THE INSTITUTE OF PETROLEUM

A RISK-BASED APPROACH TO
HAZARDOUS AREA CLASSIFICATION

THE INSTITUTE OF PETROLEUM

A RISK-BASED APPROACH TO
HAZARDOUS AREA CLASSIFICATION

November 1998

Published by
The Institute of Petroleum, London
A charitable company limited by guarantee

Copyright 1998 by The Institute of Petroleum, London:

A charitable company limited by guarantee. Registered No. 135273, England
All rights reserved
No part of this book may be reproduced by any means, or transmitted, or translated into
a machine language without the written permission of the publisher.
ISBN 0 85293 238 3
Printed by The Institute of Petroleum

CONTENTS
Page
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
1

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Content of the report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Risk criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1 Individual risk acceptability criterion for fatality due
to accidental ignited releases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2 Proposed risk acceptability criterion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Risk calculation methodology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Frequency of ignited releases - (Ffire(/yr)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Occupancy (Pocc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Vulnerability (V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Combination of risk from zones within hazardous areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Continuous release (Zone 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Primary release (Zone 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Secondary releases (Zone 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 Frequency of fires (Ffire) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 Determination of exposure (Exp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 Vulnerability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4 Estimation of release frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1 Individual risk vs. exposure for frequency of 1.0E-2/rel.source-yr. . . . . . . . . . . . . . . . . . . .
Figure 2 Individual risk vs. exposure for frequency of 1.0E-3/rel.source-yr. . . . . . . . . . . . . . . . . . . .
Figure 3 Risk-based procedure for calculation of Zone 2 hazard radii . . . . . . . . . . . . . . . . . . . . . . . .

15
15
18
20
20
22
22
23

Conclusions and recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1 Risk criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2 Continuous releases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3 Primary releases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4 Secondary releases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5 Dispersion calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24
24
24
25
25
25

6
6
8
8
9

Contents Cont.....

Page

Annex A
Frequency data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.1 Centrifugal pump leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2 Centrifugal compressor leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.3 Flange leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.4 Valves leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26
26
27
28
29

Annex B
Ignition contributors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Annex C
Exposure calculation table Zone 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Annex D
Calculations for the determination of hazardous areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D.1 Hazard radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D.2 Equivalent leak hole diameter for equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D.3 Methodology for the determination of the hazard radius by dispersion calculations . . . . . . . . . . . . . .
D.4 Area classification hazard radii for hydrogen-containing streams . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34
34
40
43
51

Annex E
LPG - Carousel example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
E.1 Approach (a) Historical experience of incidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
E.2 Approach (b) Simulation of frequency versus release size relationship . . . . . . . . . . . . . . . . . . . . . . . . 53
Annex F
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

vi

FOREWORD

1.

This report was commissioned by the Institute of Petroleum's Electrical Committee through its Working Group
revising the Area classification code - Part 15 of the Model Code of Safe Practice.

2.

The objective was to develop a means for establishing the outer boundaries of Zone 2 hazardous areas taking
account of the risks associated with contributory factors.

3.

The intention is to use the content of this report in the present update of the Area classification code and as a
source of reference for the application of the risk-based approach.

4.

Although it is believed that adoption of the procedure in this report for determining the boundaries of hazardous
areas will provide an adequate level of safe operation, the Institute of Petroleum cannot accept responsibility
of whatsoever kind, for damage or alleged damage arising or otherwise occurring in or about premises,
installations, areas or vehicles to which the contents of this report have been applied.

vii

ACKNOWLEDGEMENTS

This report was prepared by Mr K Glynne and Dr M Considine of BP International on behalf of the Institute of
Petroleum Working Group convened to review and update the Area classification code - Part 15 of the Model Code
of Safe Practice.

viii

1
SUMMARY

This report presents a risk-based approach which may be applied to the classification of an upstream or downstream
petroleum sector facility by consideration of the individual point source procedure presented in Chapter 5 of the Area
classification code for petroleum installations(1) - Part 15 of the Model Code of Safe Practice. The criterion which
has been adopted is that the total individual risk due to an ignited release should not exceed 1.0E-5/yr. For
continuous and primary releases the extent of the associated hazardous area is not affected by the amount of time
a flammable atmosphere is present. For secondary releases, however, the extent of the hazardous area generally
varies with the frequency of release. The proposed methodology for secondary releases is shown in Figure 3 (page
23).
For continuous and primary releases the extent of the hazardous area (Zones 0 and 1) may be determined using
dispersion models which reflect the nature of the release source and the environmental conditions. The probability
of a flammable atmosphere being present can also be readily determined. The only unknowns are the amount of time
an operator spends within the hazardous area (occupancy) and the frequency of ignition. Maximum ignition
frequencies are presented for varying levels of occupancy.
Secondary releases are accidental in nature and therefore the extent of the flammable atmosphere will vary
depending on the size of the leak. The objective is to establish the outer boundary of Zone 2, i.e. the minimum
distance at which unclassified ignition sources may be located. Historical data was used to develop a 'leak size vs.
frequency' relationship. By setting values for ignition probability, individuals exposure to Zone 2 release sources
and vulnerability to ignited releases, the leak size corresponding to the maximum frequency of release which
determines the Zone 2 boundary may be established. The current hazard radii presented in IP15 approximate to leak
sizes which occur at a frequency in the range 1.0E-2 to 1.0E-3 per release source-yr depending on the equipment
type.