Hazardous Area Classification

Electrical Engineering Training Module 1

October 27, 2006
Fluor Canada
Instructor: Allan Bozek, [Link].
This Training Opportunity Brought to you
by:

Kelvin Downs
Your Departmental Manager
2
Safety Moment

Ladder Safety
„ Are ladders the safest
means of access?
„ Are they properly suited
to the task?
„ Are the bases on firm
footing?
„ Do not place objects on
the top rung of
stepladders!!!

3
Premise for the Course

„ An area classification as designated by a

Professional Engineer is the area classification
• Done under professional seal
„ The classification of facilities have become more
complex
„ Need for consistency in design approach and in
documentation
„ New set of Guidelines published in the appendix of
the 2006 “Code for Electrical Installations at Oil and
Gas Facilities”

4
Learning Objectives

1. Provide you with the ability to analyze an oil, gas or chemical

processing facility and establish the degree and the extent of
a classified area.
2. Provide you with an overview of the various Codes and
Recommended Practices developed for area classification
3. Provide guidelines on how to properly document your analysis
and communicate it to third parties; who will rely on this
information for subsequent design, installation and operating
activities.
4. Provide you with an introduction to some of the various
options available to you for classifying a facility and when they
are appropriate for use.

5
Course Parameters

ƒ Will focus on Class I Hazardous Areas

• Class II and Class III areas are not covered

ƒ Zone method of area classification

• Division method will be referenced where
differences exist

ƒ North American Design and Construction

Standards as established by the CEC
• References will be made to international
standards where appropriate

6
Definition of a Hazardous Location

“Hazardous location means premises, buildings, or

parts thereof in which there exists the hazard of fire
or explosion due to…”
• Flammable gases and liquids
• Combustible dust or flyings
• Ignitable fibres and materials

CEC Section 0
7
Background History

„ Concept of a “Hazardous Location” was first

developed in the coal mining industry
• Methane and coal dust the primary
hazards
• Light and power essential to mining
operations

8
One Way of Managing the Hazard

The First “Fireman”

9
The Davy Safety Lamp

Sir Humphrey Davy

10
Background History

„ Introduction of Mechanical Ventilation to

reduce the hazard
• Primary means of hazard control used today
„ Totally enclosed motors often contained an
explosion
• Led to the development of the XP enclosure
„ Concept of intrinsic safety developed

11
Background History

„ 1920 “Extra Hazardous Location” added to the NEC

• UL labs were certifying equipment for use in hazardous
locations
„ Class I and Class II designations added in 1931
„ Class I Group designations added in 1935
„ Concept of Division 1 and Division 2 added in 1947
„ Temperature code classification added in 1971
„ Zone Area classification option added in 1996

12
Purpose of an Area Classification
Historical

„ “Identify the possibility of an explosive atmosphere

being present and influencing the design of the plant
or facility to minimize the risk of ignition”

„ Based on normal operating conditions - does not deal

with the potential of catastrophic failures

„ Primarily used for establishing the type of electrical

equipment and wiring methods that can be used
within a hazardous area

13
Purpose of an Area Classification
Present and Future

„ ATEX Directive
• Essential Health and Safety requirements with
respect to:
– Potential ignition sources from equipment in
hazardous locations
– Applies to non-electrical equipment
„ Alberta OH&S Requirements
• Hazardous area classification is used as a basis
for implementation of the OH&S code
– Regulates the work activities performed within
a classified location

14
Who is impacted by an Area Classification?

„ Engineering
„ Equipment manufacturers
„ Installers
„ Inspectors
„ Operations and Safety Personnel
„ Insurers

15
What is Impacted by a Hazardous Area
Classification?

Cost of Ownership
„ Materials
• Overall installation Cost is 50% greater for Division 1
locations when compared to Division 2
• Cost difference is less between Zone 1 and Zone 2

„ Installation
• Higher standard of care required for Zone 1 areas
• Inspection requirements are greater

„ Maintenance
• Ongoing maintenance costs are greater for Zone 1 areas

16
Safety

„ Defines the risk associated with the

performance of activities within an area

„ Defines (by code) the standard of care

required for installing, operating and
maintaining equipment within an area

17
Operations

„ Hot Work Permitting Requirements

• Provides a basis for Restricted access
„ Special procedures
• Requirement for sniffing the area for gas before
performing basic tasks
• Shutdown of equipment components before
inspection or repair
All this may have an impact on the on-line
performance of a facility

18
Defining the Hazard
The Fire Triangle

For an explosion or fire to

occur, all three elements of

I gn
the fire triangle must be

itio
present

el

nS
Fu

ou
rce
Oxygen

20
Probability of Events

Full House 1 in 500

Royal Flush 1 in 650,000

Lotto 649 Win 1 in 13,984,000

Dying 15 minutes after you bought your 649 ticket 1 in 14,000,000

Probability of an explosion from 1 gallon of 1 in 59,000,000

hydrocarbon

Probability of a simultaneous failure of both 1 in 64,000,000

process and electrical equipment

21
Relative risk of explosion within a process area

100000

Tons of Hydrocarbon Release

10000

1000

100

10

1.0

0.1

100%
1.0%
0.01%

0.1%

10%

% Probability of Explosion
22
Probability of a Component Leak
(Source API 4615)

Minor
Leaks
10 to Major Leaks
Components 9999 >10,0000
Facility Type Screened No Leaks ppmv ppmv

Light Crude 48652 97.90% 1.11% 0.90%

Heavy Crude 13756 99.54% 0.43% 0.00%

Gas Production 40178 96.23% 2.15% 1.61%

Gas Plant 57126 96.28% 1.73% 1.97%

Offshore
Platform 45694 98.60% 0.81% 0.77%

Totals 205397 97.41% 1.39% 1.18%

23
 Ignition Sources of Major Fires
Source: Factory Mutual Engineering Corp.

Source Percent of Accidents

Electrical 23
Smoking 18
Friction 10
Overheated Materials 8
Hot Surfaces 7
Burner Flames 7
Cutting, Welding, Mech. Sparks 6
Static Sparks 1
All Other 20

24
Rew and Spencer Model

Category Examples of Ignition Sources Ignition

(Strength of Potential
Source)
Certain Pilot Lights, Fired Heaters, Flares p=1
Hot Work, Electrical Faults,
Strong Smoking p > 0.5

Vehicles, Substations, Unclassified

Medium electrical equipment, Engines, Hot 0.5 > p > 0.05
surfaces
Office Equipment, Electrical
Weak Appliances, Mechanical Sparks, p < 0.05
Static electricity
Intrinsically safe equipment,
Negligible Radio Frequency Sources p=0

25
Hazardous Area Classification Risk
Assessment

„ Based on the likelihood of a flammable mixture being

present
„ Source of ignition is not a criteria for classification of
a location
„ Must be carried out before the choice of appropriately
certified equipment is made
„ Requires an understanding of process, mechanical
and electrical engineering concepts
„ Requires an understanding of the various codes and
practices and knowing which one is most suitable for
a given situation

26
Hazardous Area Classification Risk Assessment

„ Subjective in nature and will be influenced by:

• Standards and practices within an operating company
• Practices that vary between upstream, downstream and
offshore facilities
• Size and complexity of a facility
• Remote, unmanned or inaccessible facilities
• Cold weather facilities
• Operations Experience

27
Probability that an Explosive
Atmosphere will exist depends on:

„ Flammable Material Present

„ Source of Release
„ Grade of Release
• Continuous (>1000 hrs per year)
• Primary (10-1000 hrs per year)
• Secondary (1-10 hrs per year)
„ Rate of Release
„ Degree of Ventilation

28
Extent of a Hazardous Area Classification
depends on:

„ Properties of the flammable material

• Concentration
• Volatility
• Liquid temperature
• Density
„ Release rate
• Geometry of the Source of Release
• Release velocity
„ Ventilation
„ Climatic conditions
„ Topography

29
“Group Responsible” Concept

“final determinations of the classifications should involve

coordinated efforts between process engineers,
facility design engineers, fire and safety specialists,
instrument and electrical engineers”

“should also include operations and maintenance

personnel”

30
Codes, Standards and
Recommended Practices
Canadian Electrical Code
CSA C22.1 Part 1

32
Canadian Electrical Code

„ Sets the minimum standards for electrical

installations in hazardous areas
• All or portions of the code may be mandated by
law by the Authority having Jurisdiction
„ Section 18 deals with Hazardous Locations classified
using the Zone Method
• Zone Method of Classification is the required method for new
installations
• Appendix B incorporates an extensive commentary on
Section 18 – well worth reading
„ Appendix J refers to locations where the Division
method of classification is used
• Division method may be employed for existing installations
at the discretion of the Owner/User

33
 Canadian Electrical Code

CEC Section 20 provides guidance on area classification

for:
• Commercial Garages
• Aircraft Hangers
• Motor Fuel Dispensing Facilities
• Bulk Storage Plants
• Paint Application Facilities

34
CSA C22.1 (CEC Section 19)

35
CSA C22.1 (CEC Section 19)

„ Section 19 provides guidelines for upstream oil and

gas and drilling facilities
• Does not apply to
– Petroleum refineries
– Petrochemical facilities
– Gas distribution systems operated by a Utility
– Fuel supply systems for equipment

„ Not Mandated in all jurisdictions

36
CSA C22.1 (CEC Section 19)

„ Rule 19-100 (1)

• Classifications of hazardous locations established and
documented by a professional engineer under the engineer’s
seal and signature shall be the area classification
„ Appendix D19
• Engineering Guidelines for Determining Area Classification

37
CEC Standata

„ Code clarifications and

updates between formal code
book updates
„ Specific references to Section
18 and 19
„ On-line e-mail subscription is
available

[Link]/mahome/ss/safety/[Link]
38
Alberta OHSA Requirements
Part 10 – Fire and Explosion Hazards
„ Section 162 – “Employers must
insure that flammable and
combustible substances in the
workplace do not ignite”
„ “No worker may enter an area
where the atmosphere LEL
exceeds 20%”
„ Regulates placement of IC
engines, fired heaters and other
equipment in hazardous
locations
„ Requirements for static control
and hot work permitting
requirements

[Link]
39
API RP 500 & RP 505

40
API RP 500

„ API 500 refers to Division Classified area as defined

in Article 500 of the NEC
„ Issued in 1955
• Originally designed for petroleum refineries

„ Companion documents issued in 1966

• RP500B – Production Facilities
• RP500C – Gas Pipeline Transportation Facilities

„ Three documents recombined in 1991

41
API RP 505

„ API 505 refers to Zone Classified areas as defined in

Article 505 of the NEC
„ Issued for general use in 1997
• Incorporates several appendices not found in RP 500
„ Current bases for CEC Section 18
• Zone system adopted to improve safety, reliability,
maintainability and uniformity
„ Applicable to:
• Refineries
• Drilling and production facilities
• Offshore drilling and production facilities
• Pipeline facilities

42
API RP 500 & RP 505

„ Prescriptive in nature
• if this is the situation – this is how you should classify the
area.
„ Does not attempt to describe the properties of
flammable materials
• Makes reference to NFPA 325
„ Concepts are referenced from a variety of North
American and International publications
„ Incorporates more figures and diagrams than all
other API documents
„ The extent of classified areas indicated are based on
experience

43
RP 505 Figure 20

44
RP 505 Table of Contents

1. Scope
2. References
3. Definitions
4. Basic Conditions for a Fire or Explosion
5. Flammable and Combustible Liquids, Gases and
Vapors
6. Classification Criteria
7. Extent of a Classified Location

45
RP 505 Table of Contents

8. Recommendations for Common Applications

9. Recommendations for Petroleum Refineries
10. Recommendations for Drilling Rigs and Production
Platforms
11. Recommendations for Offshore Drilling Platforms
12. Recommendations for Offshore Production
Platforms
13. Recommendations for Pipeline and Transportation
Facilities

46
API 505 Appendices

A. Sample Calculations to achieve Adequate

Ventilation by Natural Means
B. Calculation of Minimum Air introduction to achieve
Adequate Ventilation using Fugitive Emissions
C. Preferred Symbols
D. Alternative method for Area Classification
E. Procedure for classifying areas
F. Alternative Ventilation Criteria

47
NFPA 497

„ Developed for the

classification of
chemical process plants
• Based on the premise that
the classification of
chemical plants should be
less strict than for
petrochemical facilities
• Appropriate for small to mid
size chemical plants

48
NFPA 497

„ Makes reference to both the Zone and Division

method of Classification
„ Incorporates an extensive list of Flammable and
Combustible materials c/w their physical properties
„ Size of a classified area is dependent on the volume,
pressure and flow rate within the process
„ Incorporates a list of point source diagrams to assist
the user in defining the extent of a classified area

49
NFPA 497 Figures

50
IEC 60079-10

„ Standard used for Area

Classification throughout
the rest of the world
„ Objective based
standard
„ Written in both French
and English

51
ISA RP 12.24.01
(IEC 79-10 Mod)

„ Revision of IEC 79-10 to

suit North American
standards and definitions
„ Recommended Practice
„ All revisions to IEC 79-10
are annotated
„ Incorporates the use of gas
detection as a means of
classifying indoor areas
Class 1 Zone 2

52
IP 15
Model Code of Safe Practice

„ Essential reading
„ Describes in detail three
different approaches to
area classification
• Introduces the concept of
the risk based approach to
area classification
• First code to use dispersion
modeling as a basis for
defining the extent of
classified areas

53
 Other HAC Standards

Doc # Agency Type Name

AGA American Gas USA Classification of Gas Utility Area for

XF0277 Association Std Electrical Installation

IGE Institute of UK Std Hazardous Area Classification of Gas

Gas Installations
SR/25
Engineers
TP127 Transport CAN Ship Electrical Standards
Canada Std
[Link]
7/[Link]
TP6472 Transport CAN Standards Regarding Mobile Offshore
Canada Std Drilling Units
[Link]
72/[Link]

54
Codes vrs Recommended Practices

„ CEC are mandatory requirements

• Set the minimum standards
• Formal Variance is required to deviate from the CEC
„ OH&S rules are mandatory requirements
• Vary from Province to Province
„ Code for Electrical Installations at Oil and Gas
Facilities are mandatory requirements in Alberta
„ Recommended practices are not mandatory –
Guidelines only
• RP-505
• ISA RP 12.24.01 (IEC 79-10 Mod)

55
NFPA 325

„ Not a code, standard or

recommended practice
• Compilation of fire protection
properties of approximately
1500 materials and
substances
• Not originally intended for
classifying facilities
• Incomplete information

„ Referenced in RP 500, RP
505 and ISA 12.24.01 as the
reference for flammable and
combustible materials
properties

56
IEC 60079-20

„ Designed specifically for area

classification purposes
• Complete set of material
properties

„ Minor discrepancies in data

between IEC 79-20 and
NFPA 325
• Test methods are similar

57
WHMIS MSDS
Material Safety Data Sheets

„ Updated every three years

„ Extensive listing of chemicals at the CCOHS Website
(Paid Subscription)
• [Link]
„ Completely describes the physical data and the fire and
explosion hazards for a material

58
Definitions
Class I, Zone 2, Gp. IIA, TCode T2A

Class Definition of the Hazard

Zone Probability that a hazard may exist

Group Characteristics of the Hazardous Substance

Temp Maximum Surface Temperature allowable in

Code the area

60
Class – Definition of the Hazard

Class I – Flammable gases

Class II – Combustible Dusts

Class III – Ignitable Fibres or Flyings

Non-hazardous – Areas where Class I,II or III

substances are not expected to be present in
quantities as to require special precautions

61
Class I, Zone 0
(CEC 2006 Definition)

Class I locations shall be further divided into three

zones based on the frequency of occurrence and
duration of an explosive gas atmosphere as
follows:
a) Zone 0, comprising Class I locations in which
explosive gas atmospheres are present
continuously or are present for long periods;

Greater than 1000 hrs/year

(10% of the time) Table 3 RP505

62
 Class I Zone 1
(CEC
(CEC 2006
2006 Definition)
Definition)

b) Zone 1, comprising Class I locations in which:

i. Explosive gas atmospheres are likely to occur in

normal operation or;
Deleted in ii. Explosive gas atmospheres may exist frequently
the 2006
CEC
because of repair or maintenance operations or
edition because of leakage; or
iii. The location is adjacent to a Class I, Zone 0
location, from which explosive gas atmospheres
could be communicated.
Greater than 10hrs/year and less than 1000hrs/year (0.1% – 10% of the time)
Table 3 RP 505

63
 Class I Zone 2
(CEC
(CEC 2006
2006 Definition)
Definition)

c) Zone 2, comprising Class I locations in which:

i. Explosive gas atmospheres are not likely to

occur in normal operation and, if they do occur,
they will exist for a short time only; or

ii. Flammable volatile liquids, flammable gases, or

vapours are handled, processed, or used, but in
which liquids, gases, or vapours are normally
confined within closed containers or closed
Delete in systems from which they can escape only as a
the 2006 result of accidental rupture or breakdown of the
CEC
edition
containers or systems or the abnormal operation
of the equipment by which the liquids or gases
are handled, processed, or used; or
64
 Class I Zone 2
(CEC
(CEC Definition)
Definition)

c) Zone 2, comprising Class I locations in which:

Delete in
iii. Explosive gas atmospheres are normally
the 2006 prevented by adequate ventilation but may occur
CEC as a result of failure or abnormal operation of the
edition ventilation system; or

iv. The location is adjacent to a Class I, Zone 1

location from which explosive gas atmospheres
could be communicated, unless such
communication is prevented by adequate
positive-pressure ventilation from a source of
clean air, and effectively safeguards against
ventilation failure are provided
Less than 10hrs/year (<0.1% of the time)
Table 3 RP 505
65
Unclassified

Areas that are not classified Zone 0, 1 or 2

(Less than 1 hour per year (0.01% of the time)

66
Area Classification Shading Conventions for
Drawings

67
Division Classification System

Division 1

Risk
Division 2

Not Classified

1 hr/Year 10 Hr/Year 1000 Hr/Year

Duration of Time Gas Is

Present

68
Zone Classification System

Zone 0

Zone 1

Risk
Zone 2

Not Classified

1 Hr/Year 10 Hr/Year 1000 Hr/Year

Duration of Time Gas Is

Present
69
Zone vrs Divisions
Source:
Source: “Adapting
“Adapting to
to the
the Dual
Dual Area
Area Classification
Classification System”
System” ,, Paul
Paul Babiarz,
Babiarz, Danny
Danny Liggett,
Liggett, Craig
Craig Wellman,
Wellman,
1996
1996 PCIC
PCIC Conference
Conference Paper
Paper

Comparison of Zones and Divisions

Classified Area Time that Estimated % of Estimate % of
Hazardous Division Areas in Zone Areas in
Gases are North America Europe
Present in
Ignitable
Concentrations
Zone 0 Continuously < 2%
Normally
Division 1 Present < 5%
Occasionally in
Normal
Zone 1 Operations > 60%
Not Normally
Zone 2 Division 2 Present > 95% < 40%

70
“Normal” Operation
(ISA
(ISA RP
RP 12.24.01)
12.24.01)

„ Normal operations is considered the situation when

facility equipment is operating within its design
parameters. Minor releases of flammable material
may be part of normal operations. Minor releases
include the releases from mechanical packings on
pumps.
„ Failures that involve repair or shutdown (such as the
breakdown of pump seats and flange gaskets, and
spillage caused by accidents) are not considered
normal operation.

71
“Abnormal” Operation
(API
(API RP
RP 505)
505)

72
Abnormal Operations

„ Start-up and Shutdown

„ Plant maintenance activities
„ Reasonable to ignore if the activity is expected to
exist less than 1% of the time (100hrs per year) and
no continuous or primary grade releases expected

73
 Group

Describes the Characteristics of the Hazardous Substance

in terms of:
„ MESG – Maximum Experimental Safe Gap
• The maximum gap between two parallel metal surfaces under
specified test conditions that will prevent an explosion from
propagating to an adjacent test chamber
„ MIE – Minimum Ignition Current
• The minimum energy required from a capacitive spark discharge
to ignite the gas or vapor
„ MIC – Minimum Ignition Current Ratio
• The ratio of minimum inductive current required to ignite a gas or
vapor as compared to the minimum inductive current required to
ignite methane

74
MESG Explained

Hot Gases are forced through

threaded connections and
fittings

Explosion

Sealing Compound
Gases must be cooled sufficiently to
prevent external atmosphere from being
75
ignited
MESG Test Apparatus
Westerburg Explosion Test Vessel

76
Group – Characteristics of the Hazardous
Substance

Group I Intended for describing atmospheres that contain

“firedamp” (Comprised mostly of methane)

Group IIA Flammable material having a MESG greater than

0.90mm or a minimum MIC ratio greater than 0.80

Group IIB Flammable material having a MESG greater than

0.50mm and less than 0.90mm or a minimum MIC
ratio greater than 0.45 and less than 0.80
Group IIC Flammable material having a MESG greater than
0.50mm or a minimum MIC ratio greater than 0.45

77
Comparison between Division and Zone
Methods for Group Classification

Division System Zone System

Group MESG MIC Group MESG MIC
(mm) Ratio (mm) Ratio

A Acetylene
IIC ≤0.50 ≤0.45
B ≤0.45 ≤0.40

>0.45 >0.40 >0.50 >0.45

C IIB
≤0.75 ≤0.80 ≤0.90 ≤0.80

D >0.75 >0.80 IIA >0.90 >0.80

78
Examples

Group Material MESG MIE MIC

Ratio
(mm) (mJ)

Methane 1.12 0.28 1.0

Propane 0.97 0.28 0.97

IIA Butane 1.07 0.25 0.94

Heptane 0.91 0.24 0.88
Pentane 0.93 0.28 0.97
H2S 0.89 0.068 0.51
IIB
Ethylene 0.65 0.070 0.53
Hydrogen 0.28 0.019 0.25
IIC
Acetylene 0.25 0.017 0.25

79
MIE in Practical Terms

CH4/Air
H2/Air
10
Typical range of
spark discharge
energy from a
human body
Ignition Energy (mJ)

1.0

Stoichiometric
CH4/Air Mixture
0.1 0.274 mJ

Stoichiometric
Air/H2 Mixture
0.017 mJ

0
20 40 60 80
Fuel (% Volume)
80
Auto-Ignition Temperature

“The lowest temperature of a heat surface at which,

under specified conditions, the ignition of a
flammable substance in the form of a gas or vapor
mixture with air will occur”
API RP 505, IEC 79-10 - Mod

“The minimum temperature required to initiate or cause

self-sustained combustion of a solid, liquid or gas
independently of a heated or heating element.”
NFPA 497

81
Temperature Code

„ Used as a means to indicate the maximum operating

temperature of an electrical device
• Some equipment items are marked with a maximum
operating temperature
• If no temperature code or maximum operating temperature is
indicated, 100ºC is assumed
• Temperature code may be ambient compensated

“Equipment shall not be installed in areas where the

vapour or gas ignition temperature is less than the
maximum external temperature of the equipment”

CEC 18-054
82
Temperature Codes
(NEC
(NEC and
and CEC)
CEC)

T1 - 450ºC T3A - 180ºC

T2 - 300ºC T3B - 165ºC

T2A - 280ºC T3C - 160ºC

T2B - 260ºC T4 - 135ºC

T2C - 230ºC T4A - 120ºC

T2D - 215ºC T5 - 100ºC

T3 - 200ºC T6 - 85ºC

83
ASTM 659 Test Method for AIT

84
Variables that affect AIT

„ Molecular structure of the hydrocarbon mixture

„ % composition of the vapor in air mixture
„ Hot surface material
• Type and reactivity of other materials present
„ Rate and duration of heating
„ Environmental Conditions
• Initial temperature
• Atmospheric pressure

85
Auto-Ignition Temperature

No relation between a
Group Classification and
the Auto-ignition
temperature (AIT) of
flammable material

86
AIT of Selected Materials

Material Auto-Ignition Temperature (ºC)

NFPA 325 NFPA 497 IEC79-20 CEC
Hydrogen 500 520 560 429
Methane 537 630 537 537
Propane 450 450 470 432
Butane 287 288 372 287
Ethane 452 472 515 472
H2S 260 260 270 260
Pentane 260 243 258 260
Crude Oil - - 560 -
Naphtha 232 288 290 288
Gasoline 280 280 - 280

87
Auto-Ignition Temperature

“Experimental studies, testing and practical experience

has shown that surface temperatures must often be
several hundreds of degrees higher than the
published minimum AIT to induce ignition”

“In general, ignition of hydrocarbons by hot surface

should not be assumed unless the surface
temperature is 360ºF (182ºC) above the accepted
AIT of the hydrocarbon involved”
API RP 2216 - Ignition Risks of Hot Surfaces

88
Hazardous Materials
Hazardous Materials

„ NFPA Classification of Hazardous Materials

• Flammable Gases
• Flammable Liquids
– Class IA, IB, IC
• Combustible Liquids
– Class II, Class III
„ Does not cover
• Flammable Mists
• Compressed Liquefied Gases
• Cryogenic Flammable Liquids

90
Highly Volatile Liquids

„ Compressed Liquefied gases

• Kept in a liquid state by pressure
• When released behave like heavier than air gases
• Example: Propane Storage Tanks

„ Cryogenic Flammable Liquids

• Kept in a liquids state by temperature
• Behave like flammable liquids when released
• Example: LPG Terminals

91
Flammable Gases

„ Lighter than air (Vapor density < 1.0)

• Seldom accumulate to form a hazardous mixture except in
enclosed area

„ Heavier than air (Vapor density > 1.0)

• Fall to grade when released and can form an ignitable
mixture for extended periods of time

Gases with a vapor density between 0.8 and 1.2 may

exhibit characteristics of both

92
Flammable Vapors

„ Very similar to flammable gases except that they are

in the vapor phase.
„ Exist at temperatures below their boiling point
„ Significant variance in persistence time

93
Definition of Flashpoint

„ Every flammable liquid has a vapour pressure which

is a function of temperature
• Temperature increases > Vapour Pressure increases
„ Flashpoint is defined as the Lowest temperature at
which a flammable liquid gives off enough vapor to
form an ignitable mixture with air near the surface of
the liquid
„ Surface phenomenon

94
Flashpoint Illustrated

Ignition can only occur when the material

is in the vapour state.
Liquids cannot burn

Transition area from liquid to vapour

Open Container

95
Definition of Boiling Point

„ Temperature at which the vapor pressure of the liquid

equals the surrounding atmospheric pressure
„ Volume phenomenon
„ Not a factor in Area Classification

96
NFPA Definition
Class I Flammable Liquid

Any liquids with a flash point < 37.8°C (100°F)

„ When released at ambient temperature, will readily

evaporate and form a gas-vapor mixture
„ Tend to disperse rapidly to below their LEL
„ Behave like heavier than air gases

97
Flammable Liquids Classification

Class Flashpoint Boiling point Examples

IA Below 22.8°C Below 37.8°C Ethyl Ether

(73°F) (100°F)
Pentane

IB Below 22.8°C Greater than Acetone

(73°F) 37.8°C (100°F)
Gasoline

IC At or above Below 37.8°C Naphtha

22.8°C (73°F) (100°F)
Xylene

98
Combustible Liquids Classification

Class Flash point Examples

II above 37.8°C (100°F) and below Fuel Oil

60°C (140°F)
Kerosene

IIIA above 60°C (140°F) but below Cresol

93°C (200°F)
Ethylene Glycol

IIIB above 93°C (200°F) Asphalt

Transformer Oil

99
Flammable / Explosive Limits

„ Range of composition of material in air which will

burn

UFL – Upper Flammable Limit

LFL – Lower Flammable Limit
UEL – Upper Explosive Limit
LEL – Lower Explosive Limit

100
 Graphical Explanation of LEL and UEL

LEL UEL

Too Lean Explosive Range Too Rich

0% LEL 100% LEL 100%

Saturation

101
LEL and UEL for Selected Gases and Liquids

Flammable Substance LEL% UEL%

Methane 5.3 15
Ethane 3 12.5
Propane 2.3 9.5
Hydrogen 4.0 75
H2S 4.0 46
Gasoline 1.3 6.9
Crude Oil 1 7

102
Flammability Relationships

IT
UPPER LIM
CONCENTRATION OF FUEL

AUTO

E
UR
IGNITION
SS FLAMMABLE
RE FLAMMABLE REGION
REGION
MIST
RP
PO
VA

LOWER LIM
IT

TEMPERATURE AIT
FLASH POINT AIT

103
Properties of Hazardous
Mixtures
Properties of Hazardous Mixtures

„ Estimating the density of a mixture

• Comparison to the density of air
„ MESG
• Lead to Group Classification
„ LFL and UFL
„ AIT
• Difficult to estimate – Must be determined experimentally

105
Heavier than Air or Lighter than Air?

„ Air has a molar weight of 28.96g/m at 0°C and Sea

Level
„ Calculate the molar weight of the mixture and divide
by the molar weight of air

106
Density Example

Material % by Molar % X Mole

Volume Weight Wt.

Methane 50% 16.04 8.02

Ethane 10% 30.07 3.0

H2S 15% 34.08 5.11

Nitrogen 15% 28.02 4.2

Heptane 5% 100.2 5.0

Octane 5% 114.22 5.71

Total 100% 31.04

107
Density Example

Molar Weight of Material 31.04

= = 1.07
Molar Weight of Air 28.96

Material mixture is heavier than air

“For practical applications, a gas that has a relative density

below 0.8 is regarded as being lighter than air. If the relative
density is above 1.2, it is regarded as being heavier than air.
Between these values, both of these possibilities should be
considered”
RP-505 [Link]

108
Calculating the MESG of Mixtures

„ Application of Le Chatelier’s Principle

Where Xi denotes the % volume of the species i and

MESGi is the MESG of the species

109
 Calculating the MESG of Mixtures

Material % by Volume MESG (mm)

Ethylene 45 0.65
Propane 12 0.97
Nitrogen 20 ∞
Methane 3 1.12
Isopropyl Ether 17.5 0.94
Diethyl Ether 2.5 0.83

The relationship then becomes:

1
MESGmix = = 0.9442mm
0.45 + 0.12 + 0.20 + 0.03 + 0.175 + 0.025
0.65 0.97 ∞ 1.12 0.94 0.83

110
Determining the Group Classification

Division System Zone System

Group MESG MIC Group MESG MIC
(mm) Ratio (mm) Ratio
A Acetylene
IIC ≤0.50 ≤0.45
B ≤0.45 ≤0.40
>0.45 >0.40 >0.50 >0.45
C IIB
≤0.75 ≤0.80 ≤0.90 ≤0.80
D >0.75 >0.80 IIA >0.90 >0.80

Mixture has MESG of 0.9442 and is therefore Group IIA

111
Approximating UFL and LFL of a Mixture

„ Le Chatelier’s Principle applies again

„ Must use only the flammable limit components
„ Applies only to mixtures with air
„ LFL is not influenced by pressure
„ UFL is influenced by pressure

112
 UFL and LFL Mixture Example

Material % by Vol. % Vol % LFL % UFL

Combustible
Ethylene 48 60 2.3 36
Propane 12 15 1.7 10.9
Nitrogen 20 - - -
Methane 4 5 4.4 17
Isopropyl 16 20 0.4 7.9
Ether

1 1
LFLmix = UFLmix =
0.60 + 0.15 + 0.05 + 0.2 0.60 + 0.15 + 0.05 + 0.2
2.3 1.7 4.4 0.4 36 10.9 17 7.9

LFLmix = 1.16% UFLmix = 17%

113
Estimating the flammability of a process stream

Rule of Thumb
If the total % combustibles in a mixture exceed the %LFL for
the mixture, the mixture can be considered flammable
Material % by Mole % % UFL
Vol. Fraction LFL
Ethylene 0.5 0.15 2.3 36
Hexane 0.8 0.24 1.1 7.5
Methane 2 0.61 4.4 17
Total Combustibles 3.3
2.37%
Air 97.7
Total 100

Total Combustibles% > %LFL » Mixture is Flammable

114
Estimating the AIT of a Mixture

Material % Composition Published AIT

IsoButane 1% 460ºC (860ºF)

nButane 1% 287ºC (550ºF)
IsoPentane 53% 420ºC (788ºF)
nPentane 4% 260ºC (500ºF)
IsoHexane 23% 264ºC (507ºF)
nHexane 1% 225ºC (437ºF)
Cyclohexane 5% 245ºC (473ºF)
DiMethylButanes 11% 405ºC (761ºF)
Gasoline Tipate 280ºC (536ºF)

(88 Octane)

115
Estimating the AIT of a Mixture

„ The only certain method of ascertaining the AIT of a

mixture is by lab testing
„ My personal ROT
• Use the lowest AIT whose composition exceeds
5% of the mixture

116
AIT Mixture Example

Material % by Vol. AIT ºC

Ethylene 45 450

Propane 12 450

Nitrogen 20 -

Methane 3 537

Isopropyl Ether 17.5 443 AIT

Diethyl Ether 2.5 180

117
Mixture Rules of Thumb

„ For H2S, Group IIB classification requires >25% H2S by

composition (RP 505)

„ For Hydrogen, Group IIC requires >30% Hydrogen by

composition (IP15)

118
Ventilation Concepts
Ventilation (RP-505)

Adequate Ventilation (RP-505)

„ Ventilation (natural or artificial) that is sufficient to prevent the
accumulation of significant quantities of vapor-air or gas-air
mixtures in concentrations above 25% of their lower flammable
(explosive) limit.
Inadequate Ventilation (RP-505)
„ Ventilation that is less than adequate
Enclosed areas are considered adequately ventilated if:
“1.0 cubic foot of air volume flow per minute per
square foot of floor area but at least 6 ACPH on a
continuous basis”

120
Ventilation (IEC 79-10 Mod)

“the likelihood of an explosive gas atmosphere, and

hence the zone designation depends mainly on the
grade of release and the ventilation”

„ Degree of Ventilation
• High, Medium, Low
„ Availability of Ventilation
• Good, Fair Poor

121
Grade of Release

„ Continuous
• A release that is continuous and is expected to occur for
long periods.
„ Primary
• A release that can be expected to occur periodically or
occasionally during normal operation
„ Secondary
• A release that is not expected to occur in normal operation
and if it does occur, is likely to do so infrequently and for
short periods

122
Influence of Ventilation on Type of Zone

Degree
High Medium Low
Grade of
Release Availability
Good Fair Poor Good Fair Poor Good,
Fair or
Poor
Non Zone 2 Zone 1 Zone 0 Zone 0 Zone 0 + Zone 0
Continuous Haz. +Zone 2 Zone 1
Non Zone 2 Zone 2 Zone 1 Zone 1 + Zone 1 or Zone 1 or
Primary Haz. Zone 2 Zone 0 Zone 0
Non Non Zone 2 Zone 2 Zone 2 Zone 2 Zone 1 or
Secondary Haz. Haz. Zone 0

123
Degree of Ventilation

High Ventilation
„ Can reduce the concentration at the source of release,
virtually instantaneously, resulting in a concentration
below the LEL
„ Examples:
• Dilution ventilation on acoustic hoods on gas turbines
• Laboratory exhaust ventilation systems
Medium Ventilation
„ Can control the concentration, resulting in a stable
situation in which the concentration beyond the zone is
below the LEL
„ Examples:
• Building evacuation fans exchanging air at 6 ACPH

124
Why 6 ACPH?

Combustible Build-up Curve, General Ventilation: Continuous Release

Source NFPA 69

125
Why 6 ACPH?

Combustible Decay Curve, General Ventilation: Instantaneous Release

Source NFPA 69

126
Degree of Ventilation

Low Ventilation
„ Cannot control the release while the release is in
progress and cannot prevent undue persistence of a
flammable atmosphere after the release has stopped
• Anything less than 6 ACPH

127
Availability of Ventilation

Good
„ Ventilation is available continuously
Fair
„ Ventilation is expected to be present during normal
operation. Discontinuities are permitted provided they
occur infrequently and for short periods.
Poor
„ Ventilation that does not meet the standard of fair or
good, but discontinuities are not expected to occur for
long periods

128
Influence of Ventilation on Type of Zone
(IEC 60079-10)

Degree
High Medium Low
Grade of
Availability
Release
Good Fair Poor Good Fair Poor Good,
Fair or
Poor

Non Zone 2 Zone 1 Zone Zone 0 Zone 0 + Zone 0

Continuous Haz. 0 +Zone 2 Zone 1

Non Zone 2 Zone 2 Zone Zone 1 + Zone 1 Zone 1 or

Primary Haz. 1 Zone 2 or Zone Zone 0
0
Non Non Zone 2 Zone Zone 2 Zone 2 Zone 1 or
Secondary Haz. Haz. 2 Zone 0

129
Buoyancy Considerations

„ Majority of releases are from pressurized sources

„ Shape of a hazardous region is not related to density
but to angle of release and how close the release
point is to the ground.

130
 Dispersion Modeling

Extent of Area > UFL

Extent of Area
Between LEL Extent of Area
and UEL Between 25% LEL
An 100% UEL

Atmospheric Vent
131
Dispersion Modeling

Extent of Area > UFL

Extent of Area
Between 25% LEL
An 100% UEL

Wind Direction

Extent of Area
Between LEL
and UEL

Atmospheric Vent
132
Dispersion Modeling
CH44 Release inside Building

UFL = 17%

CH4

LFL = 5.3%

133
Dispersion Modeling CH44 Release
Different Release Rates

2 kg/sec 8 kg/sec 32 kg/sec

134
Dispersion Modeling CH44 Release
Different Release Directions

135
Application of the Principles
Four Approaches to Area Classification

1. Classification by Direct Example

• NEC/CEC
• API RP 500/505
• NFPA 497
• IP15

2. Source of Hazard Method (Point Source

Concept)
• Appendix D RP 505
• IEC 79-10 Mod
• IP 15

137
Four Approaches to Area Classification

3. Hybrid Approach
• Use direct example where appropriate
• Modify classifications based on fugitive emissions studies,
use of gas detection, vapor barriers ect.

4. Risk Based Approach

• IP 15
• Applicable to situations where the release rate may be an
unknown, unspecified and variable quantity

138
Classification by Direct Example

„ Most commonly used method of area classification in

North America
„ Easiest to use
„ Requires a judgment be made on the basis of what
hazardous materials might be present and the
probability of the containment systems leaking
„ Extent of an area classification is made by
referencing the figures and diagrams published in
established codes and standards

139
Classification by Direct Example
Work Process
Based
Based on
on Appendix
Appendix E
E API
API 505
505

„ Step 1 – Determine the need

„ Step 2 – Assignment of the Classification

• Based on the probability of a hazardous material being
present in ignitable quantities
• Are the hazardous materials heavier or lighter than air

140
Classification by Example Work Process
Based
Based on
on Appendix
Appendix E
E API
API 505
505

„ Step 3 – Determine the extent of the hazardous area

based on the figures provided in CEC, RP505 and
the Code for Electrical Installations at Oil and Gas
Facilities
„ Step 4 – Assign the Group and the temperature code
based on the materials present
• Reference NFPA 325, CEC, MSDS Sheets
„ Step 5 Document the Hazardous Locations
• Area Classification Drawing Plan View and cross
sections where applicable

141
Gas Station Example

142
Gas Station Pump
CEC
CEC 20-004
20-004

143
Gas Station Storage Tank
(CEC
(CEC 20-004)
20-004)

144
Gas Station Garage
(CEC
(CEC 20-102
20-102 ))

145
Group and Temperature Classification

„ Refer to CEC Appendix B Auto-Ignition Temperature

and Gas Groups Table
„ Gasoline
• Group IIA
• AIT of 280°C
– Corresponds to T2A temperature code

146
Resulting Area Classification

147
Drilling Rig Example

148
Drilling Rig Classification Challenges

„ Materials vary in composition

• Crude Oil
• Gas/Condensate

„ Large number of potential ignition sources

• Combustion engines
• Tools

„ Large variety of configurations

• Enclosed, partially enclosed and open type derricks

149
Drilling Rig Classification Challenges

„ Unconventional release sources

• Dissolved gas in under balance drilling operations
• Pressure kicks
• Fugitive emissions from residual mud on drilling equipment
• Stuffing box emissions
• Vapours present in oily water drainage systems

„ High risk of personnel being within the classified area

„ Area classification is not typically reviewed by a

Professional Engineer

150
Code for Electrical Installation at Oil and
Gas Facilities

151
API RP 505 Drilling Rig

152
IP 15 Drilling Rig

153
Classification of an Upstream Facility
by Direct Example

154
Typical Process Building
RP 505

155
Tank Farm RP 505

156
Pig Launcher RP 505

157
Pump (RP 505)

158
Resulting Classification

159
Inherent Problems with the Classification by
Example Work Method

„ Subject to abuse and incorrect use

• User does not have to fully understand the process; Only
required to apply the recommendations stated in the code or
practice
• Application figures are only a guideline and require the
application of sound engineering judgment
„ Does not dwell on the group or temperature
classification
• The user is required to reference recommended
practices for complete definition
„ Tend to over-classify facilities
„ Leads to inconsistencies between users and
applications
• Diagrams are frequently misinterpreted

160
Hybrid Method
Hybrid Method

„ Uses the guidelines provided by the Classification by

Direct Example publications where appropriate

„ Incorporates concepts related to material properties,

ventilation, fugitive emissions and other methods of
determining hazard radii as referenced by a variety of
publications

162
Hybrid Method Work Process

1. Review of Government Regulations and selection

of Industry Codes and References
2. Assemble Project Data
3. List all Hazardous Materials and Material
Properties
4. Identify all Material Release Sources
5. Assign an Area Classification
6. Document the Area Classification

163
Hybrid Approach

Data Requirements
„ Process Descriptions
• PFDs
• P&IDs
• Material Balance Sheets
„ Equipment List
„ Plot Plan

164
Overview of the Process

165
Mixture Analysis

166
Flammable Materials Data Sheet

167
Potential Sources of Release

„ Process Equipment
„ Rotating Equipment
„ Piping Connections
„ Flanges
„ Pumps
„ Valves
„ Tank Fugitive Emissions
„ Sample Connections
„ Pig Launchers
„ Analyzer Emissions
168
Potential Sources of Release

169
Pig Launcher - Tank Farm

170
Potential Sources of Release

171
Dehy Building

Enclosed areas are considered adequately ventilated if:

“1.0 cubic foot of air volume flow per minute per square foot of
floor area but at least 6 ACPH on a continuous basis” RP 505

„ Outside Dimensions
14’W X 24’L X 12’H
Volume 4032 ft3
Area 336 ft2

„ Air flow required for “Adequate Ventilation”

14’ X 24’ = 336 ft3/min
6 ACPH = 6 X 4032/60 = 403 ft3/min
403 ft3/min or 6 ACPH is required by API 505

172
Heating Requirements

„ To maintain the interior temperature at a nominal

50ºF under ambient conditions of -45ºF would require
15kW of supplemental heat

„ May be a problem with local freeze-up on certain

lines requiring the addition of indoor heat trace as a
precautionary measure

173
API 505 Fugitive Emissions Calculation

Adequate Ventilation (RP-505)

„ Ventilation (natural or artificial) that is sufficient to
prevent the accumulation of significant quantities of
vapor-air or gas-air mixtures in concentrations above
25% of their lower flammable (explosive) limit.
„ A fugitive emissions calculation estimates the amount
of hazardous material likely to be present in an
enclosed area under normal operating conditions
„ The results are used for to calculating the amount of
air movement required to achieve the definition of
“adequate” ventilation

174
API 4615 Background

„ Summarizes the results of

several studies conducted
by API and published in
1993
„ 185,000 components in 20
different facilities
„ A total of 4796
components were found to
be leaking
„ Intent was to support the
EPA clean air act of 1990
„ Not originally intended for
area classification
purposes

175
API 4638

„ Explains a variety of
methods for performing
fugitive emission calculations
„ Provides background
definitions, step by step
procedures and working
examples

176
Component Definitions
(as per API 4615)

Connections Open ended devices

„ Threaded „ sample connections
connections
„ Drains
„ Tubing fittings
„ Bleed valves
„ Valve connections
Other
Flanges
„ compressor seals
Pumps and pump „ pressure relief valves
seals
„ Hatches
Valves „ dump lever arms
„ Excludes check „ polished rod stuffing
valves boxes
„ Instruments
„ sight glasses
177
Stream Types

„ Gas
„ Heavy Oil
• < 20 API
„ Light Oil
• ≥ 20 API
„ Water/Oil
• (Water Content 50% - 99%)

178
EPA Average Emission Factors
(lb/Component/day)
Heavy Oil Light Oil Water/Oil
(<20 API (≥20 API (Water
Gas Gravity) Gravity) Content 50%
- 99%)
Valve 2.4E-01 4.4E-04 1.3E-01 5.2E-03

Connector 1.1E-02 4.0E-04 1.1E-02 5.8E-03

Flange 2.1E-02 2.1E-05 5.8E-03 1.5E-04

Open-End 1.1E-01 7.4E-03 7.4E-02 1.3E-02

Other 4.7E-01 1.7E-03 4.0E-01 7.4E-01

Pump 1.3E-01 Not 6.9E-01 1.3E-03

Available

179
Fugitive Emission Factors
Abnormal Operation (Gas Service)
(lbs/component/day)
(lbs/component/day)

Component Normal Abnormal Emissions

Increase

Connections 1.1E-02 1.4 127 X

Flanges 2.1E-02 4.3 204 X

Pumps and pump seals 1.3E-01 3.9 30 X

Valves 2.4E-01 5.2 21 X
Open ended devices 1.1E-01 2.9 26 X
Other 4.7E-01 4.7 10 X

180
Variables effecting Emission Rates

• Fluid phase • Batch/continuous process

• Valve type/ • Equipment size
packing/configuration
• Pump seal type
• Pressure
• Fluid toxicity/corrosiveness
• Gasket type
• Pump rpm
• Temperature • Service life
• Flange type • Compressor seal type
• Flange bolting procedures
• Unit type
• Inspection frequency

181
Methods for Estimating Components

1. Physical Count
2. Estimate from P&IDs
3. API 4638 Approximation
• Count the number of valves
• Number of flanges = number of valves
• Number of connectors = 3 X number of valves
• Number of open ended devices = 10% of the number of
valves
• Number of “other” components = 5% of the number of
valves

182
Fugitive Emissions Calculation
RP 505 Appendix B

„ Calculation determines what ventilation rate is

required to ensure that the fugitive emissions do not
exceed 25% of the LEL of the hazardous material
present.
• Based on perfect mixing
„ Safety factor of 4 is applied
„ All calculations are done using imperial
measurements
• Use care when converting to metric values

183
Fugitive Emissions – Dehy Building

Component No. HC Emission Total

Type (lbs/Component/day) Emissions
(lbs/day)

Valve 42 2.4E-01 10.08

Connector 126 1.1E-02 1.38

Flange 42 2.1E-02 0.882

Open-End 6 1.1E-01 0.66

Other 3 4.7E-01 1.41

Pump 0 1.3E-01 0

Total 14.4

184
Fugitive Emissions Calculations Cont’d

„ Convert lbs/day to lbs/hour

• 14.4 lbs/day / 24 = 0.6 lbs/hour

„ Calculate the mole weight of the Hydrocarbon Emission

• 24.46 (from mixture analysis)

185
Calculate the cubic feet/pound-mole weight
of the Hydrocarbon mixture

„ Assumption: volume of one pound-mole of

ideal gas = 359 ft3 at standard temperature-
pressure (32ºF at 14.7 psia)
„ Ideal gas law (PV=nRT)
„ Charles’ Gas Law (V1T2 = V2T1)
• Volume varies proportionately to the
temperature in degrees Rankin (Fº + 460)

186
Volume of ideal gas at 90ºF

„ At 90ºF and 14.7 psia, 359 ft3 would occupy:

(359)(460 + 90)/(460 +32) = 401ft3

187
Calculate the Hydrocarbon Leak Rate

(E)(V)
G=
60(mw)

Where:

G = Leak rate,cfm
E = Emission rate, lbs/hour
V = Volume, ft3/lb-mole
mw = average mole weight
60 = 60 minutes per hour

188
Hydrocarbon Leak Rate

E = 0.6 lbs/hour
V = 401 ft3/lb-mole
mw = 24.46
60 = 60 minutes per hour

(0.6)(401)
G= = 0.1639 ft3/min
60(24.46)

189
Hydrocarbon Concentration
(as
(as per
per NFPA
NFPA 69)
69)

C = (G/Q) (1-e-kn)
or
C = (G/Q)

(1 – e-kn approaches 1 after steady state conditions)

Where:
C = Concentration of hydrocarbon in air, percent (in decimal
format)
G = Leak rate
Q = Fresh air introduction rate
N = number of air changes
K = quality factor

190
Required Fresh Air Introduction Rate

100% LEL (from mixture analysis = 3.31%)

Required to maintain a 25% LEL

Required fresh air introduction rate

0.1639 ft3/min
Q= = 21.15 ft3/min
(0.25 X 0.031)

191
Application of Safety Factor

„ Safety factor of 4 is applied

(as per RP 505 [Link].8)

„ Required ventilation rate =

4 X 21.15 ft3/min = 84.61 ft3/min
„ Volume of Dehy building = 4032 ft3

„ Equivalent to
84.61 ft3/min X 60 min/hr / 4032ft3 = 1.25 ACPH

192
Application of the Results

„ The Dehy building ventilated at 1.25 ACPH is

considered adequately ventilated
• Typical value for an upstream process building is between
0.5 and 2 ACPH

„ For ventilated areas < 3 ACPH, RP 505 recommends

continuous monitoring by fixed gas detectors to
assure the LEL remains at the 25% level or below
• Generally tied in with ventilation fans sized at 12 ACPH

193
Design of the HVAC System

„ Must provide a good quality of ventilation

• good mixing
• no stagnant areas
„ Must be reliable and provide good availability
• 99% availability target
„ Designed to extract fugitive emissions
• Heavier than air releases
• Lighter than air releases
„ Must be capable of stabilizing an abnormal release
• Consistent with the IEC definition of a Medium degree of ventilation

194
Ventilation Strategies

„ Natural Ventilation
„ Artificial Ventilation
„ Recirculation Ventilation

195
Natural Ventilation

Wind Driven Flow Stack Driven Flow

196
 Natural Leakage

Weather Wind Indoor Delta Air Infiltration [ACPH]

Speed Outdoor Pressure
Condition Temp Across
(m/s)
Difference Building Tight Typical Leaky
[K] Building Building Building
[Pa]

Mild 2 5 .2 0.07 0.1 0.4

Moderate 5 15 1 0.2 0.3 1.0

Severe 7 25 2 0.3 0.5 1.6

197
 Mechanical Extract Ventilation

Air Movement
Gravity
Louvers

XP Fan

Air Movement
Gravity XP Fan
Louvers

Crossflow Ventilation Crossflow Ventilation

Lighter than Air Density Materials Heavier than Air Density Materials

198
Mechanical Supply Ventilation

199
Dehy Building
HVAC Design Option #1

Turbine Ventilator

Wind (>2mph)

GD GD

I
Gravity
Louvers
Air Movement XP Fan
12 ACPH

Stack
Effect
Fixed Fixed
Louvers Louvers

200
Turbine Ventilator

Dehy Building requires 85 CFM

201
Dehy Building
HVAC Design #2

Fan Affinity Law – Fan output CFM is directly proportional to fan speed

GD GD I VFD

Gravity
Louvers XP Fan
Fan sized for 12 ACPH
2 ACPH Normal Conditions
Air Movement 12 ACPH on Gas Detection

Fixed Fixed
Louvers Louvers

202
Plan Layout

Fixed
Insure no Stagnant Air Pockets
Louver
1 ACPH

U/
H

H
U/

Recirculated Air

Gravity
Louver
Air Flow Exhaust Fan
12 ACPH
H

U/
U/

H
Fixed
Louver
1 ACPH

203
Fan Recirculation Options

Typical Unit Heater Configuration

Heat Medium Supply

Thermostat
Air Flow Fan Motor T MS

Motor Starter Switch

Heat Control is by turning
on and off the fan
Heat Medium Return

204
Fan Recirculation Options

HM Control Soleniod
T Thermostat
Heat Medium Supply

Heat Control is by turning

on and off HM Supply

Air Flow Fan Motor MS Motor Starter Switch

Fan runs continuously to

provide air movement
throughout inside the building
Heat Medium Return

205
Classification around Ventilation Openings

206
Naturally Ventilated Enclosed Areas

„ Method for naturally ventilating enclosed areas by

means of the stack effect is provided in RP-505
[Link].5with a working example in Appendix B

„ Provides 12 ACPH of ventilation (one complete air

change each five minutes)

„ Method for calculating adequate ventilation is only

applicable to building with volumes of 1000 ft3 or less

207
Natural Ventilation
RP 505 Appendix A

Stack Effect
208
Sizing Ventilation Louvres

V
A=
1200 h( Ti – To )/ Ti

Where:
A – Free Area of inlet (or outlet) opening(s) (includes a
50% effectiveness factor)
V – Volume of building to be ventilated, in cubic feet
h – height from the center of the louver opening to the Neutral
Pressure Level (in feet)
Ti – temperature of indoor air (degrees Rankin)
To – temperature of outdoor air (degrees Rankin)

209
Calculating the Height to the Neutral
Pressure Level

H
h=
1 + [(A1/A2)2(Ti/To)]
Where:
h – height from the center of the louver opening to the
Neutral Pressure Level (in feet)
A1 – free area of lower opening, in square feet
A2 – free area of upper opening in square feet
H – Vertical distance (center to center) between A1 and A2 in
feet
Ti – temperature of indoor air (degrees Rankin)
To – temperature of outdoor air (degrees Rankin)
Note: If Ti < To the ration Ti/To
should be inverted
210
Application to the Inlet Separator Building

Dimensions of Inlet Separator Building

12’L X 10’W X 8’H
Volume of Building - 960 ft3
Ti - 110ºF or (110 + 460 = ) 570ºR
To - 95ºF or (95 + 460 = ) 555ºR
H – (distance between A1 and A2) – 7ft
Assume A1 = A2
7
h=
1 + [(570/555)]

h = 3.45 ft

211
Sizing Ventilation Louvers for the Inlet
Separator Bldg

V = 960 ft3
h = 3.45 ft
Ti = 110ºF or (110 + 460 = ) 570ºR
To = 95ºF or (95 + 460 = ) 555ºR

960
A=
1200 3.45(570 – 555)/ 570

A = 2.65 ft2 for inlet and outlet

212
Sizing Louvers

Outlet Louver consists of a roof vent that extends along

length of building
Size of vent opening is 10ft X 0.5ft
Total area = 5ft2

Inlet Louvers
4 – 10” X 10” louvers for an effective area of 2.75ft2

213
Potential Sources of Release

214
Analyzer/Custody Transfer Building

„ Building is inadequately ventilated

„ Sources of release include emissions from the
analyzer and the custody transfer meter run
„ Analyzer is certified for use in Class 1 Zone 2
locations
„ Number of small sample lines that may be prone to
freeze-up

Use of gas detection may be an appropriate strategy for

classifying the building

215
Use of Combustible Gas Equipment as a
basis for Area Classification (RP-505)

„ Gas detectors must be of stationary type

„ Adequate number must be installed
„ Gas detectors must be calibrated a minimum of every
three months or as specified by the equipment
manufacturer
„ The temperature code of electrically operated
equipment does not exceed 80% of the AIT for the
flammable materials present in the building

216
Combustible Gas Detection for Use in
Hazardous Locations (CEC Appendix H)

„ Provides suggestions for use of combustible gas

detectors as supplementary protection for equipment
not approved for the Zone
„ Effectively allows you to place non-hazardous
equipment in Zone 2 locations and Zone 2 equipment
in Zone 1 locations
„ Does not change the area classification as per RP-
505
• Recommends that all essential services such as lighting,
process instrumentation and gas detection be approved for
the Class Group and Zone of the area

217
Use of Combustible Gas Detection

Analyzer Approved for use in Zone 2 Locations

CEC Appendix H RP-505

Audible and visible alarm is actuated when LEL reaches 20%

Equipment is disconnected when LEL reaches 40%
Equipment is de-energized in the failure of gas detection equipment

218
CEC 2006
Rule 18-070 Changes

219
Gas Detection Application Considerations

„ Density of the gases being detected

„ Location of gas detectors
„ Redundant heads
„ Effects of ventilation flow
„ Adverse environments
• Temperature
• Airborne particles
• Contaminants
• Corrosive compounds
• Vibration
„ Accessibility for calibration and maintenance

220
Gas Detection Technology
Catalytic Bead

„ Platinum coil embedded in

a catalyst
„ Flammable gas reacts with
the catalyst creating heat
which changes the
resistance in the platinum
coil which is monitored
„ Sensitive to contamination
and “poisoning”
• Halogens
• Sulphur compounds

221
Gas Detection Technology
Infrared

„ Measurement is based
on the absorption of IR
radiation as it passes
through a volume of gas
• Immune to all chemical
poisons
• Does not need oxygen or
air to detect gas
• Lower maintenance than Open Path IR Gas Detector
catalytic bead
• Will not detect hydrogen

Point Source IR Gas Detector

222
Maintenance of Gas Detection Equipment

„ “Combustible gas detection instruments should never

be used as a substitute for safe electrical design”
Appendix H H.1.3 CEC

„ Consideration must be given to environmental

conditions
• Temperature
• Airborne particles
• Contaminants
• Corrosive compounds
„ Gas detectors must be adjusted to detect all gases
that may be encountered
• State what gases the gas detectors must be calibrated for on
the area class drawings

223
Gas Detector Calibration

Combustible Correction factor for Correction factor for

Gas Sensors Calibrated Sensors Calibrated on
on Propane Methane

Methane 0.55 1.0

Propane 1.0 1.82
Butane 1.0 1.82
Pentane 1.22 2.22

Hexane
Heptane
Gasoline 0.85 1.54

224
Gas Detector Location Guidelines

„ Locate the detector near the hydrocarbon release

source
„ Locate the detector where gas emissions are likely to
accumulate
• Take into account the density of the gas
• May need to place detectors in high and low locations
„ Outdoor applications require special consideration
• Environmental contamination of detector heads
• Topography and wind direction play a role
• Open path IR detectors better suited to outdoor applications

225
Gas Detector Location Guidelines

„ Intake or exhaust duct placement in

mechanical ventilation systems requires
special attention
• LEL alarm set point should be set as low as reasonably
practical
„ Locate gas heads with calibration maintenance
activities in mind
„ Incorporate redundancy into the design
„ Document the rational for placement of the gas
heads

226
Gas Detection Maintenance

„ CEC Appendix H5 recommends that the installation

be calibrated in accordance with the manufacturer’s
instructions or Paragraph 4.8.2(f) of RP 500 (1991
Editions)
• Paragraph 6.8.2 (f) in RP 505
• Gas detectors calibrated at least every three months

227
Gas Detection Operations and Maintenance

„ Comprehensive guide on the

operations and maintenance
of gas detections systems
„ Guidelines for selection and
placement of gas detectors

228
Potential Sources of Release

229
Use of Vapour-tight Barriers

„ Effective way of locating non-hazardous rated

equipment adjacent hazardous areas
„ Benefits include
• Reduced on-site wiring costs
• Allows equipment to be pre-commissioned

230
Use of Vapour-tight Barrier

231
Definition of a Vapour-tight Barrier

“a barrier that will not allow the passage of significant

quantities of gas or vapor at atmospheric pressure”
RP 500/505

232
Compressor/Pump Building

Cable Transit Detail

Location of vapour-tight walls should be specified

on the area class drawings

233
Unclassified Areas (RP505)

234
Fired Heaters/Flare Stack (RP505)

Source of ignition is not a criteria for classification of a location

235
Fired Heater Considerations

Occupational Health and Safety Code Part 10

236
Generator Buildings

237
Batteries

„ Certain battery designs liberate hydrogen during the

recharge cycle
• Lead Acid
• Lead Calcium
• Lead Antimony

„ Battery design that do not liberate hydrogen

• Nickel cadmium
• Nickel hydride

238
Batteries RP505

Valve-regulated lead acid (VRLA) batteries are also known as sealed lead acid

239
Batteries Continued

„ VRLA Batteries incorporate a catalyst to recombine

oxygen and hydrogen into water
• Overcharging can cause the battery to liberate hydrogen
through a safety vent
• Typical UPS is designed to prevent overcharging
– Equalization charge cycle can cause a battery to liberate
hydrogen

240
CEC Appendix B
Notes on Rules

241
Battery Rooms

„ Locations surrounding VRLA batteries are generally

unclassified provided:
• Installed in open type racks
• Ventilation is present > 1 ACPH

„ Battery rooms incorporating open type lead calcium

batteries required special attention (Refer to RP505
Section 8.2.6)

242
Vendor Skid Packages

„ Responsibility for the Area Classification of a skid

package building often blurred
„ Some contracts require the skid vendor to perform
the area class study
• Client defines the area classification and then rely on the
vendor to sign and stamp the drawings
• Most skid vendors subcontract the task

243
Vendor Skid Building
Area Classification Problems

„ Skid vendor does not have access to the process

parameters
„ Documentation by the skid vendor is often lacking
• Number of ACPH required
• Gas detection operating parameters
„ Signing and stamping the drawings are often an
issue.

244
Options

1. Specify in detail what is required by the vendor

• Documentation requirements
• Design details on drawings
• Performance verifications
2. Have the Client’s Consultant perform the area class
study
• Ventilation and gas detection requirements are defined
during the vendor drawing review stage
• Single source of responsibility

245
 Remote Locations

„ CEC 2006 Appendix B

• Note on rule 18-006

Related to the Definition of a Zone 2 location (<10hrs per Year)

246
Area Classification Worksheet

247
Resulting Area Classification

248
Area Classification Study

„ Description of the Process

„ Codes and Recommended Practices Used
„ List of assumptions
• Normal verses Abnormal Operation

„ Hazardous Materials Worksheet

„ Source of Release Worksheet

249
Area Classification Study

„ Fugitive Emission Calculations

„ Ventilation Calculations
„ List of recommendations
• Installation and operations

„ Rational for gas detector placement

„ Area Classification Drawings
• Plan view and cross sections

„ Professional Engineering Stamp

250
Drawing requirements

„ Area Classifications Information

• Class
• Zone
– Provide a legend consistent IEC recommendations
• Group Classification
– May be more than one Group for a facility
• AIT
– Indicate a Maximum temperature and what material it is
based on rather than a Temperature Code
„ Cross section drawing details where appropriate

251
Notes to the Drawings

„ Assumptions
„ Reference the Area Classification Study
Document
„ Indicate ventilation requirements for each
building
„ Indicate gas detection and equipment operating
requirements
„ Indicate walls that are required to be vapour-tight

252
Refinery Application

253
Refinery Plot Plan

254
RP 505 Figure 20

255
Area Classification Example 3 - Upgrader

256
Area Classification Worksheet for a
Refinery

257
Area Classification - Upgrader

258
Area Classification Section Details

259
Considerations for Refinery Facilities

„ Natural barriers and the use of elevation as means to

define an area classification
„ Drains
„ Gas Detection
• Process areas
• Unclassified buildings

„ Locating electrical equipment outside of classified

areas whenever possible

260
Considerations for Refinery Facilities

„ Vehicles – Road and Rail Traffic

„ Fixed combustion engines
„ Gas turbine drives
„ Hot surfaces
„ Locations of fired heaters

261
Fluor Area Classification Work
Process
Fluor Area Classification Work Practices

„ Practice 000.100.1400
• Project Activity Model
„ Practice 000.299.0762 Apr05
• HAC Project Discipline Interface
„ Practice 000.200.1994 Feb06
• Design Review: Hazardous Area Classification
„ Practice 000.265.1940 Mar06
• Work Instruction: Hazardous Area Classification
„ Practice 000.265.4200 Jan94
• Table of Contents: Installation Assemblies and Details
– Note: Installation details are based on RP 500
„ PIP ELEHA01
• Engineering Guide for Determining Electrical Area Classification

263
Fluor Area Classification Work Process

Defined in three locations within the Project Activity

Model
„ Phase 1 - Scope Definition and Conceptual Engineering
• ENG103 – Hazardous Area Classification Memorandum/Plan

„ Phase 2 – Preliminary Engineering Construction Planning

• ENG203 – Hazardous Area Classification / Emission Source
List
„ Phase 3 – Detailed Engineering
• ENG303 – Hazardous Area Classification Design Review

264
ENG103 – Hazardous Area Classification
Memorandum/Plan

„ Deliverables include: „ Applicable Work Instructions

• Area Classification • 000.200.0762
Memorandum IFR – Hazardous Area Classification
– Requirements for a Hazardous (Generic) Project Discipline
Area Classification Interface
– Codes and Standards to be • 000.200.1994
used – Design Review Checklist
– Design Approach Hazardous Area Classification
• PIP ELEHA01
– Engineering Guide for
Determining Electrical Area
Classification

265
ENG203 – Hazardous Area Classification
Memorandum/Plan

„ Deliverables include: „ Applicable Work Instructions

• Area Classification • 000.200.0762
Memorandum - IFD – Hazardous Area Classification
– Source of Hazard Worksheet (Generic) Project Discipline
Ê Source, Degree and Interface
Extent of Hazard • 000.200.1994
• HAC plot plan - IFD – Design Review Checklist
Hazardous Area Classification
• PIP ELEHA01
– Engineering Guide for
Determining Electrical Area
Classification

266
PIP ELEHA01 Work Process

267
ENG303 – Hazardous Area Classification
Design Review
„ Activities include: „ Applicable Work Instructions
• Design review of the • 000.200.0762
Hazardous Area Classification – Hazardous Area Classification
Philosophy (Generic) Project Discipline
• Verify consistency with other Interface
key project documents • 000.200.1994
• Area Classification – Design Review Checklist
Hazardous Area Classification
Memorandum - IFC
– Source of Hazard Worksheet • PIP ELEHA01
update – Engineering Guide for
– Incorporate Fugitive Emission Determining Electrical Area
and Ventilation Requirement Classification
Studies
– Define HVAC and gas
detection requirements
• Issue HAC plot plan IFC
• Issue HAC Plans and
Sections IFC

268
Alternative Methods
NFPA 497

270
HTA Liquid at Grade
(NFPA 497)

271
HTA Liquid at Grade
(NFPA 497)

272
Adequately Ventilated Indoor Location
(NFPA 497)

273
API Alternative Method
Appendix D RP 505

„ Incorporates the results of extensive dispersion

modeling
„ Requires additional engineering skill and equipment
knowledge
„ Suitable for well-ventilated outdoor locations
„ Loosely based on the methods described in IP15 -
2002

274
RP-505 Appendix D
Point Source Concept

„ Involves determining the “hazard radius” of all

potential release sources
• Volatility of release sources
• Quantity of release materials
• Nature of the release
• Velocity of the materials being released

„ Release source boundaries are plotted on an area

diagram which is then simplified to form the overall
area classification

275
Example Pump Application

Pump #1 #2
Pump #2
(Pentane) Product Butane Pentane
Motor
Seal Low Low
Vertical Emission Emission
Pump #1 Type
(Butane)
Seal Seal

Material Oper Vapor P-suc 94 110

Temp (psig)
Pressure
(ºF)
(psia) P-dis 130 950
(psig)

P-Pump 150 319

Butane 110 60
Seal
Pentane 180 56
(psig)

Flow 90 350
276 rate gpm gpm
RP 505 Figure 20

277
 15m

15m Pump #2
(Pentane)

Motor
15m 15m 15m
Vertical
Pump #1
15m
(Butane)

Transient Vapour Zone 15m

278
Classification Procedure

1. Determine the volatility classification based on

Figure D-1
2. Estimate the mass release rate
• Table D-1 for pumps, D-4 for flanges and valves
3. Determine the hazard radius
• Figure D-3 for heavier than air
• Figure D-4 for lighter than air

279
Vapor Pressure – Temperature Volatility
Chart

„ Category 1 – Materials
that almost immediately
flash to atmosphere
„ Category 2 – Class 1A
Flammable Liquids
„ Category 3 – Class 1B
Flammable Liquids
„ Category 4 – Class II
and heavier materials

280
 1. Determine the Volatility
Classification
Butane Butane Curve
Category 1
Pentane Volatility Pentane Curve
Category 2
Volatility

Pentane Operating Temp 180ºF

Butane Operating Temp 110ºF

281
2. Estimate the mass release rate

282
Guidelines for Predicting Release Rates

Butane Pump #1
Pentane Pump #2
Category 1 Volatility
Category 2 Volatility
Flow rate = 90 gpm
Flow rate = 350 gpm
Seal Pressure = 150 psig
Seal Pressure = 319 psig
283
 3. Determine the Hazard Radius

Pentane Pump #2

Butane Pump #1

284
Resulting Area Classification

3.04m

3.04m Pump #2
(Pentane) 3.04m
Motor
3.04m 3.04m
1.52m
Vertical
Pump #1
(Butane) 3.04m

Transient Vapour Zone

285
 Extent Comparison Figure 20 verses
Appendix D Alternative Method
API 505
Figure 20
Zone 2
Zone 2
600mm
Above Grade

API 505
Alternate
Method
Zone 2
Zone 2
600mm
Above Grade

286
Problems with the Point Source Concept

„ Requires the release rate from various sources be

determined
• Vapour pressures of mixtures need to be determined

„ May reduce the extent of the area classification but

the extent may be difficult to communicate

287
Application to a Refinery

288
RP505 Annex F
Alternative Ventilation Criteria

„ Application of the Point Source method described in

IEC 60079-10
„ Applicable for use in Indoor Applications
„ Allows the hazardous classification of portions of an
interior based on the grade of release and degree of
ventilation available

289
RP505 Annex F
Alternative Ventilation Criteria

„ Illustrates a calculation method that allows the user to

predict
• A hypothetical volume
• The dispersion time of a release
• Estimate the level of air movement required to limit the
volume

290
Example Scenario

Fuel gas manifold for a gas fired steam generator

operating within a large building
Building 12H X 15W X 32L Flammable Methane
Dimensions Material

Volume 5760m3 Molar Weight 16

Air Flow 9 m3/sec %LEL 5%

ACPH 5.63 Release Source Flange

Ambient 20ºC Release Grade Secondary

Temperature

Operating 350 kPA Safety Factor X2

Pressure

291
Fuel Gas Manifold Building
As per RP505

PSV

Process
Vent

MV
Regulator
MV MV

292
Fuel Gas Manifold in Large Building as per
RP 505

Process
Manifold occupies a very small Vent
Area within the building
Does the whole building need to be classified?

293
Option 1 - Classify the building as Non-
hazardous

O&G Code 2002 Appendix B19 Note to rule 19-000

Piping systems with a pressure of 700 kPa or less
(utility gas distribution, equipment fuel supplies, Process
ect.) are considered “low risk” and do not generally Vent
require the area around them be classified.

294
Building is unclassified therefore,
common sense does not prevail

Disconnect mounted above

fuel gas manifold
Disconnect adjacent
Fuel gas regulator

295
CEC Standata

296
Option 2 – Use the Alternative Method in RP
505 Annex F

„ Estimate the hypothetical volume surrounding the

fuel gas manifold based on the level of ventilation
provided

297
Estimation of
Hypothetical Volume Vzz

298
Minimum Flow Rate Required

299
Maximum Rate of Release

(dG/dt)max = 0.006aP(M/t)0.5

(dG/dt)max = mass release in kg/sec

a = cross-sectional area of the leak in m2
P = upstream pressure in N/m2
M = molecular weight kg/kmole
t = absolute temperature of release ºK

(Multiply kPa X 1000 to get N/m2)

300
Rule of Thumb for Cross Sectional Areas of
Release

„ Use 0.25mm2 for flanges, screwed fittings, regulator

diaphrams and valve glands

„ Use 2.5mm2 for purge vents, drains, sample points,

relief valve vents, compressor shaft seals and
booster pumps
Source IGE/SR25

301
Release rate

(dG/dt)max = 0.006aP(M/t)0.5

a = 0.25mm2 = 2.5 X 10-7 m2

P = 350kPA = 350000 N/m2
M = 16 kg/kmole
t = 20ºC = 293ºK

(dG/dt)max = 1.23 X 10-4 kg/sec

302
Volumetric Flow Rate

1.23 X 10-4 kg/sec 293 = 0.0074 m3/sec

X
0.5 X 0.03328 293

LELm = 0.416 X 10-3 X 16 X 5 = 0.03328

303
Hypothetical Volume

5 X 0.0074 m3/sec
Vz = = 23.12m3
0.0016 sec-1

1/3
3Vz r
r= = 1.78m
4¶
V = 4/3¶r3
C = air changes/sec = ACPH/3600 = 5.63/3600 = 0.0016

304
Extent of Area Classification

Classified area within the building is limited to the extent

the hazard exists
Process
Rest of building remains unclassified
Vent

1.78m

305
Time of Persistance

306
 For a 100% LEL Release

-5 x Ln 5% x 0.5
t=
0.0016 100%

t = 11527 seconds = 3.2 hrs

Falls within the criteria of < than 10 hrs for a Zone 2 location

307
An interesting thought

What are the minimum number air changes it

takes to reduce a flammable release to below its %LEL
within the <10hr Zone 2 design criteria?
-5 Ln LEL% x 0.5
C=
10hrs 100%
-5 x Ln 5.0% x 0.5 = 1.84 ACPH
Methane C =
10hrs 100%

-5 x Ln 0.9% x 0.5 = 2.7 ACPH

Naphtha C=
10hrs 100%
308
Introduction to the Risk Based
Approach to Area Classification
„ Method that defines the extent of an area
classification based on an predefined acceptable
level of risk
„ Introduced into IP15 in 2002
„ Similar to the approach used in other fields for
making business and technical decisions

309
Risk Matrix

310
IP15 Risk Based Process

1. Determine the level of Individual Risk (IR)

associated with facility
2. Use the results to determine the equivalent
hole size for a given release
3. Use the hole size to determine the release
rate based on the pressure and flammable
material composition
4. Calculate the hazard radii
• Using charts provided in IP15
• Calculated using a set of equations provided

311
 Individual Risk (IR)

IR Ignited Release = Fflam x Pign x POcc x V x Nrange

Fflam = Frequency of flammable Atmosphere

Pign = Probability of Ignition
POcc = Probability of Occupancy
V = Vulnerability
NRange = Number of release sources in range

312
Summary and Wrap-up
Design Considerations

„ Based on the likelihood of a flammable mixture

being present
• Source of ignition is not a criteria for classification of a
location

„ Must be carried out before the choice of appropriately

certified equipment is made
„ Area Classification should be carried out before the
plot plan is finalized

314
Design Considerations

„ Open and Closed Drains

„ Natural barriers and depressions
„ “Abnormal” operation of equipment
„ Manned and Unmanned facilities
„ Locate electrical and continuous flame source
equipment outside of classified areas when-ever
possible

315
Design Considerations

„ For enclosed areas that are classified

• Stay involved in the design of the HVAC systems
• Specify the flammable materials required to be detected by
the gas detection systems
• Specify the location of gas detection equipment
„ Careful about reclassifying Zone 2 to Unclassified
„ Facilities such as storage pumps, loading and discharge
facilities – classification should be based on the most
volatile material anticipated
„ Not a good idea to denote small pockets of non hazardous
areas within hazardous areas
„ Be careful with unit conversions
• RP505 uses imperial units

316
Design Considerations

„ Adopt physical plant features to denote area

classification boundary lines (roads paved areas
ect.)
„ Communication is key
• Interface with other disciplines on projects
• Insure vendors are made aware of area classification
requirements
• Inspection authorities must also be made aware

317
Documentation Requirements

„ All area classification drawings should reference

an area classification study
• Signed under a professional seal
„ Specify the Auto-ignition temperature on the
drawings rather than a T-Code
• Reduce the confusion
• Buy some ºC
„ Periodically review the Oil and Gas Code
Engineering Guidelines on Area Classification

318
Operational Considerations

„ Posting of area classifications on building entrances

or plant areas
„ Training of plant and construction personnel
„ Impact of natural barriers
• snow removal operations

319
Operational Considerations

„ Beware of Operator Intervention

320
Change Management

„ Area classification may change over the life of the

facility based on operating and maintenance
experience
• Reviews should be carried out throughout the life of the
facility
• New or modified equipment
• Changes in installation protection
• Operations experience
• Changes in operational procedures
• Actual measurements

„ Must be incorporated into a facility’s change

management procedure

321
Additional References

„ Practical Considerations of Area Classification:

How Far to Classify – John H. Rannells IEEE
Industry Applications Magazine May/June 1996

„ New Area Classification Guidelines – [Link], D.

Jagger, J. Propst, IEEE Industry Applications
Magazine Jan/Feb 2000

„ Volatility and Mists – Electrical Area Classification

Important Variables, J. Propst IEEE Paper PID 99-09

322
Additional References

„ Adapting to the Dual Hazardous Area Classification System, P.

Babiarz, D. Liggett, C. Wellman, IEEE Industry Applications
Magazine March/April 1998

„ A Risk Based Approach to Hazardous Area Classification – KJ

Glynn IEE Conference Publication No. 469, IEE 1999

„ Applying the API Alternate Method for Area Classification –

[Link], L. Barrios, B Lobitz, IEEE PCIC Conference
Proceedings Denver 2005

„ More references cited in Appendix D19 – Engineering

Guidelines Code for Electrical Installations at Oil and Gas
Facilities

323
Questions?

324
Copyright (c) 1998 Institute of Electrical and Electronics Engineers. Reprinted, with permission, from the
PCIC.
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 NEW AREA CLASSIFICATION GUIDELINES
Copyright Material IEEE
Paper No. PCIC-98-2

David N. Bishop, PE David M. Jagger John E. Propst, PE

Senior Member, IEEE Member, IEEE Senior Member, IEEE
Chevron Retired Hawke America Co. Equilon Enterprises, LLC
112 Laura Lane 600 Kenrick, Suite C-10 P.O. Box 1380
Destrehan, LA 70074-3022 Houston, TX 77060-3633 Houston, TX 77251-1380

Abstract - In 1991, the American Petroleum Institute (API) (i.e., sources of release) that could allow the release of
merged their three area classification documents (RP500A flammable gases or vapors, flammable liquids, combustible
for refineries, RP500B for production and drilling facilities, dust, or easily ignitible fibers or flyings to the atmosphere.
and RP500C for transportation/pipeline facilities) into one Also shown are the boundaries of the various area
document, RP500 [1]. A common general section was classifications and other information (i.e., information on
supplemented with three other sections for specific ventilation) necessary to properly classify a location or to
recommendations for the three sectors of the industry, but, design, install, inspect, maintain, or operate electrical
for all practical purposes, the RP was composed of the three equipment at the location. At times, elevations or sections
previous recommended practices bound in a single cover. are provided where different classifications apply at different
In 1997, API created RP505 [2], Classification of Locations elevations.
for Electrical Installations at Petroleum Facilities Classified as Area classification drawings should include, as a
Class I, Zone 0, Zone 1, and Zone 2, which will serve the minimum, for all areas that are classified: (1) the Class, (2)
petroleum industry essentially as an supplement to both ISA either the Division or the Zone, and (3) the gas or gas
12.24.01 (IEC 79-10 Mod) [3] and National Electrical Code group(s), the combustible dust or dust group(s), or the
(NEC) [4] Article 505. RP500, which underwent significant ignitible fiber or flying, as applicable. In addition, it may be
changes in 1997, is presently referenced by Article 500 of desirable to include either the maximum safe operating
the NEC; it is proposed that the 1999 NEC will reference temperature or the maximum operating temperature range
RP505. This paper provides a brief overview of the two new of electrical equipment permissible in the area.
recommended practices, but primarily emphasizes the To promote uniformity of area classification drawings for
substantive changes and additions to RP500 and the petroleum facilities, the API developed the recommended
portions of RP505 with the highest impact on the industry. practices RP500, Classification of Locations for Electrical
Installations at Petroleum Facilities Classified as Class I,
Index Terms - Area classification; hazardous (classified) Division 1 and Division 2, and RP505, Classification of
locations; API RP500; API RP505 Locations for Electrical Installations at Petroleum Facilities
Classified as Class I, Zone 0, Zone 1, and Zone 2. In 1997,
I. Introduction RP500 was totally revised – organized into ISO format and
expanded significantly. Many of the recommended
The United States National Electrical Code (NEC) and classifications for equipment common to all three petroleum
the Canadian Electrical Code (CEC) [5] both provide special sectors were normalized and added to a new common
rules for installing electrical equipment in hazardous section. Numerous substantive changes were made, and
(classified) locations. Hazardous (classified) locations are several new appendices were added. The scope of RP500
those locations where fire or explosion hazards may exist was limited to those petroleum facility locations classified as
due to flammable gases or vapors, flammable liquids, Class I, Division 1 and Division 2.
combustible dust, or easily ignitible fibers or flyings. Only Also, in 1997, API created a totally new recommended
Class I materials (gases and vapors) are within the scope of practice, RP505, to supplement the new (1996) NEC Article
RP500 and RP505. Both the NEC and the CEC further 505, with a scope limited to those petroleum facility
provide guidelines for dividing such locations into "Divisions" locations classified as Class I, Zone 0, Zone 1, and Zone 2.
and "Zones", designating the probability that flammable Efforts were made to coordinate with the work of ISA's SP12
materials will be present. However, the guidelines are quite committee, who concurrently normalized IEC 79-10, the IEC
general, and it is unlikely that two individuals "classifying" standard that addresses the zone area classification scheme
the same location would arrive at the same, or perhaps even in general. RP505 also supplements and complements
similar, area classifications with only the general guidance material currently proposed for the 1998 CEC (and likely
of the two Codes. adopted by the time of the release and presentation of this
The customary means of documenting the classification paper). The new material provides allowance of area
of a location is with an area classification drawing. Typically, classification schemes using the international "Zone"
area classification drawings are plan views of locations (versus Division) scheme of area classification. This
depicting the major process equipment and components

1
scheme is optional in the United States, but is proposed as document IP 15 [7], Area Classification Code for Petroleum
mandatory for new facilities in Canada. Installations.
This paper provides a brief overview of the two new An attempt was made to be as harmonious as possible
recommended practices, including outlines of the tables of with the requirements of the NEC (considering proposed
content, but primarily emphasizes the substantive changes changes likely to be incorporated into Article 505 in the 1999
and additions to RP500 and the portions of RP505 with the Edition), germane United States Coast Guard requirements,
highest impact on the industry. It is assumed that the and certain relevant ISO and IEC documents.
reader is reasonably familiar with the contents of the NEC Definitions were added to RP500, and previously included
and the CEC and this paper will not provide significant definitions were updated to agree with other documents
tutorial of that information. In a similar manner, it is from which they had been extracted. New sections were
assumed that the reader is capable of using the text and added for USCG-regulated offshore facilities, such as
figures of RP500 and RP505 to classify most locations, so Tension Leg Platforms (TLPs) and Mobile Offshore Drilling
the paper is not intended to address many specific Units (MODUs). Additionally, a new Annex D, An Alternate
classifications, but rather to point out the changes, to give Method for Area Classification, was added, which it is
the logic behind the criteria, and to explain the sections that envisioned will eventually lead to the preparation of area
may be misunderstood. classification drawings using computer modeling. Because
of the large volume of material in Appendix D, the
II. Underlying Reasons for the Revision of RP 500 and information found in it will be covered for the most part by a
the Creation of RP505 separate IEEE-PCIC paper.
Substantive changes were made to the sections on
In addition to RP500 nearing the end of its five year ANSI unclassified locations that deal with open flame sources,
cycle life, numerous situations common to petroleum gas detector systems, and ventilation criteria. These
operations were not addressed by the First Edition of changes were reflected in RP505 as well as RP500 and will
RP500, issued in 1991, which combined previously separate be addressed in more detail below. Also, often
documents RP500A, 500B, and 500C, covering refining, misunderstood "transition zones", required by NEC Articles
producing and drilling, and transporting (pipeline) facilities, 500 and 505, but not by IEC 79-10, will be discussed.
respectively. Facilities not addressed in previous editions Following precedence set by the NEC, both RP505 and
include offshore United States Coast Guard (USCG) ISA RP12.24.01 (IEC 79-10 Mod) add the term Class I
regulated facilities, paint storage areas, and locations before Zone 0, Zone 1, and Zone 2, although international
containing batteries. Also, it had been agreed when the first standards (e.g., IEC 79-10) typically do not use the term. It
edition of RP500 was created that the second edition would was considered that the addition of the term would make the
attempt to normalize some of the equivalent situations in all transition from Divisions to Zones easier in North America,
three type facilities – for example, certain storage tanks and where those using the Division system for a long period of
vents from buildings that are classified within. Most time were accustomed to the Class designating the type of
important, however, the inclusion of the zone method of ignitible material present – Class I for gases and vapors,
area classification had been added to the NEC (and was Class II for combustible dusts, and Class III for easily
proposed for the CEC), and there was no industry standard ignitible fibers and flyings.
providing guidance for the classification of petroleum RP500 and RP505 provide appendices presenting
facilities into zones. After much deliberation, it was decided recommended designations for identifying Divisions 1 and 2
to issue two separate documents, both in the ISO format – locations and Zones 0, 1, and 2 locations, respectively, on
RP500 addressing areas classified as Division 1 and 2 and area classification drawings. These recommended
RP505 addressing areas classified as Zone 0, Zone 1, and designations are consistent, for the most part, with industry
Zone 2. practice in North America for designating Divisions and with
Consideration was given to the adoption and the recommendations of IEC 79-10 for designating Zones.
normalization (i.e., adding national deviations) of IEC 79-10, The members of the RP500 and RP505 task forces had
but it was decided that the normalization task should be seen widespread inconsistencies in designations – ranging
undertaken by a more diverse group than an industry- from the typical Division 2 designation of diagonal lines
specific group like the API, so the work was relegated to drawn with both positive slopes and negative slopes to a
ISA, who prepared ISA RP12.24.01 (IEC 79-10 Mod). It potpourri of symbols for Zone 0.
was decided that API RP505 should supplement and serve There have been suggestions and innuendoes that one of
as an appendix to ISA RP12.24.01 (IEC 79-10 Mod) solely the driving forces of the users' community to introduce the
for the petroleum industry. Such practice is suggested by Zone System in North America was to convert many existing
IEC 79-10. Division 1 locations to Zone 2 locations. The authors
RP505 was created using, as a basis for a start, many compared the recommendations of RP500 and RP505 and
existing standards, recommended practices, and other found no evidence to support such claims. In fact, in every
documents – including API RP500, ISA RP12.24.01 (IEC case, analogous Division 2 locations were defined as Zone 2
79-10 Mod), NFPA 497 [6], Recommended Practice for the locations; the two appear to be synonymous.
Classification of Flammable Liquids, Gases, or Vapors and of After the Zone 0 locations were identified, the balance of
Hazardous (Classified) Locations for Electrical Installations in the formerly designated Division 1 locations were delineated
Chemical Process Areas, and the Institute of Petroleum as Zone 1 locations. It is pointed out that there are very few
Zone 0 locations in the petroleum industry, and most of

2
these are inside atmospheric storage containment and engineering judgment normally would dictate a lesser
process systems or in the immediate proximity to vents, degree of hazard – for example, Zone 1 instead of Zone 0.
where there is little need for electrical equipment. Electrical More information on grades of release can be found in ISA
equipment in these locations usually is instrumentation or RP12.24.01 (IEC 79-10 Mod) and Appendix F of RP505.
measurement equipment, which normally can be intrinsically Inference to atmospheric vents from classified buildings
safe. Much of the reduction in Zone 0 locations can be and other enclosed areas was made in the previous edition
accredited to increased efforts by operators to reduce both of RP500, but specific recommendations are now given in
normal and abnormal discharge of products into the both RP500 and RP505. The areas around atmospheric
atmosphere – some voluntary and some because of vents from Class I, Division 1, Zone 1, Division 2, and Zone
legislation. Some say, partly tongue-in-cheek and partly 2 areas are shown below in Figs. 1, 2, 3, and 4, extracted
factual, that it will be illegal in the near future to have from API RP500 and RP505.
Division 1 locations due to more rigorous environmental
laws.

III. Common Equipment 3m(10') 1.5m(5')

Recommendations for the classification of areas

surrounding storage tanks; tank cars and tank trucks; vents, Roof vent
relief valves, and rupture disks; marine terminals handling (note)
flammable liquids; hydrocarbon-fueled prime movers;
batteries; and flammable and combustible paint products –
storage and usage areas; were normalized and placed in a
common section in the Second Edition of RP500 and also in
RP505. More detail on these subjects is given below, but it
is noted that RP500 and RP505 have created consistency of
dimensions on certain of the recommended drawings,
through consensus, that some standards have not been able Division 1 Division 2
to accomplish.

A. Storage Tanks Note:

The interior of the roof vent is Division 1.

Recommendations for the classification of areas Cross hatching has been omitted for drawing
surrounding both fixed roof and floating roof storage tanks clarity.
found in the previous edition in the refining, transportation,
and production sections were normalized and moved to this Fig. 1 Atmospheric Vent From a Division 1 Area
section.

B. Tank Cars and Tank Trucks 3m(10') 1.5m(5')

Recommendations for the classification of areas

surrounding tank cars and tank trucks found in the previous Roof vent
edition both in the refining section and in the transportation (Note)
section were normalized and moved to this section.

C. Vents and Relief Valves

Recommendations for the classification of areas

surrounding vents and relief valves found in the previous
edition in the refining, transportation, and production
sections were normalized and moved to this section.
The section on vents and relief valves includes the areas
adjacent to process equipment vents; vents from Zone 0 Zone 1 Zone 2
instruments and control devices utilizing flammable gas for
control; atmospheric vents (e.g., building ridge vents,
Note:
building roof vents, and atmospheric tank vents); and relief
valve and rupture disk discharge points. The interior of the roof vent is Zone [Link] hatching has
been omitted for drawing clarity.
The reader is cautioned that the section on process
equipment and instrument and control device vent sources
cited are based on there being continuous grades of
release. If the grade of release is not continuous, good Fig. 2 Atmospheric Vent From a Zone 1 Area

3
 1.5m(5') RP505, eliminating the former limitation of 7500 HP of its
scope. Therefore, the 7500 HP limitation imposed by
RP500 is not referenced in RP505.
Roof vent
(note)
F. Batteries

The section on batteries probably was the most difficult of

all new sections to write as there is a minimum of literature
available specifically devoted to the classification of
locations containing batteries. No significant information
was found in national or international standards. USCG
Division 1 Division 2
regulations do have some guidance, and this information
was reviewed and used as much as practical. The section
presents guidelines for classifying locations where batteries
Note:
are installed. Areas classified solely because they contain
The interior of the roof vent is Division 2. batteries are classified because of hydrogen evolution from
Cross hatching has been omitted for drawing the batteries, and, therefore, require a Group B (or Group
clarity.
IIC for the zone system) designation.
Areas containing non-rechargeable batteries do not
Fig. 3 Atmospheric Vent From a Division 2 Area
require area classification solely due to the presence of the
batteries. Also, enclosed areas containing rechargeable
1.5m(5')
batteries that (1) have no vents, (2) are of the nickel-
cadmium or nickel-hydride type, (3) have a total volume less
Roof vent than one-hundredth of the free volume of the enclosed area,
(Note) and (4) have a capacity not exceeding 1.5 ampere-hours at
a one hour discharge rate, do not require area classification
solely due to the presence of the batteries. For the purpose
of area classification, battery vents include relief devices,
such as valves that open to the atmosphere, as found in
valve-regulated lead acid (VRLA) batteries.
The section differentiates between enclosed and non-
enclosed areas; batteries that have vents and those that do
Zone 0 Zone 1 Zone 2 not; and batteries that have a charging system that is
designed to prevent inadvertent overcharging and those that
Note:
do not. Particular attention is given to batteries installed in
The interior of the roof vent is Zone 2. Cross hatching has
"battery boxes" and the venting methods of such boxes.
been omitted for drawing clarity. It is recommended that ventilation rates to achieve
adequate ventilation be based on the maximum hydrogen
evolution rate for the applicable batteries. The maximum
hydrogen evolution rate for lead antimony batteries should
be considered as 0.000269 cubic feet per minute per
o
Fig. 4 Atmospheric Vent From a Zone 2 Area charging ampere per cell at 25 C, with the maximum
charging current available from the battery charger applied
D. Marine Terminal Handling Flammable Liquids into a fully charged battery. The maximum hydrogen
evolution rate for other types of batteries (e.g., lead calcium
Recommendations for the classification of areas and nickel cadmium) should be obtained for the condition
surrounding marine terminals handling flammable liquids when the maximum charging current available from the
found in the previous edition of both in the refining section battery charger is applied into a fully charged battery. It is
and in the transportation section were normalized and cautioned that a Division 1 or Zone 0 classification normally
moved to the common section. would prohibit the installation of batteries in an area.

E. Hydrocarbon-fueled Prime Movers G. Flammable and Combustible Paint Products –

Storage and Usage Areas
Recommendations for the classification of areas
surrounding hydrocarbon-fueled prime movers found in the The section on flammable and combustible paint products
previous edition in the production section were slightly addresses only the electrical classification of locations
edited and moved to this section. where flammable and combustible paint products (for
The reader is advised that the referenced standard, NFPA example, paints, lacquers, and paint solvents) are stored or
37 [8], on which part of this section was based, was used. It does not address safe practices for the storage or
changed between the approval of RP500 and the writing of use of these products, a subject outside the scope of both
RP500 and RP505. Likewise, the section does not cover

4
rooms and other areas specifically intended for spray criteria to determine if areas adjacent to such systems
painting and similar operations where flammable and should be classified.
combustible paint products are regularly or frequently Additionally, it is recommended that adequately ventilated
applied during normal operations in the room or area. locations surrounding equipment that has continuous flame
These areas are not unique to petroleum facilities and are sources (e.g., unprotected fired vessels and flare tips) need
adequately addressed in Article 516 of the NEC, to which not be classified solely by reason of the fuel gas being
the reader should refer. Also, due to the wide variety of considered as a source of release. This is a change from
conditions and application methods encountered, the previous editions. In previous editions, wording was
section does not cover painting operations, which are not "stronger", basically stating that areas surrounding
unique to petroleum facilities. continuous or intermittent flame sources need not be
The section is divided into two main parts: (1) Storage classified. Questions arose: How far from the flame source
Areas, non-enclosed and enclosed areas (e.g., rooms, was included in "the surrounding area"? Was it intended to
cabinets, and lockers) where flammable and combustible include sources other than the fuel gas? What about
paint products are stored, and (2) Usage Areas, areas where equipment that might allow flammable fuel to be released to
flammable and combustible paint products are used. the atmosphere during purge cycles? The previous wording
“Used” is defined as operations such as cleaning paint seemed to allow abuse of the intention: to allow ordinary
brushes with flammable solvents and mixing paint with equipment to be installed in locations that already had a
solvents where volatile gases or vapors will be given off to source of ignition. Therefore, the wording was changed to
the atmosphere. Also included as “usage areas” are areas clarify the original intent. It is noted that it may be prudent
where cleaning rags containing solvents or open containers to classify portions of these locations. For example,
of paint products are present. The storage area sub-section electrical equipment may be exposed to flammable gas
does not cover areas where paint brushes are cleaned with during a purge cycle of a fired heater or furnace. Also, it is
flammable solvents, paint is mixed with solvents, and other noted that the lack of classification around unprotected fired
similar operations or areas where cleaning rags containing vessels and flare tips does not imply the safe placement of
solvents, open containers of paint products, and similar fired vessels and flare tips in the proximity of other sources
materials are present. of release, because unprotected fired vessels and flare tips
Nonenclosed and enclosed, adequately ventilated and are themselves sources of ignition. The decision of whether
inadequately ventilated, areas where flammable and or not it is safe to install unprotected fired vessels or flare
combustible paint products are stored in sealed containers tips at specific locations is outside the scopes of RP500 and
(original containers or equivalent) are unclassified. RP505.
Adequately ventilated enclosed areas where flammable and The practice of not classifying locations where non-
combustible paint products are used are unclassified if the electrical ignition sources (e.g., the open flame of an
quantities of open containers of paint are 20 liters (five unprotected fired vessel or flare tip) exist has been utilized in
gallons) or less or if the quantities of open containers of previous issues of RP 500. It is recommended that the
solvent are four liters (one gallon) or less. Adequately application of this practice be limited to unprotected fired
ventilated enclosed areas where only combustible paint vessels or flare tips and that the resulting unclassified
products are used are unclassified if the temperature is locations be restricted to their immediate vicinity. Electrical
below their flashpoints. equipment located in these unclassified locations typically is
de-energized for the majority of the time that the flame
IV. Unclassified Locations source is not present.
Although from a practical view, when an open flame is
Both RP500 and RP505 recommend that certain locations present a spark from electrical equipment in the immediate
be unclassified regardless of the ventilation rate since the area of the flame would not likely be the initiator of
occurrence of flammable gas or vapor liberation from some combustion, the location of sources of ignition is not a
apparatus is so infrequent. Examples of such locations criteria for the classification of locations. Classification is,
include the following: by definition, based on the likelihood of the presence of
(a) Locations where flammable substances are contained flammable mixtures. It is not the intent of RP500 or RP505
in all-welded closed piping systems without valves, flanges to recommend the creation of an unclassified location in
or similar devices, or continuous metallic tubing without which one can locate general purpose electrical devices that
valves, fittings, flanges, or similar devices, and are not directly associated with the combustion or ignition
(b) Locations where flammable liquids, gases or vapors systems of unprotected fired vessels or flare tips.
are transported or stored in certain containers or vessels
(primarily those approved to meet specific NFPA and V. Combustible Gas Detector Systems
Department of Transportation regulations specifying
containers for flammable liquids and gases). The concept of using combustible gas detectors
Unfortunately, a number of people have misunderstood essentially as a protection technique, or to reduce the
this recommendation and have believed that the converse of degree of classification, was introduced in RP500B several
(a) and the converse of (b) were applicable. This is not the editions ago. Areas not containing a source can be
intention of RP500. Areas containing piping and tubing considered unclassified rather than Division 2, and certain
systems with flanges do not necessarily require areas normally otherwise classified as Division 1 can be
classification. One must consider the ventilation and other classified as Division 2, provided all criteria specified are

5
met. The concept was carried forth from RP500B into In the United States ventilation is divided into two
RP500, but was modified in the Second Edition. In the First categories, adequate and inadequate, with no "gray" area
Edition of RP500, sensing a gas concentration of 40 percent between. In international standards, ventilation rates
lower flammable limit (LFL), maximum, or a gas detector typically are divided into three categories – defined by ISA
system malfunction was required to both activate an alarm RP12.24.01 (IEC 79-10 Mod) as high ventilation, medium
(audible or visual, or both, as most appropriate for the area) ventilation, and low ventilation.
and to initiate automatic disconnection of power from all High ventilation is defined as the ventilation rate that can
electrical devices in the area that were not suitable for reduce the concentration at the source of release virtually
Division 1. In the Second Edition, automatic disconnection instantaneously, resulting in a concentration below the lower
of power from all electrical devices in the area is required for flammable/explosive limit. A zone of small (even negligible)
all devices not suitable for Division 2. Redundant or extent results. Medium ventilation can control the
duplicate components (such as sensors) still may be concentration, resulting in a stable situation in which the
installed to avoid disconnecting electrical power when single concentration beyond the zone boundary is below the LFL
component malfunctions are indicated. It is cautioned that during the period of time in which the release is in progress
when automatic shutdown could introduce additional or and where the flammable/explosive atmosphere does not
increased hazard, automatic shutdown should not be persist unduly after release has stopped. Low ventilation
provided, and this method of area reduction may not be cannot control the concentration during the period of time in
feasible. This concept was extended to RP505, allowing which the release is in progress; neither can it prevent
areas normally classified as Zone 1 to be classified as Zone undue persistence of a flammable atmosphere after release
2 and areas not containing a source to be considered has stopped.
unclassified if the criteria specified are met. Ironically perhaps, the latest edition of RP500B, before it
was merged into RP500, recommended three ventilation
VI. Ventilation Criteria rates – adequate, limited, and inadequate, with limited
ventilation defined as an intermediate ventilation rate
Ventilation is a prime factor in determining area between adequate and inadequate. The former term limited
classification. Most methods used to determine whether or ventilation fairly well fits the term medium ventilation;
not ventilation is adequate involve determining the perhaps later versions of RP500 and other standards such
minimum ventilation rate at which flammable mixtures are as NFPA 30 will revert to the three-level ventilation rates.
maintained below 25% of their LFL, based to a large extent The two-level ventilation rates matches well the Division
on recommendations in NFPA 30 [9], Flammable and classification scheme – two ventilation rates and two
Combustible Liquids Code. RP 500 and 505 allow these divisions dividing hazardous (classified) locations. The
conventional methods as well, but also provide three-level ventilation rates matches well the Zone
mathematical equations and means that one can use to classification scheme – three ventilation rates and three
determine whether or not an enclosed area is adequately zones dividing hazardous (classified) locations. In fact, for
ventilated by natural or artificial means. Methodology continuous releases, although no firm recommendations are
developed for fugitive emissions by an earlier RP500B task made, a low ventilation rate normally leads to a Class I,
force was incorporated into NFPA 30. Zone 0 or Zone 1 designation ; a medium ventilation rate to
Additionally, certain buildings or other enclosed or a Class I, Zone 1 or Zone 2 designation; and a high
partially enclosed areas can be considered adequately ventilation rate to a Class I, Zone 2 or unclassified
ventilated because of their construction characteristics if (a) designation, dependent to a large extent on the rate of
for flammable liquids with heavier-than-air vapors, release, or potential rate of release, of the source.
ventilation is arranged to ventilate all areas (particularly
floor areas) where flammable vapors might collect; and, (b) VII. Transition Zones
for lighter-than-air gases, roof or wall openings are
arranged to ventilate all areas (particularly ceiling areas) A Division 2 “transition zone” normally is required by the
where gases might collect and also the buildings comply NEC between a Division 1 location and an unclassified
with any one of the three following criteria: location. In a similar manner, a Zone 1 transition zone
1. A building or area having a roof or ceiling with normally is required between a Zone 0 location and a Zone
walls comprising 50 percent or less vertical wall area of 2 location, and a Zone 2 transition zone normally is required
the total wall area possible is considered to be adequately between a Zone 1 location and an unclassified location. A
ventilated (regardless of the type of floor). vaportight barrier can be used, however, to prevent gas and
2. A building or area is considered to be adequately vapor from spreading, and in most cases, can alleviate the
ventilated provided it has neither a floor (for example, the need for a transition zone. Also, adequate positive-pressure
floor is grating) nor a roof or ceiling. ventilation from a source of clean air and effective
3. A building or area is considered to be adequately safeguards against ventilation failure can be used to
ventilated provided it is without a roof or ceiling, and eliminate the transition zone. It is noted that IEC 79-10
provided that there are no walls for a minimum of 25% of does not require transition zones. That is, a Zone 0 or Zone
its perimeter. This criteria was rewritten for the Second 1 location can abut an unclassified location, or a Zone 0
Edition of RP 500 and for RP505 to clarify the intent of the location can abut a Zone 2 location. This is a major
original document. deviation between ISA RP12.24.01 (IEC 79-10) and IEC 79-
10.

6
 VIII. Grades of Release and Division 2 for locations where flammable mixtures are
present for more than one , but less than 10, hours per year.
One of the criteria used internationally in determining the
classification of locations is the "grade of release" concept of X. Conclusions
IEC 79-10 [10]. Table 1, based on concepts from IEC 79-10
and IP-15, and extracted from RP505, relates grades of API RP500 and RP505 offer those in the petroleum
release to the time that flammable mixtures are present, industry an opportunity to standardize area classification
and, thus, indirectly to which areas should be classified as drawings – both for drawings using the Division method of
Zone 0, Zone1, and Zone 2. A similar thought process area classification and for drawings using the Zone method
could be used for Divisions 1 and 2. of area classification. Good engineering judgment must be
used with RP500 and RP505 as with all recommended
TABLE I practices, but guidelines provided should minimize
THE RELATIONSHIP BETWEEN GRADE OF RELEASE AND differences of classifications by qualified individuals
THE PRESENCE OF FLAMMABLE MIXTURES classifying the same or similar locations. Individuals in
other industries should also be able to use some of the
Grade of Release Flammable Mixture Present concepts set forth by the new recommended practices.
The audience of users of the API area classification
Continuous 1000 or more hours / year recommendations has been expanded through the addition
Primary 10 < hours/ year < 1000 of sections on operations not included before and offshore
facilities excluded in the past edition of RP500, and also
Secondary less than 10 hours / year through the issuance of RP505 that provides guidance to
those using the zone method of area classification.
Continuous grades of release normally lead to a Zone 0 Although international harmonization has not been fully
classification. Primary grades of release normally lead to a achieved, the new documents, particularly RP505, offer a
Zone 1 classification. Secondary grades of release normally start towards that long term goal.
lead to a Zone 2 classification. However, it should be noted
that the terms “Grade of Release” and “Zone” are not References
synonymous. Although continuous, primary, and secondary
grade releases normally will result in Zones 0, 1, and 2 [1] API RP500 1997, Recommended Practice for
classifications, respectively, this is not always true. For Classification of Locations for Electrical Installations at
example, poor ventilation may result in a more stringent Petroleum Facilities Classified as Class I, Division 1
classification while, with high ventilation provisions, the and Division 2 : API
converse will be true. Also, some sources may be [2] API RP505 1997, Recommended Practice for
considered to have a dual grade of release with a small Classification of Locations for Electrical Installations at
continuous or primary grade and a larger secondary grade. Petroleum Facilities Classified as Class I, Zone 0,
Zone 1, and Zone 2 : API
IX. Time Criteria for Area Classification [3] ISA-RP12.24.01 (IEC 79-10 Mod) 1998,
Recommended Practice for Classification of Locations
Although there is no firm rule relating the time that for Electrical Installations Classified as Class I, Zone
flammable mixtures occur in Zone 0, Zone 1, and Zone 2 , 0, Zone 1, or Zone 2 : ISA
and unclassified locations, many use the rule-of-thumb [4] NFPA 70, 1996, National Electrical Code: NFPA
shown in Table 2, extracted from API RP505. [5] CSA C22.1-1998, Canadian Electrical Code-Part I:
CSA
TABLE 2 [6] NFPA 497 1997, Recommended Practice for the
THE TYPICAL RELATIONSHIP BETWEEN ZONE Classification of Flammable Liquids, Gases, or Vapors
CLASSIFICATION AND THE PRESENCE OF FLAMMABLE and of Hazardous (Classified) Locations for Electrical
MIXTURES
Installations in Chemical Process Areas : NFPA
[7] Institute of Petroleum (Great Britain), Area
Zone Flammable Mixture Present Classification Code for Petroleum Installations, Part
15
0 1000 or more hours / year (10% )
8] NFPA 37 1994, Standard for the Installation and Use
1 10 < hours / year < 1000 (0.1% - 10%) of Stationary Combustion Engines and Turbines :
NFPA
2 1 < hour / year < 10 (0.01% - 0.1%) [9] NFPA 30 1996, Flammable and Combustible Liquids
Unclassified Less than 1 hour / year (0.01%) Code : NFPA
[10] IEC 79-10, Electrical apparatus for explosive gas
atmospheres – Part 10, Classifications of hazardous
The same criteria often are used for Divisions, specifying
areas: IEC
Division 1 for locations where flammable mixtures are
present for periods of time greater than 10 hours per year

7
 APPENDIX 1. TABLE OF CONTENTS OF API RP500

1. SCOPE 9 RECOMMENDATIONS FOR DETERMINING DEGREE

1.1 PURPOSE AND EXTENT OF CLASSIFIED LOCATIONS IN
1.2 SCOPE PETROLEUM REFINERIES
2 REFERENCES 9.1 INTRODUCTION
2.1 INDUSTRY CODES, GUIDES AND STANDARDS 9.2 RECOMMENDATIONS
2.2 GOVERNMENT CODES, RULES, AND 10 RECOMMENDATIONS FOR DETERMINING DEGREE
REGULATIONS AND EXTENT OF CLASSIFIED LOCATIONS AT
3 ACRONYMS AND ABBREVIATED DEFINITIONS DRILLING RIGS AND PRODUCTION FACILITIES ON
3.1 ACRONYMS LAND AND ON MARINE FIXED PLATFORMS
3.2 DEFINITIONS 10.1 GENERAL
4 BASIC CONDITIONS FOR A FIRE OR EXPLOSION 10.2 DRILLING AREAS
5 FLAMMABLE AND COMBUSTIBLE LIQUIDS, GASES 10.3 PRODUCTION FACILITIES
AND VAPORS 10.4 DRILLING WELLS
5.1 GENERAL 10.4.1 RIG FLOOR AND SUBSTRUCTURE AREA
5.2 FLAMMABLE AND COMBUSTIBLE LIQUIDS 10.4.2 MUD TANK
5.2.1 GENERAL 10.4.3 MUD DITCH, TRENCH, OR PIT
5.2.2 CLASS I LIQUIDS 10.4.4 MUD PUMP
5.2.3 CLASS II LIQUIDS 10.4.5 SHALE SHAKER
5.2.4 CLASS III LIQUIDS 10.4.6 DESANDER OR DESILTER
5.3 FLAMMABLE HIGHLY VOLATILE LIQUIDS 10.4.7 DEGASSER
5.4 FLAMMABLE LIGHTER-THAN-AIR GASES 10.4.8 BLOWOUT PREVENTER (BOP)
5.5 NATIONAL ELECTRICAL CODE GROUPING OF 10.5 PRODUCING OIL AND GAS WELLS
ATMOSPHERIC MIXTURES 10.5.1 FLOWING WELL
6 CLASSIFICATION CRITERIA 10.5.2 ARTIFICIALLY LIFTED WELLS
6.1 GENERAL 10.5.3 INJECTION WELLS
6.2 NATIONAL ELECTRICAL CODE CRITERIA 10.5.4 MULTI-WELL INSTALLATIONS
6.2.1 CLASSIFICATION CRITERIA 10.6 OIL AND GAS PROCESSING AND STORAGE
6.2.2 CLASS I, DIVISION 1 CONSIDERATIONS EQUIPMENT
6.2.3 CLASS I, DIVISION 2 CONSIDERATIONS 10.6.1 FLAMMABLE LIQUID STORAGE TANK
6.2.4 UNCLASSIFIED LOCATIONS 10.6.2 COMBUSTIBLE LIQUID STORAGE TANK
6.3 VENTILATION 10.6.3 HYDROCARBON PRESSURE VESSEL
6.3.1 GENERAL 10.6.4 HEADER OR MANIFOLD
6.3.2 ADEQUATE VENTILATION 10.6.5 PROTECTED FIRED VESSELS
6.3.3 INADEQUATELY VENTILATED AREAS 10.6.6 LAUNCHER OR RECEIVER
6.4 ADJACENT AREAS 10.6.7 DEHYDRATOR, STABILIZER, AND
6.5 USE OF COMBUSTIBLE GAS DETECTION HYDROCARBON RECOVERY UNIT
EQUIPMENT 10.6.8 VENTS AND RELIEF VALVES
7 EXTENT OF A CLASSIFIED LOCATION 10.6.9 HYDROCARBON-FUELED PRIME MOVERS
7.1 GENERAL 10.6.10 BATTERIES
7.2 OUTDOOR LOCATIONS 10.7 AUTOMATIC CUSTODY TRANSFER (ACT) UNITS
7.3 ENCLOSED LOCATIONS. 10.8 FLAMMABLE GAS-BLANKETED EQUIPMENT
8 RECOMMENDATIONS FOR DETERMINING DEGREE AND PRODUCED/PROCESSED WATER HANDLING
AND EXTENT OF CLASSIFIED LOCATIONS -- COMMON EQUIPMENT
APPLICATIONS 10.9 COMPRESSOR OR PUMP HANDLING
8.1 GENERAL FLAMMABLE LIQUIDS, GASES, OR VAPORS
8.2 RECOMMENDATIONS FOR AREAS 10.10 DRIP PANS
SURROUNDING SPECIFIC EQUIPMENT 10.11 INSTRUMENTS
8.2.1 STORAGE TANKS 10.12 SUMPS
8.2.2 TANK CARS AND TANK TRUCKS 10.13 DRAINS
8.2.3 VENTS AND RELIEF VALVES 10.14 RESERVED FOR FUTURE USE
8.2.4 MARINE TERMINAL HANDLING FLAMMABLE 10.15 SCREWED CONNECTIONS, FLANGES,
LIQUIDS VALVES, AND VALVE OPERATORS
8.2.5 HYDROCARBON-FUELED PRIME MOVERS 10.16 CONTROL PANELS CONTAINING
8.2.6 BATTERIES INSTRUMENTATION UTILIZING OR MEASURING
8.2.7 FLAMMABLE AND COMBUSTIBLE PAINT FLAMMABLE LIQUIDS, GASES OR VAPORS
PRODUCTS -- STORAGE AND USAGE AREAS

8
11 RECOMMENDATIONS FOR DETERMINING DEGREE 12.5 CLASSIFICATION OF ADJACENT SPACES
AND EXTENT OF CLASSIFIED LOCATIONS ON MOBILE 13 RESERVED FOR FUTURE USE
OFFSHORE DRILLING UNITS (MODUS) 14 RECOMMENDATIONS FOR DETERMINING DEGREE
11.1 GENERAL AND EXTENT OF CLASSIFIED LOCATIONS AT
11.2 DEFINITIONS SPECIFIC TO MODUs PETROLEUM PIPELINE TRANSPORTATION FACILITIES
11.2.2 Tanks 14.1 GENERAL
11.3 RESERVED FOR FUTURE USE 14.2 USE OF FIGURES
11.4 CLASSIFIED LOCATIONS ON MOBILE 14.3 FIGURES
OFFSHORE DRILLING UNITS (MODUs) APPENDIX A. SAMPLE CALCULATION TO ACHIEVE
11.4.1 Drilling Areas ADEQUATE VENTILATION OF AN ENCLOSED AREA BY
11.4.2 Well Test Equipment Areas NATURAL MEANS USING EQUATIONS 1 AND 2
11.4.3 Other Areas APPENDIX B. CALCULATION OF MINIMUM AIR
11.4.4 Drains. INTRODUCTION RATE TO ACHIEVE ADEQUATE
11.5 BASIS FOR AREA CLASSIFICATION VENTILATION USING FUGITIVE EMISSIONS
11.5.1 Ventilation and Pressurization APPENDIX C. DEVELOPMENT OF VENTILATION
11.5.2 Ventilation and Pressurization of Hazardous CRITERIA
(Classified) Locations APPENDIX D. INFORMATIVE ANNEX -- AN ALTERNATE
11.5.3 Ventilation and Pressurization of Unclassified METHOD FOR AREA CLASSIFICATION
(Non-Hazardous) Locations D.1 INTRODUCTION
11.6 CLASSIFICATION OF HAZARDOUS D. 2 EXPLANATION OF “POINT SOURCE” CONCEPT.
(CLASSIFIED) LOCATIONS D. 3 DETERMINATION OF VOLATILITY
11.7 DRILL FLOOR AND DERRICK AREAS CLASSIFICATION
11.8 SUBSTRUCTURE OR MOONPOOL AREAS D.4 DETERMINATION OF THE HAZARD RADIUS FOR
11.9 MUD SYSTEM PROCESSING EQUIPMENT AREA CLASSIFICATION PURPOSES
OVERVIEW D.5 APPLICATION TO NON-ENCLOSED,
11.10 MUD TANKS (AFTER DISCHARGE OF FINAL ADEQUATELY VENTILATED LOCATIONS
DEGASSER) CONTAINING A HEAVIER-THAN-AIR GAS OR VAPOR
11.11 MUD DITCHES OR TROUGHES SOURCE
11.12 MUD PUMPS D.5.1 GENERAL
11.13 MUD PROCESSING EQUIPMENT (BETWEEN D.5.2 POINT SOURCE LOCATED NEAR OR ABOVE
THE BELL NIPPLE AND MUD DISCHARGE OF FINAL GRADE - ADEQUATELY VENTILATED LOCATION.
DEGASSER) D.5.3 PUMPS -- ADEQUATELY VENTILATED AREA.
11.14 DESANDER OR DESILTER (BETWEEN MUD D.5.4 EQUIPMENT CONTAINING MEDIUM AND
DISCHARGE OF FINAL DEGASSER AND THE MUD LOW PRESSURE RESTRICTIONS (ORIFICES,
PIT) DRAINS, ETC.)
11.15 VENTS D.5.5 COMPRESSORS
11.16 DIVERTER LINE OUTLET D.5.6 INSTRUMENT AND PROCESS VENTS AND
11.17 BLOWOUT PREVENTER (BOP) DRAINS TO ATMOSPHERE
11.18 WELL TEST EQUIPMENT AREAS D.5.7 FLANGES AND VALVES
11.19 ROOMS USED TO STORE PAINT (PAINT D.6. DETERMINING THE HAZARD RADIUS FOR
LOCKERS) SOURCES HANDLING LIGHTER-THAN-AIR GASES
11.20 BATTERY ROOMS AND VAPORS
11.21 RESERVED FOR FUTURE USE D.6.1 POINT SOURCE LOCATED ABOVE GRADE
11.22 HELICOPTER FUEL STORAGE AREAS D.6.2 COMPRESSORS
11.23 CLASSIFICATION OF ADJACENT SPACES D.7 APPLICATION TO INADEQUATELY VENTILATED
12 RECOMMENDATIONS FOR DETERMINING DEGREE AREAS
AND EXTENT OF CLASSIFIED LOCATIONS AT D.8 NOTES
DRILLING RIGS AND PRODUCTION FACILITIES ON D.8.1 MISTS (IEC 79-10, modified)
FLOATING PRODUCTION UNITS APPENDIX E. PROCEDURE FOR CLASSIFYING
12.1 GENERAL LOCATIONS
12.2 FLOATING PRODUCTION STORAGE AND APPENDIX F. PREFERRED SYMBOLS FOR DENOTING
OFFLOADING UNITS (FPSOs) CLASS I, DIVISION 1 AND DIVISION 2 HAZARDOUS
12.3 TENSION LEG PLATFORMS (TLPs) (CLASSIFIED) LOCATIONS
12.4 SPARS, CAISSONS, AND SIMILAR UNITS

9
 APPENDIX 2. TABLE OF CONTENTS OF API RP505

1. SCOPE PETROLEUM REFINERIES

1.1 PURPOSE 9.1 INTRODUCTION
1.2 SCOPE 9.2 RECOMMENDATIONS
2 REFERENCES 10 RECOMMENDATIONS FOR DETERMINING DEGREE
2.1 INDUSTRY CODES, GUIDES AND STANDARDS. AND EXTENT OF CLASSIFIED LOCATIONS AT
2.2 GOVERNMENT CODES, RULES, AND DRILLING RIGS AND PRODUCTION FACILITIES ON
REGULATIONS LAND AND ON MARINE FIXED PLATFORMS
3 ACRONYMS AND ABBREVIATED DEFINITIONS 10.1 GENERAL
3.1 ACRONYMS 10.2 DRILLING AREAS
3.2 DEFINITIONS 10.3 PRODUCTION FACILITIES
4 BASIC CONDITIONS FOR A FIRE OR EXPLOSION 10.4 DRILLING WELLS
5 FLAMMABLE AND COMBUSTIBLE LIQUIDS, GASES 10.4.1 RIG FLOOR AND SUBSTRUCTURE AREA
AND VAPORS 10.4.2 MUD TANK
6 CLASSIFICATION CRITERIA 10.4.3 MUD DITCH, TRENCH, OR PIT
6.1 GENERAL 10.4.4 MUD PUMP
6.2 SOURCES OF RELEASE (IEC 79-10, Mod) 10.4.5 SHALE SHAKER
6.3 ZONE DESIGNATION (IEC 79-10, Mod) 10.4.6 DESANDER OR DESILTER
6.4 EXTENT OF ZONE (IEC 79-10, Mod) 10.4.7 DEGASSER
6.5 NATIONAL ELECTRICAL CODE CRITERIA 10.4.8 BLOWOUT PREVENTER (BOP)
6.5.1 NEC CLASSIFICATIONS 10.5 PRODUCING OIL AND GAS WELLS
6.5.2 CLASS I, ZONE 0 CONSIDERATIONS 10.5.1 FLOWING WELL
6.5.3 CLASS I, ZONE 1 CONSIDERATIONS 10.5.2 ARTIFICIALLY LIFTED WELLS
6.5.4 CLASS I, ZONE 2 CONSIDERATIONS 10.5.3 INJECTION WELLS
6.5.5 VENT OPENINGS. 10.5.4 MULTI-WELL INSTALLATIONS
6.5.6 DUAL CLASSIFICATION. 10.6 OIL AND GAS PROCESSING AND STORAGE
6.5.7 CLASSIFICATION RESTRICTIONS. EQUIPMENT
6.5.8 RELATIONSHIP BETWEEN GRADE OF 10.6.1 FLAMMABLE LIQUID STORAGE TANK
RELEASE AND ZONE CLASSIFICATION. 10.6.2 COMBUSTIBLE LIQUID STORAGE TANK
6.5.9 UNCLASSIFIED LOCATIONS 10.6.3 HYDROCARBON PRESSURE VESSEL
6.6 VENTILATION 10.6.4 HEADER OR MANIFOLD
6.6.1 GENERAL 10.6.5 PROTECTED FIRED VESSELS
6.6.2 ADEQUATE VENTILATION 10.6.6 LAUNCHER OR RECEIVER
6.6.3 INADEQUATELY VENTILATED AREAS 10.6.7 DEHYDRATOR, STABILIZER, AND
6.7 ADJACENT AREAS HYDROCARBON RECOVERY UNIT
6.8 USE OF COMBUSTIBLE GAS DETECTION 10.6.8 VENTS AND RELIEF VALVES
EQUIPMENT 10.6.9 HYDROCARBON-FUELED PRIME MOVERS
7 EXTENT OF A CLASSIFIED LOCATION 10.6.10 BATTERIES
7.1 GENERAL 10.7 AUTOMATIC CUSTODY TRANSFER (ACT) UNITS
7.2 OUTDOOR LOCATIONS 10.8 FLAMMABLE GAS-BLANKETED EQUIPMENT
7.3 ENCLOSED LOCATIONS. AND PRODUCED/PROCESSED WATER HANDLING
8 RECOMMENDATIONS FOR DETERMINING DEGREE EQUIPMENT
AND EXTENT OF CLASSIFIED LOCATIONS – COMMON 10.9 COMPRESSOR OR PUMP HANDLING
APPLICATIONS FLAMMABLE LIQUIDS, GASES, OR VAPORS
8.1 GENERAL 10.10 DRIP PANS
8.2 RECOMMENDATIONS FOR AREAS 10.11 INSTRUMENTS
SURROUNDING SPECIFIC EQUIPMENT 10.12 SUMPS
8.2.1 STORAGE TANKS 10.13 DRAINS
8.2.2 TANK CARS AND TANK TRUCKS 10.14 RESERVED FOR FUTURE USE
8.2.3 VENTS, RELIEF VALVES, AND RUPTURE 10.15 SCREWED CONNECTIONS, FLANGES,
DISKS VALVES, AND VALVE OPERATORS
8.2.4 MARINE TERMINAL HANDLING FLAMMABLE 10.16 CONTROL PANELS CONTAINING
LIQUIDS INSTRUMENTATION UTILIZING OR MEASURING
8.2.5 HYDROCARBON-FUELED PRIME MOVERS FLAMMABLE LIQUIDS, GASES OR VAPORS
8.2.6 BATTERIES 11 RECOMMENDATIONS FOR DETERMINING DEGREE
8.2.7 FLAMMABLE AND COMBUSTIBLE PAINT AND EXTENT OF CLASSIFIED LOCATIONS ON MOBILE
PRODUCTS – STORAGE AND USAGE AREAS OFFSHORE DRILLING UNITS (MODUS)
9 RECOMMENDATIONS FOR DETERMINING DEGREE 11.1 GENERAL
AND EXTENT OF CLASSIFIED LOCATIONS IN 11.2 DEFINITIONS SPECIFIC TO MODUs

10
 11.2.1 Locations and Spaces APPENDIX A. SAMPLE CALCULATION TO ACHIEVE
11.2.2 Tanks ADEQUATE VENTILATION OF AN ENCLOSED AREA BY
11.2.3 Ventilation NATURAL MEANS USING EQUATIONS 1 AND 2
11.3 RESERVED FOR FUTURE USE APPENDIX B. CALCULATION OF MINIMUM AIR
11.4 CLASSIFIED LOCATIONS ON MOBILE INTRODUCTION RATE TO ACHIEVE ADEQUATE
OFFSHORE DRILLING UNITS (MODUs) VENTILATION USING FUGITIVE EMISSIONS
11.4.1 Drilling Areas APPENDIX C. PREFERRED SYMBOLS FOR DENOTING
11.4.2 Well Test Equipment Areas CLASS I, ZONE 0, ZONE 1, AND ZONE 2 HAZARDOUS
11.4.3 Other Areas (CLASSIFIED) AREAS (IEC 79-10, MOD)
11.4.4 Drains APPENDIX D. INFORMATIVE ANNEX – AN ALTERNATE
11.5 BASIS FOR AREA CLASSIFICATION METHOD FOR AREA CLASSIFICATION
11.5.1 Ventilation and Pressurization D.1 INTRODUCTION
11.5.2 Ventilation and Pressurization of Hazardous D. 2 EXPLANATION OF “POINT SOURCE” CONCEPT.
(Classified) Locations D. 3 DETERMINATION OF VOLATILITY
11.5.3 Ventilation and Pressurization of Unclassified CLASSIFICATION
(Non-Hazardous) Locations D.4 DETERMINATION OF THE HAZARD RADIUS FOR
11.6 CLASSIFICATION OF HAZARDOUS AREA CLASSIFICATION PURPOSES
(CLASSIFIED) LOCATIONS D.5 APPLICATION TO NON-ENCLOSED,
11.7 DRILL FLOOR AND DERRICK AREAS ADEQUATELY VENTILATED LOCATIONS
11.8 SUBSTRUCTURE OR MOONPOOL AREAS CONTAINING A HEAVIER-THAN-AIR GAS OR VAPOR
11.9 MUD SYSTEM PROCESSING EQUIPMENT SOURCE
OVERVIEW D.5.1 GENERAL
11.10 MUD TANKS (AFTER DISCHARGE OF FINAL D.5.2 POINT SOURCE LOCATED NEAR OR ABOVE
DEGASSER) GRADE – ADEQUATELY VENTILATED LOCATION.
11.11 MUD DITCHES OR TROUGHS D.5.3 PUMPS – ADEQUATELY VENTILATED AREA.
11.12 MUD PUMPS D.5.4 EQUIPMENT CONTAINING MEDIUM AND
11.13 MUD PROCESSING EQUIPMENT (BETWEEN LOW PRESSURE RESTRICTIONS (ORIFICES,
THE BELL NIPPLE AND MUD DISCHARGE OF FINAL DRAINS, ETC.)
DEGASSER) D.5.5 COMPRESSORS
11.14 DESANDER OR DESILTER (BETWEEN MUD D.5.6 INSTRUMENT AND PROCESS VENTS AND
DISCHARGE OF FINAL DEGASSER AND THE MUD DRAINS TO ATMOSPHERE
PIT) D.5.7 FLANGES AND VALVES
11.15 VENTS D.6. DETERMINING THE HAZARD RADIUS FOR
11.16 DIVERTER LINE OUTLET SOURCES HANDLING LIGHTER-THAN-AIR GASES
11.17 BLOWOUT PREVENTER (BOP) AND VAPORS
11.18 WELL TEST EQUIPMENT AREAS D.6.1 POINT SOURCE LOCATED ABOVE GRADE
11.19 ROOMS USED TO STORE PAINT (PAINT D.6.2 COMPRESSORS
LOCKERS) D.7 APPLICATION TO INADEQUATELY VENTILATED
11.20 BATTERY ROOMS AREAS
11.21 RESERVED FOR FUTURE USE APPENDIX E. PROCEDURE FOR CLASSIFYING
11.22 HELICOPTER FUEL STORAGE AREAS LOCATIONS
11.23 CLASSIFICATION OF ADJACENT SPACES E.1 INTRODUCTION
12 RECOMMENDATIONS FOR DETERMINING DEGREE E.2 STEP 1 – NEED FOR CLASSIFICATION
AND EXTENT OF CLASSIFIED LOCATIONS AT E.3 STEP 2 – ASSIGNMENT OF CLASSIFICATION
DRILLING RIGS AND PRODUCTION FACILITIES ON E.4 STEP 3 – EXTENT OF CLASSIFIED LOCATIONS
FLOATING PRODUCTION UNITS E.5 STEP 4—DETERMINATION OF GROUP
12.1 GENERAL E.6 DOCUMENTATION
12.2 FLOATING PRODUCTION STORAGE AND ANNEX F (INFORMATIVE). ALTERNATE
OFFLOADING UNITS (FPSOs) VENTILATION CRITERIA (IEC 79-10, MOD)
12.3 TENSION LEG PLATFORMS (TLPs) F.1 NATURAL VENTILATION
12.4 SPARS, CAISSONS, AND SIMILAR UNITS F.2 ARTIFICIAL VENTILATION
12.5 CLASSIFICATION OF ADJACENT SPACES F.3 DEGREE OF VENTILATION
13 RESERVED FOR FUTURE USE F.4 ASSESSMENT OF DEGREE OF VENTILATION
14 RECOMMENDATIONS FOR DETERMINING DEGREE AND ITS INFLUENCE ON THE HAZARDOUS AREA
AND EXTENT OF CLASSIFIED LOCATIONS AT F.5 AVAILABILITY OF VENTILATION
PETROLEUM PIPELINE TRANSPORTATION FACILITIES F.6 PRACTICAL GUIDE
14.1 GENERAL F.7 CALCULATIONS TO ASCERTAIN THE DEGREE
14.2 USE OF FIGURES OF VENTILATION
14.3 FIGURES

11
 Module 1
Hazardous Area Classification
Tutorial
Tutorial Exercise #1

Read Appendix D19 on Engineering Guidelines provided in “Code for Installation in Oil
and Gas Facilities” (Section 19)

Tutorial Exercise #2

Read the following sections in API RP505

Section 1 – Scope
Section 3 – Definitions
Section 5 – Flammable and Combustible Liquids, Gases and Vapors
Section 6 – Classification Criteria
Section 7 – Extent of a Classified Location
Appendix B – Calculation of Minimum Air Introduction Rate to Achieve Adequate
Ventilation Using Fugitive Emissions
Appendix E – Procedure for Classifying Locations

Review the Diagrams in Section 8 – 14

Tutorial Exercise #3

Briefly review the following documents and note their content for future reference

NFPA 325 – Guide to Fire Hazard Properties of Flammable Liquids, Gases, and Volatile
Solids

NFPA 497 – Recommended Practice for the Classification of Flammable Liquids, Gases
or Vapors and of Hazardous (Classified) Locations for Electrical Installations in
Chemical Process Areas

API 4638 – Calculation Workbook for Oil and Gas Production Equipment Fugitive
Emissions
 Tutorial Exercise #4

Consider the following mixture:

LFL UFL
% Volume Compounds Mole Weight MESG (mm) (%vol/vol) (%vol/vol) AIT (°C)
15% Methane Gas (CH4) 16.04 1.14 4.00% 17.00% 537
40% Hydrogen Sulfide (H2S) 34.08 0.89 4.00% 45.50% 270
25% Propane Gas (CH3CH2CH3) 44.09 0.92 1.70% 10.90% 470
10% Butane Gas (C4H10) 58.12 0.98 1.40% 9.30% 372
10% Pentane Liquid (C5H12) 72.15 0.93 1.40% 7.80% 258
100%

Estimate:

1. The mixture density

2. Lower flammable limit
3. The material Group classification
4. The AIT of the material

Tutorial Exercise #5

Consider the following mixture:

LFL UFL
% Volume Compounds Mole Weight MESG (mm) (%vol/vol) (%vol/vol) AIT (°C)
10% Nitrogen (N2) 28.02 1E+15
40% Hydrogen Gas (H2) 2.016 0.28 4.00% 77.00% 560
30% Methane Gas (CH4) 16.04 1.14 4.00% 17.00% 537
20% Ethane Gas (CH3CH3) 30.07 0.91 2.50% 15.50% 515
100%

Estimate:

1. The mixture density

2. Lower flammable limit
3. The material Group classification
4. The AIT of the material
Tutorial Exercise #6

The following information has been provided to support the area classification of facility

• PFDs
• Hazardous Materials Worksheet
• Plot plan
• P&IDs for selected areas of the plant
• Partially completed Area Classification worksheet

Perform the following:

1. Complete the yellow sections identified in the area classification worksheet

2. Estimate the fugitive emissions for the interior of the BU-102 Treater
Building. Assume the following:
• The P&IDs provide the information necessary to perform the analysis.
• LFL for the building mixture was calculated to be 0.73%. Mixture density
to air is estimated at 2.35
• Ambient temperature of 35C

3. Estimate the ventilation required to meet the definition of “adequate”

ventilation as per API RP 505.
• Assume the building dimensions to be 28L X 6.1H X 6.1W (all units in
meters)

4. Describe in words how you would design the HVAC system for the building.
• Describe where you would locate gas detectors
• Describe where you would locate vents, fans and louvers
• Describe the operation of the HVAC system

5. Hand-sketch the area classification on the plot plan. Indicate what notes you
would include on the drawing.
 Solvent Co-Injection Project - Hazardous Area Classification Materials Schedule Document No.: Process Doc#1

Revision A
Date: Oct 27/06
Notes: 1. Values provided are mole composition % from the normal operating case
2. Trace refers to values below 1 mol %
3. Pieces of equipment not simulated, designed yet, or designed by vendor are left blank
4. Glycol and steam streams do not have any hazardous material

C1 C2 H2S C3 C4 C5 C6 C7 C8 C9 C10 C11 + H2O N2 C02

Methane Ethane Hyd Sul Propane Butane Pentane Hexane Heptane Octane Nonane Decane Water Nitrogen CarDioxide
Mole Weight 16.04 30.07 34.08 44.09 58.12 72.15 86.17 100.2 144.22 121.35 137.95 160 18.02 28.02 44.01
MESG 1.14 0.91 0.89 0.92 0.98 0.93 0.93 0.91 0.94 1 1 1 1.00E+15 1.00E+15 1.00E+15
LFL (%vol/vol) 4.0% 2.5% 4.0% 1.7% 1.4% 1.4% 1.0% 1.1% 0.8% 0.8% 0.8% 0.7%
UFL (%vol/vol) 17.0% 15.5% 45.5% 10.9% 9.3% 7.8% 8.4% 6.7% 6.5% 2.9% 5.4% 5.1%
NFPA Material Class GAS GAS GAS GAS GAS I I I I I II III Mixture Analysis
AIT 537 515 270 470 372 258 233 215 206 205 210 205 Haz Area Density Estimated
Stream % Vol Total Trace Total Mole Weight MESG Group Rel. to Air Flammability Check LFL UFL AIT (deg C)
Solv Injection Wellhead 62 0.00 0.00 0.00 0.00 0.00 0.00 0.00 2.9 3.35 2.17 0.00 2.50 89.02 0.00 0.01 99.95 0.05 30.42 0.96 IIA 1.06 Flammable 0.83% 4.99% 205
Solv Producer Well 1 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 2.22 95.22 0.00 0.06 97.51 2.49 20.74 1.00 IIA 0.72 NonFlammable 0.70% 5.10%
SAGD Producer Well 47 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 2.22 95.22 0.00 0.06 97.51 2.49 20.74 1.00 IIA 0.72 NonFlammable 0.70% 5.10%
101-E-101 4 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 2.50 96.90 0.00 0.00 99.40 0.60 21.46 1.00 IIA 0.75 NonFlammable 0.70% 5.10%
101-E-104 18 5.05 0.00 0.01 0.00 0.00 0.00 2.19 7.14 7.65 4.37 1.54 1.01 70.60 0.02 0.41 99.99 0.01 42.83 0.98 IIA 1.49 Flammable 1.10% 6.05% 206
101-E-108 Glycol - - - - - - - - - - - - - - - NonFlammable
101-E-109 21 86.24 0.00 0.15 0.00 0.00 0.00 1.27 1.93 0.00 0.00 0.00 0.00 2.59 0.32 6.31 98.82 1.18 20.25 1.13 IIA 0.70 Flammable 3.64% 16.24% 537
101-E-111 7 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 1.16 0.00 0.00 2.69 93.71 0.00 0.00 97.56 2.44 22.87 0.98 IIA 0.79 Flammable 0.73% 5.46% 206
101-E-112A/B Lube oil - - - - - - - - - - - - - - - NonFlammable
101-E-120 41 0.00 0.00 0.00 0.00 0.00 0.00 0.00 3.89 6.18 5.76 3.59 5.05 74.69 0.00 0.00 99.15 0.85 46.28 0.97 IIA 1.61 Flammable 0.95% 4.73% 205
29 0.00 0.00 0.01 0.00 0.00 0.00 7.49 25.96 30.01 19.42 8.40 8.23 0.06 0.00 0.10 99.69 0.31 124.13 0.95 IIA 4.31 Flammable 0.95% 5.17% 205
101-E-121A/B
40 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 98.46 1.52 0.00 0.00 99.98 0.02 157.81 1.00 IIA 5.48 NonFlammable 0.70% 5.10%
66 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 98.46 1.52 0.00 0.00 99.98 0.02 157.81 1.00 IIA 5.48 NonFlammable 0.70% 5.10%
101-E-122
Glycol - - - - - - - - - - - - - - - NonFlammable
101-K-105A/B 20 86.24 0.00 0.15 0.00 0.00 0.00 1.27 1.93 0.00 0.00 0.00 0.00 2.59 0.32 6.31 98.82 1.18 20.25 1.13 IIA 0.70 Flammable 3.64% 16.24% 537
101-MX-101 4 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 1.16 0.00 0.00 2.69 93.71 0.00 0.00 97.56 2.44 22.87 0.98 IIA 0.79 Flammable 0.73% 5.46% 205
101-P-101A/B 3 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 2.50 96.90 0.00 0.00 99.40 0.60 21.46 1.00 IIA 0.75 NonFlammable 0.70% 5.10%
101-P-103A/B 14 0.00 0.00 0.00 0.00 0.00 0.00 1.25 5.75 9.13 8.52 5.31 69.59 0.44 0.00 0.00 99.99 0.01 149.10 0.99 IIA 5.18 Flammable 0.78% 4.98% 205
101-P-106A/B 19 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 99.99 0.00 0.01 100.00 0.00 18.02 0.89 IIB 0.63 NonFlammable 4.00% 45.50%
101-P-107A/B 29 0.00 0.00 0.01 0.00 0.00 0.00 7.49 25.96 30.01 19.42 8.40 8.23 0.06 0.00 0.10 99.69 0.31 124.13 0.95 IIA 4.31 Flammable 0.95% 5.17% 205
101-P-108A/B Glycol - - - - - - - - - - - - - - - NonFlammable
101-P-112 29 0.00 0.00 0.00 0.00 0.00 0.00 8.02 26.74 30.45 19.62 8.48 6.69 0.00 0.00 0.00 100.00 0.00 123.83 0.95 IIA 4.30 Flammable 0.96% 5.19% 205
101-P-114 Glycol - - - - - - - - - - - - - - - NonFlammable
101-P-116A/B Oily Water 0.50 0.50 1.00 0.50 0.50 0.00 0.00 3.00 3.00 2.00 0.00 0.00 89.00 0.00 0.00 100.00 0.00 26.88 0.94 IIA 0.93 Flammable 1.06% 6.17%
101-P-117A/B Lube Oil - - - - - - - - - - - - - - - NonFlammable
101-P-120A/B 43 0.00 0.00 0.00 0.00 0.00 0.00 3.33 15.36 24.38 22.74 14.15 19.91 0.11 0.00 0.01 99.98 0.02 132.41 0.97 IIA 4.60 Flammable 0.95% 4.80% 205
101-P-121A/B 45 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 18.02 0.89 IIB 0.63 NonFlammable 4.00% 45.50%
101-P-122A/B 40 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 98.46 1.52 0.00 0.00 99.98 0.02 157.81 1.00 IIA 5.48 NonFlammable 0.70% 5.10%
101-P-123A/B 26 1.29 0.00 0.00 0.00 0.00 0.00 8.80 29.23 31.60 18.12 6.38 4.18 0.11 0.00 0.25 99.96 0.04 120.26 0.95 IIA 4.18 Flammable 0.96% 5.36% 205
101-P-301A/B 48 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 1.82 98.17 0.00 0.00 99.99 0.01 20.60 1.00 IIA 0.72 NonFlammable 0.70% 5.10%
101-PK-100 Chem Inhibiter - - - - - - - - - - - - - - - NonFlammable
101-PK-102 Foam Water - - - - - - - - - - - - - - - NonFlammable
101-PK-103 Flare Gas 90.00 2.00 0.00 0.00 0.00 0.00 0.00 1.00 1.00 1.00 1.00 1.00 3.00 0.00 0.00 100.00 0.00 22.22 1.12 IIA 0.77 Flammable 3.45% 15.03% 537
101-T-100 Glycol - - - - - - - - - - - - - - - NonFlammable
101-T-101 Oily Water 0.50 0.50 1.00 0.50 0.50 0.00 0.00 3.00 0.00 0.00 0.00 0.00 94.00 0.00 0.00 100.00 0.00 21.03 0.93 IIA 0.73 Flammable 1.44% 9.51% 205
101-T-102 Diesel - - - - - - - - - - - - - - - 230.00 IIA 7.99 Flammable 1.30% 7.50% 257
101-T-103A/B Lube Oil - - - - - - - - - - - - - - - NonFlammable
101-T-105 30 0.00 0.00 0.01 0.00 0.00 0.00 7.49 25.96 30.01 19.42 8.40 8.23 0.06 0.00 0.10 99.69 0.31 124.13 0.95 IIA 4.31 Flammable 0.95% 5.17% 205
101-V-100 Steam - - - - - - - - - - - 100.00 100.00 0.00 NonFlammable
1 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 2.22 95.22 0.00 0.06 97.51 2.49 20.74 1.00 IIA 0.72 NonFlammable 0.70% 5.10%
101-V-101 2 6.14 0.01 0.01 0.00 0.00 0.00 1.06 3.30 3.32 1.70 0.00 0.00 83.23 0.02 0.49 99.28 0.72 27.28 1.01 IIA 0.95 Flammable 1.31% 7.48% 206
3 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 2.50 96.90 0.00 0.00 99.40 0.60 21.46 1.00 IIA 0.75 NonFlammable 0.70% 5.10%
5 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 1.16 0.00 0.00 2.69 93.71 0.00 0.00 97.56 2.44 22.87 0.98 IIA 0.79 Flammable 0.73% 5.46% 205
6 97.66 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.39 1.74 99.79 0.21 16.54 1.14 IIA 0.57 Flammable 4.00% 17.00% 537
101-V-102
7 0.00 0.00 0.00 0.00 0.00 0.00 1.24 4.44 5.40 3.77 1.78 12.47 70.82 0.00 0.02 99.94 0.06 53.06 0.97 IIA 1.84 Flammable 0.84% 5.09% 205
8 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 18.02 0.89 IIB 0.63 NonFlammable 4.00% 45.50%
7 0.00 0.00 0.00 0.00 0.00 0.00 1.24 4.44 5.40 3.77 1.78 12.47 70.82 0.00 0.02 99.94 0.06 53.06 0.97 IIA 1.84 Flammable 0.84% 5.09% 206
10 97.66 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.39 1.74 99.79 0.21 16.54 1.14 IIA 0.57 Flammable 4.00% 17.00% 205
101-V-103
11 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 18.02 0.89 IIB 0.63 NonFlammable 4.00% 45.50% 205
14 0.00 0.00 0.00 0.00 0.00 0.00 3.91 14.01 17.03 11.88 5.62 39.31 7.98 0.00 0.05 99.80 0.20 128.50 0.97 IIA 4.46 Flammable 0.84% 5.09% 205
14 0.00 0.00 0.00 0.00 0.00 0.00 3.91 14.01 17.03 11.88 5.62 39.31 7.98 0.00 0.05 99.80 0.20 128.50 0.97 IIA 4.46 Flammable 0.84% 5.09% 205
101-V-104 15 0.00 0.00 0.01 0.00 0.00 0.00 6.99 23.54 26.15 15.77 5.97 4.35 16.69 0.00 0.10 99.57 0.43 104.71 0.95 IIA 3.64 Flammable 0.95% 5.25% 205
16 0.00 0.00 0.00 0.00 0.00 0.00 1.25 5.75 9.13 8.52 5.31 69.59 0.44 0.00 0.00 99.99 0.01 149.10 0.99 IIA 5.18 Flammable 0.78% 4.98% 205
18 5.05 0.00 0.01 0.00 0.00 0.00 2.19 7.14 7.65 4.37 1.54 1.01 70.60 0.02 0.41 99.99 0.01 42.83 0.98 IIA 1.49 Flammable 1.10% 6.05% 206
19 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 99.99 0.00 0.01 100.00 0.00 18.02 0.89 IIB 0.63 NonFlammable 4.00% 45.50% 205
101-V-105
20 86.24 0.00 0.15 0.00 0.00 0.00 1.27 1.93 0.00 0.00 0.00 0.00 2.59 0.32 6.31 98.82 1.18 20.25 1.13 IIA 0.70 Flammable 3.64% 16.24% 205
26 1.29 0.00 0.00 0.00 0.00 0.00 8.80 29.23 31.60 18.12 6.38 4.18 0.11 0.00 0.25 99.96 0.04 120.26 0.95 IIA 4.18 Flammable 0.96% 5.36% 205
 Solvent Co-Injection Project - Hazardous Area Classification Materials Schedule Document No.: Process Doc#1

Revision A
Date: Oct 27/06
Notes: 1. Values provided are mole composition % from the normal operating case
2. Trace refers to values below 1 mol %
3. Pieces of equipment not simulated, designed yet, or designed by vendor are left blank
4. Glycol and steam streams do not have any hazardous material

C1 C2 H2S C3 C4 C5 C6 C7 C8 C9 C10 C11 + H2O N2 C02

Methane Ethane Hyd Sul Propane Butane Pentane Hexane Heptane Octane Nonane Decane Water Nitrogen CarDioxide
Mole Weight 16.04 30.07 34.08 44.09 58.12 72.15 86.17 100.2 144.22 121.35 137.95 160 18.02 28.02 44.01
MESG 1.14 0.91 0.89 0.92 0.98 0.93 0.93 0.91 0.94 1 1 1 1.00E+15 1.00E+15 1.00E+15
LFL (%vol/vol) 4.0% 2.5% 4.0% 1.7% 1.4% 1.4% 1.0% 1.1% 0.8% 0.8% 0.8% 0.7%
UFL (%vol/vol) 17.0% 15.5% 45.5% 10.9% 9.3% 7.8% 8.4% 6.7% 6.5% 2.9% 5.4% 5.1%
NFPA Material Class GAS GAS GAS GAS GAS I I I I I II III Mixture Analysis
AIT 537 515 270 470 372 258 233 215 206 205 210 205 Haz Area Density Estimated
Stream % Vol Total Trace Total Mole Weight MESG Group Rel. to Air Flammability Check LFL UFL AIT (deg C)
101-V-108 Glycol - - - - - - - - - - - - - - - 100.00 0.00 NonFlammable
101-V-109 Oily Water 0.50 0.50 1.00 0.50 0.50 0.00 0.00 3.00 0.00 0.00 0.00 0.00 94.00 0.00 0.00 100.00 0.00 21.03 0.93 IIA 0.73 Flammable 1.44% 9.51% 205
22 86.24 0.00 0.15 0.00 0.00 0.00 1.27 1.93 0.00 0.00 0.00 0.00 2.59 0.32 6.31 98.82 1.18 20.25 1.13 IIA 0.70 Flammable 3.64% 16.24% 537
23 90.04 0.00 0.16 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.68 0.34 6.58 97.80 2.20 17.61 1.14 IIA 0.61 Flammable 4.00% 17.02% 537
101-V-110
24 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 99.97 0.00 0.00 99.97 0.03 18.02 0.89 IIB 0.63 NonFlammable 4.00% 45.50%
25 4.17 0.00 0.05 0.00 0.00 0.00 18.47 42.85 26.45 6.26 0.00 0.00 0.09 0.00 0.80 99.14 0.86 105.65 0.94 IIA 3.67 Flammable 0.99% 6.52% 205
16 0.00 0.00 0.00 0.00 0.00 0.00 1.25 5.75 9.13 8.52 5.31 69.59 0.44 0.00 0.00 99.99 0.01 149.10 0.99 IIA 5.18 Flammable 0.78% 4.98% 205
101-V-120 40 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 98.46 1.52 0.00 0.00 99.98 0.02 157.81 1.00 IIA 5.48 NonFlammable 0.70% 5.10% 205
41 0.00 0.00 0.00 0.00 0.00 0.00 0.00 3.89 6.18 5.76 3.59 5.05 74.69 0.00 0.00 99.15 0.85 46.28 0.97 IIA 1.61 Flammable 0.95% 4.73% 205
42 0.00 0.00 0.00 0.00 0.00 0.00 0.00 3.89 6.18 5.76 3.59 5.05 74.69 0.00 0.00 99.15 0.85 46.28 0.97 IIA 1.61 Flammable 0.95% 4.73% 205
101-V-121 43 0.00 0.00 0.00 0.00 0.00 0.00 3.33 15.36 24.38 22.74 14.15 19.91 0.11 0.00 0.01 99.98 0.02 132.41 0.97 IIA 4.60 Flammable 0.95% 4.80% 205
45 0.50 0.50 1.00 0.50 0.50 0.00 0.00 3.00 0.00 0.00 0.00 0.00 94.00 0.00 0.00 100.00 0.00 21.03 0.93 IIA 0.73 Flammable 1.44% 9.51% 205
47 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 2.22 95.22 0.00 0.06 97.51 2.49 20.74 1.00 IIA 0.72 NonFlammable 0.70% 5.10% 205
101-V-301 48
59 3.87 0.00 0.01 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 95.65 0.01 0.32 99.87 0.13 18.00 1.14 IIA 0.63 NonFlammable 4.00% 17.03%
SK-A1-101-B-100 PFD
SK-A1-101-B-101 PFD
SK-A1-101-B-102 PFD
SK-A1-101-B-103 PFD
SK-A1-101-B-104 PFD
SK-A1-101-B-105 PFD
SK-A1-101-B-106 PFD
SK-A1-101-B-004 P&ID
SK-A1-101-B-005 P&ID
SK-A1-101-B-006 P&ID
SK-A1-101-B-007 P&ID
 Area Classification Study Datasheet
Client: Gigabuck oil REV BY DATE APPR. REVISION
Project: Solvent Co-injection Project
Facility:
Area: Main Plant A for practice
HORIZONTAL DISTANCE
MAJOR EQUIPMENT IN AREA PROCESS SOURCE OF RELEASE FROM SOURCE TO:

Explosive Flammable AIT

Flammable Process Group Liquid Temperature Vapor Description Grade of Boundary Boundary Boundary Remarks
Location Equipment Description Ventilation Material Temperature (Deg Classification Class Class Density of Containment Description of Release of Zone 0 of Zone 1 of Zone 2 Code Reference
No. (See Note 4) C) and Pressure (See Note 5) (See Note 3) (See Note 6) (See Note 7) System Release Source (See Note 2) (See Note 1) (See Note 1) (See Note 1)
1 Reference Area Class Plot Wellhead Solvent Co-injection Injector Well NatV Naphtha Class I / 205C Wellhead Flanges, Connections, Diagram B11 Below ground depressions are classified Zone 1
220 Group IIA Neutral Secondary 3m
Plan Drawing HVL T3 Casing Sample Points CEC Section 19
2 Reference Area Class Plot Wellhead Solvent Co-injection Producer Well NatV Bitumen, Methane, Naphtha Wellhead Flanges, Connections, Wellhead is classified for consistancy with other
Plan Drawing 205C Casing Sample Points Diagram B11 wellsite facilities
155 Group IIA Class IIIA LTA Secondary 3m
T3 CEC Section 19 Class IIIA flammable material is normally
unclassified
3 Reference Area Class Plot Wellhead SAGD Producer Well NatV Bitumen, Methane Wellhead Flanges, Connections, Wellhead is classified for consistancy with other
Plan Drawing 205C Casing Sample Points Diagram B11 wellsite facilities
154 Group IIA Class IIIA LTA Secondary 3m
T3 CEC Section 19 Class IIIA flammable material is normally
unclassified
4 Reference Area Class Plot 101-E-101 FWKO Feed Cooler NatV Bitumen, Naphtha, Methane Exchanger Flanges, Connections Class IIIA material. Extent of area class
Plan Drawing 205C negligable
155 Group IIA Class IIIA LTA Secondary
T3 Area surrounding vessel is classified for
continuity with adjacent equipment items
5 Reference Area Class Plot 101-E-104 Overhead Vapor Compressor NatV Methane, Bitumen, 206C Exchanger Flanges, Connections Interior of [Link] Area surrounding cooler is classified for
200 Group IIA Class I HTA Secondary
Plan Drawing Naphtha T3 Cooler RP505 consistancy with adjacent equipment items
6 Reference Area Class Plot 101-E-109 Produced Vapor Cooler NatV Methane, Naphtha 537C Exchanger Flanges, Connections Interior of [Link] Area surrounding cooler is classified for
150 Group IIA GAS LTA Secondary
Plan Drawing T1 Cooler RP505 consistancy with adjacent equipment items
7 Reference Area Class Plot 101-E-120 Stripper Overhead Condenser NatV Naphtha 205C Exchanger Flanges, Connections Interior of [Link] Area surrounding cooler is classified for
180 Group IIA Class I HTA Secondary
Plan Drawing T3 Cooler RP505 consistancy with adjacent equipment items
8 Reference Area Class Plot 101-E-121A/B Solvent Preheater NatV Bitumen, Naphtha 205C Exchanger Flanges, Connections Figure 48
230 Group IIA Class I HTA Secondary 3m
Plan Drawing T3 RP505
9 Reference Area Class Plot 101-E-122 Dry Bitumen Cooler NatV Bitumen Exchanger Flanges, Connections Class IIIA material. Extent of area class
190 N/A Class IIIA N/A HTA Secondary
Plan Drawing negligable
10 Reference Area Class Plot 101-K-105A/B Produced Gas Compressor GAV Adequate Methane, Naphtha Compressor Seals, Flanges Extent of Gas detection calibrated for methane to be
537C Reference Fugitive Emissions
Plan Drawing 150 Group IIA GAS LTA Secondary Building located at peak of building.
T1 Calculation for 101-BU-106
101-BU-106
11 Reference Area Class Plot 101-MX-101 FWKO Feed Mixer GAV Adequate Bitumen, Naphtha, Methane Mixer Connections Extent of Process stream mostly water vapour
205C Reference Fugitive Emissions
Plan Drawing (Trace) 140 Group IIA Class I LTA Secondary Building
T3 Calculation for 101-BU-102
101-BU-102
12 Reference Area Class Plot 101-P-101A/B FWKO Feed Pumps GAV Adequate Bitumen, Naphtha, Methane Indentify Pump Housing Pump seals, Flanges Process stream mostly water. Insufficient
Identify Determine Extent of
Plan Drawing Flammable Estimate Reference Fugitive Emissions quantities of hydrocarbons to create flammable
155 Group Estimate AIT Grade of Building
Liquids Density Calculation for 101-BU-102 mixture
Classification Release 101-BU-102
Class
13 Reference Area Class Plot 101-P-103A/B Flash Separator Circulation Pumps GAV Adequate Bitumen, Naphtha Pump Housing Pump seals, Flanges Extent of Trace amounts of methane, n-Hexane, butane.
205C Reference Fugitive Emissions
Plan Drawing 250 Group IIA Class I HTA Secondary Building Gas detection calibrated for pentane to be
T3 Calculation for 101-BU-102
101-BU-102 mounted at floor level
14 Reference Area Class Plot 101-P-106A/B Oily Water Pumps GAV Adequate Trace amounts of Naphtha, Pump Housing Pump seals, Flanges Extent of Insufficient quantity of flammable material to
Not Reference Fugitive Emissions
Plan Drawing and Bitumen 45 N/A N/A HTA Secondary Building create a flammable mixture
Flammable Calculation for 101-BU-102
101-BU-102
15 Reference Area Class Plot 101-P-107A/B Solvent Injection Pumps NatV Naphtha, Methane Indentify Pump Housing Pump seals, Flanges
Determine State extent of
Plan Drawing Flammable Estimate
45 Group IIA Estimate AIT Grade of Zone 2 State RP505 reference
Liquids Density
Release Boundary
Class
16 Reference Area Class Plot 101-P-112 Solvent Loading Pump NatV Naphtha Indentify Pump Housing Pump seals, Flanges
Determine State extent of
Plan Drawing Flammable Estimate
25 Group IIA Estimate AIT Grade of Zone 2 State RP505 reference
Liquids Density
Release Boundary
Class
17 Reference Area Class Plot 101-P-116A/B Flare KO Pumps GAV Adequate Methane, Ethane, n- Pump Housing Pump seals, Flanges Flammable material composition will vary
Extent of
Plan Drawing Hexane, Propane, Butane, HVL/Class 205C Reference Fugitive Emissions
45 Group IIA LTA/HTA Secondary Building
Pentane, Naphtha, Bitumen I/ Crude Oil T3 Calculation for 101-BU-107
101-BU-107
18 Reference Area Class Plot 101-P-120A/B Stripper Solvent Pumps GAV Adequate Naphtha Indentify Pump Housing Pump seals, Flanges
Determine Extent of
Plan Drawing Flammable Estimate Reference Fugitive Emissions
45 Group IIA Estimate AIT Grade of Building
Liquids Density Calculation for 101-BU-107
Release 101-BU-107
Class
19 Reference Area Class Plot 101-P-122A/B Stripper Bottom Pumps GAV Adequate Bitumen Pump Housing Pump seals, Flanges Extent of Pump is handling Class II liquids of very low
205C Reference Fugitive Emissions
Plan Drawing 228 Group IIA Class II HTA Secondary Building flammablility
T3 Calculation for 101-BU-107
101-BU-107
20 Reference Area Class Plot 101-P-123A/B Solvent Recycle Pump NatV Naphtha Indentify Pump Housing Pump seals, Flanges
Determine
Plan Drawing Flammable Estimate Figure 51
20 Group IIA Estimate AIT Grade of 3m
Liquids Density RP505
Release
Class

10/26/2006 Page 1 of 3 Tutorial Area Classification Worksheet Area Class Worksheet

 HORIZONTAL DISTANCE
MAJOR EQUIPMENT IN AREA PROCESS SOURCE OF RELEASE FROM SOURCE TO:

Explosive Flammable AIT

Flammable Process Group Liquid Temperature Vapor Description Grade of Boundary Boundary Boundary Remarks
Location Equipment Description Ventilation Material Temperature (Deg Classification Class Class Density of Containment Description of Release of Zone 0 of Zone 1 of Zone 2 Code Reference
No. (See Note 4) C) and Pressure (See Note 5) (See Note 3) (See Note 6) (See Note 7) System Release Source (See Note 2) (See Note 1) (See Note 1) (See Note 1)
21 Reference Area Class Plot 101-P-301A/B Produced Fluids Transfer Pump GAV Adequate Bitumen Pump Housing Pump seals, Flanges Extent of Insufficient quantity of flammable material to
Reference Fugitive Emissions
Plan Drawing 154 N/A Class IIIA N/A LTA Secondary Building create a flammable mixture
Calculation for 101-BU-102
101-BU-102
22 Reference Area Class Plot 101-PK-103 Flare Stack NatV Methane, Ethane, n- Flare Connections Designed by vendor
Plan Drawing Hexane, Propane, Butane, HVL/Class T3 RP505
45 Group IIA LTA/HTA Secondary Unclassified
Pentane, Naphtha, Bitumen I/ Crude Oil 205C [Link]

23 Reference Area Class Plot 101-T-101 Sump Tank NatV Methane, Ethane, n- Tank Fill and tank Connections 0.5m
Plan Drawing Hexane, Propane, Butane, HVL/Class T3 surrounding
30 Group IIA LTA/HTA Secondary Figure 8 RP 505
Pentane, Naphtha, Bitumen I/ Crude Oil 205C atmospheric
vent
24 Reference Area Class Plot 101-T-105 Fresh Injection Solvent Storage Tank NatV Naphtha Tank Fill and tank Connections
3m surrounding
Plan Drawing Indentify
Determine tank and to
Flammable Estimate
30 Group IIA Estimate AIT Grade of elevation of Figure 7 RP505
Liquids Density
Release containment
Class
dyke
25 Reference Area Class Plot 101-V-101 Inlet Separator NatV, GAV Bitumen, Naphtha, Methane Vessel Flanges, Connections
3m surrounding
Plan Drawing Adequate GAS
T3 HTA/LTA vessel on
155 Group IIA Class I Secondary Figure 48 RP505
205C (Note 9) exterior of 101-
Liquids
BU-102
26 Reference Area Class Plot 101-V-102 FWKO Drum NatV, GAV Bitumen, Naphtha, Vessel Flanges, Connections Note: Trace amounts of propane, butane, and
3m surrounding
Plan Drawing Adequate Methane, Ethane, n-Hexane GAS pentane
T3 vessel on
130 Group IIA Class I HTA/LTA Secondary Figure 48 RP505 Blanketed vessel (methane, ethane, n-Hexane)
205C exterior of 101-
Liquids
BU-102
27 Reference Area Class Plot 101-V-103 Blend Treater NatV, GAV Bitumen, Naphtha, Vessel Flanges, Connections Note: Trace amounts of propane, butane, and
3m surrounding
Plan Drawing Adequate Methane, Ethane, n-Hexane GAS pentane
T3 vessel on
(Trace) 130 Group IIA Class I HTA/LTA Secondary Figure 48 RP505 Blanketed vessel (methane, ethane, n-Hexane)
205C exterior of 101-
Liquids
BU-102
28 Reference Area Class Plot 101-V-104 Flash Separator NatV, GAV Bitumen, Naphtha, Vessel Flanges, Connections Note: Trace amounts of propane, butane, and
3m surrounding
Plan Drawing Adequate Methane, Ethane, n-Hexane GAS pentane
T3 vessel on
(Trace) 250 Group IIA Class I HTA/LTA Secondary Figure 48 RP505 Blanketed vessel (methane, ethane, n-Hexane)
205C exterior of 101-
Liquids
BU-102
29 Reference Area Class Plot 101-V-105 Overhead Accumulator NatV Methane, Bitumen, GAS T3 Vessel Flanges, Connections Trace amounts of ethane, n-hexane, propane,
45 Group IIA HTA/LTA Secondary 3m Figure 48 RP505
Plan Drawing Naphtha Class I 205C butane, and pentane
30 Reference Area Class Plot 101-V-109 Flare KO Drum NatV Methane, Ethane, n- Vessel Flanges, Connections
Plan Drawing Hexane, Propane, Butane, GAS T3
45 Group IIA HTA/LTA Secondary 3m Figure 48 RP505
Pentane, Naphtha, Bitumen Class I 205C

31 Reference Area Class Plot 101-V-110 Produced Vapor Separator GAV Adequate Methane, Naphtha Vessel Flanges, Connections To extent of Trace amounts of ethane, n-hexane, propane,
GAS T2A Reference Fugitive Emissions
Plan Drawing 40 Group IIA LTA/ HTA Secondary building butane, and pentane
Class I 232C Calculation for 101-BU-106
101-BU-106
32 Reference Area Class Plot 101-V-120 Steam Stripping Column NatV Naphtha, Bitumen T3 Vessel Flanges, Connections Trace amounts of methane, ethane, n-hexane,
227 Group IIA Class I HTA Secondary 3m Figure 48 RP505
Plan Drawing 205C propane, butane, and pentane
33 Reference Area Class Plot 101-V-121 Stripper Overhead Accumulator NatV Naphtha Vessel Flanges, Connections Trace amounts of methane, ethane, n-hexane,
T3 3m surrounding
Plan Drawing 45 Group IIA Class I HTA Secondary Figure 48 RP505 propane, butane, and pentane
205C vessel
34 Reference Area Class Plot 101-V-301 Production Separator NatV, GAV Bitumen, Methane (Trace) Vessel Flanges, Connections Trace amounts of ethane, n-hexane, propane,
GAS T3 3m surrounding
Plan Drawing Adequate 154 Group IIA LTA/HTA Secondary Figure 48 RP505 butane, and pentane
Crude Oil 205C vessel
35 Reference Area Class Plot Piperacks Piperacks throughout plant NatV all Gas Piping System Flanges, Connections State relavent sections from
T3 State Area
Plan Drawing Group IIA Class I LTA/HTA Secondary RP505 for Fugitive Emissions
205C Classification
Crude Oils Analysis
36 Reference Area Class Plot 101-BU-102 Treating Building GAV Adequate Methane, Naphtha, Piping system, Piping connections, State minimum ventilation requirements and gas
GAS State relavent sections from
Plan Drawing Bitumen, Produced Water T3 Vessels, Pumps Flanges, Valves, Pump State Area detector gas sensing calibration
Max 250C Group IIA Class I LTA/HTA Secondary RP505 for Fugitive Emissions
205C housing seals, Sample Box, Classification
Class IIIA Analysis
Sample connections

10/26/2006 Page 2 of 3 Tutorial Area Classification Worksheet Area Class Worksheet

 HORIZONTAL DISTANCE
MAJOR EQUIPMENT IN AREA PROCESS SOURCE OF RELEASE FROM SOURCE TO:

Explosive Flammable AIT

Flammable Process Group Liquid Temperature Vapor Description Grade of Boundary Boundary Boundary Remarks
Location Equipment Description Ventilation Material Temperature (Deg Classification Class Class Density of Containment Description of Release of Zone 0 of Zone 1 of Zone 2 Code Reference
No. (See Note 4) C) and Pressure (See Note 5) (See Note 3) (See Note 6) (See Note 7) System Release Source (See Note 2) (See Note 1) (See Note 1) (See Note 1)
37 Reference Area Class Plot 101-BU-106 Solvent Compressor Building GAV Adequate Methane, Naphtha, Piping system, Piping connections, Building must be ventilated at a minimum of 0.61
Plan Drawing Produced Water Vessels, Flanges, Valves, ACPH with no stagnent locations. HVAC design
Compressor Compressor seals RP505 should account for LTA and HTA emissions.
Housing Interior of Figure 17 for vent openings Gas detection calibrated for methane shall be
Building Appendix B for fugitive mounted above 101-K-105 compressor and 101-
1.5m emissions/ventilation design V-110A at ceiling level. Gas detectors calibrated
GAS T3
Max 150C Group IIA LTA/HTA Secondary surrounding all calculation procedure. for Hexane should be mounted 0.3m above floor
Class I 205C
doors, windows API 4638 for fugitive emission level adjacent 101-V-110A. Gas detection to be
and vent and calculation procedure interlocked with evacuation fan sized for 12
fan openings Doc B-101-E-017 Appendix D ACPH. Refer to document B-101-E-017 for
for ventilation calculations additional details on the design the of the HVAC
and gas detection system.

38
39
NOTES:
1) Hazardous Area Classification (reference CEC Part 1 Section 18 and IEC 79-10) 5) Explosive Group Classification (reference CEC Part 1 Section 18)
Class I Zone 0Hazardous Areas in which an explosive gasatmosphere is present continuously or is present for long periods. Group IIA Atmospheres containing methane, propane, or gases or vapors of equivalent hazard
Class I Zone 1Hazardous Areas in which an explosive gasatmosphere is likely to occur in normal operation. Group IIB Atmospheres containing ethylene or gases or vapors of equivalent hazard
Class I Zone 2Hazardous Areas in which an explosive gas atmosphere is not likely to occur during normal operation Group IIC Atmospheres containing acetylene, hydrogen or gases or vapors of equivalent hazard
and, if it occurs, will exist only for a short period of time.

2) Source and Grade of Release (reference API RP 505 and IEC 79-10)
Continuous Grade Release is where flammable gas release is continuous or is expected to occur for long period 6) Temperature Classification (reference CEC Part 1 Section 18
Primary Grade Release is where a flammable gas release is expected to occur periodically or occasionally during normal operatio Temp. Class Max. Surf. Temp Temp ClassMax. Surf. Temp.
Secondary Grade Release is where flammable gas is not expected to occur in normal operation and if it does occur, is likely to do so infrequently and for short period T1 450C T3 200C
T2 300C T3B 165C
3) Flammable Liquid Class (reference RP-505 & NFPA 30) T2A 280C T3C 160C
Class I liquids are flammable liquids that are handled at temperatures above their liquid flashpoint and on release, would vaporize rapidly and substant T2B 260C T4 135C
Class II liquids are flammable liquids that are handled at temperatures below their flashpoint and on release, do not produce sufficient vapors to form an ignitable mixt T2C 230C T4A 120C
Class II liquids are liquids that normally do not produce vapors at sufficient quantity to be considered for electrical classification purpose T2D 215C T5 100C
Crude Oils are a specific classification since crude oil is a mixture of hydrocarbons of widely varying composition. Crude oils are normally considered a Class I flammable liqu. T6 85C
Flammable Highly Volatile Liquids (HVL'sare flammable liquids including butane, ethane, propane and natural gas that vaporize substantially upon relea

4) Ventilation (reference IEC 79-10 and RP505) 7) Vapor Density (reference RP-505)
(NatV) Natural Ventilationoccurs in open air and sheltered areas where a ventilation rate > 6 ACPH occurs naturally. Lighter than Air (LTA) are gas vapors whose density isless than 1.0 relative to air
(GAV) General Artificial Ventilatio occurs in areas where fans are used to improve the general ventilation in the are Heavier than Air (HTA) are gas vapors whose density is greatethan 1.0 relative to air
Adequate Ventilation is defined as 6 ACPH with no stagnant areas
Inadequate Ventilation is ventilation that is not adequate
Dilution Ventilation is ventilation of an enclosed area at such a rate that the formation of a flammable atmosphere is negligib 8) Zone 2 area extends 3m from all ventilation duct openings in module and 3m from all other module openings including doors, windows and removable equipment access pa

(LAV) Local Artificial Ventilatio occurs in areas where a forced or extract ventilation system is applied to a sma 9) Zone 1 boundry extends for 1.5m from all ventilation duct openings in modu
inadequately ventilated local area where an explosive atmosphere may otherwise occu
(NoV) No Ventilationof an enclosure or building by natural or artificial means.

10/26/2006 Page 3 of 3 Tutorial Area Classification Worksheet Area Class Worksheet

SK-A1-101-A-001 – Plot Plan
 Module 1
Hazardous Area Classification
Examination

1. An area classification risk assessment requires:

a. An understanding of industry codes and standards
b. Process, mechanical and operations and HSE input
c. Knowledge of hazardous material properties
d. An understanding of the process and the potential sources of release
e. All of the above

2. The extent of an area classification may be determined by:

a. The electrical code
b. The properties of hazardous materials
c. Ventilation
d. Climatic conditions and topography
e. All of the above

3. The properties of flammable gases and liquids can be obtained from

a. NEC and the CEC
b. RP500 and RP505
c. NFPA 325
d. ISA RP 12.24.01 (IEC 79-10 Mod)
e. All of the above

4. “Normal” Operations as it applies to area classification is the situation where

a. No leaks are present in a facility
b. A facilities equipment is operating within its design parameters
c. The facility is operating at design capacity
d. The facility is manned
e. No gas detection alarms are present

5. Group IIA in the Zone Method of classification is equivalent to the following

group in the Division Method of Classification
a. Group A
b. Group B
c. Group A and B
d. Group C
e. Group D
6. RP 500 and 505 define adequate ventilation in an enclosed space as being:
a. 6 air changes per hour
b. 1.0 cubic foot of air volume per minute per square foot of area but at least
6 ACPH on a continuous basis
c. Ventilation that is sufficient to prevent the accumulation of flammable
gases above 25% of their LEL
d. Enclosed spaces that have gas detection
e. Both b and c

7. Le Chatelier’s principle may be used to approximate the following in flammable

mixtures:
a. Auto-Ignition Temperature
b. Density
c. MESG
d. LEL and UFL
e. Both c and d

8. Gas Detection may be used as a basis for area classification in enclosed spaces
provided:
a. Gas detectors are of a stationary type
b. An adequate number of gas detectors are installed to cover an area
c. Gas detectors are calibrated every three months
d. The temperature code of electrically operated equipment in the area does
not exceed 80% of the AIT defined for the area
e. All of the above

9. Which of the following does not impact the probability of a hazardous atmosphere
existing within a given area:
a. Flammable material present
b. Grade of release
c. Degree of ventilation
d. Ambient temperature
e. Rate of release

10. Which of the following is NOT true:

a. Vapor-tight barriers may be used as an effective means of separating
classified areas from unclassified areas
b. An Auto-Ignition temperature for hazardous mixtures is difficult to
approximate and can only be positively determined by experimental
means
c. Gases with a vapor density of between 0.8 and 1.2 may exhibit
characteristics of both lighter than air and heavier than air gases.
d. The Classification by Example approach to area classification is widely
accepted method for area classification
e. Liquids can burn
 Module 1
Hazardous Area Classification
Tutorial Answers
1. An area classification risk assessment requires:
a. An understanding of industry codes and standards
b. Process, mechanical and operations and HSE input
c. Knowledge of hazardous material properties
d. An understanding of the process and the potential sources of release
e. All of the above

2. The extent of an area classification may be determined by:

a. The electrical code
b. The properties of hazardous materials
c. Ventilation
d. Climatic conditions and topography
e. All of the above

3. The properties of flammable gases and liquids can be obtained from

a. NEC and the CEC
b. RP500 and RP505
c. NFPA 325
d. ISA RP 12.24.01 (IEC 79-10 Mod)
e. All of the above

4. “Normal” Operations as it applies to area classification is the situation where

a. No leaks are present in a facility
b. A facilities equipment is operating within its design parameters
c. The facility is operating at design capacity
d. The facility is manned
e. No gas detection alarms are present

5. Group IIA in the Zone Method of classification is equivalent to the following

group in the Division Method of Classification
a. Group A
b. Group B
c. Group A and B
d. Group C
e. Group D
6. RP 500 and 505 define adequate ventilation in an enclosed space as being:
a. 12 air changes per hour
b. 1.0 cubic foot of air volume per minute per square foot of area but at least
6 ACPH on a continuous basis
c. Ventilation that is sufficient to prevent the accumulation of flammable
gases above 25% of their LEL
d. Enclosed spaces that have gas detection
e. Both b and c

7. Le Chatelier’s principle may be used to approximate the following in flammable

mixtures:
a. Auto-Ignition Temperature
b. Density
c. MESG
d. LEL and UFL
e. Both c and d

8. Gas Detection may be used as a basis for area classification in enclosed spaces
provided:
a. Gas detectors are of a stationary type
b. An adequate number of gas detectors are installed to cover an area
c. Gas detectors are calibrated every three months
d. The temperature code of electrically operated equipment in the area does
not exceed 80% of the AIT defined for the area
e. All of the above

9. Which of the following does not impact the probability of a hazardous atmosphere
existing within a given area:
a. Flammable material present
b. Grade of release
c. Degree of ventilation
d. Ambient temperature
e. Rate of release

10. Which of the following is NOT true:

a. Vaportight barriers may be used as an effective means of separating
classified areas from unclassified areas
b. An AutoIgnition temperature for hazardous mixtures is difficult to
approximate and can only be positively determined by experimental
means
c. Gases with a vapor density of between 0.8 and 1.2 may exhibit
characteristics of both lighter than air and heavier than air gases.
d. The Classification by Example approach to area classification is widely
accepted method for area classification
e. Liquids can burn
 LFL UFL
% Volume Compounds Mole Weight MESG (mm) (%vol/vol) (%vol/vol) AIT (°C)
15% Methane Gas (CH4) 16.04 1.14 4.00% 17.00% 537
40% Hydrogen Sulfide (H2S) 34.08 0.89 4.00% 45.50% 270
25% Propane Gas (CH3CH2CH3) 44.09 0.92 1.70% 10.90% 470
10% Butane Gas (C4H10) 58.12 0.98 1.40% 9.30% 372
10% Pentane Liquid (C5H12) 72.15 0.93 1.40% 7.80% 258
100%

1. Estimate the mixture density

Calculate the mole weight of the mixture

0.15*16.04 + 0.4*34.08 + 0.25*44.09 + 0.1*58.12 + 0.1*72.15 = 40.07

Divide by the molar weigh of air (28.96)

40.07/28.96 = 1.38
If result > 1.0, mixture is heavier than air

1.38 > 1.0 Mixture is heavier than air

2. Estimate the lower flammable limit

Apply Le Chateliers’ Principle

LFL = 1/(0.15/4 + 0.4/4 + 0.25/10.9 + 0.1/1.4 + 0.1/1.4) = 2.35%

3. Estimate the material group classification

Apply Le Chateliers’ Principle to calculate the MESG of the mixture

MESGmix = 1/(0.15/1.14 + 0.4/0.89 + 0.25/0.92 + 0.1/0.98 + 0.1/0.93) = 0.96

If MESG > 0.9 Mixture is Group IIA

4. Estimate the AIT of the mixture

 Pentane has the lowest AIT therefore the AIT of the mixture is 258ºC
Exercise 2 Answers

LFL UFL
% Volume Compounds Mole Weight MESG (mm) (%vol/vol) (%vol/vol) AIT (°C)
10% Nitrogen (N2) 28.02 ∞
40% Hydrogen Gas (H2) 2.016 0.28 4.00% 77.00% 560
30% Methane Gas (CH4) 16.04 1.14 4.00% 17.00% 537
20% Ethane Gas (CH3CH3) 30.07 0.91 2.50% 15.50% 515
100%

1. Estimate the mixture density

Calculate the mole weight of the mixture

0.1*28.02 + 0.4*2.016 + 0.3*16.04 + 0.2*30.07 = 14.42

Divide by the molar weigh of air (28.96)

14.42/28.96 = 0.49
If result < 1.0, mixture is lighter than air

0.49 < 1.0 Mixture is lighter than air

2. Estimate the lower flammable limit

Apply Le Chateliers’ Principle. Calculate using the flammable limit components only

LFL = 1/(0.44/4 + 0.33/4 + 0.22/2.5) = 2.78%

3. Estimate the material group classification

Apply Le Chateliers’ Principle to calculate the MESG of the mixture

MESGmix = 1/(0.1/∞ + 0.4/0.28 + 0.3/1.14 + 0.2/0.91) = 0.52

If MESG > 0.5 and < 0.9 Mixture is Group IIB

4. Estimate the AIT of the mixture

Ethane has the lowest AIT therefore the AIT of the mixture is 515ºC