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INSTITUTION OF GAS ENGINEERS AND MANAGERS

IGEM/UP/16
Communication XXXX

IGEM/TSP/10/344

Founded 1863
Royal Charter 1929
Patron
Her Majesty the Queen

Hazardous area classification for Natural
Gas installations downstream of primary
meter installations
DRAFT FOR COMMENT
1

This draft Standard IGEM/UP/16 has been prepared by a Panel under the chairmanship
of Barrie Church.

2

This Draft for Comment is presented to Industry for comments which are required by
30th December 2010, and in accordance with the attached Reply Form.

3

This is a draft document and should not be regarded or used as a fully approved and
published Standard. It is anticipated that amendments will be made prior to
publication.
It should be noted that this draft Standard contains intellectual property
belonging to IGEM. Unauthorised copying or use by any unauthorised person
or party is not permitted.

4

This is a copyright document of the Institution of Gas Engineers and Managers.
Enquiries should be addressed in the first instance to:
Peter Hurst
IGEM
IGEM House
26-28 High Street
Kegworth
Derbyshire, DE74 2DA
Tel: 0844 375 4436
Fax: 01509 678198
Email: peter@igem.org.uk

Attached is the Draft for Comment of IGEM/UP/16 – “Hazardous area classification for Natural
Gas installations downstream of primary meter installations” and the associated comment
form.
We wish to make it as easy as possible for those of you representing industry bodies to issue
the draft to your Members. You can either forward this email with attachment complete or
forward it without the attachment and invite them to visit our website via
http://www.igem.org.uk/Drafts.html where the Draft and Comment Form are posted.
Organisations to which this Draft has been circulated:
Organisation

Representative

AIGT
Association of Registered Gas Installers
BSI/GSE/30
CIBSE
CIPHE
DNO Collaboration Forum
Energy Institute
ENA
EUSkills
Gas Forum
Gas Safe Register
GIRSAP
GISG
HSE
HVCA
ICOM
National Grid
Northern Gas Networks
Ofgem
Organisation of Professional Gas Operatives
SBGI
Scotia Gas Networks
UKLPG
Wales and West Utilities
YPN

John Barratt
Tony Brunton
Bernard Williams
Hywel Davies
Kevin Welman
Ian Aldridge
Mark Scanlon
Angela Love
Ian Smith
Clare Temperley
Mark Rolfe
Terry Mundy
Angela Love
Andrew Cox
Bob Towse
David Hughes
Ian Aldridge
Chris Gorman
Steve Brown
Wim Rutjes
Martin Atkinson
Paul Denniff
Jeff Watson
Chris Clarke
Mark Berry

IGEM
COUNCIL
Membership Committee
Marketing Committee
Audit Committee
TCC
GTDC + PSR/25
GMC
GUC + PUP/16

IGEM/UP/16
Communication XXXX

Hazardous area classification for Natural
Gas installations downstream of primary
meter installations
Draft for Comment

Founded 1863
Royal Charter 1929
Patron: Her Majesty the Queen

IGEM/UP/16
Communication XXXX

Hazardous area classification for Natural
Gas installations downstream of primary
meter installations
Draft for Comment

Price Code: C10H
© The Institution of Gas Engineers and Managers
IGEM House
26-28 High Street
Kegworth
Derbyshire, DE74 2DA
Tel: 0844 375 4436
Fax: 01509 678198
Email: general@igem.org.uk

ISBN 978 1 905903 XX X ISSN 0367 7850 Published by the Institution of Gas Engineers and Managers For information on other IGEM Standards visit our website.igem. is a violation of copyright law. Copyright laws protect this publication. unless stated otherwise. Reproduction or retransmission in whole or in part. without the prior written consent of the copyright holder. IGEM. www. in any manner.uk . All rights reserved Registered charity number 214001 All content in this publication is.org. the property of IGEM.Copyright © 2010.

5 A3. units and symbols 24 2 References 26 Concepts A3.IGEM/UP/16 – Draft for Comment CONTENTS SECTION PAGE 1 Introduction 1 2 Scope 4 3 Legal and allied considerations 6 4 Considerations of relevance to the determination of zone classifications  4.4 Zoning  4. 26-28 High St.1 Natural ventilation  6.10 Ventilation 8 8 8 8 9 9 9 10 10 10 11 5 Information for commercial and industrial designs  5. . Website: www.8 Commissioning  4.6 Presence of other hazards  4.igem.2 A3. acronyms.2 Confined installation  5.1 A3.1 Introduction  4.5 Electrical discharges  4.2 Continuous mechanical ventilation 17 17 21 7 Maintenance 22 8 Generic risk assessments 23 1 Glossary.7 28 28 28 28 29 29 30 30 APPENDIX 3        and requirements for hazardous areas General Hazardous area concept Grade of release Rate of release Environment/ventilation Zone classification Extent 4 Worked examples 32 5 Examples of generic risk assessments 37 ©IGEM. IGEM House.6 A3.3 A3.3 Containment  4.4 A3.9 Safe maintenance  4. DE74 2DA.3 Congested installation  5.1 Design and installation  5.org.7 Design  4. Derbyshire.2 Risk Assessments  4. Kegworth.uk.4 Ventilation 12 12 13 15 15 6 System design checklist for Zone 2 NE compliance  6.

hoses and connections of MOP  0. Website: www. IGEM House. 42 .5 bar 41 12 Risk assessment for gas appliances of MOP  0. flexible pipes. Kegworth. Derbyshire.igem.IGEM/UP/16 – Draft for Comment FIGURES 1 Signposts to hazardous area classification 5 2 Pipework layouts showing preferred pipe locations for Zone 2 NE classification 13 3 Example of an installation with congested leak locations 15 4 Hazardous area concept diagram 29 5 Extent of the hazardous area surrounding fittings.5 bar 40 11 Risk assessment for bellows.uk. DE74 2DA.org.5 bar 38 9 Risk assessment for gas boosters of MOP  0. 26-28 High St.5 bar 39 10 Risk assessment for appliance connections and pipework of MOP  0. valve glands and regulators 31 (Secondary grade releases outdoors except those designated NE) 6 Example of a boiler room naturally ventilated 32 7 Example of a boiler room mechanically ventilated 33 8 Example of boiler room with mechanical ventilation 34 9 Example of a horizontal ceiling duct 35 10 Example of a high level loft space 35 1 Zone 2 NE natural ventilation requirements 14 2 Preliminary assessment for all pipework 17 3 Assessment for pipework in ceiling spaces or ducts 18 4 Assessment for pipework in high level spaces within rooms 19 5 Assessment for pipework in small spaces 19 6 Assessment for gas booster installations 20 7 Assessment for installations which are continuously ventilated by mechanical means 21 8 Risk assessment for rigid pipework. joints and components of MOP  0.5 bar TABLES ©IGEM.

6). for which some of these requirements will not. For installations at pressure above 500 mbar and vibrating machinery. Kegworth. methods need to be developed by personnel of adequate competency and experience. 26-28 High St. Website: www. specialist assistance is required and is outside the scope of this document. subsequent ongoing planned routine maintenance is an essential feature of the safety for any installation. The diversity of gas installations is such that it is inappropriate to provide detailed requirements for all types of installation covered by the scope of this Standard. These generic assessments relate only to equipment installed downstream of the emergency control valve (ECV). These assessments whether equipment marked and declared as being suitable for use in a hazardous area should be considered or applied. 1.4 The advice on the preparation of risk assessments assumes that industrial and commercial gas installations and pipework have been well engineered according to recognised standards such as IGEM/UP/2 and IGE/UP/10. on an installation. It is recognised that special circumstances may occur. 1. Derbyshire.7 The assessment sheets shown in Appendix 4 are intended for inclusion within site assessments. However. appointed by IGEM’s Gas Utilization Committee. It is intended primarily for designers of new pipework systems downstream of the primary gas meter installation.uk. Natural Gas (NG)) installations with an operating pressure (OP) not exceeding 500 mbar due to in-depth test work performed within the United Kingdom (UK). any improvements may be made as reasonably practicable (without excessive cost).IGEM/UP/16 – Draft for Comment SECTION 1 : INTRODUCTION 1. .3 This Standard provides information relating to the design of methane based gas installations to ensure they can be classified and maintained as Zone 2 Negligible Extent (Zone 2 NE). IGEM House. 1. 1. 1. and has been approved by IGEM’s Technical Co-ordinating Committee on behalf of the Council of IGEM. They applied retrospectively to all installations within workplaces from 30th June 2006.6 The scope of this Standard has been limited to methane based gas (for example.igem.org. 1. DE74 2DA. When existing installations are subjected to a risk assessment. In such cases. As such these requirements come into effect for all newly installed installations from 1st January 2011. In such installations it is essential that a risk assessment is always completed and 1 ©IGEM.8 It is recognised that the new advice given in this Standard relating to DSEAR and the classification of hazardous areas may be difficult to comply with for existing systems. It will also be useful for site occupiers who have the responsibility for compliance with DSEAR and the production of site risk assessments. 1.5 The Standard does not purport to cover every gas installation (see clause 1. this may be achieved by design or the use of safety controls. be appropriate. They indicate to designers and specifiers that correctly specified and designed installations normally will not leak combustible gases if properly tested and commissioned. This may be obtained from equipment manufacturers or IGEM Consultants listed on IGEM’s website. DSEAR requires the minimisation and early detection of gas leakages together with good local ventilation. Any improvements will need to meet the intent of this Standard. In essence.2 The Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) came into force in December 2002 and the requirements for the preparation of risk assessments to determine any hazardous area classification first took place on 30th June 2003. necessarily.1 This Standard has been drafted by an Institution of Gas Engineers and Managers (IGEM) Panel.

1. training. Amendments to this Standard will be issued when necessary.uk. but not precisely covered by the current text. There should be written procedures defining the extent to which “responsible engineers” can exercise their professional judgement. are allowed to exercise their professional judgement does not allow employers to abrogate their primary responsibilities. they can be adopted without waiting for modification to this Standard.12.igem.9 This Standard makes use of the Notwithstanding Sub-Section 1. it is recommended that due regard be paid to HSG48. the term “must” identifies a requirement by law in UK at the time of publication the term “shall” prescribes a requirement which. 1. 1. Additional advice may be available from the fuel supplier or by referring to Energy Institute (EI) guidance IP15. or people might have acted in a more appropriate manner to avert them. The fact that certain employees. 1. that “responsible engineers” have the skills. Kegworth. The Institution of Gas Engineers and Managers 2 ©IGEM. When “responsible engineers” are asked to undertake tasks which deviate from this they should refer the matter for higher review. “shall” and “should”. Where new and better techniques are developed and proved. it is intended. . experience and personal qualities necessary for the proper exercise of professional judgement have systems and procedures in place to ensure that the exercise of professional judgement by “responsible engineers” is subject to appropriate monitoring and review not require “responsible engineers” to undertake tasks which would necessitate the exercise of professional judgement that is not within their competence. It is therefore necessary to give proper consideration to the management of these human factors and the control of risk. DE74 2DA. Derbyshire.    terms “must”. 26-28 High St.9.IGEM/UP/16 – Draft for Comment available on site and that installations are maintained and inspected as determined by the risk assessment in order to comply with the intent of DSEAR. IGEM House. Employers must:    have done everything to ensure.10 The primary responsibility for compliance with legal duties rests with the employer.11 It is now widely accepted that the majority of accidents in industry generally are in some measure attributable to human as well as technical factors in the sense that actions by people initiated or contributed to the accidents. it is intended. so far as it is reasonably practicable. and reference needs to be made to such statutory legislation or official guidance for information on legal obligations. Website: www. deviation is considered to be acceptable. after prior consideration. or (Health and Safety Executive (HSE) Approved Codes of Practice (ACoPs) or guidance.12 Notwithstanding Sub-Section 1. will be complied with in full and without deviation the term “should” prescribes a requirement which.13 Requests for interpretation of this Standard in relation to matters within the scope.org. 1. for example “responsible engineers”. No advice can be given on hazardous areas for heavier-than-air-gases as they fall outside the scope of IGEM/SR/25 and the test work completed by the Health and Safety Laboratory (HSL). this Standard does not attempt to make the use of any method or specification obligatory against the judgement of the responsible engineer. Such terms may have different meanings when used in legislation. Nonetheless a risk assessment is required and its recommendations complied with. will be complied with unless. and their publication will be announced in the Journal of the Institution and other publications as appropriate. To assist in this. may be addressed in writing to Technical Services.

uk.igem. 3 ©IGEM. Kegworth. IGEM House. Derbyshire. 26-28 High Street. this does not relieve the responsible engineer of any of his or her obligations. DE74 2DA. . Derbyshire.org. If any advice is given by or on behalf of IGEM.14 This Standard was published in xxxxxxx 2010. 1. IGEM House. but in the context that the final responsibility is that of the engineer concerned. 26-28 High St.IGEM/UP/16 – Draft for Comment (IGEM). DE74 2DA and will be submitted to the relevant Committee for consideration and advice. Kegworth. Website: www.

4 ©IGEM. with a combined proportion of methane-plus-inerts of greater than 89% by volume.IGEM/UP/16 – Draft for Comment SECTION 2 : SCOPE 2. 2. IGE/UP/9 and IGEM/SR/25) any part of a meter installation (see IGEM/GM/7B and IGEM/GM/8).20°C to 35°C.org. Note 1: ‘Installation pipework’ includes pipe joints and fittings.1 This Standard covers gas installation pipework. Ambient temperatures are assumed to be in the range . 2. 2. soldered or brazed joints. LFL of not less than 4. 2. IGEM House. (see IGEM/UP/6 and IGEM/SR/25) engines and gas turbines. DE74 2DA. controls and associated gas appliances including appliance connections and pipework with an OP not exceeding 500 mbar installed downstream of the ECV. molecular weight not exceeding 20 kg kmol-1.6 Italicised text is informative and does not represent formal requirements.2 This Standard covers gas installations containing predominantly methane such as Natural Gas. for example.3 The intent of this Standard is to provide basic design information with the principal intent of enabling designers to achieve a gas installation that can be classified as Zone 2 NE and as such will not require the provision of electrical equipment suitable for areas/spaces classified as Zone 1. In these cases consult the fuel supplier or see EI IP-MCSP-P15. . The description of this topic is given in Appendix 3. it refers to all joints other than welded. a temperature range of –20°C to 50°C. Kegworth. Derbyshire. a gross calorific value not exceeding 45 MJ m-3. Note 2: In this Standard where the term ‘joint’ is used.igem.7 Appendices are informative and do not represent formal requirements unless specifically referenced by instruction in the main sections. between pipe risers downstream of the meter installation and the central boiler plant (see Figure 1). It may also apply to parts of common pipework within multi-occupancy domestic premises. 2. 2. (see IGE/UP/3. 26-28 High St.2.uk.8.4%. It applies to all gases. Note: This definition does not cover Liquefied Petroleum Gas (LPG) and LPG/air mixtures nor does it cover bio-gases with a specific gravity greater than 0. including landfill or biogases. 2 or 0.5 Pressures quoted are gauge pressures unless otherwise stated. A description of duties under DSEAR is given in Appendix 3. Website: www.4 The following are not covered by this Standard:     installation pipework downstream of the ECV within a domestic dwelling compressor installations.

uk.org. . IGEM House.igem. Derbyshire. 26-28 High St.IGEM/UP/16 – Draft for Comment FIGURE 1 – SIGNPOSTS TO HAZARDOUS AREA CLASSIFICATION 5 ©IGEM. Website: www. Kegworth. DE74 2DA.

in turn. DE74 2DA. need to be taken into account.org. etc.igem. Website: www. official Guidance Notes and referenced codes.3. Note: 3. . Similar considerations are likely to apply in other countries where reference to appropriate national legislation is necessary. HEALTH AND SAFETY AT WORK ETC. It places general duties on such people to ensure. so far as is reasonably practicable.2 DSEAR require the responsible person for the premises to co-operate with others working on the site to share safety information relating to the safety of the gas installation. IGEM House. such as the use of electrical equipment certificated for use in hazardous areas) are required. Note: Appendix 2 is relevant in this respect. are caused by dangerous substances. 3. the self-employed. DSEAR identifies requirements for the preparation of risk assessments to determine any hazardous area classification. etc. Derbyshire.3. This applies retrospectively to relevant installations within buildings from 30th June 2006. etc. as well as the owners of premises. 3. employers are required to classify places at the workplace as “hazardous” (that is. The responsible person then has to determine whether protective measures (for example. suppliers.uk.1 This Standard is set out against a background of legislation in force in the UK at the time of publication. Where British Standards. employees.4 The assessments given in Appendix 4 are intended for:  gas appliances and burners designed and produced to meet current British Standards Institution (BSI) or IGEM specifications as appropriate. Kegworth. Note: 3. are quoted. safety and welfare of employees and the health and safety of members of the public who may be affected by the work activity. DSEAR is an expansion of the general duty to manage risks under the Management of Health and Safety at Work Regulations (MHSWR) and require good practices that reduce risk to persons from explosions and fires etc. the health. 6 ©IGEM. designers. ACT (HSWA) HSWA applies to all persons involved with work activities.3 DANGEROUS SUBSTANCES REGULATIONS (DSEAR) AND EXPLOSIVE ATMOSPHERES 3. equivalent national or international standards. Any person engaged in the preparation of a risk assessment of gas installations with respect to DSEAR must be suitably competent.IGEM/UP/16 – Draft for Comment SECTION 3 : LEGAL AND ALLIED CONSIDERATIONS 3. All relevant legislation must be applied and relevant ACoPs. it is essential that the “equivalent standard” will achieve at least the same level of gas integrity and acceptable risk to life and property.3. manufacturers.1 DSEAR require the responsible person for the premises (the “employer”) to perform a risk assessment of each part of the gas installation to determine whether or not there are risks of gas leakage leading to potentially explosive atmospheres.  typical gas installations that are installed. which. where explosive atmospheres may occur) or “nonhazardous” areas. standards. tested and maintained to current IGEM and BSI standards (see Appendix 2).3. etc. equally may be appropriate. 26-28 High St.3 It is recognised by the gas industry and the HSE that it could be helpful to provide generic risk assessments and other information to site operators and installers.2 With particular respect to standards quoted. including employers. Furthermore. 3.

Note: GS(I&U)R do not apply to certain premises (see HSL56 Guidance Notes 28 and 29). so that such faults can be rectified before further use. It is recognised that not all existing installations installed before 1st January 2011 will comply with this new advice.4. Kegworth. 3.org. In particular.2 GS(I&U)R place responsibilities on those installing. If any serious fault is found.igem. to be an “approved class of person”. pipework. service or maintenance or safety is a member of an approved class of persons and is competent to carry out such work.1 GS(I&U)R are relevant statutory provisions of HSWA setting out general and detailed requirements dealing with the safe installation. 3. Derbyshire. explosions and similar energy releasing events. the principles of GS(I&U)R need to be applied.4.6 This publication provides information relating to those risk assessments for wellengineered gas installations.3. where they do not apply. arising from dangerous substances (chemical agents) and the explosive atmospheres created by those substances.IGEM/UP/16 – Draft for Comment 3. as well as suppliers and users of gas. as well as the user. servicing. including gas fittings. for example exothermic chemical reactions. etc. for example Gas Safe registered. appliances and flues. routine checks (carried out at least annually) for the presence of combustible gas should be recommended.uk.4. maintenance and use of gas systems. the conclusions of the Risk Assessment need to be applied and complied with. the landlord or hirer has special responsibilities to ensure that any installer they use for the gas fitting. Website: www. maintaining or repairing gas appliances. .4. IGEM House.4 GAS SAFETY (INSTALLATION AND USE) REGULATIONS (GS(I&U)R) 3.3 GS(I&U)R define the type of work that requires persons carrying out such work. These requirements indicate whether equipment certified for use in a hazardous area should be considered or applied. DE74 2DA. In these cases. 3. 26-28 High St. 3.4 The installer must check the safety of any appliance or pipework they install or work on and take appropriate action where they find faults. 7 ©IGEM. 3. Where the premises are let or hired out.5 DSEAR deals with fires. or their employers.3. However. the installer must inform both the landlord/hirer..

5 The gas system designer. of less than 0. 4.2.1.2.org.2 The UK gas industry’s past safety record indicates that properly installed. DE74 2DA.1.3 CONTAINMENT 4. However HSE publish a simple guide called "5 Steps to risk assessment" (INDG613) and the appendices of this Standard use that simpler format as a guide to what actions and precautions may be required to be put into place when assessing flammable gas installations. 4. for example regulator diaphragm rupture or fractured pipe. 4.3 This Standard uses assumptions made to enable a simplified approach for hazardous area classification for installation pipework. 4.2 One of the duties under DSEAR is that the site occupier must prepare and keep up to date risk assessments for flammable gas installations on the site. In association with sensitive tightness testing procedures as given in IGE/UP/1.1. It has an ignition temperature of approximately 450oC.8. the equipment manufacturer and installer are often best able to advise companies on the content of the Risk Assessments (see Section 8 and Appendix 3 and 4). IGE/UP/1A and IGE/UP/1B. 4. Thus work procedures will often require the preparation of specific risk assessments to ensure the safety of the work. In the UK these are encompassed in IGEM/UP/2 and BS 6891.igem.1 INTRODUCTION 4. pipework systems can be adequately validated for gas tightness from new and during their lifetime. explosions and similar events in the workplace.1.3 There are many methods of producing these assessments and detailed advice can be found in IGE/SR/24.2 RISK ASSESSMENTS 4. 4. Derbyshire. 4. 8 ©IGEM. is normally an odorised methane based gas with a specific gravity. These assessments will often be prepared during the design and construction stages of a project and should then be checked and verified prior to commissioning. this includes members of the public who may be put at risk by work activity.2. 4.5 A simplified overview of the various terms used within the gas industry in relation to hazardous areas are given below.1 Gas as defined in the scope.4 It is the responsibility of the occupier to ensure the risk assessments are competently completed and kept under review as site changes occur. . 26-28 High St. to enable a Zone 2 NE to be adopted whenever possible.2. 4.3. For more detailed information see IGEM/SR/25. 4.1 Dangerous substances can put peoples’ safety at risk from fire and explosion.1. Website: www. DSEAR puts duties on employers and the self-employed to protect people from risks to their safety from fires.uk. IGEM House.1 Gas pipework standards have been developed in the UK and elsewhere over many years with the objective of long-term safe containment. tested and maintained equipment does not pose significant explosion risks. Kegworth.IGEM/UP/16 – Draft for Comment SECTION 4 : CONSIDERATIONS OF RELEVANCE TO DETERMINATION OF ZONE CLASSIFICATIONS THE 4. compared to air. They should form part of the overall site risk assessment.4 This Standard does not address either Continuous or Primary Grade release or catastrophic failure.2.

joints and fittings may not generate a hazardous area of Zone 2 classification. Further information is provided on the detail of designs in IGEM/UP/2 and IGE/UP/10.025 mm2 is used for calculation purposes  for pipework with OP between 101 mbar and 500mbar a leak size equivalent to that which would escape from a hole of 0. IGEM House. solvents. not only to reduce electric shock risk to persons. Note: Zone 2 NE is defined as an area in which an explosive atmosphere consisting of a mixture with air of gas. Derbyshire. For the purposes of this Standard the following categories shall be used:  for pipework with OP up to 100 mbar a leak size equivalent to that which would escape from a hole of 0. but to also reduce any dangers of sparking due to electrical faults leading to ignition of any gas leakage.uk. corrosive substances in the local atmosphere. The resultant ignition if it did occur would be such that it would be unlikely to injure persons or seriously damage buildings. 26-28 High St.2 The guidance in this Standard is provided to assist the designer to determine if the design could be classified as Zone 2 NE.5 ELECTRICAL DISCHARGES Metallic gas pipework systems are required to be cross bonded to earth. this Standard uses the term “Notional Leak Size”. vapour or mist is not likely to occur in normal operation. Such equipment will not be found on typical appliances. Website: www. for example flammable dusts.5 mm2 is used for calculation purposes.3. Note: In this respect NE refers to negligible extent as described in BS EN 60079-10-1.org. This may be relevant to some shaft seals and flexible pipes used on reciprocating machines. DE74 2DA. 4. will exist for a short period only and would be of negligible extent. located in an adequately ventilated area and is well maintained. Designs not meeting the requirements for Zone 2 NE will normally require the use of electrical equipment suitable for use in a zoned area and a more detailed analysis and risk assessment by competent persons.2 In considering leakage rates from joints and fittings. . 4.3. Kegworth.IGEM/UP/16 – Draft for Comment 4. 4.6 PRESENCE OF OTHER HAZARDS Modern gas installation standards require designers and installers to consider the overall safety of the system using risk assessment techniques. This size is also used for those installations with OP not greater than 100 mbar where there are vibration issues to be considered  for pipework with OP between 101mbar and 500mbar where there are vibration issues to be considered a leak size equivalent to that which would escape from a hole of 2. Where this is not the case.. nor on typical burner systems. however caused. Joints and other leakage sources will however always generate a Zone 2 NE classification. etc.4 ZONING 4.25 mm2 is used for calculation purposes. 4. Note: This larger hole size is applicable where the vibration is such as may lead to premature failure.igem. then the classification of the Zone will be at least Zone 2 and consideration shall be given to the seeking of more specialist advice.3. It is important however. These considerations are mostly from a viewpoint of combustion and explosions associated with gas leakage with respect to the safety of the structure and of persons. 9 ©IGEM. The intention is to have problems designed out before construction. kilns and furnaces. to consider the existence of hazards from other sources.1 Work by HSL and subsequent considerations within IGEM/SR/25 have indicated that low pressure gas pipework. but if it does occur. Non-metallic gas pipework is not normally permitted above ground inside buildings. This classification of Zone 2 NE assumes that the pipework and associated controls have been designed and installed to recognised Standards such as IGEM/UP/2.

4. soldered or brazed joints) or potential gas leakage source shall be provided. . changes shall not be made to any pipework installation or the nearby environment that may adversely affect the assessment as Zone 2 NE. It may also mean that an installer will be prohibited from purging the system to gas. DE74 2DA. This may form part of a Permit to Work system.2 To achieve Zone 2 NE. by the use of lower gas pressures.3 A zone of negligible extent is not the same as a safe area.7. Such release must not lead to danger to persons or property.uk. This may include for example. it may be that a zone of negligible extent becomes more onerous if ventilation is reduced during modifications to buildings.IGEM/UP/16 – Draft for Comment 4. Kegworth. 4. generally. 4. In cases of larger plant.4 For existing installations. Derbyshire. adequate local ventilation around every gas pipe joint (other than welded.7.7. a small controlled amount of flammable gas may be released during work into a well-ventilated environment. 10 ©IGEM. changes to the structure where the change may affect ventilation air flows. 4.7. even though neither requires action with regard to potential ignition sources. before the workplace is used.9. The employer must ensure that the person(s) who carries out the verification is competent to consider the risks in the space and to determine the adequacy of the safety measures in order to ensure explosion safety. for example. Website: www. Confinement and congestion will normally restrict the availability of ventilation which may restrict the possibility of achieving a Zone 2 NE classification unless other measures are taken. written schemes of operational and maintenance methodologies are.8 COMMISSIONING DSEAR and the GS(I&U)R require that any gas installation is verified as being safe before first use. IGEM House.7 DESIGN 4. Consideration must be given to the adequacy of ventilation and removal of sources of ignition before and during maintenance.9 SAFE MAINTENANCE 4. commissioned and maintained. the employer must ensure that work equipment in the hazardous area is safe. collectively. Protective systems in use within these areas must be ‘safe’ for use. If a workplace contains areas that are.9.igem. 26-28 High St. classified as hazardous under Regulation 7(1) of DSEAR. addition of a boiler. These actions. for example when changing a small solenoid valve in a burner gas train. 4. essential. In some cases. altering ventilation. are termed “verification”.1 The uncontrolled release of flammable gas during work is not permitted by Health and Safety legislation and the GS(I&U)R. Where this is not achieved it will be necessary to consider the Zonal classification which in turn will require the use of equipment that minimises the provision of an ignition source. or will be.2 Designers and employers are duty bound to ensure that any gas pipework system and plant/equipment can be safely installed. In particular.1 The initial design of the complete gas system downstream of the ECV needs to be such that as far as practicable it can be classified as Zone 2 NE. 4. increased local ventilation or more frequent inspections.org. and work activities may need to be detailed so that they can be carried out safely.

Website: www.10. a large warehouse or a boiler house might only have a small local gas pipe and an appliance in one corner and only require local ventilation. For example. welded and brazed pipework will thus have a major design advantage over jointed systems using screwed.10. Equally more frequent maintenance visits may be required.org. 4.1 The objective of the ventilation is to provide local air movement in all positions where a pipe joint or leakage source is located to provide good dispersion of any leaking flammable gas. Thus any space above the highest ventilator location will be less well served for dilution ventilation.5 In very congested areas. Kegworth. Soldered.10.3 Most natural gases being lighter-than-air will rise to a high point in a space.10 VENTILATION 4. even well designed natural ventilation may not be enough to attain classification as Zone 2 NE. 4. Derbyshire. DE74 2DA.4 As far as practicable for natural ventilation. In this respect IGEM/UP/2 precludes the use of threaded pipe joints above 50 mm nominal bore for pressures below 500 mbar. IGEM House. 11 ©IGEM. the preferred design solution is for ventilation grilles to be located on all four walls and at both high and low levels.IGEM/UP/16 – Draft for Comment 4.2 Air change rates in themselves can be misleading since a large room with a low air change rate could have the same air flow for dispersion of a leak as a small one with a high air change rate. 4.igem. flanged or mechanical joints.uk.10. 26-28 High St. . Similarly a small volume boiler space could be densely packed with boilers and pipework requiring intensive ventilation and good air flows throughout. This is not always possible for smaller installations and thus in the design of the pipework greater use of welded systems may be preferable. Additional measures will need to be applied if there are joints/leakage sources above the highest ventilation location. 4.10.

those installing gas installations will be the link on gas safety for the gas consumer. In addition the following shall be considered during the design and subsequent installation.igem. Kegworth. to ensure adequate ventilation and to provide access for inspection and maintenance. 5.1. consideration shall be given to the provision of artificial ventilation with flow interlocks and automatic shut-off valves (AIVs).4 Ducts (above ground level) and small spaces may be classified Zone 2 NE provided they have an internal volume not less than 10 m3 and adventitious ventilation.3). As such. Where this is not practicable. 12 ©IGEM. 5. which is above 0. This level of ventilation can generally be provided by adventitious ventilation and will be available in most habitable rooms. Therefore adopting all welded/brazed or soldered construction and or thicker walled pipework. Where this is not practicable. the provision of artificial ventilation with flow interlocks and automatic shut-off valves (AIVs). Derbyshire. For internal volumes below 10 m3. DE74 2DA. The installation shall comply with IGEM/UP/2. such as increasing the ventilation to levels given in Table 1. with grilles of not less than 100 cm2 total free area.2 In un-obstructed locations. 5. the areas around new pipework joints may need to be classified as Zone 2 with a discrete zoning distance. are not conversant with the implications of DSEAR. corrosion resistance materials and freedom from adverse conditions will be a major advantage.1 DESIGN AND INSTALLATION 5. additional ventilation shall be provided. the areas around the pipework joints with an OP not exceeding 500 mbar may be classified as Zone 2 NE provided they are in a space having reasonable ventilation.1. .3 In congested or confined locations (see Sub-Sections 5. or the provision of gas detection alarm systems.IGEM/UP/16 – Draft for Comment SECTION 5 : INFORMATION FOR COMMERCIAL INSTALLATION DESIGNS AND INDUSTRIAL It is recognised that many site occupiers. The areas around existing pipework joints will be allocated a Zone 2 classification unless additional measures are taken to permit a Zone 2 NE classification. the contents of the forms given in Appendix 4 should be used as guidance when producing a standard notice which may be handed to gas consumers on completion of work. preferably externally. responsible persons etc. which is above 0.org.5 air changes per hour. 5.1. each of not less than 100 cm2 free area shall be installed near to each joint location and either at each end of the duct or on each of the perimeter walls if it is a ceiling space. Website: www.1.uk. Consequently. IGEM House. or monthly checks of the environment for lack of gas leakage with a combustible gas tester (or a combination of these measures).5 air changes per hour.1. Where the OP is above 100mbar apply other options below or see IGEM/SR/25. 26-28 High St. if ever visited. Horizontal ceiling-level ducts and spaces containing gas pipework with an OP not exceeding 100 mbar shall be ventilated. additional ventilation may be needed to ensure the air change rate is above 0.5 Where pipework is located in below ground spaces such as basements or rooms that are rarely. 5. the provision of gas detection alarm systems.5 air changes per hour. appliance plant rooms and enclosures meeting IGE/UP/10. grilles. or monthly checks of the environment for lack of gas leakage with a combustible gas tester.2 and 5.1 During the design it is important to minimise the number of joints.

leading to a larger gas cloud volume than expected based on the enclosure ventilation rate and the gas release rate.2. In such cases an assessment of the degree of local ventilation in comparison to the leak size is difficult and therefore Zone 2 rather than Zone 2 NE will generally need to be applied and reference needs to be made to IGEM/SR/25.AN EXAMPLE OF PIPEWORK LAYOUTS SHOWING PREFERRED PIPE LOCATIONS FOR ZONE 2 NE CLASSIFICATION 13 ©IGEM. which means that a leak located in the corner of an enclosure (where two walls and the floor meet. say a boiler is within 1 m of the two walls and the floor. Zone 2 NE cannot apply to yellow pipe joints behind and to the left of the obstruction (red cross-hatched area).uk. <1 m Clearly a Zone 2 area cannot impinge on a boiler.2. say 50 mm from the wall and the floor.3 In the design in Figure 2.2 If the leak location is close to three to more significant obstructions. The pipe is. 5. 26-28 High St. In this case. DE74 2DA. see Figure 2) will be confined.1 A confined leak location is one where the presence of nearby obstacles can lead to the initial high momentum of the jet release being reduced and the gas jet re-entraining flammable gas. for example walls then the space around the leak location should be described as confined. < 1m boiler FIGURE 2 . Website: www. 5. An option would be to install ventilator grilles as Table 1 in the space behind and to the left of the boiler to improve local ventilation or to fit a small air moving fan.igem.2 CONFINED INSTALLATION 5. The floor will often count as one of the obstructions. IGEM House. Zone 2 NE can only apply to the pipe clear of the obstruction (tan coloured pipes).IGEM/UP/16 – Draft for Comment 5. Derbyshire.org. as shown by the yellow ochre pipe location so that Zone 2 NE can be applied.2. the obstruction. its controls and burner flames so within the initial design the pipes will have to be moved if joints exist. . Kegworth.

Note 3: Columns 1 and 2 only apply to occupied or regularly visited spaces or external areas. a gas leak would be detected at an early stage. see IGEM/SR/25. 10% LEL High and low level vent grille free area in each wall cm2 290 445 630 770 885 1090 1250 High and low level vent grille free area in each wall cm2 400 620 880 1075 1240 1520 1760 m3 h-1 11.4%.150 151 .3 45. Note 2: For installations above with OP above 0. 2 One wall*1 High and low level vent grille free area in each wall cm2 30*2 47*2 65*2 High and low level vent grille free area in each wall cm2 42*2 65*2 91*2 *1 *2 *3 Notional Leak Size (See Sub-Section 4.63 6m .5 bar. In each case a 70kW boiler will have larger air requirements. Note 4: Figures are based upon IGEM/SR/25 buoyancy calculations with ventilators 2 m vertically apart.58 For ‘all-wall’ or ‘all-door’ ventilation.5 mm2. For vibrating environments where vibration is such as may lead to component/pipe failure use notional leak size of 2. use full height of ventilation grille. TABLE 1 – ZONE 2 NE NATURAL VENTILATION REQUIREMENTS 14 ©IGEM. Ventilation should be divided in the walls and approximately 1/3rd at high level and 2/3rd at low level. 26-28 High St. For other vertical height differences.82 4m .41 3m .25mm2 3 4 5 6 More than one More than one One wall*1 Air flow for wall.500 0.0.2) 0.org.100 101 .igem.5mm2 7 One wall*1 High and low level vent grille free area in each wall cm2 12500 17800 21700 25100 30700 35400 39600 8 Air flow for 10% LEL m3 h-1 114 182 250 318 368 450 520 Ventilators should where possible be spread on more than one wall.2 25 31.50 51 . centre to centre.8 36.200 201 . multiply free areas by factor: 1m – 1.4 52.0. These figures can only be used in areas which are regularly visited and as such.400 401 .4 18.300 301 . IGEM House.uk. DE74 2DA.2 High and low level vent grille free area in each wall cm2 8950 12700 15500 17900 21900 25300 28300 2.025mm2 1 More than one wall. Derbyshire. Note 1: Assumes Natural Gas with an LEL of about 4.0. Kegworth.7 5m – 0.IGEM/UP/16 – Draft for Comment   Pressure (mbar) 21 . . wall. Website: www.

5. . In such cases.4. In cases that are initially identified as congested.4. Kegworth. IGEM House.4.1. assuming that other requirements are met. see IGE/UP/10. For pipework within roof or loft spaces the ventilation shall comply with Table 1. may not be described as confined if there are no (or very few) large scale obstructions to the ventilation flow in that area. FIGURE 3 – EXAMPLE OF AN INSTALLATION WITH CONGESTED LEAK LOCATIONS 5. High level vents should be as high as practicable.uk.3 CONGESTED INSTALLATION A congested leak location is one where there is a significant amount of small scale obstacles that compromises the ventilation flow rate through that area. but not confined. provision for additional ventilation shall be provided in the design typically to achieve at least 0.5 air changes per hour.4 VENTILATION 5. 15 ©IGEM.4 for design information and IGEM/SR/25 where the MOP exceeds 100 mbar.igem. Note: See clause 6. while congested. it shall be enhanced by the use of interlocked mechanical ventilation to ensure Zone 2 NE remains applicable. 5. DE74 2DA. The ventilation should be on all four walls of the space where possible. then Zone 2 NE may be applicable. It is possible that such an area.5 changes per hour. There shall be adequate gas safety ventilation to dilute any potential leakage to below 10% LEL for pipework with an OP below 100 mbar and which is located in a space:   above a false or suspended ceiling within a room or below a suspended floor. the use of artificial smoke or modelling).1 As far as reasonably practicable the air change rate for spaces containing gas pipework shall be greater than 0. the ventilation shall be located to provide good air distribution throughout the space and especially where the pipework is located.IGEM/UP/16 – Draft for Comment 5.3 It is recognised that the ventilation levels given in this Standard may not be adequate for safe working within the spaces and when the space is visited for working.org. it is possible that by further investigation (for example through tracer gas techniques. 26-28 High St.2 Where good internal air movement cannot be provided by natural ventilation. Website: www. Derbyshire. it may be possible to demonstrate that the leak location is in fact reasonably well-ventilated. Where this is not possible.

DE74 2DA.IGEM/UP/16 – Draft for Comment 5. A diagonal upward flow is a preferred option. 26-28 High St. Website: www. Kegworth.uk. .4 In mechanically ventilated spaces there should be good mixing of the air and any potential gas leakages to avoid dead spaces and re-entrainment of gas into the dispersing gas/air mixtures. 16 ©IGEM. Derbyshire. Good mixing is promoted by a lack of congestion in the location of pipe joints.org.4. proper sizing and disposition of ventilation grilles to ensure air movement across the potential leak locations.igem. IGEM House.

If the fans are in continuous operation see Sub-Section 6.5 Could be Zone 2 NE See Question 13a Could be Zone 2 NE See Question 14a See IGEM/SR/25 Classify and maintain as Zone 2 NE Install ventilation in accordance with Table 1 for the space to be classified and maintained as Zone 2 NE See IGEM/SR/25 See IGEM/SR/25 TABLE 2 .org.5 changes per hour? Could be Zone 2 NE See Question 3a Classify and maintain Zone 2NE Could be Zone 2 NE See Question 4a See Question 6a See Clause 6.1. . Kegworth.2.4 See Question 9a See IGEM/SR/25 Could be Zone 2 NE See Question 11a Could be Zone 2 NE See Question 12a See Clause 6.3 Could be Zone 2 NE See Question 8a Could be Zone 2 NE See Question 10a Could be Zone 2 NE See Question 10a See IGEM/SR/25 See Question 4a See Clause 6. In many cases the installed ventilation will be in excess of these sizes to satisfy standards such as BS 8313 and IGE/UP/10.3 See Question 7a Could be Zone 2 NE See Question 7a See Clause 6.1 NATURAL VENTILATION The following is a guide to a good Zone 2 NE compliant design.1.PRELIMINARY ASSESSMENT FOR ALL PIPEWORK 17 ©IGEM.1 General Pipework QUESTION 1a Does the fuel gas being used have a SG below 0.8? ANSWER YES NO Could be Zone 2 NE See IP15 See Question 2a Note 1: SG of Natural Gas is 0.IGEM/UP/16 – Draft for Comment SECTION 6 : SYSTEM DESIGN CHECKLIST FOR ZONE 2 NE COMPLIANCE 6. is it in good condition and is the area regularly visited to detect any smells of gas? Is the pipework free of vibration that might lead to failure? Is the area visited in which the pipes/joints are located visited more often than once per month? Is the ventilation well distributed as far as practicable around the walls? Is the ventilation well distributed at high (within 15% of the height of the room from the top of ceiling) and low level (within 1 m floor)? Is the ventilation over 0. 6. DE74 2DA.igem. Derbyshire. Website: www.1.1. Advice from the gas supplier could also be sought.6. Note 2: IP15 is produced by the Energy Institute and may not contain enough practical advice as given in the standards for Natural Gas. The information provides the minimum ventilation required for DSEAR compliance. 2a Is the pressure below 100 mbar? 3a Is the space an external space with no obstructions/congestion? Is the space an open internal space such as a room or boiler house? Is the space in a room but above the location of the high level ventilation? Are there any pipe joints located above the high level ventilation grilles? Is the space greater than 10 m3 volume? 4a 5a 6a 7a 8a 9a 10a 11a 12a 13a 14a Are all pipe joints more than 1 m from 3 surfaces? If existing installation with OP below 100 mbar.uk.1. IGEM House. 26-28 High St. The requirements and limitations are the same for mechanical ventilation and the tests assume the ventilation fan is turned off.

1 It is known the space is an internal space (above ground) such as a ceiling space or duct. Note: External ventilation is always preferred.IGEM/UP/16 – Draft for Comment 6.org. 26-28 High St. 18 ©IGEM. Note: The above action enables the space to be classified and maintained as Zone 2 NE.1. If appropriate ventilation (see above) is in place the space shall be either checked for leakage on a:   6 monthly basis or 12 monthly basis if a gas detection alarm is fitted. QUESTION 1b Is the pressure below 100 mbar? 2b Is the space a horizontal service duct or ceiling void above a room? 3b Is the space a vertical service duct? 4b Is it possible to fit at least 100 mm2 free area ventilators at each end of the duct to the outside air or smoke safety ventilation according to BS 8313? 5b Is it possible to fit only high level ventilation? 6b Is the space a roof void? ANSWER YES NO Could be Zone 2 NE See IGEM/SR/25 See Question 2b Take action as See Question 3b required by clause 6.2. Note: For underground ducts.to enable the space to be classified and maintained as Zone 2 NE See Question 4b See Question 6b Ensure the space is checked for leakage on a 12 monthly basis for the space to classified and maintained as Zone 2 NE Ensure the space is checked for leakage either on a 6 monthly basis or 12 monthly basis (If gas detection alarm fitted) for the space to classified and maintained as Zone 2 NE Install ventilation in accordance with Table 1 for the space to be classified and maintained as Zone 2 NE See Question 5b See IGEM/SR/25 See IGEM/SR/25 TABLE 3 – ASSESSMENT FOR PIPEWORK IN CEILING SPACES OR DUCTS 6.1.2 Pipework in Ceiling Spaces or Ducts 6.2.2. . or. see IGEM/SR/25. Derbyshire.uk. Kegworth.2 For horizontal service ducts or ceiling voids above a room either fit 100 mm2 free area ventilators:   at each end of the duct to the outside air. DE74 2DA.1. IGEM House.igem. into the room at each pipe joint location and 100 mm2 free area ventilators on the 4 perimeter walls. preferably on all four walls.1.2. Website: www.

DE74 2DA.4 YES Could be Zone 2 NE See Question 2c Install ventilation then classify and maintain space as Zone 2 NE Classify and maintain space as Zone 2 NE PIPEWORK IN NO No need to classify space.ASSESSMENT FOR WITHIN ROOMS 6. QUESTION 1c 2c 3c ANSWER Are there are any pipe joints or potential sources of leakage in this area? Is it possible to install high level ventilation to the open air in accordance with Table 1 above the joints? Can the space be checked for leakage either on a 6 monthly basis or 12 monthly basis (If a gas detection alarm fitted)? TABLE 4 .1. Website: www. .igem. 26-28 High St.IGEM/UP/16 – Draft for Comment 6.3 High level spaces within rooms The space is in a room and above the location of the high level ventilation.1. QUESTION 1d Is the space is below 10 m3 nett volume? 2d Is the pressure below 100 mbar? 3d Is it possible to install high level ventilation to the open air in accordance with Table 1 above the joints? ANSWER YES NO Enlarge the space Could be Zone 2 NE and see Question 2d See Question 2d or To classify and maintain the space as Zone 2 NE. IGEM House. Could be Zone 2 NE See IGEM/SR/25 See Question 3d Install ventilation in See IGEM/SR/25 accordance with Table 1 and ensure the space is checked for leakage on a 6 monthly basis for the space to be classified and maintained as Zone 2 NE TABLE 5 – ASSESSMENT FOR PIPEWORK IN SMALL SPACES 19 ©IGEM. either fit full size ventilation on largest wall practicable or perform leakage checks on a monthly basis. Derbyshire. Kegworth.org. Could be Zone 2 NE See Question 3c HIGH See IGEM/SR/25 LEVEL SPACES Small spaces The space is known to be less than 10 m3 in nett volume.uk.

ASSESSMENT FOR GAS BOOSTER INSTALLATIONS 20 ©IGEM. 26-28 High St. . Website: www.IGEM/UP/16 – Draft for Comment 6. If pressure surges/pulsations occur at lower flows.org.uk. DE74 2DA. see IGEM/UP/2.1. Kegworth. IGEM House.igem. Is it possible for the space to be checked for leakage on a 6 monthly basis and the booster annually maintained by a competent person? Classify and maintain as Zone 2 NE See IGEM/SR/25 TABLE 6 . Derbyshire.5 Gas Booster installations QUESTION ANSWER 1e Is the outlet pressure below 100 mbar? 2e Does the ventilation exceed the value given in Table 1 for 0.25 mm2 notional leak size? Is there excessive vibration? 3e Note: 4e YES Could be Zone 2 NE See Question 2e Could be Zone 2 NE See Question 3e Could be Zone 2 NE See Question 4e NO See IGEM/SR/25 See IGEM/SR/25 See IGEM/SR/25 Vibration will not normally be a problem with centrifugal fan boosters.

IGEM/UP/16 – Draft for Comment 6. DE74 2DA. 26-28 High St. ARE .1.1.6. Advice from the gas supplier could also be sought.3 See Question 14f See IGEM/SR/25 TABLE 7 . QUESTION 1f ANSWER Does the fuel gas being used have a SG below 0.5 changes per hour? Is it possible to fit high and low in accordance with Table 1 and for the space to be check for leakage on an annual basis? Could See Could See be Zone 2 NE Question 3f be Zone 2 NE Question 5f See IGEM/SR/25 Could be Zone 2 NE See Question 5f Classify and maintain Zone 2 NE Could be Zone 2 NE See Question 7f See IGEM/SR/25 Could be Zone 2 NE See Question 8f Improve local ventilation/air movement then see Question 8f See Question 10f See Question 9f See Clause 6. Website: www.uk.org.3 Could be Zone 2 NE See Question 11f Could be Zone 2 NE See Question 12f Could be Zone 2 NE See Question 13f Classify and maintain as Zone 2 NE Classify and maintain as Zone 2 NE See Question 4f See Question 6f See IGEM/SR/25 Could be Zone 2 NE See Question 10f See Clause 6. Derbyshire. Kegworth.5 See Question 12f See Clause 6.8? YES Could be Zone 2 NE See Question 2f NO See IP15 Note 1: SG of Natural Gas is 0.igem. Note 2: IP15 is produced by the Energy Institute and may not contain enough practical advice as given in the standards for Natural Gas.ASSESSMENT FOR INSTALLATIONS WHICH CONTINUOUSLY VENTILATED BY MECHANICAL MEANS 21 ©IGEM.2 CONTINUOUS MECHANICAL VENTILATION The following is a guide to ensure a Zone 2 NE compliant design. IGEM House. 2f Is the pressure below 100 mbar? 3f Is the mechanical ventilation interlocked with an alarm system or an automatic isolation valve? Is it possible to fit an AIV and interlocks (see IGE/UP/10)? Is the space an external space with no obstructions/congestion? Is the ventilation well distributed as far as practicable to provide air movement over all joints? Is the pipework in non-congested areas with free ventilation? 4f 5f 6f 7f 8f 9f 10f 11f 12f 13f 14f Is the space in a room but above the location of the high level ventilation? Are there any pipe joints located above the high level ventilation grilles? Is the pipework free of vibration that might lead to failure? Is the area visited in which the pipes/joints are located visited more often than once per month? Is there high level ventilation (within 15% top of ceiling)? Is the ventilation over 0.1.

is not faulty. The site technical file shall indicate which pipework is classified as Zone 2 NE. 22 ©IGEM. Note: For more information see IGEM/UP/2. . Simple overview checks for leakage may be made by smell. where considered necessary an interval of 5 to 10 years should be adequate.igem. IGEM House. All work on gas systems shall be performed wherever practical under gas-free conditions. Kegworth. as determined necessary. 26-28 High St.IGEM/UP/16 – Draft for Comment SECTION 7 : MAINTENANCE The section on ‘ongoing controls’ in the generic risk assessments (see Section 8 and Appendix 4) emphasises the need to ensure that gas metering pipework. Physical tightness testing of existing rigid pipework should not normally be necessary.uk. Website: www. However. The maintenance shall also ensure that the design ventilation continues to be provided. as may be required.org. DE74 2DA. installation pipework and appliances. are correctly maintained during the life of the installation. the leak tightness of the gas installation as a whole. Maintenance procedures for leakage should be by using leak detection fluid (LDF) or by the use of hydrocarbon detection instruments (parts per million by volume gas detectors) or by tightness testing. a competent person is required to set down the recommended procedures for validating. Pipe sections and components and the areas around vents and breathers which are classified Zone 2 or higher shall be detailed on site plan and elevation drawings. together with their ancillaries. remains correctly interlocked. Where ‘gas-free’ conditions cannot be achieved it must be ensured that any release of flammable gas cannot lead to hazardous conditions. In such cases it should not be necessary to use ‘spark-free’ tools. At the design stage. Derbyshire. and has not been blocked up.

when a leak does occur. Derbyshire.igem.1. etc. However.. They should also be installed at the boundaries of the hazardous areas.3 In cases where the generic assessments are not considered to cover all the sitespecific details.2 The generic risk assessments for gas installations of OP not exceeding 500 mbar show that there should be no safety issues for typical well-installed installations using materials and appliances that are “fit-for-purpose”. ultimately. the area can be classified as “Zone 2 NE”.IGEM/UP/16 – Draft for Comment SECTION 8 : GENERIC RISK ASSESSMENTS 8. such as other external hazards. especially with respect to the use of electrical equipment. It is.4 It is important that gas installations are properly maintained and checked for no gas leakages on a regular basis by competent persons to ensure the continuing safety of the installation.2 The provision of ATEX EX sign(s) in areas where Zones of negligible extent (Zone 2 NE) have been determined is optional. 8. DE74 2DA. 23 ©IGEM. 8.uk. Kegworth. where it is assessed that this will enhance safety. it will be necessary to consider the wider safety implications of the installation in the risk assessment. For such installations.org. This will depend upon an assessment of whether the purpose-provided ventilation could become deliberately or inadvertently reduced.1 RISK ASSESSMENT 8. Such assessments shall be reviewed prior to any site modifications and on completion of the modifications.1.2. Where natural ventilation of a space is applied the classification of the space as “Zone 2 NE” may not be appropriate.1.2. .2. leakage will normally be negligible and natural ventilation should dilute leaks to below the flammable range in the immediate vicinity of the leak. Where 'poor' ventilation is suspected. 8. Typical generic risk assessments are given in Appendix 3. 8. The fact that any area has been designated Zone 2 NE shall also be recorded together with information of the person performing such assessments and judgements. danger from mechanical damage. For this reason new gas installation pipework shall not be installed in unventilated or 'poorly' ventilated areas. lack of maintenance.1 DSEAR requires that a risk assessment is performed on all commercial and industrial gas installations to ensure their safety. further advice should be sought where the ventilation cannot be improved. IGEM House. 26-28 High St. the responsibility of employers to ensure that the appropriate equipment is used by their employees and installed within the premises under their control. 8.1 The risk assessments shall be securely stored in a site technical file. Website: www.2 SITE RECORDS AND SIGNAGE 8.1.3 Access points into sites where hazardous areas exist should be marked with the ATEX EX sign. 8.

org. UNITS AND SYMBOLS GLOSSARY All definitions are given in IGEM/G/4 which is freely available:   as a CD. DE74 2DA. Kegworth. Website: www.uk.org. upon request by downloading a printable version from IGEM’s website. ACRONYMS AND ABBREVIATIONS ACoP ATEX AIV BSI CE DSEAR ECV EI EU EX GB GS(I&U)R HSE HSL IGEM LDF LEL LFL LPG MOP NE NG OP SG UK Approved Code of Practice Atmosphere explosive (Directive 95 & 137) automatic isolation valve British Standards Institution A mark affixed to components to indicate compliance with relevant European Directives Dangerous Substances and Explosive Atmospheres Regulations emergency control valve Energy Institute European Union explosive Great Britain Gas Safety (Installation and Use) Regulations Health and Safety Executive Health and Safety Laboratory Institution of Gas Engineers and Managers leak detection fluid lower explosive limit lower flammability limit Liquefied Petroleum Gas maximum operating pressure negligible extent Natural Gas operating pressure specific gravity United Kingdom. UNITS bar mbar mm mm2 cm2 m m3 kg kmol-1 MJ m-3 kW °C bar millibar millimetre square millimetre square centimetre metre cubic metre kilogram per kilomole megajoule per cubic metre kilowatt degree centigrade. Recommended and legacy gas metering arrangements are given in IGEM/G/1 which is freely available:   with the purchase of any IGEM Standard. upon request by downloading a printable version from IGEM’s website http://www. ACRONYMS. 24 ©IGEM. 26-28 High St. with the purchase of any IGEM Standard. .igem.igem. IGEM House. SYMBOL % percentage. Downloading from the website ensures access to the latest version.uk/. Derbyshire.IGEM/UP/16 – Draft for Comment APPENDIX 1 : GLOSSARY.

etc. ACoPs AND GUIDANCE NOTES    HSG48 Reducing error and influencing behaviour HSG65 Successful Health and Safety Management HSL56 Safety in the installation and use of gas systems and appliances GS(I&U)R ACoP   HSL134 Design of Plant. equivalent national or international standards.igem. Act 1974      Gas Appliances (Safety) Regulations 1995 Dangerous Substances and Explosive Atmospheres Regulations 2002 Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres Regulations 1996 Gas Safety (Installation and Use) Regulations 1998 Management of Health and Safety at Work Regulations 1999 Pressure Equipment Regulations 1999 Pressure Systems Safety Regulations 2000.2 A2.3 LEGISLATION    Health and Safety at Work etc. Care shall be taken to ensure that the latest editions of the relevant documents are used. DE74 2DA. Where British Standards. etc. shall be taken into account. . equally may be appropriate. 26-28 High St. The following list is not exhaustive. Low pressure (2nd family gases) BS 6501    Metal hose assemblies. Kegworth. official Guidance Notes and referenced codes. are quoted.org. Guidance on the construction and use of corrugated hose assemblies BS 6891 Low pressure pipework in domestic premises BS 8313 CoP for accommodation of building services in ducts BS 8487 Construction and design of Gas boosters in association with combustion equipment  BS EN 331 Manually operated ball valves and closed bottom taper plug valves for gas installations in buildings   BS EN 676 Automatic forced draught burners for gaseous fuels BS EN 751 Sealing materials for metallic threaded joints in contact with 1st. IGEM House.IGEM/UP/16 – Draft for Comment APPENDIX 2 : REFERENCES This Standard is set out against a background of legislation in force in the UK at the time of publication. Website: www. Derbyshire. standards. All relevant legislation must be complied with and relevant Approved Codes of Practice (ACoPs).1 A2. etc.uk. Similar considerations are likely to apply in other countries and reference to the appropriate national legislation will be necessary. 2nd and 3rd family gases and hot water 25 ©IGEM. A2. DSEAR ACoP INDG163 5 steps to risk assessment. BRITISH STANDARDS (ABBREVIATED TITLES)  BS 1552 Specification of opened bottom taper plug valves up to 200 mbar  BS 6400  Specification for installation of domestic-sized gas meters maximum rated capacity not exceeding 6 m3 h-1 (2nd and 3rd family gases). equipment and workplaces.

Website: www. tightness testing and direct purging of industrial and commercial gas installations  IGE/UP/1A Edition 2 Strength testing. .org. Derbyshire. 26-28 High St. IGEM House. IGEM STANDARDS  IGE/GM/5 Edition 3 Electronic gas meter volume conversion systems    IGEM/GM/7A Electrical connections for gas metering equipment IGEM/GM/7B Hazardous area classification for gas metering equipment IGE/UP/1 Edition 2 Strength testing.4   BS EN 1775 Gas pipework for buildings with MOP of ≤ 5 bar BS EN 13463 Non-electrical equipment for use in potentially explosive atmospheres   BS EN 60079-10-1 Classification of areas for explosive gas atmospheres Flexible metallic hose assemblies.5 BS EN ISO 15465 OTHERS  MCSP-P15 Model Code of Safe Practice Part 15: Area Classification Code for installations handling flammable fluids. Kegworth. 26 ©IGEM. low pressure Natural Gas installations IGE/UP/1B Edition 2 Tightness testing and purging of domestic sized Natural Gas IGEM/UP/2 Edition 2 Installation pipework on industrial and commercial premises IGE/UP/10 Edition 3 Installation of flues gas appliances in industrial and commercial premises   IGEM/SR/25 Hazardous area classification of natural gas installations  IGEM/G/1 3rd Impression Definitions for the end of a network.IGEM/UP/16 – Draft for Comment A2. meter installation and installation pipework IGEM/G/4 Definitions for the gas industry.uk.    A2.igem. tightness testing and direct purging of small. DE74 2DA.

27 ©IGEM. if it does occur.1. and all the zone classification charts and descriptions relate to such releases. In general.3 This Appendix does not address either Continuous or Primary Grade release or catastrophic failure.2. it may be that a manufacturer of hazardous area equipment has a specific requirement not covered by this Appendix. they take precedence. Note: A3.2 In order to ascribe Zone Classification and Extent to a potential release of a flammable substance. A3.2 Certain items of equipment may be the source of both Primary and Secondary Grades of Release. Derbyshire.2. There are three categories of Grade of Release:    Continuous Grade of Release: A release which is continuous or is expected to occur for long periods Primary Grade of Release: A release which can be expected to occur periodically or occasionally during normal operation Secondary Grade of Release: A release which is not expected to occur in normal operation and. A3.1. Continuous Grade and Primary Grade sources are “engineered releases” such as from pressure relief valves while Secondary Grade sources release only as a result of minor failure.1 In the hazardous area concept. .1 The Grade of Release states how likely a release is to occur from a potential source. 26-28 High St.1. etc. Although this Appendix provides much information and guidance.3. it is possible to select the relevant explosion protection for electrical equipment to be installed. For detailed information see IGEM/SR/25.1 This Appendix covers the various terms used within the gas industry in relation to hazardous areas. A3. Kegworth. Secondary Grade Releases typically occur from flanges.igem. Website: www. Note: Relief valves have to be piped to outside any housing in order to use the charts in Appendix. screwed fittings.org. As such.3. consideration has to be made to the Grade of Release.2 The assumptions made in this Appendix are to enable a simplified approach for hazardous area classification for installation pipework to be described. the Rate of Release and the environment into which the release occurs.3 GRADE OF RELEASE A3. A3. IGEM House.uk. where manufacturers’ instructions and certificated requirements are different from information in this Appendix. regulator breathers. A3. is likely to do so only infrequently and for short periods. Having allocated Zone Classification and Extent. for example regulator diaphragm rupture or fractured pipe.IGEM/UP/16 – Draft for Comment APPENDIX 3 : CONCEPT AND REQUIREMENTS FOR HAZARDOUS AREAS A3. designed or minor accidental releases are quantified in terms of probability of formation of flammable atmosphere (Zone Classification) and the volume of space that is likely to be influenced by such releases (Extent).2 HAZARDOUS AREA CONCEPT A3.1 GENERAL A3. DE74 2DA.

A3. IGEM House.2 This Appendix assumes natural buoyancy-driven ventilation when calculating dispersion distances for the charts and tables.2    the size and form of the likely release aperture the characteristics of the material release the pressure available to drive the release.1 This Appendix considers both internal and external types of ventilation. see IGEM/SR/25.4.1 Ascertain the Rate of Release considering: A3. dry Natural Gas non-vibratory environment. Derbyshire.4.5 ENVIRONMENT/VENTILATION A3.4 RATE OF RELEASE A3. or adequately ventilated installation housings. Note: IGEM/SR/25 describes the assessment of the adequacy of ventilation in naturally ventilated housings in greater detail. Note: IGEM/SR/25 addresses vents from relief valves and from safety shut off valve systems.5.igem. 28 ©IGEM. Kegworth. Assumptions for Secondary Grade releases are:   clean.HAZARDOUS AREA CONCEPT DIAGRAM A3. A3. Primary or Secondary Rate of release Pressure Hole size Environment Ventilation type Quality FIGURE 4 .org. It also assumes either freely ventilated for installations not housed. For MOP greater than 5 bar.5.IGEM/UP/16 – Draft for Comment HAZARDOUS AREA CONCEPT Increased ventilation Leads to Zone number Relates to probability of formation of hazardous atmosphere Extent volume of affected space Leads to Use of Zone 2 or higher equipment Nearest distances between potential releases and ignition sources Use this information to determine the above Grade of release Continuous. These conditions would be expected in installation pipework with an MOP below 5 bar. DE74 2DA. Website: www.uk. . 26-28 High St.

7 For further detail relating to Grade and Rate of Release and Ventilation.2 The Zone Classification may be described as being a measure of the likelihood of a flammable gas/air mixture being present in a particular area. “X” increases with increasing gas pressure and/or decreasing quality of ventilation and is ascertained either by dispersion modelling or by recourse to known conservative distances in established Codes of Practice. Derbyshire. Website: www. Zone 1 or Zone 2 or of Negligible Extent (NE). 29 ©IGEM.7).uk.IGEM/UP/16 – Draft for Comment A3.6. DE74 2DA. EXTENT The Extent of the hazardous area zone is the volume surrounding a potential leak source having a distance “X” as described shown in Figure 3.org.1 When the Rate of Release and ventilation for a given release have been derived.6. known as a Zone and the extent of which is “X” (see A3.6 ZONE CLASSIFICATION A3. IGEM House. It does not however apply when the extent of the zone is of NE. Under DSEAR it is not possible to have a non-hazardous (safe) area where a flammable gas exists near pipe joints. . The classification may be Zone 0. refer to IGEM/SR/25.igem. Kegworth. A3. it is possible to determine the Zone Classification. Note: A3. 26-28 High St.

Figure 3(a) . Kegworth. IGEM House. Website: www. Figure 3(b) . Where the valve is capped or plugged. In both cases all other flanges or screwed connectors follow Figures 1a or 1b. For flanges or screwed connectors follow Figures 1(a) or 1(b).Valve glands Note: Determine the zoning distance from where the spindle enters the valve body. for all Zoned classifications except those designated NE are given in IGEM/SR/25. For values of X. DE74 2DA. there will also be a Zone 1 area associated with the valve seat.Flanges Determine the zoning distance from the centre for the opening of the valve.igem.Valve connections Figure 3(d) . . VALVE GLANDS AND REGULATORS (SECONDARY GRADE RELEASES OUTDOORS EXCEPT THOSE DESIGNATED NE) 30 ©IGEM. Figure 3(c) . the threads of these components are treated as in Figures 1(a) or 1(b).org. FIGURE 5 .Screwed fittings and joints up to 50 mm nominal size Determine the zoning distance from the edges of the flange.uk. Where the valve is not capped or plugged.IGEM/UP/16 – Draft for Comment Determine the zoning distance from the centre of the fitting.EXTENT OF THE HAZARDOUS AREA SURROUNDING FITTINGS. Derbyshire. 26-28 High St.

The installation will be inspected using combustible gas detector on a 6 monthly basis to ensure there is no indication of gas leakage. it is all screwed.1. Table 1 requires low & high level ventilation each of 1240 x 0. it will be needed to increase the high level ventilation above the pipe by fitting at least 1020-800 = 220 cm2 free area grilles. the IGE/UP/10 ventilation of 800 cm2 and 1600 cm2 would be in excess of the 91 x 0.1.Naturally ventilated boiler rooms 80 m3 and 30 m3 A4. high level vent 3m appliance appliance ventilator grille m 8/5 10/6 m FIGURE 6 – EXAMPLE OF A BOILER ROOM NATURALLY VENTILATED With an MOP of 80 mbar. ventilation above the pipe is recommended of 75 cm2. The gas pipework is all welded except at the two appliances. The ventilation is located on the front wall as before based on 100 kW nett heat input to the appliances or 200 cm2 at high level and 400 cm2 at low level. Kegworth. The installation achieves Zone 2 NE classification. The boiler room is visited twice a year.5 m high. A4. The threaded joints are not within 1 m of 3 surfaces. DE74 2DA. But to achieve Zone 2 NE.igem. Again high level. 26-28 High St. The incoming pipe is located above eaves level. This is exceeded by the design low level ventilation.1 Example 1 . IGEM House.org. Ventilation is well distributed. The ventilation is located on the front wall based on 400 kW nett heat input to the appliances or 800 cm2 at high level and 1600 cm2 at low level. At say 210 mbar OP. The boiler room is visited daily. Website: www. The incoming pipe is located above low level behind the boilers.82 = 75 cm2 free area required and would be adequate. Derbyshire.1 The boiler room is 80 m3 volume and has pitched roof 3 m high.uk. 31 ©IGEM.82 (3 m height factor) = 1020 cm2. The gas pipework is working at 60 mbar.IGEM/UP/16 – Draft for Comment APPENDIX 4 : WORKED EXAMPLES A4. .2 The boiler room is 30 m3 volume and has a flat roof 2.

Ventilation is well distributed. DE74 2DA. 26-28 High St.IGEM/UP/16 – Draft for Comment appliance appliance 2. The threaded joints are not within 1 m of 3 surfaces.org.uk.igem. The high level ventilation above the pipe will need to be increased by fitting at least 620-200 = 420 cm2 free area grilles. to ensure there is no smell/indication of leaking gas. Kegworth. The installation will now achieve a Zone 2 NE classification. The installation will be inspected using combustible gas detector on a 6 monthly basis to ensure there is no indication of gas leakage. The alternative to increasing the ventilation would be to visit the boiler house on a more frequent basis. Similarly the low level ventilation will need to be increased by fitting at least 620-400 = 220 cm2 free area grilles. In which case the ventilation requirement in Table 1 falls from 620 cm2 to 65 cm2 and the IGE/UP/10 ventilation would be adequate.5 m 60 mbar 5m ventilator grille 6m FIGURE 7 – EXAMPLE OF A BOILER ROOM WITH A FLAT ROOF Table 1 requires low & high level ventilation each of 620 cm2 (ignoring the height factor). say weekly. IGEM House. This is not exceeded by the design IGE/UP/10 ventilation. 32 ©IGEM. Derbyshire. Website: www. .

Mechanically ventilated boiler room 80 m3 FIGURE 8 – EXAMPLE OF BOILER ROOM WITH MECHANICAL VENTILATION This example is as A4. The room is visited twice a year. The four perimeter vents should be centrally located or distributed along the walls.2. . Website: www.1 but here the mechanical ventilation is blowing in at high level with internal downwards facing louvres to force the air down towards the floor. A4. The pipes are threaded at 60 mbar OP. Kegworth. Thus we need low and high level ventilation of 620 cm2. This space does not communicate with any other space. If the space had access to an external wall it would be better exchange the 100 mm2 ventilator on that wall with a 65 mm2 external ventilator located as high as practical within the space. The inlet duct size to the fan is 400 cm2 free area. 33 ©IGEM. DE74 2DA. The room is 6 m square and the ceiling space is 400 mm high in which there is lighting and a pipe with screwed connections and MOP at 50 mbar. At high level this is provided by the high level ventilation but we still need ventilation above the pipe joints. In this example ventilation will be required on all four walls of 100 mm2 free area and a grille near to each joint of 100 mm2 free area.org. With these design criteria the installation will achieve a Zone 2 NE classification.igem. IGEM House. As the fans are not continuous running we must again determine the ventilation according to Table 1. The outlet natural ventilation is 800 cm2. 26-28 High St.Horizontal ceiling duct The duct is a ceiling space above an occupied room such as an office or classroom.1.3 Example 3 .uk. In this case there is no low level ventilation so we must install similar ventilation to that in A4. Derbyshire.2 Example 2 . which should be taken as a minimum of 50 cm2 as well as 620 cm2 at low level for the installation to achieve a Zone 2 NE classification.IGEM/UP/16 – Draft for Comment A4.

Kegworth.EXAMPLE OF A HIGH LEVEL LOFT SPACE 34 ©IGEM. where the surface below the tiles is sealed with a vapour permeable underlay (BS 5250:2002) which is designed to minimise air flow and to permit the control of humidity.IGEM/UP/16 – Draft for Comment FIGURE 9 . 26-28 High St. Website: www.5 air changes per hour. Derbyshire. extra high level ventilation will be needed as required by the buoyancy ventilation requirements in column 1 or 2 of Table 1 depending on whether the high level ventilation is on one or more walls. IGEM House.EXAMPLE OF A HORIZONTAL CEILING DUCT A4.igem. . However.org. In addition there may be adventitious air leakage at high level via the tiles. DE74 2DA. Loft spaces have for many years been required under UK Building Regulations to have soffit/eaves ventilation which should always exceed 0. Such ventilation will be spread throughout the loft space for good distribution and no extra high level ventilation will be need to achieve Zone 2 NE.uk. FIGURE 10 .High level loft space In this case the loft is separated by a ceiling at eaves level.4 Example 4 .

DE74 2DA. or  the room shall be ventilated at high and low level in any separating doors as per Column 2 of Table 1 back up into the ventilated parts of the building.IGEM/UP/16 – Draft for Comment A4.Basement rooms 20 m3 and 8 m3 It would be normal to have 0. For spaces over 20 m3. or  the room shall be mechanically ventilated to achieve at least 0. Derbyshire. for example with fire dampers.org. IGEM House.5 Example 5 .  for existing installations. It is noted that where this breeches fire protection within the building that the ventilators will need to be protected.  for new installations. the ventilation shall be dispersed within the room to ensure all leakage sources are ventilated and they are not in stagnant areas. the minimum requirement with 0. 35 ©IGEM.uk. Website: www. For the installation to achieve Zone 2 NE classification. .5 air change per hour locations is for an annual check for leakage using LDF or a combustible gas detector and annual maintenance of the pipework to ensure that there is no corrosion that might lead to failure.5 air changes per hour and interlocked with an automatic isolation valve in the incoming gas supply. that is within 1 m of three surfaces. Kegworth. 26-28 High St. the OP shall not exceed 50 mbar and either of the following shall be applied:  the room shall be ventilated externally at high and low levels via ducts using twice the values given in Table 1 column 2.igem.5 air changes per hour in internal spaces.

Kegworth.org. Where mechanical ventilation is provided additional consideration should be given to the naturally ventilated condition when the fan(s) are not operational. alarms or interlocks if the ventilation figures given in Table 1 are not met. DE74 2DA. These may require automatic isolation valves. Derbyshire.5 Steps to Risk Assessment. Website: www. IGEM House.uk.igem. These assessments only relate to low pressure installations design constructed and tested to recognised UK standards and to which a process of maintenance has been specified and implemented. For existing installations not meeting the recommendations in this standard. 36 ©IGEM. the Risk Assessment needs to consider additional measures for leak mitigation such as may be satisfied in manned installations or more regular site visits with a combustible gas detector. 26-28 High St. In each case they will need to be considered by a person with the ability to recognise the relevant safety issues required to satisfy the requirements of DSEAR. They are not intended to be applied as given to reciprocating gas engines and gas compressors which may be seen to be vibrating machinery. .IGEM/UP/16 – Draft for Comment APPENDIX 5: EXAMPLES OF GENERIC RISK ASSESSMENTS The following examples use the principle outlined in HSE Guidance INDG 163 .

Kegworth. Recommended sealant materials used to BS EN 751.g. Ensure no damage in service. Perform check of pipework for any noticeable leakage on disturbed joints.5 BAR Conclusions The above indicates that a Zone 2 hazardous area classification is not necessary if correctly installed. A Zone 2 NE classification shall be designated for all the pipework Hazardous zones may. IGEM House. Initial tightness test to IGE/UP/1 or IGE/UP/1A. Maintain pipework against corrosion. ensure continued ventilation. check for leakage as necessary and check for leakage on disturbed joints. joints and components of MOP  0. At all times there must be adequate ventilation within the areas that the pipework is installed. Initial tightness test to IGE/UP/1 or IGE/UP/1A. Derbyshire. In such cases.org. JOINTS AND COMPONENTS OF MOP  0. Website: www. IGEM/SR/25. The influences of external vibration and installation may also affect the zone classification of the area. TABLE 8 – RISK ASSESSMENT FOR RIGID PIPEWORK. Competent welders employed. tested. Valves selected for operation at above MOP. Maintain corrosion protection measures and support. . 37 ©IGEM. and subsequently tested to IGE/UP/1 or IGE/UP/1A.Draft for Comment Client: Problem description : Potential gas leakage from rigid pipework.g. IGEM/UP/2 and BS EN 1775. by competent persons. IGE/UP/9. BS 1552. Maintain during life.IGEM/UP/16 . e.5 bar Address: Date: Assessment performed by: Hazard Build-up of potential hazardous atmosphere Who might be harmed Persons nearby Failure of flange gasket Persons nearby Failure of valve stem seal Failure of pipe material Persons nearby Failure of threaded joints Persons nearby Failure of unions and mechanical joints Failure of welded joint Persons nearby Persons nearby Persons nearby Control of risk at installation Ongoing control Pipework to be installed in well ventilated areas to e. e. Visual inspection. Supplied by reputable manufacturers meeting European Union (EU)/UK standards selected for pressure above MOP. however be generated by external sources and. See BS EN 1775 and IGEM/UP/2. Standard flanges and gaskets selected for pressure above MOP. BS EN 60079-10-1 and BS 8487. Initial tightness test to IGE/UP/1 or IGE/UP/1A. Validate tightness during work on joints. reference may be made to standards such as IGE/UP/3. with minimum joints. in such cases. Perform checks for leakage during valve servicing. Initial tightness test to IGE/UP/1 or IGE/UP/IA. BS EN 13463. certified equipment suitable for the zone classification for the area may be required. IGEM/UP/6.uk. BS EN 331. maintained and correctly checked for leakage at intervals during service life. Gas boosters/compressors will require further consideration and added protection.igem. IGEM/UP/2. 26-28 High St.g. Perform checks for leakage during servicing. DE74 2DA.

Components must be suitable for MOP and temperature.g. in such cases. Kegworth. Failure of pipework Persons nearby Tested for leakage at manufacture.igem. BS EN 13463 and BS EN 60079-10-1. Failure of castings Persons nearby Booster selected to comply with BS 8487 Failure of mechanical seals Persons nearby Initial tightness test. tested.uk. ensure continued ventilation. reference may be made to standards such as IGE/UP/10.org. Perform checks for leakage during servicing. At all times there must be adequate ventilation within the areas that the appliance is installed. Materials specified to withstand MOP. Hazardous zones may. IGEM House. Ensure fixed to secure base as manufacturers’ instructions.) Failure of flexible connections Persons nearby See separate Risk Assessment. however. DE74 2DA. IGEM/SR/25. with minimum joints and subsequently tested to IGE/UP/1. Maintain against corrosion and according to manufacturers’ instructions. 38 ©IGEM. Website: www.Draft for Comment Problem description : Potential gas leakage from gas boosters MOP  0.5 BAR Conclusions The above indicates that a Zone 2 hazardous area classification is not necessary provided that machines and associated pipework and controls are correctly installed. IGE/UP/10. A Zone 2 NE classification shall be designated for all the pipework and gas controls. be generated by external sources and. TABLE 9 – RISK ASSESSMENT FOR GAS BOOSTERS OF MOP  0. In such cases. check for leakage as necessary and check for leakage on disturbed joints. Derbyshire. IGE/UP/12. IGE/UP/3 and IGEM/UP/6. maintained and correctly checked for leakage at intervals during service life. Maintain during life. 26-28 High St. by competent persons. Perform checks for leakage during annual servicing. Ensure no strain on castings during installation and servicing. Influences of external vibration and installation may also affect the requirement for zoned equipment.IGEM/UP/16 . Failure of components Persons nearby Components supplied by reputable manufacturers meeting EU/UK standards. zoned equipment may be required.5 bar Address: Date: Assessment performed by: Client: Hazard Build-up of potential hazardous atmosphere Who might be harmed Persons nearby Control of risk at installation Ongoing control Machines installed in well ventilated uncongested areas to e. . IGEM/UP/2. Initial tightness tests during commissioning (see IGEM/UP/4. Perform checks for leakage during servicing.

Check for leakage of incomplete combustion products and production of carbon monoxide. Components must be suitable for MOP and temperature. 26-28 High St. 39 ©IGEM. be generated by external sources and. reference may be made to standards such as IGE/UP/10. IGE/UP/12. Failure of regulator diaphragms Persons nearby Regulators made EU standards suitable for at least MOP. Influences of external vibration and installation may also affect the requirement for zoned equipment.IGEM/UP/16 .g.igem. Derbyshire.uk.org. zoned equipment may be required. Maintain pipework against corrosion and according to manufacturers’ instructions.5 bar Address: Date: Assessment performed by: Hazard Build-up of potential hazardous atmosphere Who might be harmed Persons nearby Control of risk at installation Appliances to be installed in well ventilated areas to e. in such cases. tested. by competent persons. Initial tightness tests during commissioning (see IGEM/UP/4. Failure of mechanical seals Persons nearby Initial tightness test.5 BAR Conclusions The above indicates that a Zone 2 hazardous area classification is not necessary provided that appliances and associated pipework and controls are correctly installed. Kegworth. IGE/UP/3. IGE/UP/12. A Zone 2 NE classification shall be designated for all the pipework and gas controls. with minimum joints and subsequently tested to IGE/UP/1. Perform checks for leakage during servicing. Failure of pipework Persons nearby Tested for leakage at manufacture. maintained and correctly checked for leakage at intervals during service life. IGE/UP/10. IGE/UP/3 and IGEM/UP/6. DE74 2DA. ensure continued ventilation. TABLE 10 – RISK ASSESSMENT FOR APPLIANCE CONNECTIONS AND PIPEWORK OF MOP  0.) Failure of components Persons nearby Appliances supplied by reputable manufacturers meeting EU/UK standards. . Ongoing control Maintain during life. In such cases. Website: www. At all times there must be adequate ventilation within the areas that the appliance is installed. check for leakage as necessary and check for leakage on disturbed joints.Draft for Comment Client: Problem description : Potential gas leakage from appliance connections and pipework of MOP  0. Perform checks for leakage during servicing. BS EN 13463 and BS EN 60079-10-1. IGEM House. Hazardous zones may. Perform checks for leakage during servicing. IGEM/SR/25. Materials able to withstand MOP. however.

At all times there must be adequate ventilation within the areas that the flexible pipes. It is most important that during initial installation and subsequent maintenance activities there are no additional adverse torsional stresses imposed upon the flexibles.g.Draft for Comment Build-up of potential hazardous atmosphere Caused by material failure Who might be harmed Persons nearby Control of risk at installation Hoses. Derbyshire. Hazardous zones may.igem. reference may be made to standards such as IGE/UP/10. FLEXIBLE PIPES. bellows. Hazardous area considerations – Risk Assessment – DSEAR Regulation 5 Hazard A3. Influences of external vibration and installation may also affect the requirement for zoned equipment. Ongoing control For flexibles subject to frequent movement or vibration (as on register burners. HOSES AND CONNECTIONS OF MOP  0. flexible hoses and flexible connections are installed. in such cases.. A Zone 2 NE classification shall be designated for all the pipework and gas controls. zoned equipment may be required. bellows. IGEM/SR/25. flexible hoses and flexible connections MOP  0.5 bar Client: Address: Date: Assessment performed by: . In such cases. flexible hoses and flexible connections are correctly installed.5 BAR Conclusions The above indicates that a Zone 2 hazardous area classification is not necessary provided that flexible pipes. For all other flexibles perform checks at least during annual servicing. IGE/UP/3 and IGEM/UP/6. Twisting and excessive bending shorten the life.5 Problem description : Potential gas leakage from flexible pipes.IGEM/UP/16 .org. IGEM House. to be selected for operation at above MOP. IGE/UP/12. 26-28 High St. Consider replacement policy. Kegworth. e. Website: www. maintained and correctly checked for leakage at intervals during service life. be generated by external sources and. however. tested. IGEM/UP/2 and BS 6501. TABLE 11 – RISK ASSESSMENT FOR BELLOWS. DE74 2DA. compressors and engines) perform checks for leakage quarterly. bellows and etc. 40 ©IGEM. bellows.uk. BS EN 13463 and BS EN 60079-10-1. for example every 5 years.

Hazardous area considerations – Risk Assessment – DSEAR Regulation 5 Build-up of potential hazardous atmosphere Who might be harmed Persons nearby A3.5 bar Address: Date: Assessment performed by: Client: . zoned equipment may be required. Perform checks for leakage during servicing. with minimum joints and subsequently tested to IGE/UP/1. Materials able to withstand MOP. Leak tested at manufacture and commissioning. IGE/UP/12. IGE/UP/3.IGEM/UP/16 .5 BAR Conclusions The above indicates that a Zone 2 hazardous area classification is not necessary. Leakage from test points on gas train Persons nearby Capped or plugged with suitable fitting. IGE/UP/10. ensure continued ventilation. in such cases. Failure of mechanical seals Persons nearby Initial tightness test. IGEM House.igem. Follow correct servicing/ testing procedures by competent service engineers Maintain pipework against corrosion and according to manufacturer’s instructions. 26-28 High St. IGEM/SR/25. check for leakage as necessary and check for leakage on disturbed joints. Influences of external vibration and installation may also affect the requirement for zoned equipment. Gas trains installed in position open to ventilation air flows.Draft for Comment Hazard Control of risk at installation Appliances to be installed in well ventilated areas to e. Manufactured to EU/UK standards Tested for leakage at manufacture.g. maintained and correctly checked for leakage at intervals during service life. reference may be made to standards such as IGE/UP/10. by competent persons. A Zone 2 NE classification shall be designated for all the pipework and gas controls. Failure of gas train valves or pipe-work Persons nearby Failure of components Persons nearby Failure of regulator diaphragms Persons nearby Regulators made to EU standards suitable for at least MOP. 41 ©IGEM. however. DE74 2DA. Appliances supplied by reputable manufacturers meeting EU/UK standards. In such cases. Components must be suitable for MOP and temperature. Derbyshire. Kegworth. Perform checks for leakage during servicing. provided that gas appliances are correctly installed. IGE/UP/3 and IGEM/UP/6. Ongoing control Maintain during life. TABLE 12 – RISK ASSESSMENT FOR GAS APPLIANCES OF MOP  0.org. be generated by external sources and. BS EN 13463 and BS EN 60079-10-1. Check for leakage of incomplete combustion products and production of carbon monoxide. Hazardous zones may. Materials able to withstand MOP.uk.5 Problem description : Potential gas leakage from gas appliances MOP  0. IGE/UP/12. Valves and fittings by reputable manufacturers. tested. Perform checks for leakage during servicing. Website: www. At all times there must be adequate ventilation within the areas that the gas appliances are installed.

Draft for Comment BLANK PAGE 42 ©IGEM. Kegworth. . Website: www.org. Derbyshire.igem. 26-28 High St.IGEM/UP/16 . DE74 2DA. IGEM House.uk.