fluid category A is
therefore most volatile and category C least volatile.

liquid flash point The minimum temperature to be exceeded to form an ignitable vapour/air mixture.

liquid boiling point The lowest temperature at which a flammable liquid will vaporize completely.

A boiling liquid creates large volumes of vapour. The volatility of petroleum products are therefore classified
in terms of their flash points and boiling points (measured in degrees Celsius or Kelvin) compared to
ambient temperature.

The hazard radius caused by a liquid above its boiling point will increase compared to the same liquid below
its boiling point.

vapour pressure A low vapour pressure (measured in pascal) often results from dilution, i.e. mixing of
flammable and non-flammable products. Water is the normal non-flammable liquid; at 22% alcohol by
volume spiritus are not considered flammable. Non-flammable gases include nitrogen and carbon dioxide.
When thoroughly mixed, flue gases are normally not flammable. (An exception is H2 and CO-rich off-gas
formed during the reduction of iron ore to produce steel). Oxygen sustains combustion but is not a
combustible product.

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Exercise 5
Which 2 parameters (temperatures) determine the fluid category of a flammable liquid or gas?

C. Rate of dilution

A synonym for ventilation rate. See Step 5.

D. Open-air hazard radii for pressurized sources of release

**REMINDER** IP Part 15 makes use of either

● For all grades of release, hazard radii derived from dispersion modeling, where a release rate is
determined based on “equivalent hole size” (normally from equipment supplier) using dispersion
modeling and product pressure, refer Tables C9(a) and (b) or Section 5.4; or

● For secondary sources of release, if these values are not available, a risk-based approach to
establish hole size from appropriate Level setting (Level I) using Table C6; then hazard radii using
dispersion modeling, as before.

Typical hazard radii for standard equipment are given below.

Pumps
Point sources include seals, vents, drains, valves, piping flanges and filters/strainers.
Normally secondary GOR as releasing infrequently; if frequently then primary GOR.
Due to variety of seal and shaft arrangements, use pump vendor data; alternatively hazard radii from risk-
based approach.

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Drains and Sample Points

GOR depends on usage. Primary if used >1/day. Drains used only for shutdown, secondary GOR.
Gas sample points or drains to be considered as equivalent to vents. Take into account sampling or
draining method (draining to ground/tundish/closed system and sampling open or closed e.g. for LPG
system).
Hazard radii from dispersion modeling, Section 5.4 or Tables C9(a) and (b) below.

Compressors
Point sources include seals, glands and joints.
Secondary GOR. Use pump vendor data; alternatively hazard radii from risk-based approach (based on
type of shaft seal, see table C6 below).

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Vents
Hazard radii from dispersion modeling, Section 5.4 or Tables C9(a) and (b) below.

TANK VENTS: Primary GOR; therefore Zone 1 BUT for low ventilation conditions, additionally explosive
atmosphere below, Zone 2 due to low frequency of such conditions occurring. Use pump vendor data;
alternatively hazard radii from risk-based approach (based on type of shaft seal, see table C6 below).

PROCESS VENTS: Includes vent stacks. Undiluted release, higher pressure than tank vents; therefore
larger hazard radii. GOR varies from C to P to S depending on operational conditions.

INSTRUMENT VENTS: Includes gas analysers. Diameter of smallest opening (e.g. line, vent or restriction
orifice) determines the hazard radii. GOR varies from C to P to S depending on operational conditions.

PRESSURE RELIEF VALVES (PRVs): Not considered. Must vent to a safe area.

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Piping Systems
Piping systems with appropriate design and construction and without valves, instruments or significant
numbers of flanges, should not be considered a SOR.
Guideline – More than 10 joints in close proximity leads to a secondary GOR.
Hazard radii from risk-based approach.

Pig receivers and launchers

Must be vented and drained before being opened.
Vents and drains should discharge to a safe location.
Hazard radii based on information for such incorporated devices.

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Liquid spills
Example: Road tanker offloading

Sumps, interceptors and separators

Sumps vented or open to atmosphere, collect flammable materials, considerable amounts.
Space within walls primary or secondary GOR, enclosed therefore resulting in Zone 0 or 1. Hazard radius –
Use R1 from Table 5.7 from periphery of sump, Zone 1/2 if source primary/secondary.
Interceptors and separators vented or open to atmosphere, small amounts of flammables.

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Exercise 6
Name the three factors (rates) that determine the size of a zone.
What is the main (horizontal) dimension of a zone called?

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Shape open-area zones (pressurized releases):

Releases from pressurized sources

- Shape unrelated to RD
- Spherical shape, changed if ground effect (release close to ground or other solid boundaries)
- Hazard radius = R1

E. Releases from non-pressurized sources

- Examples: Road tanker manhole covers, sumps, pools.

- Vapour pressure too low for dispersion modeling, use engineering judgment and experience.
NOTE – May be aided by gas sensing, even smell.
- Can get collection of heavier-than-air vapours in below-grade spaces such as pits, sumps, bunded
areas.
- Normally covered by Direct Examples.
- Lighter-than-air releases will disperse readily: H2, NH3.

Hydrogen

20 uJ

4% 28 % 76 %

Concentration in Air [% Vol] From: BBC Manual

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Exercise 7
What is the shape of a zone caused by a pressurized release?
Determine (i) zones and (ii) hazard radii according to IP Part 15 for:
a) Seal of centrifugal pump. Single mechanical seal. Shaft diameter 50mm. C4-C9 petroleum liquid
pumped at 300 kPa.
b) Seal of centrifugal pump. Double mechanical seal with barrier fluid. LPG pumped at 20000 kPa.
c) Flanged pipeline. Highly toxic gas. Maintained on a weekly basis.
d) PRV connected to a flare.
e) Monthly cleaning of a filter in a hexane system. Product passed through bypass line while cleaning (1
hour).
f) Open vent on diesel storage tank.
g) Inside of 5x8m sump in oily sewer system where volatile liquid lighter than and not soluble in water is
released on a regular basis.
h) Hourly sampling of LPG involving a sample bomb connected into a bypass line.
i) Exhaust of flare stack. No pilot flame or automatic flame detection. Release rate 100Nm3/h.
j) Analytical laboratory. Maximum of 100 litres of volatile product. Small open containers on a bench or
inside fume cupboard.

Step 7: Rationalize
This term has been created by the author but is based on the well-known fact that in a typical plant, many
Zone 2 locations exist, few Zone 1 locations, and few Zone 0 locations internal to the process equipment
(relation Zone 2:1:0 approximately 96:3:1%).

Zone 2 locations often overlap and fill a large percentage of the plant space.

Because in this case it is not financially and operationally beneficial to identify and exclude intermittent safe
locations, the classification is simplified by defining a Zone 2 “background” to create a “raisin cake”
classification.

The classification is further simplified by using natural plant borders as the hazardous location borders,
provided of course that the hazard volumes do not extend beyond these borders.

To determine the extent of a consolidated Zone 2 area, it is normally adequate to only consider the major
sources of release and those close to the plant periphery.

Step 8: Properties of explosive atmospheres

lower and upper explosive limits (respectively LEL and UEL) Respectively the lowest and highest
concentration in air of a flammable gas or vapour that forms an explosive mixture.

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Relation between ignition energy and concentration of a gas or vapour

The LEL (measured in % by volume) is of particular importance for dilution, as the size of the explosive
volume formed around a source of release depends on how much dilution must take place. A concentration
of not more than 20% by volume of the LEL is normally considered safe. Most organic products have a LEL
of 1-2%, while the LEL of ammonia is 16% tending to reduce its hazard radius considerably in conjunction
with its low density (60% of air) and resulting good dispersion properties.

Note Ammonia is known for being difficult to ignite. It is widely used in refrigeration systems and to produce
fertilizers and explosives and is therefore an important industrial material. In terms of being a source of
release, the following is recommended in SANS 10147: Standard electrical equipment may be used on
ammonia refrigeration systems, except that explosion protected auxiliary equipment (emergency lights,
extraction fans etc) must be used, provided that suitably positioned gas detectors set at 1% by volume
ammonia and connected to an audible/visual alarm system are installed. The gas detectors shall be
interlocked with circuit breakers remote from the refrigeration system that can isolate electrical supply to the
refrigeration system and with equipment to increase ventilation.

minimum ignition temperature (MIT) The MIT (measured in degrees Celcius or Kelvin) of a flammable
gas or vapour reflects how much energy has to be produced by a potential ignition source to ignite an
explosive atmosphere. The MIT relates to ignition by a heat or a hot surface (as opposed to ignition by a
spark or flame, that is a completely different mechanism).

temperature class The temperature class of a flammable substance is indicative of the range into which its
MIT falls, as follows:
T6 85 – 100°C
T5 100 – 135°C
T4 135 – 200 °C
T3 200 – 300°C
T2 300 – 450°C
T1 > 450°C

NOTE – Methane is a T1 gas, as is hydrogen.

minimum ignition energy (MIE) The MIE (measured in microjoules) of a flammable gas or vapour reflects
how much energy has to be produced by a potential ignition source to ignite an explosive atmosphere. The
MIE relates to ignition by an arc, spark or flame (as opposed to ignition by a hot surface, that is a completely
different mechanism).

gas group The gas group of a flammable gas or vapour is based on either its MIE or its MESG; the latter is
the maximum gap that will not allow flame transmission under certain test conditions. The two methods
generally give the same result, as both are related to the energy that must be withdrawn from the burning
gas or vapour to extinguish it (the MESG test simulates the action of a flameproof joint).

There are two main groups, ie I and II, for respectively underground mines (slightly impure methane) and
surface plants. Group II is further subdivided into IIA, IIB and IIC.

The preceding figure shows a typical ignition energy versus concentration graph for gases and vapours, in
this case for hydrogen gas. It is obvious that the ignition energy required to have a hydrogen explosion
varies according to the concentration of hydrogen in air. Hydrogen requires an ignition energy of only 20μJ
making it the explosive gas with the lowest minimum ignition energy (MIE).

Note further that not all mixtures of hydrogen with air are explosive (although the explosive range is quite
wide); hydrogen mixtures with air will only be explosive in the concentration range of 4 to 76% by volume.

The same trends exist for other explosive gases and similar curves can be drawn for them. Methane, for
example, is explosive between 5% to 15% in air and acetylene from 1,5% to 80 % in air. This indicates that
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acetylene has a wider explosive concentration range than hydrogen and methane a smaller one. The limit
concentrations are called the lower and upper explosive limits (respectively LEL and UEL).

6.3 Data sheets

Two typical data sheets are presented in SANS 60079-10-1 that are shown here with some adaptations to
align with IP Part 15.

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● Sheet for properties of flammable materials

Gases and Liquids

Facility: GAS PRODUCTION Area: STORES

No. Materi Composition Relative Flash LEL UEL Boiling Vapour Auto-ignition Group of Temp.
al density point % % Point pressure temperature explosive Class
(air=1) (°C) (v/v) (v/v) (°C) at (°C) atmosphere
operating
T (kPa)
G1 LPG 50:50% by mass 1.75 Gas 1.5 10.5 Gas Gas 450 IIA T3
propane:butane
G2 Paints Solvents and >1 >93 >200 IIA T3
resins (typical) (typical)
(hydrocarbon
based), typically
Xylene, Naphtha

Solid materials

No. Material Group of Layer smouldering Cloud ignition

explosive temperature (°C) temperature (°C)
atmosphere
S1 Bituminous coal dust. IIIC 225 (typical) 580 (typical)

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● Sheet for zoning

Gases and Liquids

Facility: PAINT ROOM Area: MAIN PRODUCTION AREA

Equipment SOR Grade Flammable Material Ventilation Hazardous Area EPL Reference
ID Item of Material P T State Type Degree Availa= Zone Horiz Vert
release No. (kPag) (°C) (S/A/B/ (N/A) (Open-air/ bility (m) (m)
(C/P/S) C/ G(i)/ Adq/ (G/F/P)
G(ii)) Inadq)
ABC Projects, P1453-X450-002 Rev. E - Process Flow Diagram.
X1 Open or Liquid S G2 Atm Atm C A Adq G 2 Room Gc IP Part 15, Clause 6.
leaking surfaces
containers
NOTE 1 – Abbreviations used: Ventilation type: N Natural
SOR source of release F Forced/artificial
Grade of release: C Continuous Ventilation availability: G Good
P Primary F Fair
S Secondary P Poor
P: Pressure
T: Temperature
State: S solid
A fluid category A
B fluid category B
C fluid category C
G(i) fluid category G(i)
G(ii) fluid category G(ii)

Solid materials

Facility: R.O.M. STOCKPILE FEED CONVEYORS, STOCKPILE Area: SURFACE COAL HANDLING
AND DRAW POINTS

Equipment SOR Grade Flammable Material Ventilation Hazardous Area EPL3 Reference
ID Item of Material P T State Type Degree Availa= Zone Horiz Vert
release No. (kPag) (°C) (S/A/B/ (N/A) (Open-air/ bility (m) (m)
(C/P/S) C/ G(i)/ Adq/ (G/F/P)
G(ii)) Inadq)
ABC Projects, P1453-X450-001 Rev. E - Process Flow Diagram.
X2 R.O.M. Dust - S1 Atm Atm S N Open-air G Fire - IP54 SANS 60079-10-
Stockpile layers on hazard min. + 2 Clause 7.
Feed equipment Tmax.
Conveyors
- R.O.M. - - S1 Atm Atm S N Open-air G 22 ≤1m Dc SANS 60079-10-
Stockpile 2.

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Module 7: More on Ventilation

7.1 Introduction

As stated earlier, ventilation in locations where flammable gases or vapours occur, could serve to reduce
the extent of a hazardous location, or could so affect the frequency and duration of an explosive
atmosphere that a less hazardous zone can be allocated.

NOTE - Ventilation is however counter-productive in locations where flammable dusts are present - either in
conjunction with flammable gases/vapours or separately - and can actually promote the formation of
explosive dust clouds.

Some more ventilation aspects are introduced in this Module.

7.2 Types of ventilation

Ventilation can be natural or artificial.

natural ventilation Air movement caused by the forces of nature.

artificial ventilation Air movement caused by man-made machines. This includes dilution ventilation and
overpressure ventilation.

7.3 Artificial ventilation

Dilution ventilation

Dilution ventilation is artificial ventilation of sufficient capacity to reduce a hazardous location to a safe
location, ie the flammable gas or vapour is diluted at the source of the release to such an extent that the
hazard radius becomes negligibly small. It is used in enclosed areas, normally as localized ventilation in
situation (c) described above, as this form of ventilation is more effective and cheaper (lower air
consumption) than general ventilation. Typical figures for the flow rate required are 90 volume
changes/hour for a gas turbine hood and 30 volume changes/hour for a closed analyser house. Ventilation
must be monitored; ventilation failure will within a short space of time result in formation of an explosive
atmosphere and therefore requires automatic (by interlocking) isolation of non-explosion protected
equipment or switching off processes that produce flammable gases and vapours.

Overpressure ventilation

Overpressure ventilation is artificial ventilation of an enclosed area not containing a source of release. By
pumping fresh air into the enclosed area, an overpressure (at least 50 Pa) compared to the surrounds is
created and the flammable gas or vapour is not allowed to penetrate the enclosed area. The enclosed area
should be fairly well sealed to keep the air consumption low. Ventilation must be monitored; ventilation
failure will within a short space of time result in formation of an explosive atmosphere and therefore requires
automatic (by interlocking) isolation of non-explosion protected equipment or switching off processes that
produce flammable gases and vapours.

Overpressure ventilation can also be used to maintain an enclosed area containing only secondary sources
of release as Zone 2, even if the surrounding area is Zone 1 or 0.

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Standards for applying artificial (dilution and pressurization) ventilation

The concepts of dilution and pressurization ventilation are discussed given in SANS 10119, although the
specific terms are not used.

The IEC 60079 series have three parts dealing with dilution and pressurization ventilation and providing for
certification of such ventilated enclosures:

Part 2 deals with the pressurization ventilation (called pressurization) of equipment enclosures.

Part 13 deals with the pressurization ventilation (called pressurization) of rooms, buildings and modules (eg
control rooms, electrical substations).

Part 16 deals with the pressurization ventilation of analyzer houses. Since internal as well as (possibly)
external sources of release are present, dilution as well as pressurization ventilation are required (the former
is called pressurization by continuous dilution).

Practical limitations of artificial ventilation

◘ Operator tolerance: The tolerance limit of operators is approximately 6 air changes/hour or 0,3m/s.

◘ Loss of product: Volatile products being placed under vacuum in an extraction system.

◘ Loss of heat

◘ Size of ventilated area: General artificial ventilation can only be applied to relatively small enclosed
areas if the purpose is dilution.

Optimization of ventilation

The direction of air flow has to optimize dilution; for example from top to bottom for heavier-than-air vapours
(as opposed to natural ventilation that is normally restricted from bottom to top due to thermal effects/rising
of hot air inside buildings with heat-generating equipment.

Ventilation failure

The monitoring of ventilation needs to be reliable, either (a) direct monitoring with flow or pressure switches
or (b) indirect monitoring with gas sensors, although monitoring of fan motor current can sometimes be used
in a Zone 2. The monitoring equipment must be suitably explosion protected.

Following ventilation failure, an audible/visual alarm must be activated. In cases where ventilation failure
will within a short space of time result in formation of an explosive atmosphere, automatic (by interlocking)
isolation of non-explosion protected equipment is required; alternatively processes that produce flammable
gases and vapours can be stopped. These precautions are normally required when the source of release is
continuous or primary. In other cases, a procedure must exist to determine when isolation must be
manually applied. The point of isolation must be in a safe location.

In cases where reliability of ventilation is critical, means such as a back-up fan or emergency electrical
supply for the fan can be applied.

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Discharge versus suction artificial ventilation

Advantages of the two types of artificial ventilation are:

Discharge ventilation Suction (extraction) ventilation

Considerable reach. Note: Reach limited to one fan diameter (suction
ventilation combined with discharge ventilation
delivers good results).
Ducts under positive pressure; no contamination Note: Ducts under negative pressure.
of ventilation air.
Standard fan if in-line. Note: Explosion protected fan.
Enclosure under positive pressure: Keeps dust Note: Enclosure under negative pressure.
an external vapours out.
Cooling of equipment
Laminar flow (flow rate <2m/s) can be sufficient if
no ignition sources in air flow.
Vapours are removed at point of release; smaller
hazard radius than discharge ventilation.
Lower air speed; better creature comfort.
Can remove/filter out contaminants.
Can remove toxic products.

7.4 Gas sensors

Their ability to measure gas/vapour concentration relative to the LEL allows gas sensors to be used for a
number of applications:

a) To alert operators to large gas or vapour clouds formed by secondary sources of releases such as
draining or filling of vessels, cleaning of equipment, spillage.
b) To define the border of a hazard zone in cases of large enclosed areas depending on natural
ventilation that is influenced by the weather and process conditions.
c) Can have two settings, ie an early warning setting (eg 20% of LEL) and a power trip setting (eg 50%
of LEL).

Gas sensors need to be:

- self-calibrating and self-diagnosing and of fail-to-safe design;
- resistant to environment, eg poisoning gases, dust; and
- carefully positioned and set to be effective.

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Module 8: Practical Example of the classification of a meter station

8.1 Determining system parameters

The first step in determining the area classification is to gather information that will asset with the determination of the
extent of the zone as detailed below:

a) Site location and parameters (should metering station be open to atmosphere)

Criteria Units Value
Site location: Johannesburg, South Africa
Altitude above mean sea level M 1684
Average Minimum Temperature ºC 0
Average Maximum Temperature ºC 35
Average relative humidity % 50
Average rainfall per annum mm/yr 604
Prevailing wind direction N
Wind speed (Average) m/s 6.9

b) Determining the process parameters.

The Gas Metering Station has the following operating conditions:
1) Maximum temperature(Ambient temperature) : +40°C
2) Maximum pressure : 380 kPa
3) Location : Inside a closed room
8.2 Table of Flammable Materials
The flammable material present, Liquefied Petroleum Gas (LPG), is as listed with their properties
summarised in Table 1 below. The MSDS of LPG is included as Appendix A.
Composition Molar Relative Flash Ignition Boiling Vapour
Mass density to Point Temp Point pressure
(kg/kmol) air ºC ºC ºC at 20ºC
Liquefied kPa
Petroleum Butane/Propane/Propylene 44.10 1.75 N/A 450 -42 N/A
Gas (LPG)
LFL (Vol %) Equipment Temperature
Group Class
2.2 IIA T2

8.3 Sources of release

Flow Regulator, Valve & Meter Flanges:
Flanges used to connect the LPG supply line through a flow regulator; valve and meter may leak with the
deterioration of seals over time. As detailed in SANS 60079-10-1 this is considered a secondary source
of release that is only affective during abnormal conditions.

Meter probe point:

The meter probe is inserted into the supply line to measure the pressure and temperature of the LPG.
Deterioration of the seal or improper installation of the probe may result in leakage. . As detailed in
SANS 60079-10-1 this is considered a secondary source of release that is only affective during
abnormal conditions.

8.4 Grades of Release

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From the descriptions given under (5.2) above it is clear that the sources of release may be classified
per type of source. Hence, the grades of release are also classified according to type of source as
summarized in Table 2. It is important to note that for each source type the grade of release is the
same. This is an acceptable approach as described in SANS 60079-10-1:2016.

8.5 Determination of Zones

By taking the ventilation, ambient conditions, process conditions and the released material into
consideration, the following Zone classification is concluded:

TYPE OF SOURCE GRADES OF RELEASE

Total
Connection or Equipment duration of Zone
Grade Comments
Equipment type Description explosive Classification1
atmosphere
Flanges used to
connect
Up to
Flanges regulator and Secondary Zone 2
10h/year
meter to the
LPG supply line

Up to
Meter probe Meter Secondary Zone 2
10h/year

1
Zone classification in accordance with the recommendation of SANS 60079-10-1: 2016 Table D1

8.6 Zone Details

The steps as proposed in SANS 60079-10-1: 2016 were followed to determine the release rates and
effects for LPG in this situation.

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Module 9: Working Group Approach and Records

9.1 Team approach

Classification of hazardous locations should only be undertaken by well experienced, multi disciplinary
teams. The Occupational Health and Safety Act, 1993 (Act 85 of 1993) and the Mine Health and Safety Act,
1996 (Act 29 of 1996) require the owner (user) of the plant or mine to classify potentially hazardous
locations (in the latter Act, some compulsory hazardous locations are specified), and as such it is the
owner’s responsibility to ensure that hazardous location studies be undertaken at regular intervals to ensure
that all modifications to the plant or mine that could affect the hazard are taken into account.

9.2 Information required

A hazardous location classification study should only be undertaken once full information regarding the
process is known. This information that should be available includes the full characteristics and properties
of all explosive materials used, handled or produced in the process, process conditions, normal and less
frequent (eg maintenance) processes, equipment construction, sources of release and duration of releases,
plant or building layouts and materials of construction, and ventilation conditions. Ypical documents
considered are:
○ Process descriptions
○ List of flammable materials, properties e.g. MSDSs, locations
○ Site layouts and General Assemblies (GAs)
○ Process and Instrumentation Diagrams (P&IDs)
○ Process Flow Diagrams (PFDs), Mechanical Flow Diagrams (MFDs)
○ Existing area classification drawings (if operational plant)

9.3 Participants

○ Main Engineering Construction Company: Project Manager, Process, Electrical/Instrumentation,

Mechanical
○ Subcontractors
○ Client/end user/plant owner: Project Manager, Process, Civils, Electrical/Instrumentation

9.4 Engineering issues

The classification principles set out in previous Modules are applied to derive at the appropriate
classification. An overview of flammable materials, whether they can be released and whether there is the
potential for them to form explosive atmospheres when released (draft area classification) should be done
initially. At this stage, it is essential that a classification strategy is discussed and agreed. This includes
aspects such as:

- The level of detail and depends on the size of the plant and considerations such as cost of initial
installation versus cost and complexity of maintenance. For example, two almost identical plants in
terms of equipment, slightly different flammable materials. One plant classified, other not.
Possibility of swopping of equipment real. In addition, second (safe) plant can use different/more
volatile flammable materials in future.
- Staff skill level and approach to maintenance (in-house, subcontracted).
- Initial costs versus cost of maintenance
- Standards to be used. Single standard for gases and vapours and another for dusts. Only
exception, when provision is not made for particular equipment (Example: Use of API RP505 for
horizontal storage tank when main classification standard is UK IP Code Part 15).

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- Differentiation between process streams, between different process conditions (Examples (a) gas
with 50% by volume flammable product vs 30%; (b) pressure 3000 vs 300 kPa; (c) gas composition
IIA → IIB).

9.5 Documentation records

It is strongly recommended that the classification study be fully documented. The documentation should
cover all issues considered in deciding on the final classification. All assumptions and calculations made
should be included so as to ensure full traceability of the process at a later stage.

Report/minutes

At the very least, minutes of a hazardous location audit meeting should be kept. The ideal is to compile a
document (report) detailing the information mentioned in 9.1 and in addition the decisions taken on the
classification and the reason for certain choices or preferences.

Material Properties and Zoning Tables

Hazardous location drawings

Hazardous location drawings both in plan and elevation (and sections where necessary) should be
produced for all hazardous locations other than simple blanket type classifications of defined areas. The
drawings should show both the type and extent of zones. Small zones (eg a Zone 1 cause by a sampling
point) may be described in a Note on the drawing. Tables should be included of the properties of flammable
materials present. Examples of tables that can be used are given in Annex C of SABS IEC 60079-10. The
inclusion of a signature block for plant management promotes the ownership of the classification and
defines responsibility.

It is strongly recommended that the drawings refer to the report mentioned below.

Example of area classification drawings are shown in this Module.

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Typical area classification of surface operations where explosive vapours are present

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Typical area classification of surface operations where explosive vapours are present (2)

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Module 10: Demarcation of Hazardous Locations

SANS 10108 recommends that hazardous locations be physically demarcated to assist with access control,
the inspection of apparatus and hot work. Although an international convention for demarcation does not
presently exist, the following guideline may be used.

 Identify location as hazardous, specify zones

 Plant control room - classification drawing(s)
 Plant entry points/borders –

Ex
 Mine – flashing light, physical border

Distinctive features:
- triangular shape
- black letters on a yellow background with black edging (the yellow part to take up at least 50 %
of the area of the sign).

Other explanatory data may be added, see examples below.

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Bibliography
Information has been obtained from several publications including the following.

1. SANS 10087-1 The handling, storage and distribution of liquefied petroleum gas in domestic,
commercial, and industrial installations - Part 1: Consumer liquefied petroleum gas cylinder
installations.
2. SANS 10087-3 The handling, storage and distribution of liquefied petroleum gas in domestic,
commercial, and industrial installations - Part 3: Bulk liquefied petroleum gas and allied facilities at
consumers’ premises.
3. SANS 10087-7 The handling, storage and distribution of liquefied petroleum gas in domestic,
commercial, and industrial installations - Part 7: Storage and filling sites for refillable liquefied petroleum
gas (LPG) containers of capacity not exceeding 9 kg.
4. SANS 10108 The classification of hazardous locations and the selection of apparatus for use in such
locations.
5. SANS 10089-2 The petroleum industry, Part 2: Electrical installations in the distribution and marketing
sector.
6. SANS 10119 Reduction of explosion hazards by segregation, ventilation and pressurization of electrical
equipment.
7. SANS 60079-10-1 and 10-2 Electrical apparatus for explosive gas atmospheres - Part 10: Classification
of hazardous areas.
8. SANS 60079-20 Electrical apparatus for explosive gas atmospheres - Part 20: Data for flammable
gases and vapours relating to the use of electrical apparatus.
9. American Petroleum Institute Recommended Practice 500: 1997 Recommended Practice for
Classification of Locations for Electrical Installations at Petroleum Facilities Classified as Class I,
Division 1 and Division 2.
10. American Petroleum Institute Recommended Practice 505: 1997 Recommended Practice for
Classification of Locations for Electrical Installations at Petroleum Facilities Classified as Class I, Zone
0, Zone 1 and Zone 2.
11. NFPA 497: 1997 Recommended Practice for the Classification of Flammable Liquids, Gases, or Vapors
and of Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas.
12. NFPA 52: 1992 Compressed natural gas (CNG) vehicular fuel systems.
13. Institute of Petroleum (UK) Model code of safe practice in petroleum industry – Part 9: Liquefied
petroleum gas. Volumes 1 and 2.
14. Institute of Petroleum (UK) Model code of safe practice in petroleum industry – Part 15: Area
classification code for petroleum installations.
15. Imperial Chemical Industries Ltd (UK) Electrical installations in flammable atmospheres, Engineering
codes and regulations.
16. LP Gas Association’s Code of Practice 1-1, Code of Practice 1: Bulk LPG Storage at Fixed Installations,
Part 1: Design, Installation and Operation of Vessels Located above Ground.
17. LPG Association/Institute of Petroleum Technical Memorandum No 70 Storage and dispensing of LPG
as an automotive fuel at petrol filling stations.
18. HSE Petroleum Installations (SABS 1020 file).
19. Institute of Gas Engineers, IGE/SR/25 Hazardous Area Classification of Natural Gas Installations.
20. AS/NZS 2430 Classification of hazardous areas.
21. HG Bass Intrinsic safety, Instrumentation for flammable atmospheres. Quartermaine House Ltd, 1984.
22. RH Garside Area classification - An alternative approach. IEE 5th International Conference on
Electrical Safety in Hazardous Environments, April 1994.
23. JA Bossert Hazardous locations, Guide for the testing, construction, and installation of equipment in
explosive atmospheres. Canadian Standards Association, 1994.
24. WF Hickes and KJ Brown Assessment of explosion probability for intrinsically safe apparatus.
Conference on Electrical Safety in Hazardous Environments, IEE, 1971.
25. Sira Area Classification Course Notes, November 2002.

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