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Hazardous Area Classification and Control of Ignition Sources

This Technical Measures Document refers to the classification of plant into hazardous areas, and
the systematic identification and control of ignition sources

The relevant Level 2 Criteria are 5.2.1.3(29)c, 5.2.1.11(64)f, 5.2.1.13 and 5.2.4.2(94)a.

Design of plant, pipework and general plant layout is considered in Technical Measures Documents
on Plant Layout, Design Codes - Plant, Design Codes - Pipework, Plant Modification / Change
Procedures, Maintenance Procedures.

The Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR) provide for
the first time a specific legal requirement to carry out a hazardous area study, and document the
conclusions, in the form of zones.

General Principles

Hazardous Area Classification for Flammable Gases and Vapours

Area classification may be carried out by direct analogy with typical installations described in
established codes, or by more quantitative methods that require a more detailed knowledge of the
plant. The starting point is to identify sources of release of flammable gas or vapour. These may
arise from constant activities; from time to time in normal operation; or as the result of some
unplanned event. In addition, inside process equipment may be a hazardous area, if both
gas/vapour and air are present, though there is no actual release.

Catastrophic failures, such as vessel or line rupture are not considered by an area classification
study. A hazard identification process such as a Preliminary Hazard Analysis (PHA) or a Hazard
and Operability Study (HAZOP) should consider these abnormal events.

The most commonly used standard in the UK for determining area extent and classification is BS
EN 60079 part 101, which has broad applicability. The current version makes clear the direct link
between the amounts of flammable vapour that may be released, the ventilation at that location,
and the zone number. It contains a simplistic calculation relating the size of zone to a rate of
release of gas or vapour, but it is not helpful for liquid releases, where the rate of vaporisation
controls the size of the hazardous area.

Other sources of advice, which describe more sophisticated approaches, are the Institute of
Petroleum Model Code of Practice (Area Classification Code for Petroleum Installations, 2002), and
the Institution of Gas Engineers Safety Recommendations SR25, (2001). The IP code is for use by
refinery and petrochemical type operations. The IGE code addresses specifically transmission,
distribution and storage facilities for natural gas, rather than gas utilisation plant, but some of the
information will be relevant to larger scale users.

Zoning

Hazardous areas are defined in DSEAR as "any place in which an explosive atmosphere may occur
in quantities such as to require special precautions to protect the safety of workers". In this context,
'special precautions' is best taken as relating to the construction, installation and use of apparatus,
as given in BS EN 60079 -101.

Area classification is a method of analysing and classifying the environment where explosive gas
atmospheres may occur. The main purpose is to facilitate the proper selection and installation of
apparatus to be used safely in that environment, taking into account the properties of the flammable
materials that will be present. DSEAR specifically extends the original scope of this analysis, to take
into account non-electrical sources of ignition, and mobile equipment that creates an ignition risk.

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

Zone 0: An area in which an explosive gas atmosphere is present continuously or for long periods;
Zone 1: An area in which an explosive gas atmosphere is likely to occur in normal operation;
Zone 2: An area in which an explosive gas atmosphere is not likely to occur in normal operation
and, if it occurs, will only exist for a short time.
Various sources have tried to place time limits on to these zones, but none have been officially
adopted. The most common values used are:

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


Zone 1: Explosive atmosphere for more than 10, but less than 1000 h/yr
Zone 2: Explosive atmosphere for less than 10h/yr, but still sufficiently likely as to require controls
over ignition sources.
Where people wish to quantify the zone definitions, these values are the most appropriate, but for
the majority of situations a purely qualitative approach is adequate.

When the hazardous areas of a plant have been classified, the remainder will be defined as non-
hazardous, sometimes referred to as 'safe areas'.

The zone definitions take no account of the consequences of a release. If this aspect is important, it
may be addressed by upgrading the specification of equipment or controls over activities allowed
within the zone. The alternative of specifying the extent of zones more conservatively is not
generally recommended, as it leads to more difficulties with equipment selection, and illogicalities in
respect of control over health effects from vapours assumed to be present. Where occupiers
choose to define extensive areas as Zone 1, the practical consequences could usefully be
discussed during site inspection.

As an example:

A proposal was made to zone an aircraft hanger as Zone 1, although the use of fuels handled
above their flash point would be a rare event. It proved difficult to obtain a floor-cleaning machine
certified for Zone 1 areas, though the floor needed sweeping regularly. The option of writing out an
exception to normal instructions to allow a non Ex-protected machine to be used regularly is not
recommended. Instead, a more realistic assessment of the zones is needed, and special
instructions issued for the rare event of using more volatile fuels.

A hazardous area extent and classification study involves due consideration and documentation of
the following:

The flammable materials that may be present;


The physical properties and characteristics of each of the flammable materials;
The source of potential releases and how they can form explosive atmospheres;
Prevailing operating temperatures and pressures;
Presence, degree and availability of ventilation (forced and natural);
Dispersion of released vapours to below flammable limits;
The probability of each release scenario.
These factors enable appropriate selection of zone type and zone extent, and also of equipment.
The IP code gives a methodology for estimating release rates from small diameter holes with
pressurised sources, and shows how both the buoyancy and momentum of the release influence
the extent of a zone. It tabulates values for an LPG mixture, gasoline, natural gas, and refinery
hydrogen for pressures up to 100barg. Similarly the IGE code gives a methodology for natural gas,
relating the leak rate to the hole-size and the operating pressure. The tables of dispersion distances
to the zone boundary address in the main quite large diameter deliberate vents. There is in practice
little overlap between the codes.

The results of this work should be documented in Hazardous Area Classification data sheets,
supported by appropriate reference drawings showing the extent of the zones around (including
above and below where appropriate) the plant item.

Selection of Equipment

DSEAR sets out the link between zones, and the equipment that may be installed in that zone. This
applies to new or newly modified installations. The equipment categories are defined by the ATEX
equipment directive, set out in UK law as the Equipment and Protective Systems for Use in
Potentially Explosive Atmospheres Regulations 1996. Standards set out different protection
concepts, with further subdivisions for some types of equipment according to gas group and
temperature classification. Most of the electrical standards have been developed over many years
and are now set at international level, while standards for non-electrical equipment are only just
becoming available from CEN.

The DSEAR ACOP describes the provisions concerning existing equipment.

There are different technical means (protection concepts) of building equipment to the different
categories. These, the standard current in mid 2003, and the letter giving the type of protection are
listed below.

'q' - Powder filling


EN 50017, 1998
'o' - Oil immersion
EN 50015, 1998
'e' - Increased safety
EN 50019, 2000
'ib' - Intrinsic safety
EN 50020, 2002
'm' - Encapsulation
EN 50028, 1987
's' - Special protection
Zone 0 Zone 1 Zone 2
Category 1 Category 2 Category 3
'ia' intrinsically safe 'd' - Flameproof enclosure Electrical
EN 50020, 2002 EN 50018 2000 Type 'n' - EN 50021 1999
Non electrical
EN 13463-1,
Ex s - Special protection if 'p' - Pressurised
specifically certified for Zone 0 EN 50016 2002
Correct selection of electrical equipment for hazardous areas requires the following information:

Classification of the hazardous area (as in zones shown in the table above);
Temperature class or ignition temperature of the gas or vapour involved according to the table
below:

Temperature Classification Maximum Surface Ignition Temperature of gas or


Temperature, °C vapour, °C
T1 450 >450
T2 300 >300
T3 200 >200
T4 135 >135
T5 100 >100
T6 85 >85

If several different flammable materials may be present within a particular area, the material that
gives the highest classification dictates the overall area classification. The IP code considers
specifically the issue of hydrogen containing process streams as commonly found on refinery
plants. Consideration should be shown for flammable material that may be generated due to
interaction between chemical species.

Ignition Sources - Identification and Control

Ignition sources may be:

Flames;
Direct fired space and process heating;
Use of cigarettes/matches etc;
Cutting and welding flames;
Hot surfaces;
Heated process vessels such as dryers and furnaces;
Hot process vessels;
Space heating equipment;
Mechanical machinery;
Electrical equipment and lights
Spontaneous heating;
Friction heating or sparks;
Impact sparks;
Sparks from electrical equipment;
Stray currents from electrical equipment
Electrostatic discharge sparks:
Lightning strikes.
Electromagnetic radiation of different wavelengths
Vehicles, unless specially designed or modified are likely to contain a range of potential
ignition sources

Sources of ignition should be effectively controlled in all hazardous areas by a combination of


design measures, and systems of work:

Using electrical equipment and instrumentation classified for the zone in which it is located.
New mechanical equipment will need to be selected in the same way. (See above);
Earthing of all plant/ equipment (see Technical Measures Document on Earthing)
Elimination of surfaces above auto-ignition temperatures of flammable materials being
handled/stored (see above);
Provision of lightning protection
Correct selection of vehicles/internal combustion engines that have to work in the zoned areas
(see Technical Measures Document on Permit to Work Systems);
Correct selection of equipment to avoid high intensity electromagnetic radiation sources, e.g.
limitations on the power input to fibre optic systems, avoidance of high intensity lasers or
sources of infrared radiation
Prohibition of smoking/use of matches/lighters
Controls over the use of normal vehicles
Controls over activities that create intermittent hazardous areas, e.g. tanker loading/unloading
Control of maintenance activities that may cause sparks/hot surfaces/naked flames through a
Permit to Work System
Precautions to control the risk from pyrophoric scale, usually associated with formation of
ferrous sulphide inside process equipment

Direct Fired Heaters, Hot Oil Systems and Processes Operating Above Auto-Ignition Temperatures
A range of petrochemical and refinery processes use direct fired heaters, e.g. steam crackers for
ethylene production. Clearly, if the fuel supply to the heater or the pipework carrying the process fluid
leaks close to the furnace, any leak must be expected to find a source of ignition, either directly at the
flames, or by a surface heated by a flame. In these circumstances, hazardous area classification, and
appropriate selection of ATEX equipment is not suitable as a basis of safety for preventing fire and
explosion risks.

Instead, safety should be achieved by a combination of a high standard of integrity of fuel and
process pipelines, together with a means of rapid detection and isolation of any pipes that do fail.
The consequences of the failure of a pipe carrying process materials within the furnace should be
considered in any HAZOP study.

Other processes (such as hot oil heating circuits) may handle products above their auto-ignition
temperature. Any such processes should be specifically identified in a safety case. Again, area
classification is not a suitable means of controlling the ignition risks, and the same considerations
apply, as with fired heaters.

Lightning Protection
Protection against lightning involves installation of a surge protection device between each non-
earth bonded core of the cable and the local structure. Further guidance can be found in BS
6651:19991 - (Code of practice for protection of structures against lightning). Ignitions caused by
lightning cannot be eliminated entirely, particularly with floating roof tanks, where vapour is usually
present around the rim seal. In these circumstances, measures to mitigate the consequences of a
fire should be provided.

Vehicles
Most normal vehicles contain a wide range of ignition sources. These will include electrical circuits;
the inlet and exhaust of any internal combustion engine; electrostatic build up; overheating brakes,
and other moving parts. Site rules should be clear where normal road vehicles may be taken, and
areas where they must be excluded.

Standard EN 17551 sets out the requirements for diesel powdered ATEX category 2 or 3 lift trucks.
Electric powered vehicles can also be built using a combination of this standard and the normal
electrical standards. No specification is available for vehicles with spark ignition engines, and it is
unlikely that such an engine could be built economically. Vehicles certified to ATEX requirements
are however expensive, and for many applications an unprotected type has to be extensively
rebuilt. Consequently, many employers are likely to try and justify not zoning storage compounds,
where lift trucks handle flammable liquids or gases in containers. In some stores, perhaps with
limited use of a vehicle, this may be acceptable. Discussions have been held with the British
Chemical Distributors and Traders Association, with the objective of clarifying when storage areas
should be classified as zone 2. The conclusions from this exercise will be made available in due
course. Discussions are also ongoing, about vehicles with gas detection systems, designed to shut
the engine and isolate other sources of ignition in the event of a gas release. At present these are
sold without any claim for ATEX compliance, but with the suggestion they may be useful in cases of
remote risk.

For the purposes of COMAH, an assessment is needed of the risk that an ignition within a storage
compound will produce a major accident, either directly or because a fire or explosion spreads to
involve other materials. If this is possible, it is more appropriate to provide controls to prevent the
spread, rather than simply apply more conservative zoning, and more restrictive rules on the
equipment used in the store.

Where specialist vehicles (e.g. cranes) are needed during maintenance operations, proper controls
and plant isolation may allow the normal zones to be suspended. Typically these will involve written
instructions, as specified in DSEAR schedule 1, or a formal permit to work system.

Many sites will have operations of filling and emptying road tankers with flammable materials.
Controls will be needed to prevent or minimise the release of gas or vapour but controls over
ignition sources are also needed. Hazardous areas may be considered to exist during the transfer
operation, but should not be present once the transfer is complete. Safe systems of work are
needed to ensure safety where such 'transient' zones exist.

Factors for Assessor of a Safety Case to Consider

Is a full set of plans identifying hazardous areas available? For a large site they need not all
be provided in the report, but those examples relevant to the representative set of major
accidents upon which the ALARP demonstration is based must be included.
Have all flammable substances present have been considered during area classification,
including raw materials, intermediates and by products, final product and effluents? Commonly
these will be grouped for the purposes of any area classification study.
Locations where a large release is possible and the extent of hazardous areas has been
minimised by the use of mechanical ventilation should be identified, e.g. gas turbine power
generation units, compressor houses. Some reference to design codes, and commissioning
checks to ensure the ventilation achieves the design aim, should be provided. The
consequences of a loss of power to the system should be included in any section looking at
other consequences of power loss.
Have appropriate standards been used for selection of equipment in hazardous areas?
Existing plant will not meet the formula in DSEAR, but older standards distinguished between
electrical equipment suitable for zones 0, 1 and 2. Does the report identify old electrical
equipment still in service in a hazardous area, and what assessment has been made to
ensure it remains safe for use?
Is there a reference to the impact upon extent and classification of hazardous areas in the
section describing plant modification (see Technical Measures Document onPlant
Modification / Change Procedures)); passive items like new walls and buildings can influence
this if they obstruct natural ventilation of adjacent plant
Have all ignition sources been considered? A check list is provided in the DSEAR ACOP on
control and mitigation measures, and BS EN 1127 part 11 (Explosive atmospheres. Explosion
prevention and protection. Basic concepts and methodology).

Factors that could be considered during an on site inspection

If there are any large areas of zone 1 on the drawings, is there evidence that by design and
operation controls, the sources of release and consequently the location and extent of
hazardous areas have been minimised?
Do any zone 2 areas extend to places where the occupier has inadequate control over
activities that could create an ignition source, or is there any suggestion that the zone
boundaries have been arbitrarily adjusted to avoid this?
Has ignition protected electrical equipment been installed and maintained by suitably trained
staff.
Are the risks from static discharges controlled properly? Earthing of plant, drums and tankers
is the most basic requirement; other precautions are described in the references
What control measures over ignition sources are adopted in hazardous areas during
maintenance; where ignition sources must be introduced, typical precautions include the use
of supplementary ventilation, portable gas detectors, and inerting of sections of plant. A local
project on Electrical Equipment in Flammable Atmospheres was undertaken and a report of
the project’s conclusions completed.

Dust Explosions
The COMAH Regulations do not apply to any material if the only risk created is that of a dust
explosion. However, many toxic materials are handled in fine powder form, and a serious dust
explosion could cause a major accident. A dust explosion involving a non-toxic dust like polyethylene
would not result in a major accident as defined in the regulations, unless it also led to loss of
containment of a COMAH substance. A dust explosion could then be an initiator of a major accident.
Measures to prevent major accidents should address all potential initiators.

DSEAR requires that hazardous area classification for flammable dusts should be undertaken in the
same manner as that for flammable gases and vapours. Zoning as described above may be
applied, replacing 'gas atmosphere' with 'dust/air mixtures'. The zone numbers used are 20, 21 and
22, corresponding to 0,1 and 2 used for gases/vapours

The only relevant standard to help people zone their plant is BS EN 50281 part 3, 20021, which is
an adaptation of the IEC equivalent.

Where toxic dusts are processed, releases into the general atmosphere should be prevented, and
the extent of any zone 21 or 22 outside the containment system should be minimal or non-existent.
The inside of different parts of the plant may need to be zoned as 20, 21 or 22, depending on the
conditions at particular locations.

Classification of dusts relating to autoignition and minimum ignition current is undertaken similarly
to gases/vapours, but involves additional complications.

The explosibility of dusts is dependent upon a number of factors:

chemical composition;
particle size;
oxygen concentration;

Where toxic dusts are handled, in most cases occupiers will need to carry out testing of the product
for its explosion properties. Companies able to undertaken such testing are listed in the IChemE's
book on the prevention of dust explosions. There is no legally defined test for an explosible dust.
However, for many years we have used a small-scale screening test, the vertical tube test,
described in HSG 1032. The issues about representative samples of dust, and other factors that
might cause the results to vary are also discussed in this guidance. In general, dusts with a particle
size greater than 500 Jm are unlikely to cause an explosion. For most chemical products it is
preferable to test dust taken from the process, but if the particle size distribution varies, it is
common to test material that passes a 63-micron sieve, and take this as the worst case.

Ignition due to a hot surface is possible, but the temperature needed to ignite a dust layer depends
on layer thickness and contact time. For COMAH sites with toxic dusts, the most likely hazard
would arise in drying processes, if substantial quantities were held for extended periods hot enough
to start self heating or smouldering combustion.

Status of Guidance

Existing codes of practice provide information with respect to good practice for hazardous area
classification. The standards detailing selection of appropriate electrical apparatus have been
updated to take into consideration ventilation effects.

European equipment standards may become 'harmonised' when a reference to them is published in
the Official Journal of the European Community. A list of ATEX harmonised standards can be
checked on theEU web site:

Equipment built to such a harmonised standard may assume automatic conformity with those
essential safety requirements of relevant directives that are covered by the standard. The EPS
regulations describe the conformity assessment procedures that apply to different types of
equipment.

Reference Documents

HS(G)512 Storage of flammable liquids in containers, HSE, 1998.

Appendix 3 describes the requirements for hazardous area classification. The use of BS EN
60079-10: 20031, and the Institute of Petroleum Code 'Area Classification Code for
Petroleum Installations: Model Code of practice in the Petroleum Industry' Part 15 are
recommended. It suggests all drum stores should be zone 2, to a height 1m above the stack.
The same advice appears in HSG 166 and HSG 113 on ignition protected lift trucks.
Discussions with industry on the relaxation of this in particular circumstances are ongoing.

HS(G)712 Chemical warehousing: the storage of packaged dangerous substances, HSE,


1998.

This contains very limited information on hazardous area classification or control of ignition
sources

HS(G)1032 Safe handling of combustible dusts: precautions against explosions, HSE, 2nd
Edition, 2003

HS(G)1132 Lift trucks in potentially flammable atmospheres. The contents of this have been
overtaken to some degree by DSEAR, and the EPS regulations.

HS(G)1402 Safe use and handling of flammable liquids, HSE, 1996.

Appendix 3 describes the requirements for hazardous area classification. The use of BS EN
60079-141 and the Institute of Petroleum Code 'Area Classification Code for Petroleum
Installations: Model Code of practice in the Petroleum Industry' Part 15 are recommended.
This is aimed mainly at small scale handling, with containers of 200 litres or less.

HS(G)1662 Formula for health and safety: guidance for small and medium sized firms in the
chemical industry, HSE, 1997.

The guidance describes the requirements for hazardous area classification, and gives some
typical examples. These should now be seen as rather conservative. The use of BS EN
60079-14, BS EN 50281 and BS EN 605291 are recommended. This is basic level guidance,
and COMAH reports should normally reference more specific publications, such as the other
HSG series books listed, and other items in this list.

HS(G)1762 The storage of flammable liquids in tanks, HSE, 1998.

Paragraphs 35 to 39 describe the requirements for hazardous area classification. This cross
references BS EN 60079-10: 20031, and the Institute of Petroleum Code 'Area Classification
Code for Petroleum Installations: Institute of Petroleum Model Code of Safe Practice, part 15,
area classification for installations handling flammable fluids, 2nd edition 2002.

HS(G)1862 The bulk transfer of dangerous liquids and gases between ship and shore, HSE,
1999.

Appendix 2 describes the requirements for hazardous area classification. The use of BS EN
60079-101 and the Institute of Petroleum Code 'Area Classification Code for Petroleum
Installations: Model Code of practice in the Petroleum Industry' Part 15 are recommended.
Contains useful information about electrostatic hazards during unloading.

LPGA CoP 1 Bulk LPG storage at fixed installations. Part 1: Design, installation and operation
of vessels located above ground, LP Gas Association, 1998.

LPGA codes have not previously drawn a clear distinction between hazardous areas, and
separation distances required for other reasons. These are currently under revision, and will
specify hazardous areas, that in most cases will be smaller than the separation distance.
Current codes are listed on the LPGA website.

Model Code of practice in the Petroleum Industry' Part 15 is recommended. The guidance
also recommends that zones be recorded in a plan to prevent sources of ignition being
brought in.

Electrical Equipment

Standards produced by Europe in the BS EN 50014 range are gradually being superseded by
international standards produced in the range BS IEC 600791. Equipment built to older
standards, including purely national standards may remain in service, provided it is properly
maintained. The IEC range of standards also includes documents on selection, installation
and maintenance of equipment for use in explosive atmospheres.

Non-electrical equipment

The first standard for explosion protected non-electrical equipment is BS EN 13463 part 11. It
describes requirements for "Category 3" equipment. Further parts of this standard are well
advanced and will appear during 2004.
BS EN 1127-1: 19981 Explosive atmospheres - Explosion prevention and protection - Part 1:
Basic concepts and methodology, British Standards Institution.

This gives additional general advice on the many of the issues covered in this TMD.

Electrostatic ignition risks

The most recent general source of advice was drafted by a European standards working
group, but was published in the UK as BS PD R044-001 and not as a full standard. It
contains much useful advice about limiting pumping speeds, electrostatic risks from
clothing, and many detailed operations. The two parts of the older BS 5958: 19911
Code of Practice for the control of undesirable static electricity remain current, because
they contain some useful information not duplicated by the PD. The two parts are:
Part 1: 1991 General considerations;

Part 2: 1991 Recommendations for particular industrial situations

BS EN 502811. The different parts of this standard set out requirements for construction of
equipment for use in atmospheres containing explosive dusts; information about selection and
maintenance; and
BS EN 50281-3: 20021 covers the classification of areas where combustible dusts are or may
be present.
BS 6651:19991. Code of practice for protection of structures against lightning, British
Standards Institution.
Section 9 provides guidance on lightning protection of structures with inherent explosive risks.
BS 7430:19981 Code of practice for earthing, British Standards Institution.

Lightning protection. Section 23 provides guidance on lightning protection.

Further Reading Material

Cox, A.W., Lees, F.P. and Ang, M.L., 'Classification of Hazardous Locations', 1993.

This was a study led by a consortium of the chemical, electrical and mechanical engineering
institutes, and showed how the subject spanned the traditional divides. It was important in the
development of ideas, but provides no new methodology for users.

A Guide to Safety in Aerosol Manufacture, BAMA, Third Edition, 1999.

Dust Explosion Prevention and Protection: A Practical Guide, IChemE, ISBN 0852954107

A practitioner's handbook - Electrical installation and maintenance in potentially explosive


atmospheres, Publication No. 186, The Engineering Equipment and Materials Users Association,
1997.

References

1. For further information on the relevant British Standards, please access the British Standards
web site and use the search facility.
2. Further information can be obtained on these publications by accessing the HSE Direct web
site. Please note that this is a subscription site for interested parties outside of HSE.

Page last updated: 11th October 2004

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